From market trends to system solutions · Hauzer upgrade engineers can add new deposition sources...
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F O R Y O U
From market trendsto system solutions
HAUZER FOR YOU . NO. 34 . APRIL 2020
4Introduction Dave Doerwald
6Launching the Flexicoat® 1250
11New Hard Black Decorative Coating
12Performance Beyond the Customer’s Expectations
14Applications Where HiPIMS Really Shines
16Training for YOU
18Integrated Service Location in Asia
20New Al2O3 Coating from Bernex
24Coating Developments in the Aerospace Market
27New Design Applications for Cromatipic®
Publisher IHI Hauzer Techno Coating B.V. PO Box 3057 . 5902 RB Venlo . The Netherlands T +31 77 355 97 77 . [email protected]
Editor Martine van de MortelWriter Maartje Gorte
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No responsibility can be accepted for the correctness or completeness of the statements made, especially in the case of external contributions. The opinions expressed in this magazine do not necessarily refl ect those of IHI Hauzer Techno Coating B.V. We reserve the right to make technical changes. Reprinting or
reproduction of any kind is prohibited. Exceptions to this rule are possible only with the prior written permission of the publisher.
© IHI Hauzer Techno Coating B.V., all rights reserved.
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Sharing the Spotlight with Bernex
“Since the integration of IHI Bernex with Hauzer last year, there
has been a steady supply of Bernex news. In this magazine, we
share their breakthrough in their Al2O3 CVD coating, with a 300%
improvement in tool lifetime compared to the reference. We also
give their team some time in the spotlight. And we give you the
details of the successful integration of the Hauzer and Bernex
service sites in China. Both companies already had a strong
presence in Asia, and this integration allows us to coordinate our
customer service and spare parts sales even better.”
New Black Coating for Deco
“We also have a Hauzer breakthrough to share. We have
improved our black coating by making it harder and more wear-
resistant. The demand for black coatings continues to be high,
thanks to the continued boom of the construction market and
the trend for new colours such as black and rose gold in addition
to the standard chrome. Expanding this product portfolio is
an ongoing investment at Hauzer.”
“In this Hauzer For You, we are proud to announce our latest in the Hauzer Flexicoat® platform: the
Flexicoat® 1250, the modernised big brother of our well-known Flexicoat® 1200. With a 33% increase in
capacity, this machine is designed for customers in tribo, deco and tool looking for a competitive cost
of ownership and the ability to choose an even more tailored confi guration of technologies.”
STRONG TECHNOLOGY DEVELOPMENTS
New Applications for Key Technologies
“The HiPIMS technology has reached a high maturity level
for many diff erent applications. To inspire customers in the
tool and tribo sectors, we devote an article to several of
them. Cromatipic® is known as the environmentally friendly
replacement technology of the traditional electroplating
process, but we also see great potential in other applications
such as lasered and translucent components. These novel
decorative design techniques are going to change the market,
and we are keen to follow.”
Goodbye to Roel Tietema
“After 34 years at Hauzer, our Manager New Technologies, Roel
Tietema, is retiring. We wish him the best of luck. And it’s not
farewell forever – Roel will still be advising on Hauzer projects.”
HAUZER FOR YOU . NO. 345
LAUNCHING THE HAUZER
LEADING EDGE TECHNOLOGY
Hauzer is proud to announce the launch of the latest batch-coating machine in our well-known
Hauzer Flexicoat® platform. As with the other machines in the family, the Flexicoat® 1250 is
characterised by maximum fl exibility in cathode sources. Unique about this machine is that it
was designed specifi cally to off er the best cost of ownership, especially for hydrogen-free carbon
coatings and for coating larger products.
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33% loading increase compared to the Flexicoat® 1200; fully
compatible with existing Flexicoat® 1200 fi xturing.
Optimum chamber size: spacious enough to accommodate
bigger volumes and bring down coating costs, small enough
that most customers can use it at capacity.
7 positions for deposition sources that can be individually
confi gured for the coating capacity you need.
Tribo Market Developments
Due to the drive towards increased fuel effi ciency and
power density in automotive design, many automotive
components are now subjected to temperatures above
300 °C. These temperatures are too high for the diamond-like
carbon (DLC) coatings traditionally used in the automotive
sector. A tetrahedral amorphous carbon (ta-C) DLC coating,
however, can withstand temperatures of up to around
500 °C. An added benefi t of the ta-C coating is that it can be
used with a wider range of lubricants. Together, this means
that while regular DLC coating is still a massive market in
automotive, the demand for ta-C coatings is growing much
faster. In other sectors, too, ta-C is growing in importance.
With the Flexicoat® 1250, you are ready for the future, as it
can easily be confi gured for both traditional DLC and for ta-C
coatings. The larger size of the vacuum chamber allows you to
coat larger products. It also allows you to achieve a lower cost
per coating compared to the Hauzer Flexicoat® 1200, by coating
more products in a single batch. And the increased cooling
capacity keeps process times short, even at increased power.
