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forming and molding
FORMING AND MOLDING T HE SURFAC E ENGINEERS™ 40 years of experience in tool coatings, you get the benefits Application Specific Solutions Lower Cost and Improved Productivity #HITS (000) 250 200 150 100 50 0 ■ TD ■ AITiN ■ BernexTM 62 Tool: DC 53 Progressive Die Speed: 10 – 18 spm Hardness-60-62 RC Lubricant: Spray/Mist Workpiece-DP 980 Mat. Thickness: 3.2 mm Failure Mode: Galling, requiring Tool Polishing Tool life increase by Bernex™ 62 Ionbond has been offering coating services for 40 years, greatly contributing to overall cost savings and to increasing the produc tivity of forming and molding processes. With PVD, CVD and PACVD technology available Ionbond has the broadest offering of coatings in the industry and can select the process that suits a given situation without compromise. Longer tool life Improved part quality Reduced lubricant usage Reduced downtime Reduced tool maintenance Elimination of secondary operations Application and Engineering Support Ionbond offers an extended product portfolio, many years of application experience and know-how to its customers to find engineered coating solutions for forms and molds that maximize performance for specific operating conditions. Ionbond engineers assess each situation in dividually. The outcome is a system solution aimed at delivering the identified objectives. Tool material Workpiece material or resin Working temperatures Tool life expectation Tool failure mode State-of-the-art PVD, CVD and PACVD Technology A Track Record of Performance Stamping and Cold Forming Plastic Injection Molding Ionbond’s coating solutions exhibit the toughness, wear resistance, and galling resistance needed to improve the performance of punches, dies, and other tooling used in stamping, forming, and compaction applications. With superior hardness and wear resistance, Ionbond coatings protect plastic injection molds from the abrasive wear caused by fi ber reinforced and engineered resins, along with protecting critical mold surfaces from handling-related damage. The high density of the coatings protects mold surfaces from corrosive out-gassing of resins thus preventing pitting and improving part quality. The ultimate benefits of Ionbond coatings are improved resin flow, superior release, and improved part surface finish. Advanced high-strength steels Stainless steels Low carbon and HSLA steel Aluminum and copper alloys Titanium and nickel alloys Coated and plated materials Hot Forming Forming applications performed at elevated temperatures are extremely demanding on tool surfaces. Ionbond PVD and Bernex CVD coatings possess superior toughness, reduced friction and resist corrosive attack and erosive and abrasive wear. They make the tool last longer and increase the quality of the work piece. Die casting Hot forging Warm forming Hot extrusion Mold cavities Cores Ejector Pins Sleeves Runner systems Feed screws Sprue bushings and gates Added Capabilities and Services CVD for complex Shapes and Features CVD continues to find applications in the coating of molds, dies and forming tools. The nature of the chemical vapor deposition process makes it possible to coat surfaces that cannot be reached by a PVD process and makes it an ideal solution for tools with open dimensional tolerances, demanding mate rials and complex geometries. The coating materials include titanium-based nitrides and carbides as well as different forms of aluminum oxides and doped elements. Complex geometries Inner contours Demanding materials Service Ionbond’s services don’t stop with the coating. It is committed to providing added services and value including surface preparation to meet the needs of its customers. Pre- and postcoating polishing Quality certifications Failure analysis services T HE SURFAC E ENGINEERS™ Quality Assured Ionbond tool coating centers hold an extensive range of international accreditations, including ISO 9001, ISO 9002, AS 9100, TS 16949, and are approved by numerous OEMs in the tool industry. On top of the quality system Ionbond has a mindset that focuses on the needs of its customers and constantly works on improving products and processes. Reliability and Delivery Fast turnaround times Pick-up and drop-off service You make it first, we make it last Ionbond Molding and Forming Coatings Technology PVD PVD PACVD CVD Coating Ionbond™ 01 Ionbond™ 30 Ionbond™ 43 Bernex™ 02 TiN CrN a-C:H TiC 2 – 4 4 – 6 1 – 3 3 – 8 Deposition temperature 425 °C 150 – 400 °C 160 – 200 °C 1000 °C Service temperature 450 °C 700 °C 300 °C 300 °C Friction vs. steel 0.55 0.55 < 0.1 0.2 Microhardness HV 0.05 2800 2000 – 2600 2000 – 2800 3500 Inner features Limited Limited Limited Yes, incl. hidden details Typical coating thickness (µm) Cross sections Typical applications Blanking Piercing Trimming Cold forging Plastic injection molding Forming Flanging Drawing Cold extrusion Aluminum die casting Plastic injection molding Hot forging For a complete coating listing please see www.ionbond.com Non-ferrous forming Disc media molding Other select plastic injection molding applications Open tool dimensional Tolerance forming Flanging Drawing Extrusion of steel, stainless steel, HSLA steel, AHSS steel alloys Competence and Innovation – Worldwide Ionbond is a global leader in surface enhancement technology and has been dedicated to serving high demanding industries such as tool making, automotive, industrial, aerospace, racing, medical and many others. Ionbond has a global presence with 40 coating centers in strategic locations ready to work in partnership with manufacturers and their suppliers to provide cost-effective solutions to the most pressing needs facing the industry. 40 years of presence has enabled a deep understanding of the material requirements and future trends facing the industries. With ISO 9001 and specific certifications for individual industries and numerous manufacturer approvals Ionbond is the partner for coating services. Europe Key Locations for Tool Coatings IHI Ionbond AG Industriestrasse 211 CH-4600 Olten Phone: +41 62 287 86 86 Fax: +41 62 287 85 93 eMail: [email protected] Ionbond France – Lyon 25, rue des Frères-Lumière BP 143 FR-69680 Chassieu Phone: +33 4 72 79 46 60 Fax: +33 4 72 79 46 61 eMail: [email protected] Ionbond France – Beauvais 272 Route de Beauvais FR-60370 Berthecourt Phone: +33 3 44 22 55 90 Fax: +33 3 44 22 60 04 eMail: [email protected] Ionbond Czechia – Ostrava CzechCoating s.r.o. Dolni Becva 20 CZ-75655 Dolni Becva Phone: +42 571 647 360 Fax: +42 571 647 345 eMail: [email protected] Ionbond UK – Mansfield Unit 4, Windsor Court Fletchers Way Crown Farm Industrial Park GB-Mansfield, Nottinghamshire NG19 OFN Phone: +44 1623 683 210 Fax: +44 1623 625 591 eMail: [email protected] Ionbond Germany – Sachsen Gewerbering 10 DE-09337 HohensteinErnstthal Phone: +49 372 349 88 88 Fax +49 372 349 88 99 eMail: [email protected] Ionbond Italia – Milano via del lavoro 74 IT-20040 Busnago (Milano) Phone: +39 039 608 20 93 Fax: +39 039 608 24 22 eMail: [email protected] Ionbond Netherlands – Venlo Groethofstraat 22b NL-5916 PB Venlo Phone: +31 77 465 65 65 Fax: +31 77 351 34 99 eMail: [email protected] Ionbond Sweden – Linköping Svedengatan 2F SE-58273 Linköping Phone: +46 13 25 33 03 Fax: +46 13 25 33 23 eMail: [email protected] See our website for a full list of all coating centers including Asia and North America. www.ionbond.com T HE SURFAC E ENGINEERS™ 05.2013 Ionbond Tinkap Turkey – Bursa Nosab Minareci Çavus Mahallesi Dokumacilar Sitesi 105 sokak 5, blok No. 17 TR-16140 Nilüfer Bursa Phone: +90 224 411 1057 Fax: +90 224 411 1054 eMail: [email protected]
