The Coating Equipment

Transcription

1 The Coating Equipment

2 We are the Tool Coating People We have developed the right technology, built the appropriate production plants and thereby made the best PVD and CVD diamond coatings in the world a reality. In CemeCon s own job coating centre, which is one of the biggest in the world, tens of thousands precision tools are coated for our customers every day. For 30 years, the experience and know-how gained here have been feedback into the ongoing development of our PVD and CVD diamond coating machines. This also enables our customers to benefit in terms of productivity, ergonomics, processing quality and cost-effectiveness. 2

3 We coat according to your order in our job coating center You coat with our coating equipment within your own production line You are the customer. The choice is yours. Whether you take advantage of our job coating service, or integrate our coating equipment into your production, you will always achieve a premium result. We simplify things for you. We offer any desired level of support for developing your own individual coating solution. You may test at our coating service center and transfer the whole process into your own facility if you wish to do so. Would you like to develop your own processes independently? The fully open recipe editor included in our machines gives you a fully featured tool and all the opportunities to do so. While being assisted by our experts, you will notice the benefit of harmonised processes and have access to our knowhow of Best Practices to achieve the optimal PVD- and CVD diamond coatings. The choice is yours! 3

4 PVD Sputter Coatings from CemeCon Smooth, droplet-free coatings for cutting tools and components Since 1986, CemeCon has been a pioneer in developing hard-material coatings using PVD Sputter technology. During Sputtering, the material is vaporized for producing the coating and turns from a solid state directly into the gaseous phase. In traditional processes, the coating material must be melted. This inevitably creates droplets that form defects in the coating structure and lead to a very rough surface. During Sputtering, these droplets do not appear. A valuable advantage of Sputter technology, which ensures a perfect coating and extremely smooth, defect-free surfaces. Another advantage of Sputter technology is a significant reduction in the film s internal stress. This allows AITiN coatings to be deposited to a thickness of 15 µm. An unbeatable advantage in all applications with a great demand for wear volume. Integrated Plasma Booster and pulsed substrate BIAS technology in all PVD systems make for very high plasma ionization. The results are thorough but gentle cleaning, activation of surfaces and outstanding coating adhesion. Scratch test adhesion values of 100 Newtons are standard for CemeCon DC Sputter systems. HiPIMS is the evolution of the Sputter technology. With the CC800 HiPIMS CemeCon is offering the cost-effective production of pure HiPIMS coatings as the only company worldwide. Extremely smooth: In contrast to processes that leave droplets on the surface (left), surfaces from the PVD Sputter process (right) are extremely smooth. i Sputtering is enormously flexible. It can be used to produce all known coatings. Whether it is metals, oxides, nitrides, borides or carbides with Sputtering, almost any coating material can be deposited. Sputtering knows no limits from the smallest micro-tool with less than a 0.1 millimeter diameter to hob cutters or very heavy components. Both electrically conductive and non-conductive coatings can be produced on both electrically conductive and nonconductive substrates. Most coatings are produced at temperatures of 250 C to 500 C. The Sputtering process also allows temperatures below 150 C. 4 PVD Sputter Coatings from CemeCon

5

6 DC Sputter Coating System CemeCon coating systems with DC Sputter technology are especially flexible and applicable universally. For decades they have been the backbone of many tool coatings around the world. Depending on the quantities required, the ML and XL versions are available. Both of them coat quickly and easily with all nitride-, boride- and carbonbased materials. Add-on modules allow further individual adjustments. The CC800 /9 ML is the economical system for medium lot quantities and frequent changes in batch and coating material. With the optional flex module, your capacity can be further enlarged and quickly adapted to current order volume. Due to its high flexibility, the CC800 /9 ML line has proved its worth in research and development. The system s open, modular design allows it to be equipped with many extensions and options, such as measuring devices. CemeCon has developed the CC800 /9 XL for large batch quantities or large components. With the same external dimensions as the ML model, it has considerably larger coating volume. It coats drills or cutting inserts and tools up to a length of 800 milimeters and 650 millimeters in diameter in just one operation. The electro-hydraulically driven quick-change table allows fast loading and unloading of tool batches. 6 DC Sputter Coating System