Deco Market Developments
Within the decorative sector, there is a limit to the feasible size
of coating machines. Too big, and small products will never fi ll
it up to full effi ciency. A larger chamber does, however, make it
possible to easily coat larger objects as well. The Flexicoat® 1250
is designed to sit in this sweet spot. It is designed to provide an
economical cost per coating for small objects such as spectacle
frames, while still being spacious enough to effi ciently coat
trendy larger bathroom fi xtures such as rain showers.
Increased cathode power to reduce cycle time and keep
Optimum cooling performance (up to 8 positions for cooling
plates) for low-temperature hydrogen-free carbon coatings.
Optional retractable central cooling and heating feature.
Increased accessibility for ease of use.
Flexible setup to fi t more existing building layouts.
HAUZER FOR YOU . NO. 347 HAUZER FOR YOU . NO. 34
The Flexicoat® 1250 is also the most fl exible system in the
Hauzer platform, allowing you to confi gure it for the entire
range of decorative coatings that you use as manufacturer or
coating provider in the decorative sector.
Tool Market Developments
An important development in the forming tool sector is the
increasing size of the tools to be coated, thanks to modern
production methods. Another ongoing trend is the investment
in weight reduction in industries such as automotive and
aerospace. With the increasing importance of light-weight
aluminium and other non-ferrous metals, the need for DLC and
ta-C coatings on forming tools is growing.
The Flexicoat® 1250 is also an ideal investment for tool
manufacturers looking to expand capacity. The larger chamber
size keeps the cost per coating down and allows for easier
and more effi cient fi xturing of larger objects such as forming
tools, moulds, dies and saw blades. The fl exible confi guration
also means that a single machine can be used for both
coating and nitriding.
Confi gured to Meet Your Needs, Today and in the Future
The Hauzer Flexicoat® platform was designed with maximum
fl exibility in mind. The Flexicoat® 1250, with its 7 deposition
source positions and 8 cooling panel positions, is the most
fl exible member of the Flexicoat® family yet.
This fl exibility is not only a hallmark of our machines, it is a
hallmark of Hauzer as a company. With every machine project,
we collaboratively discuss which coating needs the customer
has. The result: a confi guration that is just right for your
needs, whether you specialise in a single coating, regularly
switch between a few coatings or even want a machine that
can handle any R&D requirements you may have.
Investing in a Hauzer Flexicoat® is also a great way to ensure
that your company is ready to handle future market
developments. The platform’s fl exible design makes it easy
to modify your Hauzer machine, even years in the future.
Hauzer upgrade engineers can add new deposition sources
to positions previously left empty or replace old cathodes
that were installed for a coating that you no longer provide.
That way, you can breathe new life into your existing
If you are interested in
adding a Hauzer Flexicoat®
1250 system to your coating
equipment, please contact
Michiel Eerden, Director of
Sales ([email protected] or
+31 77 355 97 04).7
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CARC + Flex
PACVD by MF pulsed
Focused Ion Rapid Etch
On the cathode positions: Other plasma technologies:
CARC+ stands for circular arc evaporation. It produces very
smooth coatings, including TiAlN, AlCrN, Si-containing nano-
composite coatings and state-of-the-art hydrogen-free carbon
coatings at very high deposition speeds and low cost of
CARC+ Flex gives increased flexibility in magnetic field design.
That results in more control over ionisation and coating
properties. It also offers uniform target erosion, thicker coatings
for special applications and the possibility to program para-
meters during the coating process, so you can use different
parameters during different steps of the coating process.
Advanced Controlled Arc
Advanced controlled arc evaporation technology uses
rectangular arc cathodes to produce metal nitride, carbonitride
and oxide coatings. It is used for coating temperature-sensitive
products and achieving optimum colour uniformity for
Magnetron Sputtering (UBM)
Magnetron sputtering technology is used to produce smooth
and well-adhering coatings. It can also be used for materials with
poor electrical conductivity of for special colour requirements.
It is often used in combination with PACVD technology for
diamond-like carbon (DLC) coatings.
TECHNOLOGIES AVAILABLE ON THE FLEXICOAT® 1250
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High Power Impulse Magnetron Sputtering (HiPIMS)
HiPIMS is a specifi c kind of sputtering that combines the
advantages of high ionisation like arc evaporation with
the smoothness of magnetron sputtering. This technology
opens up extra possibilities to fi ne-tune the coating
properties, such as internal stress and coating structure,
of layers that cannot be produced with other existing
Dual Magnetron Sputtering (DMS) and T-mode
DMS technology is used for the deposition of materials
that show very low electrical conductivity. Together with
Hauzer’s T-mode technology for fast control of reactive gas
fl ow, this enables the deposition of metal oxide coatings
Diff erent from PVD, plasma-assisted chemical vapour
deposition (PACVD) does not use targets. With PACVD,
a plasma is used to crack precursor gases at relatively
low temperatures. The technology is mainly used in
combination with hydrocarbon gases to produce highly
wear-resistant carbon coatings. DLC coatings can be doped
with Si or other elements to tune the coating properties.
PACVD can be further enhanced by using a microwave
plasma source for more tuneable properties, higher
deposition rates and lower coating costs.
All Hauzer systems can be equipped with a plasma source.
