New innovations spark a bright future - Hauzer Techno Coating · The merger will have little eff...

F O R Y O U

New innovations spark a bright future

HAUZER FOR YOU . NO. 32 . MARCH 2019

4Introduction Jeroen Landsbergen

8New Daughter Company Bernex

10The End of Cr(VI)

12Industry 4.0 Interface

14Innovation with Lafer

17Automotive Tribological Coating

21HiPIMS Ta-C

24Modifications & Upgrades

26Fuel Cell Markets

30Colourful Deco Trends

33Sustainable Environment & New Colleagues

36Meet Us

Publisher IHI Hauzer Techno Coating B.V. PO Box 3057 . 5902 RB Venlo . The Netherlands T +31 77 355 97 77 . [email protected]

hauzer.nl

Editor Jacqueline DoldersWriter Maartje Gorte

Design Creation Station, Roermond

CONTENT

2 HAUZER FOR YOU . NO. 32

26

10

14

30

8

23

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.


Joining Forces

“Hauzer is pleased to announce that we have joined forces with

another equipment builder. We have purchased the Ionbond

equipment division, which will become an independent Hauzer

daughter company under the name IHI Bernex. Bernex has a

long and esteemed history in chemical vapour deposition (CVD),

an excellent complement to Hauzer’s own physical vapour

deposition (PVD) expertise.”

Eyes on Trends

“The automotive sector is very much in fl ux – diesel is slowing

down, battery-powered and hybrid cars are a growth market,

and fuel cell technology will soon start growing exponentially.

This issue of Hauzer For You looks at many of the current trends

to see where there are chances for PVD providers.”

“In decorative coating, demand for colour is still growing, which

is a great development for PVD. After regions like the Americas,

Middle East and Asia, colourful sanitary products are also

making inroads in Europe.”

“The start of a new year is an excellent time to look at the changes ahead.

Some good ones are coming up for Hauzer. And the markets, too, off er plenty of

changes and chances for coating providers who know where to look.”

EXCITING CHANGES

INTRODUCTION


“A very diff erent trend is Industry 4.0, the dawn of fully intelligent

production systems. With our new software interface, Hauzer

machines can be controlled by and talk to other devices. We are

looking forward to hearing from our customers what they have

done with these new possibilities.”

The Power of Relationships

“For a company like Hauzer, relationships are very important.

Just look at the long-term collaboration with a customer such

as Lafer, which helps us push boundaries in engineering. Or the

relationships with our customers, who need to be able to trust in

our promise of lifetime support. And of course the relationships

with our own employees, who provide the backbone to deliver

on that promise. They all get their time in the spotlight in this

Hauzer For You.”

Introducing My Successor

“On a personal note, this will be my last introduction for the

Hauzer For You. By the time this edition falls onto the mat, Dave

Doerwald will have taken over from me as Hauzer CEO. You can

read more about the change in this issue. I had a wonderful time

as CEO of Hauzer, and I wish the same for Dave.”

Jeroen Landsbergen

CEO

4

HAUZER FOR YOU . NO. 325

Change in Perspective

Jeroen started at Hauzer in 2004 and became CEO in 2014.

His commercial expertise has been invaluable for Hauzer’s

development and vision. “But the time ahead poses diff erent

challenges,” says Jeroen. “Dave has a long history within Hauzer

and understands our technology through and through. He is the

right person to pass the baton to.”

“I am not the type for elaborate goodbyes,” says Jeroen. “So let

me just say I won’t be going far – Ionbond is a sister company

within the IHI Group and very much part of the coating fi eld. I did

not only have a great time as CEO but also as product manager

and later as Chief Commercial Offi cer (CCO). I would like to thank

all our customers, employees, agents and other stakeholders for

As of 1 April 2019, Dave Doerwald will be taking over from Jeroen Landsbergen as CEO of

IHI Hauzer Techno Coating B.V. Dave Doerwald was previously Hauzer’s Chief Technology

Offi cer (CTO). Jeroen Landsbergen, who has been CEO at Hauzer since 2014,

will become CEO of IHI Ionbond, also a company within the IHI Group.

NEW HAUZER CEO: DAVE DOERWALD

INTRODUCTION


their trust and the exciting times we have had. Their presence is

what gave me the opportunity to learn and grow. I am looking

forward to this next challenge and to seeing how Hauzer will

develop under Dave’s leadership.”

Full Speed Ahead for New Business

Today’s markets require leadership that has a true technological

eye. Dave: “Sales and technology at Hauzer are closely linked.

Our systems are complex and sales means looking for solutions

together with our customers. My goal is to make sure Hauzer

stays strong in our existing markets, while maximally focusing

on new business development – new technology, markets,

applications and systems.”

Dave joined Hauzer in 1997 as recently graduated mechanical engineer and quickly became Project Manager New

Systems. In this position, he became interested in the various processes he saw up close, prompting a switch to

process engineering for tool coatings. To develop his skills more broadly, Dave took a position in sales and product

management in 2005. He focused on the tribological industry, where he saw the rise and growth of diamond-like

carbon (DLC) coatings. Under Jeroen Landsbergen, Dave returned to the technical side of the business, fi rst to lead

the Process Engineering department and later as CTO. “I have had a great career within Hauzer, coming up through

the ranks,” says Dave. “I am looking forward to this next step.”

Dave Doerwald

6


Hauzer is pleased to announce the acquisition of the equipment division of fellow IHI Group company

Ionbond. The division, producers of the highly esteemed Bernex chemical vapour deposition

(CVD) equipment, will continue as a standalone company under the name IHI Bernex.