7 Coating area Ø x h [mm] CC800 /9 ML 6 (10) Ø400 x 400 (Ø650 x 400) CC800 /9 XL Ø650 x 700 DC-MAGNETRON-SPUTTERING Substrate table, Ø x Ø satellites x number of satellites Table for quick batch change [mm] number Ø400 x Ø130 x 6 (Ø650 xø130 x 10) Mechanical or electro-hydraulic Ø650 x Ø130 x 10 Electrohydraulic Cathode Sputter cathodes items [mm] 4 x x 800 Maximum substrate dimensions Ø x h [mm] Ø400 x 800 (Ø650 x 800) Ø650 x 800 DC Drill capacity Ø6 mm x 60 mm item 1,800 (3,000) 4,500 Insert capacity 12.7 mm x 3.5 mm item 4,920 (8,200) 16,400 BIAS Maximum substrate weight [kg] 250 (500) 500 Cycle time for 3 µm Hyperlox * [h] 5 6 Processes Sputtering with Booster Technology Sputtering with Booster Technology DC Puls Substrate pre-treatment (plasma etching) Booster and MF etching Booster and MF etching Electrically conductive coatings Yes Yes Electrically non-conductive coatings No No Electrically non-conductive substrates No No Rated power [kw] Power consumption per batch for 3µm Hyperlox * Outer dimensions (w x l x h) [mm 3 ] [kwh] ,050 x 3,350 x 2,200 1,050 x 3,350 x 2,200 Weight (empty) 3,000 3,300 ~ 3,300 * On a 10 mm milling cutter ALOX SN 2 coating with 12.5 µm coating thickness COATING VOLUME 700 mm 400 mm 130 mm 400 mm 130 mm 130 mm 400 mm 650 mm 650 mm ML 6 ML 10 XL CC800 /9 ML CC800 /9 XL DC Sputter Coating System 7

8 HiPIMS the Future of PVD Coating Technology Featuring denser coatings, improved hardness / toughness and enhanced cutting results all with a deposition rate of 2 µm/h HiPIMS (High Power Impulse Magnetron Sputtering) is the next evolutionary step in Sputter technology. It combines all the advantages of common coating technologies and methods currently on the market. Like the DC Sputtering process, HiPIMS deposits smooth, droplet-free and low stress coatings in an almost unlimited variety. HiPIMS is characterised by an outstandingly high ionization of the Sputtered metal. Scratch loads up to 130 Newton prove the superb coating adhesion which is directly related to the high ionization level. HiPIMS coatings are both hard and tough at the same time thanks to the dense and nearly amorphous film structure. A consistent and homogeneous distribution of coating thickness all around three-dimensional objects like the cutting edge of a tool, facilitates optimal wear protection. CemeCon has systematically refined the HiPIMS technology to the point of being ready for industrial coating production. In terms of technology this means maximum flexibility and highest productivity with a deposition rate of 2 µm/h. Magnetron Me Me Me HiPIMS Plasma Ar + Me + Me + Me + Nearly 100% metal ionization The power peaks of HiPIMS result in an enormously dense plasma which provides an unrivalled degree of ionization to the deposited materials. The high flux of highly ionized species results in very dense and nearly amorphous coating structures. Highest adhesion The high metal ionization ensures the best possible coating adhesion. A scratch load of 120 Newton is an outstanding result for InoxaCon as a silicon doped and thereby very hard coating. FerroCon, based on AlTiN, results in a scratch value of up to 130 Newton. This enables to machine the most difficult to cut materials. Homogeneous coating all around the cutting edge The high ionization makes the coating structure very dense and compact. Such a fine grain morphology is likewise hard and tough. Coatings grow extremely homogeneous when HiPIMS is used for the deposition. Also, very complex tool geometries will receive approximately the same coating thickness all around the cutting edge. Maximum flexibility Perfect for micro tools Maximum profitability for pure HiPIMS coatings HiPIMS is a Sputter process. Almost every material can be sputtered. This means an unlimited variety of coatings through combinations of elements of the periodic system. Free of defects and without antenna effects. The HiPIMS technology is also very useful for very small geometries, as it works droplet-free and without damaging or rounding the cutting edge. The CC800 HiPIMS achieves in pure HiPIMS mode deposition rates of 2 µm/h and process times of 4 5 hours. 3 µm/h are possible when all 6 cathodes are used. 8 HiPIMS the Future of PVD Coating Technology