This enables a range of process steps, such as:
It is crucial that components are cleaned well prior to
deposition to reach perfect adhesion. The plasma source
enables etching with Ar ions, resulting in a clean, smooth
surface. The etching temperature can be controlled for
Focused Ion Rapid Etch
FIR Etch is based on Hauzer’s plasma source etching
technology. The ion beam is enhanced and steered in the
chamber, resulting in higher etch rates, perfect adhesion
and an increased productivity.
Etching can be combined with plasma cleaning, which
chemically removes carbon and oxide contamination from
With a plasma source, it is possible to do plasma nitriding
(with typical case depth of 50 µm) in the same cycle as
applying a PVD coating. This has large benefi ts, improving
the load-bearing capacity of forming tool applications.
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LEADING EDGE TECHNOLOGY
Black continues to be a highly popular coating for decorative purposes, especially for bathroom
fi xtures, jewellery and watches. Hauzer already off ered a deep black coating, with an L value of 35
and a/b values of 0. Now, we developed a matching coating to expand the application range:
the same L*a*b* values but signifi cantly harder, scoring 1800 on the Vickers hardness scale.
NEW DECORATIVE COATING: SAME BLACK,
In Search of a Coating That Stands up to Wear
Since the demand for black coatings will remain high for the
foreseeable future, Hauzer invested in a solution for those
applications that need harder, more scratch-resistant coatings.
The seed of this hard black coating came from our tribology
expertise. Originally developed for smoothness and hardness,
one of our tribology coatings was a promising base to develop
into a black coating for decorative purposes.
The benefi t of this coating being derived from a tribology coating
is that it has excellent hard-wearing properties. Ideal for objects
that get a lot of wear, such as door handles, watch cases, and
items that people carry in their pockets or in their bags.
Smooth, Glossy, Premium Feel
The fi rst customers have already taken receipt of samples,
and have been very positive in their feedback on appearance
and scratch resistance. The new coating is mirror-smooth,
producing a deep black with bright highlights that gives a
luxurious feeling. Because of the high gloss, fi ngerprints can
easily be wiped off with a dry cloth. The coating also has great
uniformity on rounded objects or complex 3D shapes. Satin or
brushed fi nishes are also possible on textured substrate.
Want to Off er This New Black Coating to Customers?
At Hauzer, we are now working on upscaling this coating and
getting it ready to work with an even wider variety of shapes.
The hard black coating can be implemented on existing
equipment. Are you interested in adding a hard, scratch-
resistant black coating to your portfolio? Or is it the smooth-
ness that makes this coating ideal for your applications?
Get in touch with Huub Vercoulen
([email protected] or +31 6 462
01 462) to discuss a solution for your
specifi c application.
The Timken Company designs a growing portfolio of engineered bearings and power transmission products.
With more than a century of knowledge and innovation, they are continuously improving the reliability and
effi ciency of global machinery and equipment to move the world forward. Timken posted $3.8 billion in sales in
2019 and employs more than 18,000 people globally, operating from 42 countries.
PERFORMANCE BEYOND THE CUSTOMER’S
LEADING EDGE TECHNOLOGYCUSTOMER SUPPORT
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On the Cutting Edge of Bearing Engineering
Bearing production has changed a great deal in the last 30
years, with the damage mechanism for bearings moving from
subsurface issues to surface issues. “Before the 1990s, cracks
would initiate around inclusions or impurities in the steel.
Since then, the industry’s ability to make cleaner steel and to
maintain tighter geometric tolerances has greatly improved.
This has resulted in a signifi cant increase in bearing
performance,” says Vikram. “Of course, every breakthrough
leads to a new challenges – industries are now moving toward
fuel effi ciency and weight reduction eff orts.”
For example, in early wind turbine designs, main shaft bearings
were required to support loads in radial direction and wind
thrust loading only on the downwind row of rollers. This uneven
loading environment gave rise to unusual wear. Furthermore,
wind energy manufacturers found it diffi cult to keep the
bearing well-lubricated under complex loading conditions,
which resulted in premature bearing damage. Putting a DLC
coating between steel surfaces dramatically reduces steel-on-
steel contact and combats adhesive wear issues. The Timken
Company expects that continuing progress in coating and
lubrication can further extend the lifetime of bearings.
Ready for the Future with Hauzer
In general, Vikram has been very happy with The Timken Company’s
collaboration with Hauzer. “Application support, technical support
and the on-time delivery, it’s all exceptional,” says Vikram.
Protecting the Customer’s Business
One of the extraordinary things about The Timken Company
is that it started producing bearings 120 years ago and is still
doing so today. “We started as a North-American company
serving predominantly automotive suppliers,” says Vikram
Bedekar, Materials Specialist in the Timken Technology Center.
“Today, we serve diversifi ed markets worldwide, including
emerging markets like wind energy and robotics. And, in
addition to engineered bearings, we have grown our portfolio
of product brands to include adjacent power transmission
products to increase our ability to serve the needs of global
industries more fully.”
Knowledge has always been the secret to The Timken
Company’s success. Roller bearings used in applications such
as turbine main shafts and gear boxes are highly engineered
to perform in extremely challenging environments. In the case
of turbine bearings, the replacement or rebuild cost could be as
high as $100,000 or more if the bearing fails prematurely.
