The Coatings · 2019. 11. 19. · Coating technology: Diamond Microhardness: 10,000 HV 0,05 Coating...

The Coatings Diamond and PVD premium coatings for cutting tools

2 Content

At a glance

CemeCon _________________________________________ 03

The Diamond-Coating-Technology ____________________ 04

CCDia®AeroSpeed® ______________________________ 05

CCDia®CarbonSpeed _____________________________06

CCDia®FiberSpeed / CCDia®MultiSpeed _______________ 07

The HiPIMS-Technology ____________________________08

AluCon® _______________________________________09

FerroCon® _____________________________________ 16

InoxaCon® _____________________________________ 17

Characteristics Of The Coating Materials ______________ 15

The Right Coating For Round-Tools ____________11 – 12

The Right Coating For Cutting Inserts _________ 13 – 14

The Sputter-Technology ____________________________ 18

ALOX® / TINALOX® ________________________________ 19

AluSpeed® _____________________________________20

HARDLOX® _____________________________________ 21

HYPERLOX® ____________________________________22

CCplusC® / SUPERTIN® ____________________________ 23

3 CemeCon

Board: Dr Oliver Lemmer and Dr Toni Leyendecker

We have developed the right technology, built the appropriate

production plants and thereby made the best PVD and diamond

coatings in the world a reality. In CemeCon’s own job coating centre,

which is one of the biggest in the world, ten thousand precision

tools are coated for our customers every day. For 30 years,

the experience and know-how gained here have been feedback

into the ongoing development of our PVD and diamond

coating machines. This also enables our customers to benefit

in terms of productivity, ergonomics, processing quality and

cost-effectiveness.

4 The Diamond-Coating-Technology

Diamond, the hardest material in the world as a coating material for maximum protection against wear. For many years, CemeCon has used the diamond technology to produce diamond coatings for cutting tools – real crystalline and nanocrystalline sp3 diamonds with a Vickers hardness of about 10,000. More than 20 years ago, CemeCon developed the diamond hot filament process and is now the world leader in diamond coatings and technologies.

In the hot filament process, diamond is produced from gas. In an Hydrogen-Methane gas atmosphere, carbon is turned into pure diamond. Depending on the application, the diamond coating can be deposited as a microcrystalline, nanocrystal-line or multi-layer coating. Fully automatic coating machines combined with pretreatment ideally adapted to the substrate enable diamond coatings to be produced with thicknesses of more than 20 µm with an outstanding adhesion.

CemeCon‘s patented multi-layer technology ensures maxi-mum stability of the individual layers within the coatings. Any cracks that may occur cannot spread beyond the layer boundaries. Thanks to their extreme hardness – with up to 10,000 HV0.05, close to that of natural diamond – all coatings in the CCDia® product group are extremely wear resistant. The performance of round tools and inserts made of solid car-bide is significantly increased by applying a CCDia® coating. The diamond coating‘s high heat conductivity is responsible for a fast heat dissipation. This is tremendously important when processing temperature-sensitive materials such as carbon-fiber and glass-fiber reinforced plastics, and enables higher processing speeds to be used when machining. All of these properties make the CCDia® line the first choice for machining graphites, composites, non-ferrous metals, green parts and ceramics according to VDI standard 3323.

Smooth, highly adhesive and resistant thanks to multi-layer diamond coating

The Diamond-Coating-TechnologyPatented multilayers for machining graphite, carbon-fiber and glass-fiber

reinforced plastics and composites, abrasive non-ferrous metals and ceramics

5

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CCDia®AeroSpeed®

CCDia®

AeroSpeed® for CFRP / GFRP /composites

The CCDia®AeroSpeed® premium diamond coating was developed in order to obtain the best possible surface quality when machining fiber materials. The excellent adhesion coupled with the unique smoothness guarantee highly reliably drilling and milling of CFRP, GFRP and composites. In addition, the very sharp edges – CCDia®AeroSpeed® does not change the microgeometry of your precision tools – are able to cut the fibers more effec-tively. CCDia®AeroSpeed® is also ideally suited to carbide grades with higher cobalt content. The increased ductility of these carbide grades in connection with a diamond coating allow a reliable drilling process in aircraft manu-facturing.

