What are the primary advantages of coatings?
Simply stated, coatings reduce costs and increase efficiency. Costs are reduced due to the fact that tools last longer, which translates to less downtime. In addition, in many cases tools can be run with dry or with minimum lubricant (or release agents in the case of forming tools) saving both operating and recycling costs. In terms of efficiency, coated tools can generally run at increased production rates, allowing for higher output per hour.

In terms of engine and machine components, coatings reduce friction and improve performance and reliability by reducing wear.

In the case of medical devices and implants, coatings offer longer in-service lifetimes and can be used for color coding, to reduce tool reflection and to minimize working temperatures of bone drills, thus protecting bone which could be damaged at high temperatures.  

How should tools and components be prepared for coating?  
Prior to coating, parts need to be extremely clean in terms of the part surface as well as any holes or internal diameters. The cleaning process is an essential element that determines the adherence, and thus the performance of the coated part or tool. All parts are cleaned by Ionbond prior to coating using a designated process, however Ionbond encourages customers to discuss the optimum requirements for their tools in order to ensure top performance. For more information on part preparation, please click here.

How is the surface finish affected?  
Our coating processes will typically add a few microns of thickness to the parts or tools. Coatings generally follow the surface condition of the tool and do not act as fillers or levelers. Depending on the process, a small amount of roughness may be added to the parts. In such cases where extremely smooth surface finishes are required, post coating polishing can be carried out if required by the customer.

What part or tool geometries can be coated?  
The CVD and ADLC processes coat tools which are fixed in the chamber and allow a uniform, homogeneous coating of the part, including many inner diameters. PVD, on the other hand, is a line of sight process so tools must be fixed in order to ensure the coating is well distributed on the necessary surface. In most cases tools are rotated in the chamber (from single to triple rotation) in order to achieve the necessary homogeneous coverage and thickness. Coating inner diameters in PVD is restricted to a depth equal to the diameter of the opening. 

Does coating affect part geometry and material properties?
In all cases, coatings will add a few microns of thickness to the parts (equal to the coating thickness). In terms of material properties, the process temperature will determine whether or not part geometries could be affected. In terms of CVD coatings, where process temperatures are generally between 800(°) C and 1000(°) C, certain materials will need to be re-heat treated after CVD coating. In the case of PVD coatings, the process temperatures are generally between 250(°) C and 600(°) C, allowing most parts to maintain their tight tolerances. In some cases, PVD coatings are deposited at under 70(°) C to avoid damaging parts made from materials such as plastics. The PACVD process is carried out at under 200(°) C, so tolerances and properties are generally not affected.

Can we mask parts to ensure certain areas are not coated?  
The degree to which masking can be performed depends on the process. Masking is generally quite easy in terms of the PVD process, which is a line of sight process, but slightly more difficult in terms of PaCVD and quite difficult in the case of CVD.

Is there a recommended or optimum substrate?  
No, use the substrate appropriate for the application. Inappropriate substrates will typically not benefit from coatings. In terms of which substrates can be coated, this depends on the coating process. ADLC coatings can be deposited on nearly any material, whether conductive or not. PVD coatings can be deposited on nearly all tool steels, carbides and metals. Magnesium cannot currently be coated by PVD. Plastics, on the other hand, can be coated, but often have an electroplated interlayer. The CVD process is suitable for coating carbides, most tool steels and metals, keeping in mind that post-heat treatment may be required for certain substrates due to the high temperature coating process (750-1050(°) C).

How long does it take to coat our parts?  
Typical lead times are 3 to 5 days. 48 hours or shorter is possible for qualified customers. In the case of test parts, more time is required depending on the nature of the part in order to properly examine such things as the required process paths and fixturing within the chamber.

Can coatings be removed? 
Yes and without heat or damage to tools. Coatings do not have to be removed for recoating.

Is tool condition important?  
Yes. Coatings will make a properly engineered tool work better but will not usually make a poorly designed or bad condition tool work better.