Coated Bearings – from Almost Unknown to a Requirement
Timken started investigating the application of PVD coatings
in the early 1990s. At that time, PVD technology was unknown
to most of the industry. Around 2009-2010, Timken pioneered
the application of diamond-like carbon (DLC) coatings on roller
bearings. “Since then, our coatings have shown a great deal of
promise in paper mills, cement plants, agriculture equipment
such as large tractors and combines, as well as automotive
applications,” says Vikram.
The transition to coated bearings has been very successful.
“Once we apply wear-resistant coating on our products, we
rarely hear any complaints from our customers. Our DLC
coatings are now widely accepted as the solution to many
challenging applications that were diffi cult to meet before,”
says Vikram. “Since commercialising our proprietary
DLC coatings, we have received widespread industry acclaim,
including a prestigious Engineering Materials Achievement
award from ASM International in 2017.” This award recognised
The Timken Company’s engineering coatings for “signifi cant
contributions to the fi eld of material science and evidence of
Timken Technology Center
HAUZER FOR YOU . NO. 34 13
NYSE / TKR www.timken.com
NEW DESIGN APPLICATIONS FOR
MARKET DEVELOPMENT LEADING EDGE TECHNOLOGY
Cromatipic® is known in the automotive industry as Hauzer’s clean and environmentally friendly
alternative to chrome electroplating. However, design trends are changing, both in automotive and
beyond. Designers now want to incorporate backlighting in metal-look design elements.
Cromatipic® holds great promise for those applications.
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DESIGN DRIVES TECHNOLOGYNEW STYLING OPPORTUNITIES
The two main techniques for incorporating backlights
are lasering and translucent application. Translucent
elements look like solid metal when unlit, but allow
backlighting to shine through. With lasering, the
metal-look coating is ablated in certain areas by laser.
The coated parts block out the backlight, while the parts
where the coating has been removed are as transparent as
Both translucency and lasering set new requirements for the
coating properties. A translucent coating needs to be as thin
as possible. A lasered coating has to be able to deal with the
edges that occur by lasering. All of this is in addition to the
normal coating properties customers expect.
Hauzer results show that Cromatipic® can achieve
translucency. Laser ablation tests on Cromatipic®
coatings, done with our partners who can match the
laser’s frequency to the specific Hauzer coating, have
also led to positive internal results with successful
evaluation. Right now, Hauzer is working with
customers looking to apply backlighting to determine
their requirements and incorporate new test
standards in the Hauzer Iberica Cromatipic®
Are you looking to offer an extra wow factor to
your potential customers with
Cromatipic®? Please get in touch
with Emilio Rodriguez Cabeo, +31 63
039 52 48 or [email protected]
Cromatipic lasered plaques
with backlighting off
Cromatipic lasered plaques
with backlighting on
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The Benefi ts of Training
Operators, process engineers and service technicians who have
done a training course with Hauzer can benefi t your business in
many ways that translate directly into productivity gains:
They intimately know the coatings and relevant process
parameters, so they know how to get the most effi cient yield
and improved utilisation – for instance, through shorter cycle
They can do the most essential maintenance and repairs
themselves, resulting in higher production quality: yield,
uptime and reproducibility.
They can involve technicians with the right information for
more effi cient repairs and service.
Our training can cover the full production cycle, including
cleaning, pre-treatments and post-treatments. Hauzer trainers
are also happy to discuss market requirements and changes
during the training. We aim to help our customers improve the
utilisation of their equipment through new possibilities, both
An investment in a Hauzer machine is an investment in the future. You can expect your Hauzer
machine to operate at full capacity for two decades or more. And with the occasional upgrade,
it will even keep up with new machines in terms of fl exibility and results. In this Hauzer for You,
you can read all about the benefi ts of training for YOU – to improve the Yield,
Output and Utilisation of your Hauzer machine.
TRAINING FOR YOU
with the existing confi guration of the machine and through
potential modifi cations.
Who Should Take the Course?
We advise you to always have at least one operator, process
engineer and maintenance technician available who has
been trained at Hauzer. This ensures broad know-how in the
organisation, which is crucial to maximise yield, output and
utilisation of your equipment.
When to Go for Training and Where?
If you already own a Hauzer machine, any time is a good time
for a refresher course; especially if you have brought in new
Hauzer trainers are happy to welcome you in Venlo, where
our experts are at hand to answer any question. We also off er
training on site, on your own system, if your production schedule
allows for the necessary downtime.
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TRAINING COURSE TOPICS
Product fi xturing
Start-up processes and machine handling
Basic knowledge of PVD coating
Finding the root cause of a failure
Understanding the machine
Manuals and alarms
For Process Engineers
Understanding the PVD coating process and
Writing, importing and exporting recipes
Analysing trend data and batch reports
Analysing quality control data
For Plant Managers and Sales Managers
Market changes and market requirements
New possibilities for full machine utilisation
Getting the most out of your machine confi guration
Available modifi cations and their eff ects on
To book a training course or discuss a custom
training programme or service contract, please
contact your account manager or call Hauzer
headquarters (+31 77 355 9777).