Technical data

Coating technology:

Diamond

Microhardness:

10,000 HV0,05

Coating material:

Multilayer, sp3

Color:

Grey-Shiny

Max. operating temperature:

650 °C

Available coating thicknesses:

~~ 3 µm • –

~~ 9 µm • •

~~ 14 µm • •

Perfect surface quality throughout the entire tool life

100uncoated

980CCDia ®AeroSpeed®

Material: CFRP, IMA-M21E

Tool: Carbide countersink-drill

d = 5.6 mm

dcountersink = 12.5 mm

f = 0.05 mm

n = 6000 min-1

Tool life criterion: Weartransition radius countersink

Tool life(number of holes)

1000

900

800

700

600

500

400

300

200

100

0

6 CCDia®CarbonSpeed

Ultrahard protection against abrasive wear: CCDia®CarbonSpeed is the best coating solution when the cost-effective machining of graphites and green parts is the main aim. It can be applied to more than 80 carbides for fine crystalline smooth multilayer structures for highly reliable processes and the best workpiece surfaces.

Cost-effectiveness combined with a highly reliable process

for graphites / green compacts

Technical data

Coating technology:

Diamond

Microhardness:

10,000 HV0,05

Coating material:

Multilayer, sp3

Color:

Grey


650 °C


400CCDia®CarbonSpeed

7 µm

Material: EDM graphite ISO-63

Tool: End mill

vc = 600 m/min

fz = 0.06 mm/tooth

Tool life(m)

20uncoated

450

400

350

300

250

200

150

100

50

0

CCDia®

CarbonSpeed

~~ 7 µm • • •

~~ 9 µm • • –


7 CCDia®FiberSpeed / CCDia®MultiSpeed

for CFRP / GFRP / ceramics

Coating thicknesses of 3 to 14 µm make CCDia®FiberSpeed and CCDia®MultiSpeed universal and economical solutions for drilling and milling of fiber composites and ceramics. The very good adhesion gives highly reliable processes and the various coating thicknesses can give sharp edges as well as maximum wear volumes.

High wear volume for maximum performanceTechnical data

Coating technology:

Diamond

Microhardness:

10,000 HV0,05

Coating material:

Multilayer, sp3

Color:

Grey


650 °C


CCDia®

FiberSpeedCCDia®

MultiSpeed

~~ 3 µm • • – –

~~ 9 µm • • • •

~~ 14 µm • • – •

Material: CFK, M21E

Tool: Solid carbide drill, ø5.6 mm

fz = 0.06 mm/tooth

n = 6500 min-1

Tool life(number of holes)

150uncoated

1000

900

800

700

600

500

400

300

200

100

0

950CCDia®FiberSpeed


8 The HiPIMS-Technology

HiPIMS (High Power Impulse Magnetron Sputtering) com-bines the advantages of all conventional coating tech-nologies for cutting tools available on the market. The smoothness of the sputtering, the high hardness values, compact coating structures and scratch resistance to over 130 newtons, tools coated in this way are exceptionally resistant to wear in extremely hard, especially tough and oxidation-resistant materials such as stainless steel, titanium or nickel-based alloys.

But HiPIMS coatings can also deliver top performance in unalloyed, alloyed and high-speed steels.The high metal ionisation of nearly 100 per cent gives the best adhesion, even in cold-welded materials, which are particularly difficult to machine.In addition, coatings deposited by HiPIMS technology give extremely homogeneous surfaces, even on very complex 3D geometries.

The HiPIMS-TechnologyHiPIMS, the PVD coating technology of the future

9


for aluminium, titaniumand non-ferrous metals

TiB2 and HiPIMS. The unique combination of a nano-crystalline coating material, which effectively prevents built-up edges, and the HiPIMS technology for the smoothest coatings, maximum coating adhesion and a hardness of up to 5,000 HV0.05. Guarantor for optimal machining of non-ferrous metals.

