From market trends to system solutions · Hauzer upgrade engineers can add new deposition sources...

of 32 /32
FOR YOU From market trends to system solutions HAUZER FOR YOU . NO. 34 . APRIL 2020

Embed Size (px)

Transcript of From market trends to system solutions · Hauzer upgrade engineers can add new deposition sources...

  • 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®

    29Team Spotlight

    32Meet Us

    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



    2 HAUZER FOR YOU . NO. 34

  • 24

    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.






    3 HAUZER FOR YOU . NO. 34

  • 4 HAUZER FOR YOU . NO. 344

  • 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.”



    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.”

    Dave Doerwald


    HAUZER FOR YOU . NO. 345



    FLEXICOAT® 1250


    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.

    6 HAUZER FOR YOU . NO. 34

  • 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

    costs down.

    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.


  • 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

    8 HAUZER FOR YOU . NO. 34

  • Arc

    CARC +

    CARC + Flex






    PACVD by MF pulsed


    Plasma etching

    Focused Ion Rapid Etch

    Plasma cleaning

    Plasma nitriding

    PACVD Microwave

    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

    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

    decorative coatings.


    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.


    9 HAUZER FOR YOU . NO. 34

  • 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

    like Al2O3.


    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.

    Microwave Technology

    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:

    Plasma Etching

    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

    temperature-sensitive products.

    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.

    Plasma Cleaning

    Etching can be combined with plasma cleaning, which

    chemically removes carbon and oxide contamination from

    the surface.

    Plasma Nitriding

    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.

    10 HAUZER FOR YOU . NO. 34

  • 11 HAUZER FOR YOU . NO. 34


    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.



    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.




    12 HAUZER FOR YOU . NO. 3412 HAUZER FOR YOU . NO. 34

  • 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

    industrial impact”.

    Vikram Bedekar

    Materials Specialist

    Timken Technology Center

    HAUZER FOR YOU . NO. 34 13

    NYSE / TKR




    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.

    14 HAUZER FOR YOU . NO. 34


    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

    the substrate.

    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®

    competence center.

    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

    15 HAUZER FOR YOU . NO. 34

  • 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.


    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

    employees recently.

    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.


    16 HAUZER FOR YOU . NO. 34


    For Operators

    Day-to-day maintenance

    Cleaning components

    Product fi xturing

    Start-up processes and machine handling


    Troubleshooting Course

    Basic knowledge of PVD coating

    Finding the root cause of a failure

    Understanding the machine

    Manuals and alarms

    Standard maintenance

    For Process Engineers

    Understanding the PVD coating process and

    turn-key operation

    Writing, importing and exporting recipes

    Analysing trend data and batch reports

    Analysing quality control data

    Standard maintenance

    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

    confi guration

    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).

    17 HAUZER FOR YOU . NO. 3417 HAUZER FOR YOU . NO. 34



    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.

    18 HAUZER FOR YOU . NO. 34

  • 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

    [email protected]

    Contact details for Hauzer

    T +86 21 346 376 11

    F +86 21 346 376 10

    [email protected]


    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

    (Shanghai) Ltd.

    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.




    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


  • 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


    k w




    Time (min)

    Reference coating (RC) RC pre- & post-reatment TC006-V4 + pre- & post-treatment TC006-V4 only post-treatment

    Interrupted cutting of

    tempered steel


    Cutting conditions

    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


    k w




    Time (min)


    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 or +41 79 292 43 89)

    or Philippe Ricklin (Philippe.Ricklin or +41 79 330 29 59)

    for more information.

    Cutting conditions


    Vc = 220 m/min

    Ap = 2 mm

    Fn = 0.2 mm

    23 HAUZER FOR YOU . NO. 34




    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

    aerospace strategies.

    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.


    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

    Component Shapes

    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


    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.


    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

    coating performance.


    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

    and uniformity.

    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] or +31 77 355 97

    80) to discuss how to boost

    your business with HiPIMS.


    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.



    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



    30 HAUZER FOR YOU . NO. 34


  • 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

    PVD technology.


    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.




    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!