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HAUZER AND BERNEX INTEGRATE SERVICE LOCATIONS IN ASIA
IHI Hauzer Techno Coating and IHI Bernex, the two Hauzer Group companies within the IHI Group,
both have a strong presence in the Asia market. As of 2020, this presence has become even stronger with
the integration of the Bernex and Hauzer customer service teams in a single location in Shanghai, China.
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IHI Hauzer Techno Coating (Shanghai) Co., Ltd.
Room 101, 6# No. 188 Xinjun Ring Road,
Shanghai Caohejing Pujiang Hi-Tech Park,
Minhang District, Shanghai, 201114, P.R. China
Contact details for Bernex
T +86 21 346 371 65
Contact details for Hauzer
T +86 21 346 376 11
F +86 21 346 376 10
TWO STRONG TEAMS COMBINED
The Bernex Customer Service Asia team, originally based in
Kunshan, China, relocated to the Hauzer location in nearby
Shanghai. The joint teams, retaining the same people, will be
operating under the legal entity of IHI Hauzer Techno Coating
Joining forces is in line with the aim of the IHI Group to
maximise synergies in manufacturing, expertise and service.
From a single customer service location, the Hauzer and
Bernex teams will be able to align on service, spare parts and
administration. This will the allow the two companies to better
understand each other’s technology and coordinate spare
parts delivery, to reinforce our presence in Asia and, most
importantly, to serve our customers better.
Some impressions of the new service location. From top to bottom:
the workshop, office and lobby. Previous page: the laboratory
19 HAUZER FOR YOU . NO. 34
IHI Bernex is pleased to announce the next generation of chemical vapour deposition (CVD) coatings
for carbide-based cutting tool applications. This coating family is based on a proven multi-layer structure:
a layer of highly structured α-aluminium oxide (α Al2O3) on top of a layer of titanium carbo-nitride deposited
at medium temperature (MT-TiCN), combined with specifi c pre- and post-treatments of the cutting tool.
In this article, we will show that this new generation of coatings can make tools for cutting operations
last much longer than the reference coatings.
AL2O3 CVD COATING THAT TRIPLES
THE LIFETIME OF CUTTING TOOLS
MARKET DEVELOPMENT LEADING EDGE TECHNOLOGY
20 HAUZER FOR YOU . NO. 34
Textured Multilayer Coating Architecture
Michael Auger, CEO of IHI Bernex, says: “We began with the
desire to be able to tailor the multi-layered coating structure
to the specifi c demands of the cutting application, either
continuous turning or interrupted cutting. With this idea, we
have developed several diff erent variations of the coating.” A
typical cutting application requires a thick layer of the columnar
MT-TiCN, to provide the necessary level of wear resistance. The
IHI Bernex process engineers were able to then apply a highly
textured α Al2O3 layer on top of the MT-TiCN layer, to maximise
the tool’s performance for continuous turning or interrupted
By including the correct interlayers between the MT-TiCN
and the Al2O3, IHI Bernex coating engineers created new
transition layers and the ability to texture the crystallographic
orientation of the Al2O3 coating. This allows them to tailor
the crystallographic benefi ts of the CVD coating to the fi nal
application. In many cases, this crystallographic texturing
coeffi cient as measured by X-ray diff raction is greater than 8.
The fi gure below shows an example of an α Al2O3/MT-TiCN
Image of α Al2O3/MT-TiCN coating on a carbide-based cutting tool
21 HAUZER FOR YOU . NO. 34HAUZER FOR YOU . NO. 3421
Pre- and Post-treatments that
Elevate Coating Performance
A great coating alone is not enough. It
needs to be paired with the right cutting
tool design, the correct carbide powder
grade, and the tool preparation (pre-
treatment) and after-coating process
(post-treatment) steps to further
improve the coating performance. The
development of this coating, therefore,
also included developing the specifi c
pre- and post-treatment.
This fi ts the way IHI Bernex provides
solutions. Michael: “We have the know-
ledge and tools in Olten, Switzerland,
to off er our customers the complete
package, so we did. Through diligent
tuning of the coating and treatment
factors, we were able to achieve superior
performance compared to the reference
Interrupted Cutting Test Results
To test the eff ect of the new coating,
IHI Bernex compared inserts coated
with the CVD reference coating, the
reference coating with pre- and post-
treatment, the new generation of
coatings with only the post-treatment
and the new coating with both the pre-
and post-treatment. For interrupted
cutting of CK45 tempered steel, the
new generation of coatings with the
proper pre- and post-treatments led
to a dramatic increase in tool life (see
below). Whereas the comparable
reference coating failed after 15
minutes, the new generation of coating
surpassed 45 minutes of tool life.
Continuous Turning Test Results
For continuous turning of alloyed
steel, IHI Bernex compared a diff erent
variation of this next-generation
coating with the reference coating.