To avoid built-up edges and offering maximum coating adhesion

Technical data

Coating technology:

HiPIMS

Coating material:

TiB2-based

Color:

Silver


1,000 °C


~~ 1 µm • • –

~~ 2 µm • • •

~~ 4 µm – – •

AluCon®

Tool life

(m)

11Coating ofcompetitor:

TiAlSiN

14

13

12

11

10

XCon®

AluCon®

14,48Material: TiAl6V4

Tool: Inserts with x-geometry

vc = 100 m/min

fz = 0.6 mm

ae = 15.28 mm

ap = 0.8 mm

vb = 0.34 mm

Cooling: Oil

AluCon®

CCDia

® AeroS

peed

®

CCDia

® Carbon

Spee

dAL

OX®

AluCo

n®

Ferro

Con®

CCDia

® MultiSp

eed

AluSp

eed®

CCDia

® FiberS

peed

TINAL

OX®

Inoxa

Con®

HARD

LOX®

Supe

rtin®

HYPE

RLOX

®

CCplu

sC®

CCDia

® AeroS

peed

®

CCDia

® Carbon

Spee

dAL

OX®

AluCo

n®

Ferro

Con®

CCDia

® MultiSp

eed

AluSp

eed®

CCDia

® FiberS

peed

TINAL

OX®

Inoxa

Con®

HARD

LOX®

Supe

rtin®

HYPE

RLOX

®

CCplu

sC®

CCDia

® AeroS

peed

®

CCDia

® Carbon

Spee

dAL

OX®

AluCo

n®

Ferro

Con®

CCDia

® MultiSp

eed

AluSp

eed®

CCDia

® FiberS

peed

TINAL

OX®

Inoxa

Con®

HARD

LOX®

Supe

rtin®

HYPE

RLOX

®

CCplu

sC®

Turning / Grooving

Drilling

Steel

Stainless steel

Cast Iron

Aluminium

Graphite / Green Compact

Ceramics

Titanium

Hard Materials (>50 HRC)