IONBOND EQUIPMENT DIVISION INTEGRATED

INTO HAUZER


Highly Anticipated Joining

Hauzer purchasing the Ionbond equip-

ment division is in line with the IHI

concept of having the equipment

production activities aligned to

maximise the use of synergies. Finalising

the acquisition was a highly anticipated

event, with the total life cycle of

equipment development now focused

in an equipment group.

Michael Auger, Bernex CEO, says:

“Bernex is profi table and growing, and

we are looking forward to the synergies

that will come from working with Hauzer.

Both companies have a lot to off er.”

Jeroen Landsbergen, Hauzer CEO, adds:

“The Bernex portfolio is an excellent

complement to the Hauzer portfolio,

allowing the two companies to serve

more customers together. We are both

equipment manufacturers and speak the

same language when it comes to doing

business.”

Leader in CVD Solutions

Bernex CVD systems set the industry

standard in CVD enhancement of wear,

friction and temperature protection of

tools and components. Bernex machines

are renowned for their reliability and

have proven themselves in hundreds of

installations worldwide.

The company, located in Olten,

Switzerland, has over 45 years of ex-

perience with developing technology,

equipment and recipes for CVD coatings.

They have expanded the CVD technology

to include CVA (for aluminium coatings)

and CVI (for coating the internal surfaces

of porous materials such as carbon fi bre

bodies). Their expertise in developing

proprietary coatings for specifi c custo-

mer applications sets Bernex apart in

the fi eld.

MARKET DEVELOPMENT LEADING EDGE TECHNOLOGY

Michael Auger, Bernex CEO

9 HAUZER FOR YOU . NO. 329 HAUZER FOR YOU . NO. 32

Bernex Expanding Production Capacity

The merger will have little eff ect on the day-to-day activities

and contact persons of both companies, since Bernex is

becoming an independent company within the Hauzer

group. Bernex engineering and manufacturing will remain

in Olten, where it is expanding its production capacity.

Bernex Service Center Asia will remain in Kunshan, China.

For more information, see the new Bernex website:

ihi-bernex.com.

Good news for PVD providers in Europe! In February 2019, the committee established

under the Regulation concerning the Registration, Evaluation, Authorisation and Restriction

of Chemicals (the REACH Committee) decided that the authorisation period for use of chromium

trioxide (CrO3), a hexavalent chromium compound for the use for plating on automotive

plastic components, is to be limited to 7 years from the sunset date of 2017.

HEXAVALENT CHROMIUM TO BE PHASED OUT

BY 2024

MARKET DEVELOPMENT


ADVANTAGES OF CROMATIPIC® TECHNOLOGY

Electroplating PVD

Metal touch Metal touch

Cold to the touch (thick coating) Limited cold-touch effect (thin coating)

Not translucent/transparent Can be translucent/transparent

Limited number of substrate materials Wider range of substrate materials

Excellent wear protection Excellent wear protection

Uses toxic CrO3 No toxic substances

Coating has limited corrosion resistance in combination with mechanical loads, such as stone chipping

Coating has excellent corrosion resistance

Masking required to realise partial plating Line of sight process

Brittle coating Flexible coating

Boost for Alternative Technologies

This is excellent news for providers of alternative technologies.

An alliance of PVD providers, uniting the big players in the

market, has been a clear voice promoting PVD as alternative to

electroplating. PVD is a fully mature substitute technology that

may now get increasing interest on the market. A window of 7

years from the sunset date puts enough regulatory pressure

on OEMs that they will have to act now to look into alternatives.

Hexavalent chrome (CrVI) has long been a substance of very

high concern (SVHC) in Europe. Fortunately, the electroplating

providers’ lobby did not succeed in extending the authorisation

period to 12 years from the sunset date.

Chromium trioxide is a carcinogenic substance. In spite of this, CrO3 is still widely authorised to be used on an

industrial scale in chrome electroplating, as part of the etching step and often the chrome deposition step. For

plating of plastic components, in many sectors including the automotive industry, use of chrome electroplating

is a design choice rather than a functional one. Several advantages make Cromatipic® interesting as coating

technology compared to electroplating.


The idea of Industry 4.0 is an inspiration in many sectors. Self-learning systems that help you

increase throughput and reduce error rates, sophisticated statistical analyses that help you optimise

timing and maintenance schedules, and perhaps even robot-assisted 24/7 productivity. Of course,

we are not there yet. But with External Data Interface 4.0 (EDI 4.0), our new software interface,

Hauzer machines are ready for whatever you have in mind.

READY FOR INDUSTRY 4.0

CUSTOMER SUPPORT RELIABILITY & QUALITY


Communicate and Control

EDI 4.0 enables data exchange between Hauzer machines

and customer systems. This makes two-way communication

possible. In fact, you can control the entire system remotely,

except loading, unloading and other physical activities.

The new software interface is an extension of the previous

interface, which has been available on Hauzer machines for a

long time. Previously, it was already possible to download all

the data the machine was logging. For most customers, that

is an unproductively large amount of data. With EDI 4.0, it is

possible to export only the data you need for your specifi c

application.

Benefi ts For the Future and Today

The sky is the limit when it comes to systems to connect. As

Industry 4.0 becomes more commonplace, more and more

off -the-shelf customer systems will become available that are

geared towards adding intelligence to your production systems

or towards monitoring and steering by machine data. Hauzer’s

EDI 4.0 is set up to be very fl exible, so you are free to connect

it to any system you choose.

Pioneering companies can already use the new Hauzer software

interface to signifi cantly error-proof their operations. A great

and easy add-on is a barcode scanner: simply scan the barcode

on the batch order and the machine automatically chooses the

right recipe and settings. Or have your Enterprise Management

System (EMS) or Enterprise Resource Planning (ERP) system

manage your batches. And by exporting log data to determine

yield, you immediately get a better sense of your effi ciency.