On the next page, you can see, as
measured by fl ank wear, the tool life
is again greatly improved. After 8
minutes of continuous turning, the
reference tool is already exhausted,
0 5 10 15 20 25 30 35 40 45 50
Reference coating (RC) RC pre- & post-reatment TC006-V4 + pre- & post-treatment TC006-V4 only post-treatment
Interrupted cutting of
INTERRUPTED CUTTING TEST
Vc = 80 m/min
Ap = 1 mm
Fn = 0.1 mm
22 HAUZER FOR YOU . NO. 34
Turning of tempered steel
with CVD-coated inserts
0 5 10 15 20 25
Reference coating TC006-V1
CONTINUOUS TURNING TEST
which is defi ned at 0.2 mm of wear.
The tool with the IHI Bernex next-
generation CVD coating tool only
reached the exhaustion point after 25
Looking Ahead to the Next Great
Hristo Strakov, IHI Bernex Head of
Technology, places the new coating in
context of the IHI Bernex approach:
“We are continuously improving our
CVD coatings, often guided by customer
and market requirements. The recent
innovations in our coating equipment
have allowed us to achieve these
phenomenal results. But I don’t think we
will ever be fi nished. We continue to be
approached for applications with even
higher demands and requirements, and
we aim to answer that challenge.”
Are you interested in including these
superior CVD coatings in your product
off ering and helping your customers
extend the lifetime of their tools?
The Bernex sales team is ready to answer
your questions and to work together
to come to the right solution for your
Contact Daniel Schranz (Daniel.Schranz
@ihi-bernex.com or +41 79 292 43 89)
or Philippe Ricklin (Philippe.Ricklin
@ihi-bernex.com or +41 79 330 29 59)
for more information.
Vc = 220 m/min
Ap = 2 mm
Fn = 0.2 mm
23 HAUZER FOR YOU . NO. 34
COATING DEVELOPMENTS IN
THE AEROSPACE MARKET
MARKET DEVELOPMENT LEADING EDGE TECHNOLOGY
24 HAUZER FOR YOU . NO. 34
Aerospace is a challenging sector for coatings. Components in the hot section of turbines
are routinely exposed to temperatures above 1000 °C, under conditions that strongly
promote oxidation and corrosion. And with new engine models, the temperatures
in engines are going up even further. IHI Bernex is becoming a very strong player in
aerospace with their chemical vapour deposition (CVD) coatings.
25 HAUZER FOR YOU . NO. 34
Physical vapour deposition (PVD) coatings also
play a role in aerospace. While CVD is an excellent
coating type for the hot section of engines,
protective PVD coatings are applied for sand,
ash and water erosion protection on jet engine
components in the cold section. Tribological PVD
coatings are used to reduce the wear and increase
the maintenance intervals on fl ight control
actuators and other parts of the hydraulic system,
as well as on guide pins used during construction
of the jet engine and wings.
If you are interested in using
PVD for these aerospace
applications, please contact
Geert-Jan Fransen (+31 77 355
97 14 or [email protected])
technologies that use powder-based additives.” The additives
make the complex coating structure of the Bernex advanced
aerospace coating possible.
Join the Future of Aerospace Coatings
For Bernex, the knowledge built over the past 15 years is really
starting to pay off , with an increasing client roster in aerospace.
Coating of aerospace components is initially done by the
companies that build aeroplane engines, and then usually
repeated many times by the airlines themselves, during repairs
and overhauls of engines. Bernex is also still investing in their
strategy of having the right product at the right time. Currently,
Bernex is running three development projects for long-term
Are you interested in expanding your
business with the Bernex aerospace CVD
coatings? Contact Daniel Schranz (+41 79
292 43 89 or [email protected]
com) or Philippe Ricklin (+41 79 330 29 59
or [email protected]) for more information.
THE ROLE OF PVD IN AEROSPACE
An Industry of Long-term Investments
Bernex started developing equipment and coating
architectures for the aerospace market 15 years ago. Hristo
Strakov, Bernex Head of Technology, says: “Aerospace is a
very conservative market with a long approval and validation
cycle. That is why the Bernex strategy has always been to focus
on the next generations of coatings, not on what is required
today. Coatings take time to develop. When the market starts
demanding certain properties, our advanced future coating
will be ready.”
This strategy requires a lot of insight in where the market will
go and what properties are expected to become important.
The result has worked very well. Aerospace accounts for over
30% of the Bernex turnover, and this is still growing.
Complex Coating Architecture + Complex
Bernex specialises in the CVD coatings that are often applied
to components in the hot section, mainly aluminium-based
diff usion coatings with complex architectures. Hristo: “To
withstand the conditions in newer models of aeroplanes, low
percentages of additives can be used to increase the corrosion
protection, such as silicon, hafnium, chromium and cobalt.
Another important characteristic of turbine components is
their complex geometries. Turbine blades, for instance, have
long internal cooling channels that also need coating. CVD is a
highly successful technology for depositing complex coatings
on complex shapes, and often meets very tight homogeneity
Highly Specialised Control Equipment
Much of the Bernex investment in aerospace coatings has
gone into developing the equipment to control the additives.