CFRP / GFRP

Steel

Stainless steel

Cast Iron

Aluminium


Ceramics

Titanium


CFRP / GFRP

Milling

Steel

Stainless steel

Cast Iron

Aluminium


Ceramics

Titanium


CFRP / GFRP

The Right Coating For Round-Tools

CCDia

® AeroS

peed

®

CCDia

® Carbon

Spee

dAL

OX®

AluCo

n®

Ferro

Con®

CCDia

® MultiSp

eed

AluSp

eed®

CCDia

® FiberS

peed

TINAL

OX®

Inoxa

Con®

HARD

LOX®

Supe

rtin®

HYPE

RLOX

®

CCplu

sC®

CCDia

® AeroS

peed

®

CCDia

® Carbon

Spee

dAL

OX®

AluCo

n®

Ferro

Con®

CCDia

® MultiSp

eed

AluSp

eed®

CCDia

® FiberS

peed

TINAL

OX®

Inoxa

Con®

HARD

LOX®

Supe

rtin®

HYPE

RLOX

®

CCplu

sC®

CCDia

® AeroS

peed

®

CCDia

® Carbon

Spee

dAL

OX®

Ferro

Con®

CCDia

® MultiSp

eed

AluSp

eed®

CCDia

® FiberS

peed

TINAL

OX®

Inoxa

Con®

HARD

LOX®

Supe

rtin®

HYPE

RLOX

®

CCplu

sC®

Reaming

Threading

Gear Cutting

Steel

Stainless steel

Cast Iron

Aluminium


Ceramics

Titanium


CFRP / GFRP

Steel

Stainless steel

Cast Iron

Aluminium


Ceramics

Titanium


CFRP / GFRP

Steel

Stainless steel

Cast Iron

Aluminium


Ceramics

Titanium


CFRP / GFRP

CCDia

® Carbon

Spee

dAL

OX®

Ferro

Con®

AluCo

n®

CCDia

® MultiSp

eed

AluSp

eed®

CCDia

® FiberS

peed

TINAL

OX®

Inoxa

Con®

HARD

LOX®

Supe

rtin®

HYPE

RLOX

®

CCDia

® Carbon

Spee

dAL

OX®

Ferro

Con®

AluCo

n®

CCDia

® MultiSp

eed

AluSp

eed®

CCDia

® FiberS

peed

TINAL

OX®

Inoxa

Con®

HARD

LOX®

Supe

rtin®

HYPE

RLOX

®

CCDia

® Carbon

Spee

dAL

OX®

Ferro

Con®

AluCo

n®

CCDia

® MultiSp

eed

AluSp

eed®

CCDia

® FiberS

peed

TINAL

OX®

Inoxa

Con®

HARD

LOX®

Supe

rtin®

HYPE

RLOX

®

Steel

Stainless steel

Cast Iron

Aluminium


Ceramics

Titanium


CFRP / GFRP

Drilling

Milling

Steel

Stainless steel

Cast Iron

Aluminium


Ceramics

Titanium


CFRP / GFRP

Turning / Grooving

Steel

Stainless steel

Cast Iron

Aluminium


Ceramics

Titanium


CFRP / GFRP

The Right Coating For Cutting Inserts

CCDia

® Carbon

Spee

dAL

OX®

Ferro

Con®

AluCo

n®

CCDia

® MultiSp

eed

AluSp

eed®

CCDia

® FiberS

peed

TINAL

OX®

Inoxa

Con®

HARD

LOX®

Supe

rtin®

HYPE

RLOX

®

CCDia

® Carbon

Spee

dAL

OX®

Ferro

Con®

AluCo

n®

CCDia

® MultiSp

eed

AluSp

eed®

CCDia

® FiberS

peed

TINAL

OX®

Inoxa

Con®

HARD

LOX®

Supe

rtin®

HYPE

RLOX

®

CCDia

® Carbon

Spee

dAL

OX®

Ferro

Con®

AluCo

n®

CCDia

® MultiSp

eed

AluSp

eed®

CCDia

® FiberS

peed

TINAL

OX®

Inoxa

Con®

HARD

LOX®

Supe

rtin®

HYPE

RLOX

®

Reaming

Steel

Stainless steel

Cast Iron

Aluminium


Ceramics

Titanium


CFRP / GFRP

Threading

Steel

Stainless steel

Cast Iron

Aluminium


Ceramics

Titanium


CFRP / GFRP

Gear Cutting

Steel

Stainless steel

Cast Iron

Aluminium


Ceramics

Titanium


CFRP / GFRP

15 Characteristics Of The Coating Materials

Characteristics Of The Coating MaterialsSp

utte

ring

Dia

mon

dHiP

IMS

CCDia®AeroSpeed®

CCDia®CarbonSpeed

CCDia®FiberSpeed

CCDia®MultiSpeed

AluCon®

FerroCon®

InoxaCon®

ALOX®

AluSpeed®

CCplusC®

HARDLOX®

HYPERLOX®

SUPERTIN®

TINALOX®

Thin

Plus

Plus

Thin

Thin

Plus

Plus

Plus

Thin

Gold

Plus

Thin

Blue

Plus

Plus

Thin

Blue

Gold

C

C

C

C

C

C

C

C

TiB2-based

TiB2-based

TiB2-based

AlTiN-based

AlTiN-based

AlTiN-based

TiAlSiN-based

TiAlSiN-based

TiAlN-based

TiAlN-based

TiAlN-based

TiAlN-based

TiB2-based

TiAlN+C-based

TiAlN/TiSiN-based

TiAlN/TiSiN-based

AlTiN-based

AlTiN-based

AlTiN-based

AlTiN-based

TiN-based

TiAlN-based

TiAlN-based

TiAlN-based

TiAlN-based

3

9

14

7

9

9

3

14

1

2

4

3

4.5

6

1.5

3

4.5

6

6

10

2

3

1.5

3

3

4.5

4.5

6

3

1.5

3

3

3

Coating material Version

16 FerroCon®

~~ 3 µm • • •

~~ 4.5 µm • – –

~~ 6 µm – – •

for unalloyed, alloyed andhigh-speed steel

The premium HiPIMS coating for high-performance applications in unallo-yed, alloyed and high-speed steel. Optimum adhesion, smoothest surfaces, high hardness values and toughness for your tool. Pure performance.