Secure Connections

EDI 4.0 communicates securely through a SQL server to which

other systems can also be connected. The SQL server is

connected to your local network, which of course needs tight

security at all times. Coating recipes and other business data

are valuable, proprietary information; the more components

and systems are able to read and use information from your

Hauzer machine, the more carefully the network needs to be

protected.

Why Start Now?

This is a good time to get started with Industry 4.0. As the

concept is becoming more well known, more companies are

creating intelligent software or custom sensors to help make

your production line more self-suffi cient. Governments,

too, may be promoting the concept as a way to increase

productivity and innovation in industry: the Italian

government, for example, is paying companies a premium for

investments in smart industry.

EDI 4.0 is available as an add-on for all new Hauzer machines

and for most older ones as well. As long as your system has

Windows 10, MySQL and Citect 7.2, Citect2016 or higher, you

can have it upgraded to unlock these new opportunities.

For more information, please contact

Albert Hendriks, the sales manager

responsible for modifi cations, by e-mail

at [email protected] or by phone at

+31 77 3559 711.

Data that can be exported:

Selected recipe

Active recipe

List with available recipes on the

machine

Batch header data (batch number,

used recipe, start or end date and

time)

The last scanned barcode on the

machine

ROOM FOR EXPERIMENTATION

Some options for interaction:

Remote start up

Remote recipe selection

Reading machine data

Accessible for connection with

other systems

The vast majority of Hauzer machines is set up stand-alone. Operators input the batch data by hand and pick the right recipe,

and the machine logs stay on the machines. But for customers who are interested in experimenting with Industry 4.0 and

intelligent control, EDI 4.0 off ers many options to interact and connect with the system.

Batch actuals data (date and

time, recipe step, temperatures,

pressures, gas fl ows, cathode

and bias voltage, current)

Overview actual machine state

(shut down, standby, venting,

pumping, start process, process,

leak test)

And much more


Italian coating service provider Lafer is one of Hauzer’s longest-running customers, which Lafer and

Hauzer celebrated last year with a spectacular party in and around Piacenza, Italy. Established in 1986,

Lafer has always focused on developing innovative coatings for specialised applications.

Primo Civardi, Lafer’s Technology Manager and director of the production plant, shares how Lafer’s

relentless focus on innovation has brought the company to where it is today.

FLEXIBLE MACHINES, SPECIALIST INNOVATIONS

CUSTOMER SUPPORT

Team from Lafer

and Hauzer.


LEADING EDGE TECHNOLOGY OPERATING EXCELLENCE

Finding the Right Match with Technology

When Lafer first started, their focus was on chemical vapour

deposition (CVD) coating. Primo: “This was a very good time

for us and we made CVD coatings for several years. CVD was

a new technology for Italy and everyone was eager to learn.

But this type of coating was complicated for technical reasons,

and the market was not ready to take full advantage. When we

had occasion to be in contact with Hauzer and physical vapour

deposition (PVD) technology, we decided that this was a good

direction for Lafer. We bought our first PVD unit, a Hauzer

machine, in 1991.”

Establishing a Reputation for Innovation

The second Hauzer machine followed quickly, in 1993, and

many more after. “One of the key points in the Lafer story,”

Primo explains, “is that we participated in the Superlattice

Coating Project from 1995 to 1997, a large European project to

coat aeronautical components. This was the real start to our

specialisation in coatings with wear-resistant properties.” In

the late ‘90s, Lafer bought another Hauzer unit dedicated to

just that kind of coating.

Specialised in Problem Solving

This focus on innovation and specialisation has

remained a key part of the Lafer company culture.

Primo, who has been with the company since its

early days, is always looking for specialisation

opportunities. “The market changes rapidly

nowadays,” he says, “so you have to keep up to date

with production capabilities. Coating production

has become much more complicated, and focusing

on innovation and specialisation is the only way to

retain market interest. You have to really dive into

the client’s specific application. What materials do

they use? What results are they looking for? Then

you develop a highly specific coating recipe that

solves their exact problem.”

Luigi Parenti, Lafer CEO, and Michiel Eerden,

Hauzer Director of Sales.

Gabriel Jordan, Hauzer Manufacturing Engineer, and Primo Civardi, Lafer

Technology Manager.


Teamwork Inside and Outside the Company

Lafer has an excellent R&D team to create these highly specific

coatings. Their 10 R&D engineers are all specialists in their own

right. Primo: “But more importantly, it is a true team, motivated

to make things better. Technology-wise, we need to keep our eyes

open and urge all our suppliers, Hauzer and others, to develop

the upcoming technologies. At Lafer, we are kind of a collector of

new things. That is why we value our long-time relationship with

Hauzer so much. If you know each other in such detail, it is easier

to ask for new features, modifications, coating properties – the

elements that ignite new research.”

Rik Smabers, Hauzer COO, and Primo Civardi, Lafer Technology Manager.

The specialised component coating hall at Lafer with two Flexicoat® 1200

and one Flexicoat® 1500 PVD/PACVD systems.

Celebrating 27 Years of Collaboration

In the spring of 2018, Lafer and Hauzer celebrated their long

history together in Piacenza. Primo: “It is important to spend

time together outside of work, outside the technical issues. We

arranged some surprises for our guests from Hauzer. Lafer’s

owners have a high-powered road-legal prototype sports car

that we took for a spin. In addition, we arranged a flight with an

ultralight aircraft. Flying over the Lafer plant and surrounding

area on a sunny day definitely gives you a new perspective on

the industry!”

Prepared for a Bright Future

Primo’s perspective on the future is equally high level. “Nobody

knows what the future will bring, really. We prepare through

specialisation and innovation, working on automotive, industrial

and medical applications and more. There are so many different

possible coatings, and so many problems that can be solved

with the right coating. We need our machines to be as flexible as

possible, and our people to be even more so.” In a competitive

market where time can be of the essence, Lafer stands out with

its excellent quality in innovative applications. As Primo says:

“We are in a good situation. Every day, we meet new clients who

are looking for something extraordinary.”