9

10 HiPIMS Coating System CC800 HiPIMS combines all the advantages of the classical DC Sputter coating system with the capabilities of the latest HiPIMS technology. The system is equipped with a total of six Sputter cathodes, four of which can be operated in either HiPIMS or DC mode. The additional two DC cathodes can be operated, for example, to provide more complex multilayer coatings, to deliver color and top coatings, or simply to increase deposition rates. The absolutely free combination of these technologies within one process gives an unlimited range of coating designs at very low production costs. Deposition rates of 2 µm/h and process times of 4 5 hours can be achieved in pure HiPIMS mode. When simultaneously operating of all 6 cathodes, 3 µm/h are reached. This was a so far unthinkably low production time for a coating capacity of round shank tools or indexable inserts before now. The CC800 HIPIMS is able to deposit all available CemeCon Sputter coatings and almost all PVD coatings available on the market. Furthermore, it is the perfect machine for the development of custom-built processes. The customerfriendly user interface DataView and the integrated planning tool DataPlan facilitate the design of individual coating solutions. Your coating will make your product stand out on the market, allowing users to gain a competitive edge. Other features such as user-friendly remote control by tablet and phone, the maintenance-friendly assembly, fully automatic cathode shutters, automatic door closing and the unit for a quick exchange of the coating table complete the picture of CC800 HiPIMS being the optimum coating system for the production and development of state-of-the-art high performance coatings. 10 HiPIMS Coating System

11 CC800 HiPIMS Coating area, Ø x h [mm] Ø400 x 400 Substrate table, Ø x Ø satellites x number of satellites Table for quick batch change Sputter cathodes [mm], number items [mm] Ø400 x Ø130 x 6 Optional Maximum substrate dimensions Ø x h [mm] Ø400 x 800 Drill capacity Ø6 mm x 60 mm item 1,800 6 x 500 (including 4 optional HiPIMS/DC and another 2 DC; all cathodes equipped with shutters) HiPIMS HIGH POWER IMPULSE MAGNETRON SPUTTERING Cathode HiPIMS DC Insert capacity 12.7 mm x 3.5 mm item 4,920 Maximum subtrate weight [kg] 250 BIAS Deposition rate µm/h In pure HiPIMS mode 2 μm/h. In DC or combi mode up to 3 µm/h. Cycle time for FerroCon * [h] 4.5 Processes Substrate pre-treatment (plasma etching) Electrically conductive coatings HiPIMS and Sputtering using booster technology. All established CemeCon coatings are possible. Booster, MF and HiPIMS etching Yes HiPIMS DC Puls Electrically non-conductive coatings Yes Electrically non-conductive substrates Rated power [kw] 80 Power consumption per batch for 3 µm FerroCon * [kwh] 120 Outer dimensions (b x l x h) [mm 3 ] 1,450 x 3,350 x 2,200 Yes Weight (empty) [kg] ~ 3,500 Closing of chamber doors Automatic closing * Pure HiPIMS coating on 10 mm milling cutter COATING VOLUME Intuitive touch control and pneumatic actuators for chamber doors facilitate daily operation of the unit. 400 mm 130 mm 400 mm HiPIMS High-energy HiPIMS plasma HiPIMS Coating System 11

12 CVD Diamond Coatings from CemeCon Patented Multilayers for machining graphite, glass- or carbon-reinforced plastics and composites The world s hardest material used as a coating for maximum wear protection when machining graphites, fiber-reinforced plastics (composites) and abrasive non-ferrous metals. For many years, CemeCon has used CVD technology to produce diamond coatings for cutting tools and components true crystalline sp 3 diamond with a hardness of nearly 10,000 Vickers. More than 20 years ago, CemeCon developed the hot filament process to market maturity and is now the world leader in diamond coatings and technologies. In the hot filament process, diamond is produced from gas. In a H 2 -C x H y gas atmosphere, carbon is turned into pure, crystalline diamond in vacuum. This can produce up to four carat diamond per hour. Depending on the application, it can be deposited as a micro-crystalline, nano-crystalline or Multilayer coating. The fully automatic coating technology, paired with optimal pretreatment of the substrate, allows the deposition of coatings with thicknesses of more than 20 µm and outstanding adhesion. CemeCon s patented Multilayer technology ensures maximum stability by interlocking the individual layers within the coatings. If cracks arise, they cannot spread beyond the layer boundaries. Thanks to their extreme hardness with up to 10,000 HV 0.05 close to natural diamond all coatings in the CCDia product group are extremely wear resistant. Performance of shank tools and indexable inserts made of solid carbide is significantly increased with a CCDia coating. The diamond coating s high heat conductivity makes for fast heat dissipation. This is enormously important when processing temperature-sensitive materials such as carbon- and glass-fiberreinforced plastics, and allows higher processing speed during machining. All of these properties make the CCDia line of coating materials the first choice for machining graphites, composites, nonferrous metals, green parts and ceramics according to VDI standard More and more components are enhanced with a diamond coating. Diamond is extremely hard and barely deformable. It is chemically inert to nearly all media, has very low friction and high heat conductivity. These unique properties constantly open new fields of application for diamond coatings in many industries. SUBSTRATE Micro-Crystalline Diamond Coating SUBSTRATE Nano-Crystalline Diamond Coating SUBSTRATE Multilayer Diamond Coating source: Airbus 12 CVD Diamond Coatings from CemeCon