Performance thanks to HiPIMSTechnical data

Coating technology:

HiPIMS

Coating material:

AITiN-based

Color:

Anthracite


1,100 °C


FerroCon®

398FerroCon®

Material: 40CrMoV4-6

Tool: Cutting insert

vc = 250 m/min

ap = 3 mm

z = 2

Tool life(workpieces)

420

400

380

360

340

320

300

280

260

240

220

200211AlCrN


17 InoxaCon®

for hardened and stainlesssteels / titanium

Developed for machining of hardened and high alloyed steel as well as titanium. Its very high thermal stability makes the silicon-doped material InoxaCon® the first choice for your high-end tools.

Heat resistant and reduced reweldingTechnical data

Coating technology:

HiPIMS

Coating material:

TiAlSiN-based

Color:

Copper


1,100 °C


InoxaCon®

~~ 1.5 µm • • –

~~ 3 µm • • •

XCon®

Max. wear

(µm)

97AlCrN

InoxaCon®

0

10

20

30

40

50

60

70

80

90

100

26

Material: 1.4301

Tool: Solid carbide mill, ø8 mm

vc = 80 m/min

fz = 0.035 mm/tooth

ae = 5 mm

ap = 3 mm

z = 4


18 The Sputter-Technology

PVD Sputter-TechnologySmooth, droplet-free coatings for cutting tools

Since 1986, CemeCon has been a trailblazer in developing hardcoatings by using the PVD sputter technology. During sputtering, the material is vaporised and deposited as a coating directly from solid into gas. In tra-ditional processes, the coating material must be melted. This inevitably creates droplets that become blemishes on the coating struc-ture and lead to a very rough surface. During sputtering, these droplets do not appear. The USP of the sputter technology is the extremely smooth surface.

Another advantage of the sputter technology is a significant reduction of the internal stress inside the coating. This enables the deposition of, e.g. AlTiN layers up to a layer thickness of 15 µm and more. An unbeatable advantage in all applications with a great deal of wear volume.

Furthermore, adhesion values – determined by a scratch test – of about 100 newtons are typical.

Sputtering is tremendously flexible. It can be used to produce all known coating composi-tions. There are no limits to the tools that can be coated – from the smallest microtool measuring less than 0.1 mm to big hobs.

19 ALOX® / TINALOX®

for steel from soft to medium hardness

These TiAlN coatings are universally suitable for machining most common steels. The optional finishing additional smoothness to the adds coatings which are already smooth and free of droplets.From thin to thick, with coating thicknesses from 1.5 to 10 µm, all kinds of cutting tools can be optimised to their specific applications.

The universal solution for steel

ALOX®

TINALOX®

Tool life(%)

105

90

75

60

45

30

15

00

56Standard

TiAlN

Material: 100Cr6

Tool: Cutting insertCNGP120408/K313

vc = 246 m/min

fz = 0.2 mm/tooth

ap = 1.5 mm

Cooling: Wet

100ALOX®

Technical data

Coating technology:

Sputtering

Coating material:

TiAIN-based

Colors:

Anthracite / blue / gold


1,000 °C


~~ 1.5 µm • • –

~~ 3 µm • • •

~~ 4.5 µm • – –

~~ 6 µm – – •

~~ 10 µm – – •


20 AluSpeed®

0 AluSpeed®

Material: Aluminium 7075


vc = 960 m/min

fz = 0.084 mm/tooth

n = 38200 min-1

Wear (µm)after 100 milled

components

74uncoated

0

10

20

30

40

50

60

70

80

90

68Competitor

(TiCN)

Protection against cold welding

for aluminium / non-ferrous-materials

TiB2, this sputtered coating composition has nearly no affinity to non-ferrous materials, especially aluminium. There is virtually no material adhesion, the optimised adhesion in combination with the very high hardness guarantees highly reliable processes and maximum productivity.

AluSpeed®

Technical data

Coating technology:

Sputtering

Coating material:

TiB2-based

Color:

Silver


900 °C


~~ 2 µm • • •


21 HARDLOX®

HARDLOX® for titanium / stainless steel / steels up to 70HRC

Silicon doping gives HARDLOX® an especially high hardness and oxida-tion-resistance. The sputtering results in a very smooth surface. Titanium, stainless steel or hardened steels, HARDLOX® is just perfect for machining at high temperatures.