Contact pressures have always aff ected the automotive industry’s choice in coatings. But today’s

requirements are diff erent from those of the last century. In the late eighties and early nineties, wear

protection was the key property that the industry was looking for. This need emerged when direct-

injection turbo diesel engines were developed, with a continuous increase in power densities that caused

engine components to fail. Today, the industry is facing challenges such as CO2 reduction and protection

for high-load gasoline engine components. And Hauzer is developing new solutions to meet these

challenges, such as a dedicated Hauzer Flexicoat® machine concept.

TRENDS IN AUTOMOTIVE TRIBOLOGICAL COATINGS

LEADING EDGE TECHNOLOGY


Diesel injection components such as

high-pressure diesel pump plungers

and injection needles were the fi rst to

be coated. Tribological physical vapour

deposition (PVD) or plasma-assisted

chemical vapour deposition (PACVD)

layers gave the required protection.

Quickly after, tribological coatings

found their way to many other engine

components. Nowadays, piston rings,

piston pins, mechanical tappets and

other components are coated in

massive numbers. This article discusses

two fast-changing sections within

automotive coating: piston rings and

gasoline injection components.

Reducing CO2 Emissions with

Piston Ring Coating

A large percentage of all piston rings

produced around the world receive a

PVD coating to extend their lifetime.

Traditionally, these are chromium

nitride (CrN) or other chrome-based

coatings, because of their benefi cial

wear-resistant properties. Since the

introduction of worldwide CO2 emission

regulations, the friction-reducing pro-

perties of tribological coatings have

also gained importance. Hydrogen-free

carbon coatings can deliver around

20% friction reduction. This is one of

the reasons why hydrogen-free carbon

coatings and other carbon-containing

coatings are gaining importance over

CrN-coated piston rings.

In addition, hydrogen-free carbon

coatings exhibit improved wear and

scuffi ng resistance. These properties

are gaining importance as, again in

an attempt to reduce CO2 emissions,

the automotive industry is moving

to lower-viscosity engine oils. These

lower-viscosity engine oils result in a

thinner oil fi lms between moving parts

and more metal-on-metal contact.

Thicker Coatings = Longer Cycle Times

Piston rings typically require relatively

thick coatings. Thicknesses of 20 micron

and more are quite common. With

these thicknesses, high deposition

rates become important to reduce cycle

times and overall costs. An important

drawback of hydrogen-free carbon

coatings is that the coating needs to be

produced at moderate temperatures

(around 160-240°C) to retain the desired

coating properties. At these moderate

temperatures, the deposition rates

are only a fraction of those at elevated

temperatures. This tends to result in

longer cycle times.


To overcome the problem of low

deposition rates for thick piston ring

coatings, Hauzer developed a dedicated

Hauzer Flexicoat® 1000 machine concept

that incorporates several additional

cooling features. The extra cooling

allows higher deposition rates without

raising deposition temperature.

The cooling features are traditionally

positioned at the outside of the

substrate table. A unique new option

is a retractable cooling feature set up

in the centre position of the substrate

table. This unlocks an even larger

surface area for cooling. The set-up

does not require disconnection of water

cooling connections from batch to batch,

eliminating the risks of potential vacuum

leaks.

These combined features result

in a 36% reduction of cycle time

compared to the classical Hauzer

Flexicoat® 1000 model. At the same

time, a redesign of the cathode and

substrate table set-up resulted in a

57% increase in batch load. Geert-Jan

Fransen, Product Manager Tribological

Coatings, says: “Together, these features

make the dedicated Flexicoat® F1000 the

most effi cient and productive coating

unit available on the market. Feel free

to get in touch if you are interested in

calculating coating costs for your specifi c

parts and application.”

DEDICATED HIGH-PRODUCTIVITY PISTON RING SOLUTION


Tribological Coatings for Gasoline Engines

The use of tribological coatings was

strongly driven by developments in

diesel engines, with their extremely

high local contact pressures for several

engine components. In recent years,

new developments in gasoline engines

are also putting excessive loads on

components, which need additional

or alternative wear protection. Diesel

fuel has a lubricating function that

gasoline lacks. As such, the need for

wear-resistant coatings appears at lower

contact pressures in gasoline engines

than in diesel technology.

Coatings for gasoline injection com-

ponents, water injection parts and

components of the turbocharging sys-

tem are currently under development.

Diamond-like carbon (DLC) coatings

produced by PACVD are well known

for this application. But hydrogen-free

carbon coatings are also increasingly

introduced in this sector, either produced

by arc technology or HIPIMS sputtering

(see also the article on page 21).

Hauzer is focusing, together with our

customers, on validating new coatings

and new deposition technologies. Andre

Hieke, Global Segment Manager for

Automotive Components at Ionbond,

says: “We were able to win a large

automotive project for gasoline injection

components, in close cooperation with

Hauzer.”

The Future of Automotive

More interesting developments are

Retractable cooling feature in the dedicated Hauzer piston ring solution. Depending on the process step,

the retractable heater (red) or retractable cooling features (blue) are lowered into the centre position.

happening. The industry is preparing to

phase out Cr electroplating processes.

In sectors from the automotive to the

printing industry, applications are

arising where alternative coatings are

preferred to electroplating.

In addition, the automotive market is

moving in the direction of e-mobility

(see the article on page 26 about

fuel cells). Geert-Jan: “This opens up

new possibilities. In e-mobility, too,

applications are popping up where

protective coatings are needed.

Hauzer’s tribological experts stand

ready to assist you in validating

state-of-the-art coatings for your

applications, for all our deposition

technologies.”