13

14 Diamond Coating System Smooth, best adhesion and wear resistant thanks to Multilayer coating The CC800 /9 DIA coats tools for processing fiber-reinforced plastics, graphite and abrasive nonferrous metals with the world s hardest coating material real diamond crystals. With the CC800 /9 DIA, extremely smooth, especially adhesive nanocrystalline, crystalline or Multilayer diamond coatings can be deposited on more than 80 different tungsten carbide grades. Thanks to the hot filament process, even complex three-dimensional tools and components receive very homogeneous coating thickness distribution within tight tolerances. Despite its compact external dimensions, the CC800 /9 DIA is the largest-capacity automatic diamond coating system on the market. Three independently operating coating chambers make it especially flexible and economical. 14 Diamond Coating System

15 Coating area, number x (b x t x h) [mm] CC800 /9 DIA 1 x (740 x 360 x 30) or 3 x (50 x 560 x 70) Maximum substrate dimensions Ø x h [mm] Tools 30 x 500 Maximum substrate weight [kg] 250 HOT-FILAMENT DIAMOND COATING SYSTEM Filaments Processes Hot filament Electrically conductive coatings Yes Electrically non-conductive coatings Electrically non-conductive substrates Yes Yes Horizontal Vertical Rated power [kw] 90 External dimensions (w x l x h) [mm] 1,260 x 3,600 x 2,070 Weight (empty) [kg] 4,000 Micro end mills with CCDia Carbon Speed for graphite machining Composite airplane wings, drilling and reaming the rivet holes with diamond-coated tools Router with CCDia MultiSpeed Plus 17 µm pure Diamond Counter sink drill with CCDia AeroSpeed, the benchmark in aircraft production Diamond Coating System 15

16 Turnkey In-house Coating Systems In-house coating competence is a competitive advantage CemeCon is doing coatings - every single day. And it does it in one of the world s largest coating centers for cutting tools. A turnkey solution brings this wealth of experience and proven CemeCon coatings into your production. With cutting tools, the coating is often the crucial competitive advantage. The skill gained through integrating your own coating system ensures you full control over your product and allows flexibility and fast reaction. The complete package, including the coating system, substrate pretreatment and peripherals, covers the entire workflow. This entirety is the result of technology and a proven process, easing your entry into in-house coating technology. With experience from 300 completed systems, and as your project partner, CemeCon takes responsibility for creating an individual turnkey solution. The service team draws up the time, space and utility plan, handles country-specific details, assists in cooperation with public authorities and delivers a coating production ready to use. You gain from CemeCon s continuous development of coatings. Our development team will help you at any time with future applications. Comprehensive support and services ensures the system s continuous operation. CemeCon turnkey solutions for maximum flexibility and highest productivity. 16 Turnkey In-house Coating Systems

17 The Wolf coating center for components and cutting tools in Bruchmühlbach Three good reasons for choosing a CemeCon turnkey coating line Proven coating recipes from CemeCon s job coating service on proven coating systems. An individually adapted production process that ensures fast and efficient production runs. Service right from the start: CemeCon handles complete advance planning and sets up the system and peripherals. Coating, substrate and geometry adjusted by one supplier makes for the perfect tool. Take advantage of having your own coating technology! CC800 : premium coating, simple and efficient CemeCon s CC800 system series includes modularly designed models for smooth, droplet-free PVD Sputter and HiPIMS coating, as well as for superhard CVD diamond coatings. All of them combine premium quality with maximum performance in a compact design. fully automatic process control graphical user interface full internet connectivity flexible design for all available coatings open to future materials CemeCon advises the individual customer and offers solutions adapted to nearly any component size or unit quantity. Whether a tool manufacturer, contract coater or in research and development, every customer gets a complete turnkey solution designed to their needs, including complete peripherals: Pre- and posttreatment technology, cleaning, cooling and compressed air systems, as well as quality inspection equipment. All components are integrated into their production processes and infrastructure and existing machines are used effectively. CemeCon s job coating service is the ideal place to give your employees intensive training on the selected system model and on coating processes specifically adapted to suit your applications. Technicians will instruct you in the simple operation of your new coating system on site. So you can be sure that you can deliver the first coated tools immediately after your in-house system is installed. 24/7 support for machine customers around the world i Turnkey In-house Coating Systems 17