Easy Cutting at high temperatures

Process time(sec)

0

20

40

60

80

100

120

31HARDLOX®

3 µm

108Competitor

(AlTiN)

Material: Titan TiAl6V4


vc = 60 m/min

fz = 0.06 mm/tooth

ae = 12.4 mm

ap = 14.8 mm

z = 4

Cooling: Water-cooled

Technical data

Coating technology:

Sputtering

Coating material:

TiAIN/TiSiN-based

Color:

Copper


1,100 °C


~~ 1.5 µm • • –

~~ 3 µm • • •


22 HYPERLOX®

For enhanced performance in cast iron and steel

for cast iron / steel up to 60HRC

HYPERLOX®, the universal solution for all types of cast iron and steel up to 60HRC, is AlTiN-based. The high content of aluminum results in high hard-ness. The smooth and droplet-free surface and the very good adhesion of the coating make HYPERLOX® perfect for end mills, the Plus versions also feature greater wear volumes to increase tool life and productivity.

HYPERLOX®

Technical data

Coating technology:

Sputtering

Coating material:

AITiN-based

Colors:

Anthracite / blue


1,000 °C


Tool life(m)

90TiAlN6 µm 80

AlTiN3 µm

120

HYPERLOX® Plus6 µm Material: 42CrMoV4

Tool: End mill, ø52 mm

vc = 135 m/min

fz = 1.3 mm/tooth

ap = 1 mm

n = 800 min-1

z = 4

Cooling: Dry

125

112,5

100

87,5

75

62,5

50

37,5

25

12,5

0

~~ 3 µm • • – •

~~ 4.5 µm • – • –

~~ 6 µm – – • •


23 CCplusC® / SUPERTIN®

for threading tools

for soft steels

Reduced friction and wear. These properties make CCplusC® the first choice for threading tools. The carbon top layer acts as a solid lubricant, while the TiAlN anti-wear layer gives extended tool life.

Efficient and friction-reducingTechnical data

Coating technology:

Sputtering

Coating material:

TiAIN+C-based

Color:

Black


900 °C


~~ 3 µm

Technical data

Coating technology:

Sputtering

Coating material: TiN-based

Color: Gold


700 °C


~~ 3 µm

CCplusC®

SUPERTIN®

Tool life(m)

1100TiCN

2083CCplusC ®

Material: 1.7225

Tool: Tap M10

vc = 25 m/min

Thread depth = 25 mm

2200

2000

1800

1600

1400

1200

1000



Developed for easy cutting, SUPERTIN® scores highly above all in wet cutting.

Editor | CemeCon AG | Adenauerstr. 20 A 4 | 52146 Wuerselen | Germany www.cemecon.com

CC_E

N_2

019_

V1.

2Germany CemeCon AG / Phone: +49 2405 4470 122 / [email protected]

USA CemeCon Inc. / Phone: +1 607 562 2363 / [email protected]

China CemeCon Suzhou Coating Technology Co. Ltd. / Phone: +86 512 891 74919 / [email protected]

Japan CemeCon K.K. / Alexander Marxer / Phone: +81 3 6459 4430 / [email protected]

Czech Republic CemeCon s.r.o. / Phone: +420 539 003 501 / [email protected]

Denmark CemeCon Scandinavia A/S / Phone: +45 7022 1161 / [email protected]

India M+V Marketing & Sales Pvt. Ltd. / Manish Adwani / Phone: +91 9158 99 99 56 / [email protected]

Korea Hangil trading company / Mr. Hong-Sik Cho / Phone: +82 10 9389 7825 / [email protected]

Taiwan DKSH Taiwan Ltd. / Tim Liu / Phone: +886 4 2472 1782 / [email protected]

Russia ZAO Rosmark-Steel / Ilya Mozgov / Phone: +7 812 336 27 27 / [email protected]

The Coatings · 2019. 11. 19. · Coating technology: Diamond Microhardness: 10,000 HV 0,05 Coating...

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Transcript of The Coatings · 2019. 11. 19. · Coating technology: Diamond Microhardness: 10,000 HV 0,05 Coating...