Tetrahedral amorphous carbon (ta-C) coating, a hydrogen-free diamond-like carbon (DLC)

coating, is in growing demand in the automotive industry. Compared to hydrogenated DLC coatings,

hydrogen-free DLC coatings have increased thermal stability and improved mechanical and tribological

properties in combination with low-viscosity oils, which is important in certain automotive applications.

New test results show that ta-C coating applied by HiPIMS, smoother than ta-C applied traditionally,

has excellent cavitation wear resistance and adhesion. Ruud Jacobs, Process Manager Tribological

Coatings, says: “From a technical perspective, we consider the HiPIMS carbon coating to be

one of the best – if not the best – performing coatings available.”

NEW RESULTS: HiPIMS TA-C RESISTS CAVITATION WEAR

LEADING EDGE TECHNOLOGY


ta-C (arc) ta-C HiPIMS

Thickness [µm] 0.1 + 0.9 0.6 + 0.7

Roughness Ra [µm] 0.08 0.01

Roughness Rp [µm] 1.0 0.08

Hardness HV 10mN 2000 - 6500 4000

Adhesion (HrC) 1 - 2 1 - 2

Sp3 content Up to 65% 30 - 40%

Bubbles That Create Shock Waves

HiPIMS ta-C, the hydrogen-free DLC coating of choice for appli-

cations that require smoothness, is undergoing regular tests in

various applications such as tappets, diesel and gasoline injec-

tors and fuel pumps. The wear and lifetime results have been

very promising. In this new test, focused on adhesion and cavi-

tation wear resistance, Robert Bosch GmbH Powertrain Solu-

tions tested HiPIMS ta-C on roller shoes from a diesel pump.

In the test, an ultrasonic sonotrode was used to create

cavitation in the centre of the roller shoe bore. Cavitation

occurs when gases dissolved in liquid create bubbles. When

pressurised, the cavitation bubbles collapse, generating

violent microjets or shock pressure waves characterised by

high velocities, pressures and temperatures. The resulting

microimpacts on the surface lead to plastic deformation of

the substrate surface, forming undulations (waviness) on the

surface that damage the coating. The typical lifetime of hard

coatings with the used test parameters is 90 to 900 min.

ta-C (CARC+)

ta-C

Cr

a-C / ta-C HiPIMS

ta-C

Cr

a-C:H:Me

undulations, is additionally stressed by the bending. After

1080 minutes of cavitation testing, most of the HiPIMS ta-C

coating was still intact on the substrate surface. Dr. Ulrich May

from Robert Bosch GmbH Powertrain Solutions: “The coating

performance is excellent and should open opportunities for

other types of applications, too.”

Excellent Adhesion and Cohesion

HiPIMS ta-C on the roller shoes showed extremely good

adhesion and cohesion in the complex shape of the roller

shoe bore. As can be seen in the pictures below, failures start

mainly at substrate failures (probably caused by micron-scale

non-metallic inclusions). The coating surface shows typical

undulations caused by plastic deformation of the substrate

underneath the coating. The coating, which has to follow the

Overview of cavitation damage zone after

270 min. exposure time. Failed area is

very small.


720 min. exposure time. More and bigger

delaminations. Undulations in the coated

areas are clearly visible.


1080 min. exposure time. Failed areas

coalesce.


From Hydrogenated DLC to Smooth Ta-C

Low friction and high wear resistance have always been

very important properties when it comes to coatings for

the automotive industry. Extremely high volumes of valve

train components, piston system parts and fuel injection

components are routinely coated with diamond-like

carbon (DLC) coatings.

1990s. Introduction of the ‘classical’ hydrogenated DLC

coatings (a-C:H/a-C:H:Me) as tribological coatings for

engine parts.

2000s. Growing demand for hydrogen-free DLC

coatings, in particular the amorphous carbon (a-C) and

tetrahedral amorphous carbon (ta-C) coatings. For some

applications, especially for those where friction

reduction counts, hydrogen-free DLC coatings have

superior properties to hydrogen-containing DLCs.

2010s. Hydrogen-free DLC coatings taken into mass

production. The fi rst application was a thin ta-C layer

on mechanical tappets, produced in Hauzer Flexicoat®

1500 machines equipped with sputter cathodes for

the adhesion layer and circular arc (CARC) cathodes

for the highly sp3-hybridised carbon top layer. Other

applications followed, requiring diff erent thicknesses (up

to 30 micrometres for piston rings) and a wide range of

sp2/sp3 ratios. Because the deposition method results in

Diamond-like carbon (DLC) coatings come in many varieties, classifi ed by

their ratio of sp3-bonded carbon (diamond), sp2-bonded carbon (graphite)

and hydrogen. The more sp3-bonded carbon in a coating, the harder it

usually is. Tetrahedral amorphous carbon (ta-C) is a hydrogen-free carbon

coating with high sp3/sp2 ratio (on the left side of the triangle.)

ta-C ta-C:H

sp3

sp2 H

sputtered a-C a-C:Hno films

HC polymers

graphitic C

J. Robertson, Materials Science and Engineering, 2002 (129-821)

Increasing HiPIMS Productivity with Larger Batches

These excellent test results are another good reason to invest in

HiPIMS ta-C. However, compared to ta-C by CARC+ technology,

the HiPIMS process has a lower deposition rate. Increasing the

batch size and using specialised fi xtures for the most effi cient

loading can both give a signifi cant boost to HiPIMS productivity,

for smooth, droplet-free results in a manageable process

time. Now, HiPIMS technology is also available on the Hauzer

Flexicoat® 1500, the largest batch-coating system in the Hauzer

portfolio. The required cathode power density and the recipe

that was developed in the Hauzer Flexicoat® 1200 system have

been expanded to the Flexicoat® 1500. This is another important

step towards optimising HiPIMS ta-C to a competitive production

process.

droplets, post-coating surface treatment is nearly always

mandatory to get to the desired smoothness.