18 Peripherals and accessories integrated in the most optimal way Coating quality depends on all of the necessary steps in the process fitting together perfectly. CemeCon offers all of the components for a complete in-house coating center from one source perfectly matched with one another. The CemeCon advantage: Accessories and all components, machines and processes for pre- and post-treatment and quality control are always adapted to customer requirements and existing infrastructure. Blasting and cleaning systems CemeCon blasting and cleaning systems provide the best possible substrate preparation. Blasting systems free tools of burrs and grinding burn and remove loose carbide grains and cobalt smearing. If necessary, preparation of cutting edges can be optimized. Cleaning systems remove impurities gently and completely. The product line extends from manual systems for small or medium production quantities to fully automatic systems for large coating centers. All of the solutions are environmentally friendly and economical, thanks to the regeneration of blasting and cleaning media. Cooling systems During coating, cooling systems dissipate heat and provide necessary process reliability. CemeCon offers compact, robust, energy-saving cooling systems for every system size and every coating technology. Targets Blasting system Quality control Thanks to a special bonding process, CemeCon Targets ensure the highest quality and process reliability. They are optimally adapted to the coating process and, thanks to the plug technology, are available in a wide choice of materials. When it comes to quality control when goods are received or dispatched, CemeCon offers the right testing device for every need. Tailor-made quality assurance packages can be assembled from ball cratering test devices, Rockwell testers, microscopes and impact testers. 18 Peripherals and accessories

19 Coating Equipment at a Glance Coating area Ø x h* Substrate table, Ø x Ø satellites x number of satellites Table for quick batch change Sputter cathodes Maximum substrate dimensions Ø x h Drill capacity Ø6 mm x 60 mm Insert capacity 12.7 mm x 3.5 mm Maximum substrate weight Cycle time for 3 µm Hyperlox SN 2 ** Processes Substrate pre-treatment (plasma etching) Electrically conductive coatings Electrically non-conductive coatings Electrically non-conductive substrates [mm] [mm] number items [mm] [mm] CC800 /9 ML 6 (10) Ø400 x 400 (Ø650 x 400) Ø400 x Ø130 x 6 (Ø650 x Ø130 x 10) Mechanical or electro-hydraulic CC800 /9 XL 4 x x 800 Ø400 x 800 (Ø650 x 800) CC800 HiPIMS Ø650 x 700 Ø400 x 400 Ø650 x Ø130 x 10 Ø400 x Ø130 x 6 Electro-hydraulic Optional item 1,800 (3,000) 4,500 1,800 item 4,920 (8,200) 16,400 4,920 6 x 500 (including 4 optional HiPIMS/DC and another 2 DC; all cathodes equipped with shutters) CC800 /9 DIA 1 x (740 x 360 x 30) or 3 x (50 x 560 x 70) Depending on use Filaments Ø650 x 800 Ø400 x 800 Tools Ø30 x 500 [kg] 250 (500) Depending on process Depending on process [h] FerroCon Depending on process Sputtering with Booster Technology Booster and MF etching Sputtering with Booster Technology Booster and MF etching HiPIMS and Sputtering with Booster Technology. All established CemeCon coatings may be used. Booster, MF and HiPIMS etching Yes Yes Yes Yes No No Yes Yes No No Yes Yes Hot filament Rated power [kw] Power consumption per batch for 3µm Hyperlox ** Closing of chamber doors Outer dimensions (w x l x h) [kwh] FerroCon Depending on process manually manually automatically automatically [mm 3 ] 1,050 x 3,350 x 2,200 1,050 x 3,350 x 2,200 1,450 x 3,350 x 2,200 1,260 x 3,600 x 2,070 Weight (empty) 3,000 3,300 ~ 3,300 ~ 3,500 4,000 * CC800 /9 DIA: Coating area, number x (b x t x h) ** On a 10 mm milling cutter Coating Equipment at a Glance 19

20 GERMANY USA CemeCon AG Phone: CemeCon Inc. Phone: CC_EN_11 / 17 CHINA JAPAN CZECH REPUBLIC DENMARK INDIA KOREA TAIWAN RUSSIA CemeCon Coating Technology Co., Ltd. Suzhou Phone: china@cemecon.com CemeCon K.K. Contact: Alexander Marxer Phone: japan@cemecon.com CemeCon s.r.o. Phone: info@cemecon.cz CemeCon Scandinavia A/S Phone: info@cemecon.dk M+V Marketing & Sales Pvt. Ltd. Contact: Manish Adwani Phone: india@cemecon.com Hangil trading company Contact: Mr. Hong-Sik Cho Phone: hongsik.cho@hangilkorea.com DKSH Taiwan Ltd. Contact: Vincent Chu Phone: taiwan@cemecon.com ZAO Rosmark-Steel Contact: Ilya Mozgov Phone: mozgov@rosmark.ru Editor CemeCon AG Adenauerstr. 20 A Würselen Germany