Hristo: “Bernex equipment is designed to very precisely control
the percentage of dopant added to the coatings and even
vary it during the coating process. This is not possible with
26 HAUZER FOR YOU . NO. 34
LEADING EDGE TECHNOLOGYLEADING EDGE TECHNOLOGY
HiPIMS, the High-Power Impulse Magnetron Sputtering technology, is now 20 years
old. Hauzer has been involved in developing this technology from the beginning,
because we saw great potential. Today, the technology has reached industrial
scale, with a reliable, stable process, so it can add value in many diff erent types of
applications in the tribo, tool and deco sectors.
APPLICATIONS WHERE HIPIMS REALLY SHINES
Valuable Properties of HiPIMS Coatings
One of the main benefi ts of HiPIMS technology is the coating
smoothness and uniformity, even on complex shapes.
Compared to conventional physical vapour deposition (PVD)
processes, the unique feature of HiPIMS is its high ionisation,
which allows users to control coating density and the coating
distribution on sharp edges. This opens up new horizons in
LEADING EDGE TECHNOLOGY RELIABILITY & QUALITY
27 HAUZER FOR YOU . NO. 34
with modulation (PWM) mode, a feature unique to Hauzer.
By changing pulse parameters and pulse sequences, Hauzer
HiPIMS users can influence and tailor the coating’s properties
for specific applications in terms of hardness, Young’s modulus
Tool Application: Micro Tools
Cutting tools that are smaller than 3 mm in cutting diameter are
often called micro tools. These kinds of tools are used in, for instance,
manufacturing watches and mobile phone components. One way
to enhance the performance of micro tools is by changing the
HiPIMS deposition parameters to influence the coating’s growth
conditions and modulate its mechanical properties. The ratio
between hardness and Young’s modulus (the H/E ratio) is often used
to describe the ductility or brittleness of thin films. With Hauzer
HiPIMS, compared to conventional sputtering technology, this ratio
can be increased to reduce the brittleness while retaining the wear
For complex shapes, the H/E ratio is important to stabilise
and reduce vibrations during the cutting process. This helps
to protect the micro tool’s cutting edge. HiPIMS technology offers the
possibility to grow a TiSiN film with a dense nanostructure, very good
adhesion and an H/E ratio of 10.5, ideal for tools for materials that are
difficult to machine. In the picture, the micro tool coated with HiPIMS
TiSiN shows no delamination on the sharp cutting edges.
The Hauzer HiPIMS approach enables users to really tune the
plasma process, by selecting and modifying a wide range of
parameters in the recipe. In addition to changing parameters
such as power, current, voltage, duty cycle, pulse on or pulse off
time, users can reprogram the pulse sequence with the pulse
Micro tool coated with HiPIMS TiSiN
TiSiN with hardness 3730±90 HV0.05 and a
Young’s modulus of 354±10.5 GPa
28 HAUZER FOR YOU . NO. 34
No Post-treatment Needed
The right coating can extend the life of high-precision micro
tools, but the coating process itself is not without risk.
Usage of conventional arc coatings, very common in the tool
industry, can damage the fi ligree cutting edges and result in a
rough surface. A post-treatment is mandatory for this kind of
PVD deposition technology to smoothen the surface, but this
can cause a fair amount of breakage.
HiPIMS coatings, in contrast, are smooth, nearly defect-free
and uniform, with a reduced “antenna” eff ect on the cutting
edge. The coating is consistently of good quality and requires
no post-treatment for these kinds of tools. That means more
tools will pass quality control.
Tool Application: New and Old Manufacturing Methods
HiPIMS also adds value to old manufacturing methods.
The process of skiving to cut internal and external gears is
experiencing a renaissance. The fi rst patent on skiving was
granted in 1910, and today’s production equipment can
provide the high-precision synchronisation that is necessary
for the skiving process. One disadvantage of skiving is
insuffi cient tool lifetime – and here, HiPIMS technology can
help. It can deposit a wear-resistant coating with very uniform
distribution around the cutting edges, to signifi cantly enhance
the tool life and help establish skiving as a high-productivity
Tribo Application: Smoother Surface for Tapping and
For tribological applications where high hardness and a low
friction coeffi cient are needed, a tetrahedral amorphous
carbon (ta-C) diamond-like carbon (DLC) coating is a good
candidate. Today, ta-C coatings made with Hauzer equipment
are mostly deposited by Hauzer CARC+ technology. HiPIMS can
help to achieve a smoother surface, which provides less torque,
less friction and a longer component lifetime. If you routinely
coat small parts that need post-treatment, the smoothness of
HiPIMS will save you even more time and money.
In the tool industry, too, ta-C coatings are becoming very
successful for tapping and forming of nonferrous materials
such as aluminium, especially with a silicon content up 10%.
Any new Hauzer machine can be confi gured
with HiPIMS. And any Hauzer machine already
in the fi eld can be modifi ed to include HiPIMS
technology. The benefi t of Hauzer equipment
for HiPIMS is that we off er diff erent chamber
sizes, which can help keep the cost per part
low by coating more items in a single batch.
Although the running time goes up for larger
systems, increasing the capacity more than
compensates for that.
Hauzer is continually working towards even
better performance of all our coating tech-
nologies, including HiPIMS. Interested to see
what Hauzer can do for you? We always
collaborate with our customers to see where we
can enhance their specifi c coatings. We can also
look into creating entirely new coatings, upgrading
recipes with new additions, and boosting the
performance of your coating architecture with
multilayer or nanolayer structure.