The solution to the high roughness of traditionally

deposited ta-C is HiPIMS technology, the droplet-free

alternative. Hauzer off ers HiPIMS ta-C in a Hauzer

Flexicoat® 1200 machine with sputter cathodes that can

run pulsed DC magnetron sputtering for the adhesion

layer and a HiPIMS cathode for the hard ta-C top layer.

Hauzer Flexicoat® 1500.


When you invest in a PVD system, you want to be able to keep using it for many years. Hauzer systems

are built with a robust design and the flexibility to allow many kinds of technologies and upgrades. After 35

years of machine manufacturing and with over 500 systems produced, modification has become an important

expertise at Hauzer. After a system is upgraded, it can often be used for many more years as a serious

production tool or for the development of next generations of successful PVD coatings.

HARD AT WORK AT THE MODIFICATION FRONT

CUSTOMER SUPPORTOPERATING EXCELLENCE RELIABILITY & QUALITY


We have been involved in developing systems for all kinds of

applications. In addition to our main markets – decorative,

tribo and tool – we have always served special applications.

For all these markets, we see common issues in knowledge and

upgrade planning.

Retaining In-House Knowledge

As time goes by, machines get older and the people that work

with the machine change. If these changes are gradual, the

original team can sometimes compensate by training the new

people. Sometimes, changes are more drastic, leading to a lot

of experience disappearing at once. For all these cases, Hauzer

offers training to make sure the machine is used efficiently and

correctly. These training sessions can be for operators, service

technicians, process engineers, quality engineers or anybody

else working with PVD equipment. Training sessions are held on

site or at Hauzer, depending on customer requirements.

Planning Your Upgrade With Care

Whether you have a single machine or a complete machinery

park with multiple Hauzer machines, modification of a machine

can have a far-reaching impact. Usually, some planned downtime

of the machine will be necessary. Hauzer engineers always work

with our customers to minimise the effects of this downtime.

Sometimes, it is possible to produce a certain stock in advance

to overcome the lack of productivity during the modification.

If a customer is planning multiple modifications to different

machines, we take a helicopter view of the total project. Creating

a planning for all upcoming projects helps everyone keep an

overview. Often, this planning also reveals possibilities and

needs to do maintenance or modifications on other equipment

in the total production line.

Complex Process for Highly Skilled Workers

New Hauzer machines are configured to order. Modifying

older machines can be considered engineering to order.

An experienced team of Hauzer engineers prepares the

modification, including a new set of machine documentation.

The assembly of the modification is handled by Hauzer’s more

experienced technicians. Since these technicians are on site

anyway, they often take the opportunity to explain how the

modification works exactly and how it improves the behaviour

of the machine.

As you can imagine, it requires a lot of planning to have all the

necessary capacity for a modification, bringing together the right

technicians and engineers at the right moment. Hauzer Customer

Service will always try to help everybody as soon as possible.

Because of the sheer number of modifications, in addition to the

production of new machines, it is important that you plan any

upcoming modification in time. Hauzer would be happy to help

bring your existing machine and your team’s knowledge to the

next level.


The automotive market is about to start changing even more rapidly than it is already. Now the demand for

greenhouse gas–free solutions has never been higher, hydrogen technology is off ering zero emissions and

the potential to scale to worldwide use. This is what will drive the rapid ramp-up of fuel cell production in the

next few years. An excellent opportunity for coating providers interested in providing high volumes of coating

for the fuel cell industry, for instance with the Hauzer Metalliner® inline coating system.

TOWARDS FULL VEHICLE ELECTRIFICATION

CUSTOMER SUPPORTLEADING EDGE TECHNOLOGY OPERATING EXCELLENCE

for the fuel cell industry, for instance with the Hauzer Metalliner inline coating system.


Protective Coatings in High Volumes

One of the scaling challenges is the high volume of protective coating that

is needed. A fuel cell stack as used in a passenger vehicle is built out of

many stainless steel plates, carbon foam sheets and catalyst membranes.

More than 300 of each are required to obtain a 100kW cell for a passenger

car, and the entire steel surface needs to be coated to enable a long cell

lifetime of over 5000 hours.

China is currently producing the largest

number of electric passenger cars by

far. The Chinese automotive industry

also recognises fuel cell technology as

an enabler for massive electrifi cation.

It is already preparing for large-scale

production and is increasing its eff orts

to develop fuel cell technology to a

mature level. This is a big opportunity for

suppliers who can provide production

solutions and meet the requirements

set by the local automotive companies.

However, this scale-up includes several

challenges that the industry must

resolve. Fuel cell stack.

Rapid Market Expansion

The main automotive companies in Europe, China, Japan and Korea have

announced ambitious targets for electrifi cation with fuel cell technology.

It is forecast that more than half a million fuel cell electric vehicles (FCEVs)

will be produced up to 2025, and more than 3 million in total up to 2030.

Annual market growth levels of over 40% can be expected in 2022, as the

industry is ramping up and preparing for serious pilot series in 2025. Most

of the OEMs plan to establish a production level of 30,000 to 50,000 FCEVs

in 2025.

2022 2025 2030

FCEV annual production level* 100,000 300,000 1,000,000

Compound annual growth rate (%) for FCEV production

44% 27% 15%

Total bipolar plate area to be coated (million m2 / year)**

5,3 16 53

* Including passenger cars, excluding medium and heavy-duty vehicles. * Sources: McKinsey 2018, Hydrogen Counsel 2018, Greencarreports 2018.