Whether you are in tribo,
deco or tool, contact:
Philipp Immich ([email protected]
hauzer.nl or +31 77 355 97
80) to discuss how to boost
your business with HiPIMS.
HIPIMS EQUIPMENT ON HAUZER MACHINES
29 HAUZER FOR YOU . NO. 34
At Bernex, we grew a lot in recent years, thanks to our focus
on our strategic plan, markets and opportunities. We did
several large investments, completely renovated our factory
floor and switched to a new IT system that matches Hauzer’s.
That almost makes it feel like we’re a start-up, even though
we’re almost 120 years old.
Bernex is a very international environment, and our
employees tend to stay for a long time: proud to be part
of a Swiss manufacturer with a long history. Our people
have to think outside the box, because designing and building
the best equipment requires both creativity and engineering
discipline. It’s important to me that we have a good
atmosphere and that people feel comfortable sharing their
opinions so we can maximise our potential.
In this section, we give our people a chance to introduce themselves. Now Bernex and Hauzer
are integrated, we would like to take the opportunity to introduce some of the Bernex team,
as well as welcoming a new Hauzer colleague and saying goodbye to another.
MICHAEL AUGERBERNEX CEO
I have worked for Bernex a total of 15 years now. It’s a really
interesting time to be a manufacturing company, with major
changes in the automobile and aerospace industry. By
listening to our customers, and our commitment to innovation,
we have been able to overhaul our standard equipment to
create superior coating results. I am looking forward to what
the future will bring.
Some people are so intimately entwined with the history of
a company that it is difficult to consider them going separate
ways. For Hauzer, Roel Tietema is someone like that. After
a 34-year career at Hauzer, Roel reached retirement age
in December 2019 and stepped down as Manager New
STEPPING DOWN: ROEL TIETEMA
30 HAUZER FOR YOU . NO. 34
HIGHLY SKILLED WORKFORCE
I started at Hauzer in September 2019 as sales manager for
the Cromatipic® business unit. Until 2016, I had been working
on a similar type of plastic metallisation technology, so I
bring with me a lot of experience with UV PVD technology,
its applications and the market. I had known Hauzer for
many years as a renowned, leading player in PVD equipment.
Recently, because the EU chemical directive REACH decided
to terminate authorisation for use of Cr-6 by 2024, it was
a good opportunity for me to join Hauzer and contribute
to establishing Cromatipic® as successor technology.
Working at Hauzer allows me to work on challenging, high-
end solutions with customers, with excellent support from
the Hauzer organisation and its people. There are attractive
business opportunities. I am based in Vienna, Austria, and
care for customers in large parts of Europe.
I think everyone at Hauzer is a highly trained or experienced
specialist in his or her field, and I find Hauzer to be a very
desirable place to work. It’s great to work for the leader in
WOLFGANG STRASKYSALES MANAGER CROMATIPIC
When I first started at Bernex, I covered Europe and Asia.
Since my mission was to develop our sales, I used the 15 years
of experience I had China by then to increase our footprint
there as well as in Korea and Japan. Thanks to the support of
our local agents and a good understanding of the customer’s
needs and culture, we made Bernex into the benchmark
CVD cutting tool coating solution. Since then, it has been a
pleasure to work with our customers around the world to
develop their needs.
Bernex needed to find a second pillar to its strategy. Chemical
vapour aluminising (CVA) is going strong as ever. Since 2007,
we are getting great results in the aerospace industry, where
Bernex is now known as a recognised partner.
Technical sales is a great field for me, since I like the people
and the challenge. The culture and approval cycles are very
different in Asia and Europe, for instance, which influences
how I can best help customers in those areas. Challenge
is important to me anyway. The first time I stayed with a
company for 10 years, I said: “Never again!” Now, I’ve already
been at Bernex for 19 years and I never regretted it. Coating
is fascinating, an industry without limits. It’s like coming to a
new job every morning.
PHILIPPE RICKLINBERNEX DIRECTOR SALES
MICHAEL AUGERBERNEX CEO
Roel joined Hauzer in 1986, only three years after it was
established. For 16 years, he was Manager Electrical
Engineering, with responsibility for the electrical engineering
and software for the Hauzer physical vapour deposition
(PVD) machines. In 2002, Roel became Manager Process
Engineering, leading R&D projects for coating processes
and the hardware features required for them. In the last 10
years, Roel held the position of Manager New Technologies,
expanding Hauzer’s business and serving more customers
through his keen eye for new technological possibilities.
Roel’s retirement party was attended by dozens of his Hauzer
contacts from all over the world. Fortunately, we won’t have
to do without Roel entirely yet – he will remain involved with
Hauzer on a part-time advisory basis.
31 HAUZER FOR YOU . NO. 34
Meet us...As always, Hauzer has the intention to be present at many industry events. Due to the
COVID-19 crisis, unfortunately, we can't be sure yet which events will take place this year.
Please visit our website for an up-to-date schedule
We're looking forward to seeing you in person in 2020!