** Assuming 400 bipolar plates per fuel cell, about 15 half plates per m2.

Large fuel cell stacks have been

around for some time, for stationary

energy backup systems. Automotive

applications, however, need the

technology to produce light-weight,

compact stacks. This technology is

maturing fast. Fuel cell technology

is key to accelerating electric vehicle

adoption, as it enables fuelling in only

a few minutes and extends the range

of electrical vehicles to at least 500km.

The fi rst prototype cars from Toyota,

Honda and Hyundai are already on the

market, and Daimler has introduced its

fi rst model last year. More European

OEMs are sure to follow soon.


Hauzer’s expertise in protective coa-

tings and high-output coating systems

can offer the solution. The Hauzer

Metalliner® inline coating system, in-

troduced in 2012, is a high-volume

platform that allows continuous coa-

ting onto sheet materials. Metalliner®

Today’s qualified coating is a good base, but continuous

improvement in production technology is necessary to meet

tomorrow’s quality and reliability requirements in a fast-

growing automotive market. Even though the Metalliner®

coating has already been tested extensively by important

institutes and industrial players, Hauzer is working on

optimising the coating material to enable an increased fuel

cell lifetime for the automotive market after 2025. This will

also open up new applications like heavy-duty transportation,

buses, trains and stationary systems. In addition, Hauzer is

working on a technology with very high coating speed for

steel sheets or coil materials. This technology will be used in

next-generation coating equipment to increase productivity

and reduce cost of operation. As the market demand will

increase towards several million fuel cell passenger cars in

2030, production costs need to drop continuously. Hauzer

will be part of the solution with our cost-effective coating

systems.

Hauzer Metalliner® system for continuous inline PVD

coating, operational in several industries since 2012.

Example of a coated stainless steel bipolar plate.

The complete fuel cell stack for a passenger car

uses about 400 plates.

systems have been running in different

industries for many years. Recently,

automotive companies have shown

high interest because of their need to

coat many millions of bipolar plates for

fuel cells in the near future. Metalliner®

uses a coating process which has proven

itself for tribological applications and is

a good base for today’s bipolar plate

coating. This baseline has been tested

and qualified at various industries and

institutes in 2017 and 2018.

WORKING TOWARDS THE FUTURE


The automotive fuel cell technology is

in a ramp-up phase, working to sol-

ve some challenges on the technology

side. If you are in that industry, you

will need to be able to scale from

prototyping to pilot and fi rst series

production in a short time, while mini-

mising risks. One of the Hauzer special-

ties is building customised equipment

that perfectly suits the needs of our

customers. Our engineers can help you

determine the best equipment strategy,

starting with feasibility tests and opti-

mising your processes in our laboratory.

Hauzer machines can work with your

own coating recipes or with a coating

developed and proven by Hauzer and

our partner companies.

Are you up to the challenge of massive

fuel cell production by 2025? Allow

us to help you grow your business in

this quickly expanding market. If you

would like to be one of the driving

forces shaping this important future

sector, please contact Roel Bosch

([email protected], +31 77 355 9746).

GROW YOUR BUSINESS

FUEL CELL COATING PERFORMANCE TEST

Performance test of plates coated with three

diff erent Hauzer Metalliner® coatings. Improved corrosion protectionBaseline High-deposition-rate coating

-0,2

0,8

1

0,6

0,4

0,2

04 9 14 19 24

Co

rro

sio

n c

urr

en

t (µ

A/c

m₂)

Time hours

The so-called corrosion current needs

to stay below 1 µA/cm2 for 24 hours to

ensure a stable performance of the fuel

cell during its lifetime (Department of

Energy Standards, 2017). Hauzer has

developed three coatings where this is

easily achieved: a baseline coating, a

coating with improved corrosion pro-

tection for future fuel cell stacks that are

more subject to changes in operating

conditions, and a high-deposition-

rate coating that provides improved

corrosion protection and enables higher

productivity for future market demand.



The PVD market is getting more infl uence from design trends than ever before.

Consumers are demanding more colour in their daily lives, and PVD is growing as a technology

to apply this colour to a wide range of products. Compared to 5 years ago, the demand for

decorative PVD in a variety of sectors has increased. With manufacturers of sanitary products,

mobile phones, cars, eyewear and cookware all working to distinguish themselves in the market,

2019 is an excellent year to expand a decorative PVD business.

TRENDS AND OPPORTUNITIES

IN DECORATIVE PVD

MARKET DEVELOPMENT


“The PVD faucet fi nishes market size in

US, Germany, and China is expected to

value USD 11.8 billion by 2020, exhibiting

a 7.3% compound annual growth rate

during the forecast period. Increasing

expenditure on renovation by hotel

groups and rise in home constructions

are expected to drive demand for PVD

faucet fi nishes. Increasing urbanisation

is another factor fuelling market growth.”

Grand View Research, Inc.

PVD FAUCETFINISHES

Samples of decorative Hauzer fi nishes.

Recent trends show that brown coatings are also increasingly

in demand, in addition to black. Designers marketing brown

as a warm colour are setting this trend, not just in the sanitary

industry but many others. Hauzer is meeting this demand by

developing additional decorative PVD coating recipes. Andreas:

“We really focused on brownish colours recently. I look

forward to running the samples for our customers to test.”

HAUZER DEVELOPINGBROWN PVD

After several crisis years, housing investments are on the rise again. This

increases the demand for sanitary products. (Source: Stichting Economisch

Instituut voor de Bouw.)

Colourful Sanitary Products Are Popular

The sanitary industry is a clear example. In Europe, the

most popular colour for sanitary products has until recently

been chrome. In the Americas, Middle East and Asia, oil-

rubbed bronze showerheads, golden faucets and many more

colourful products have been popular for decades. PVD is

well known in those regions as a technology to apply colour

to these products. And even in Europe, markets have started

to embrace other colours for sanitary applications in the

past 2 to 3 years.

Growing PVD Colour Range

PVD technology, too, is developing. PVD colours in the

sanitary industry started with golden, nickel, brass, bronze

and anthracite. Recently, a clear global trend towards black

has become visible. Black is strongly requested by consumers,

0

30

25

20

15

10

5

2005 2007 2009 2011 2013 2015 2017 2019 2021 2023

New construction Restoring and refurbishing

Housing investment, 2005-2023 (billion euro, prices 2016)

for products such as radiators, toilet paper holders,

water drains and towel holders. Andreas Fuchs, Process

Manager Decorative Coatings, says: “The deeper the black,

the better. We expect the production of black to remain strong

for the coming years.”


HIGHLY SKILLED WORKFORCE

CREATING A CULTURE THAT SUPPORTS SUSTAINABILITY

Sustainability features prominently in the Hauzer vision: “We live in a world with an urgent

need for sustainability. IHI Hauzer Techno Coating contributes to that by creating better material

properties and manufacturing technologies, leading to sustainable products, reduced energy

consumption and less pollution.” Standing behind a vision like that requires consciously investing

in a company culture that can achieve and sustain that vision, now and in the future.


HIGHLY SKILLED WORKFORCE

“I have a technical background but have been in B2B sales

management for years now, responsible for Asia-Pacific and

later Europe for my previous employer. I was looking for a

new challenge with no time difference with the main office

and a little less travel - I am only on the road 40% of the time

now – and Hauzer ticked all my boxes: high-quality, high-tech

systems and collaboration with large international players in

automotive and aerospace. New Business is a very diverse job,

which makes it very interesting. Where are the new markets,

and what are they? In different applications, different projects,

different sectors? Hauzer is a very enjoyable place to work: a

small company with short lines of communication and a clear

vision of what strong customer focus looks like. Right now, I’m

still learning. My job did not come with a user manual, and

it is really important to understand the technology and our

capabilities to a high degree. In new business, especially, the

challenge is to find and focus on the projects that match these

capabilities and fit our equipment roadmap.”

The right coatings can make tools last three times longer

and reduce the need for coolant or lubricant. This can make

industries more efficient and reduce emissions. Hauzer is also

working to popularise Cromatipic®, the environmentally friendly

electroplating alternative without hexavalent chrome or volatile

organic compounds. “A Hauzer machine is an investment that

needs to last for decades,” says Petra Vermeeren, HR Advisor.

“And so Hauzer also strives to still be here decades from now.”

Always Something to Look Forward To

Petra: “We have many staff events every year. These vary

from big events like the staff party to small celebrations like a

treat during a coffee break.” Some of these events are only for

Hauzer employees, giving them the chance to mingle and get to

know each other better. For some events, partners or children

are invited as well. “Many of our employees invest a lot of time

and effort into Hauzer, some by travelling abroad frequently,”

explains Petra. “It is important to extend our appreciation to the

people at home who make that possible.”

Bigger Than One Person Alone

Hauzer aims to be a great place to work, to attract and retain

the necessary experts. But also because nobody within Hauzer

can build a machine by him- or herself. That is why the goal is to

create a culture where people can easily knock on each other's

doors to collaborate or brainstorm. Petra: “The collegiality at

Hauzer is highly valued and one of the main reasons why people

stay at Hauzer as long as they do.”


JORIS UMMELSSALES MANAGER NEW BUSINESS

“After obtaining my mechatronics degree, I started my

career at a Dutch company working as a service engineer

and account manager at their large customer support

department. This gave me a strong vision on customer

support and some expertise that can be of benefit to Hauzer.

The differences are also interesting – I am used to broadly

oriented customers, while Hauzer really develops specific

machines for their customers and has much more in-house

knowledge. Hauzer products are high quality and that creates

a kind of high-quality mindset throughout the company.

Everyone is constantly looking for improvements, and you

can get much more done without needing third parties.

I have only worked here for a few months but I already feel at

home. Right now, I am still getting my bearings and learning

the work processes, but I already have ideas for new projects.”

LUC KURVERSTECHNICAL ACCOUNT MANAGER CUSTOMER SUPPORT

“I am a process engineer working on the HiPIMS process, hard

coatings and CARC processes. Currently, I’m optimising deposition

parameters and electrical pulse parameters for HiPIMS, and I’m

also working on interface engineering. Working on two different

projects is nice, it keeps you sharp. In the future, I’d like to focus on

developing more materials with flexible parameters and growing

my expertise in materials, thin layers and coatings and plasma

deposition methods. I also look forward to developing my skills and

contributing to Hauzer in multidisciplinary research in the areas of

biomedical coatings and renewable energy.

I have lived in many countries – I did my master’s in Applied Physics

in India, worked in Germany on a scholarship, migrated to Australia

for my PhD and then moved to Switzerland to work as a scientist –

and I’m constantly amazed by how well Dutch people speak English,

even in small villages. I have a long-standing association with

Eindhoven and have been visiting here more often since 2006.

Moving to Eindhoven was a dream of mine, and I’m happy it

came true."

RAJESH GANESANPROCESS ENGINEER


Hannover MesseApril 1-5HannoverGermany

PIAE 2019April 3-4Mannheim Germany

CIMTApril 15-20Shanghai China

SVCApril 30 - May 1Long Beach CAUSA

Automotive Interiors Expo Stuttgart May 21-23StuttgartGermany

Wiener Motoren SymposiumMay 16-17Vienna Austria

EMO

September 16-23

Hannover

Germany

FCVC

September 26-28

Rugao

China

HORN Technology days

June 5-7

Tübingen

Germany

Meet us...Hauzer is looking forward to seeing you at the following exhibitions and conferences.

New innovations spark a bright future - Hauzer Techno Coating · The merger will have little eff...

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