Mechanical engineering

Increase lifetime, improve operating efficiency and reliability of various engineered components

Industrial components coating solutions | Ionbond
Ceramic extrusion

Coatings for mechanical components

Many mechanical components in industrial machinery have to operate under adverse conditions, for example high loads, aggressive environments, lack of lubrication or the presence of abrasive particulate. In addition, there are high demands on maintenance-free durability and operational cost savings.

Whitepaper

CVD Coatings for Engineered Components

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Industrial components coating solutions | Ionbond

Engineered components coating applications

Tribobond™ coatings are designed to meet the challenges that mechanical components are exposed to. They extend the lifetime of components, which is a strong contributing factor to sustainability, and often become an enabling element without which operation is not possible.

Water pump engine

Compressors

Tribobond™ coatings are applied to components of various compressors to improve wear performance. Coating the vanes of refrigeration compressors makes them less dependent on lubrication and therefore friendlier for CFC-free operations. Coating the rotors of screw compressors allows more reliable operation in dry conditions and provides additional corrosion protection. Even common piston compressors benefit from heavy-duty Tribobond™ films.

Pumps

Tribobond™  coatings provide performance enhancement for virtually any type of industrial pump. In addition to the moving components of the pumps, elements such as mechanical shafts seals are also regularly coated with Tribobond™ coatings. These seals can be made out of steel, cemented or silicon carbides.

Valve pipes

Valves

In many industries, including oil and gas, food and the chemical and pharmaceutical industries, coatings on valves help combat abrasive wear, prevent seizing and galling, decrease actuation forces and provide lubricant-free operation. Tribobond™ and Ionbond™CVD coatings are successfully implemented in many of these industries to protect valves of various types.

Bearings

Rolling contacts in bearings and gears are typically subjest to high contact loads. Certain coatings in the Tribobond™ family are specifically designed to  help reduce rolling contact fatigue, one of the failure modes in such contacts. Specialty Tribobond™ films help minimize the adverse effects  of contact fatigue and increase the load-carrying capacity. In addition, these films decrease friction in poor lubrication conditions, thus increasing transmission efficiency.

Hydraulic motor

Hydraulics

Pistons, piston rings and piston rods of hydraulic and pneumatic actuators are subject to high wear and are usually protected with hard chrome plating or sprayed coatings. Tribobond™ coatings are a powerful alternative to these technologies. The environmental limitations of chrome plating is forcing manufacturers to look for alternatives. For this application, sprayed coatings are often not cost effective, since the parts require grinding after processing. Tribobond™ coatings do not require post-finishing and are environmentally neutral, making them an ideal solution for hydraulic and pneumatic actuators.

Tribobond™ coatings are also widely used to treat components of hydraulic motors, pumps and transformers. These coatings shine in heavy-duty devices with high loads and low rotational speeds, when efficient lubrication is difficult.

Collet chucks

Long-term dimensional stability is critical for precision machine and metrological tools. With their high hardness and negligent wear rate, Tribobond™ coatings are widely applied to maintain the accuracy and longevity of machine tools and related accessories.

Locating pins

Locating pins

Modern manufacturing often relies on automated  robot-assisted assembly operations that run with virtually no interruptions. That means long-term reliable operation of every single element of the assembly line is crucial. Tribobond™ coatings help provide the wear reduction and lifetime increase of mechanical assembly line elements that make this type of operation possible.

Among such components are locating pins that help fix sheet metal components for welding. Frequent  insertion of these pins in openings in the sheet metal leads to wear and some adhesive effects. Failure of these locating pins may lead to expensive stoppage of an assembly line. Tribobond™ coatings help prevent both wear and galling issues on such pins, substantially extending their life.

Welding pins

A similar application are resistance welding pins. In addition to wear properties, these pins must be electrically insulating  to enable the correct path of the welding current. Application of Tribobond™ or Bernex™ coatings increases the lifespan of these pins by several times, while providing the necessary electrical properties.

Ceramic extrusion

Textile

Protection against premature abrasive wear is critical in virtually all stages of textile manufacturing, including spinning, weaving and  knitting. Both cotton and synthetic threads can be highly abrasive to elements of textile machinery. With stricter environmental regulations being enacted, replacing hard chrome plating, which common in the industry, is becoming an important issue. Tribobond™ and Ionbond™ CVD coatings offer an environmentally friendly and effective protection against wear of key textile consumable components.

Ceramics manufacture

Extending the lifetime of extrusion dies, such as those used for manufacture of fine-walled ceramic inserts of catalytic converters and diesel/gasoline particulate filters, offers immediate commercial benefits for users. Specialty Ionbond™ CVD coatings protect the inner channels of these very expensive tools. With proper die management, multiple recoating cycles are possible, thus further extending the life of the die.

Premium coatings for industrial components

Ionbond’s coating portfolio for Industrial Components is specifically designed to accommodate applications in diverse industries, including aerospace, transportation, power generation and general engineering.

Industrial Components
Microsection Tribobond 01

Tribobond™ 01 Industrial Components

Traditional coating for a wide range of component application

Tribobond™ 01 TiN is arguably the oldest and most popular of PVD coatings. Aesthetically pleasing gold color and excellent mechanical properties al-lowed this coating to become an ultimate general purpose coating across a very wide range of applications and industries.

Tribobond™ 01 TiN  effectively  protects  against  abrasive  wear,  galling  and  fretting and is widely used on many components of industrial machinery. Due to its characteristic yellow color Tribobond™ 01 sometimes is used a wear indicating film.

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Industrial Components
Microsection Tribobond 15

Tribobond™ 15 Industrial Components

Wear resistance coating for high temperature applications

Ionbond’s Tribobond™ 15 TiAlCrN coating possesses an impressive combination of properties; high hardness, excellent toughness and high impact fatigue wear resistance. Tribobond™ 15 also features high temperature stability, which makes it an excellent candidate for high temperature applications such as parts of turbochargers, piston rings and titanium components like engine valves and other high temperature exposed parts.

Tribobond™ 15 TiAlCrN protects against abrasive, adhesive and erosion wear, fretting, galling  and at normal and elevated temperatures.

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Industrial Components
Microsection Tribobond 15

Tribobond™ 20

Wear resistance coating for high temperature applications

Ionbond’s Tribobond™  20 AlTiN coating is designed to provide wear and oxidation protection at temperatures of up to 850°C.  It possesses an impressive combination of properties: high hardness, excellent toughness and impact fatigue wear resistance. Despite its high hardness, Tribobond™ 20 is fairly ductile, which makes it a strong performer in hard particulate erosion applications (e.g. for protection of compressor blades of jet engines).

Other high temperature applications such as parts of turbochargers, piston rings or engine valves also benefit from the unique combination of Tribobond™ 20 properties.

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Industrial Components
Microsection Tribobond 30

Tribobond™ 30 Industrial Components

High temperature resistant coating with excellent toughness

Tribobond™ 30 CrN has a good combination of properties; high hardness, excellent toughness, high wear and impact fatigue resistance. Tribobond™ 30 resists oxidation of up to 700ºC making it a good candidate for high temperature applications. It features a lower residual stress than many other coatings allowing the deposition of thicker layers. CrN can be deposited at low temperatures, which makes it irreplaceable for temperature-sensitive substrates. Tribobond™ 30 CrN is often used as an environmentally friendly replacement for electroplated hard chromium. It can be deposited directly onto the machined components and does not require grinding back to size. Tribobond™ 30 CrN protects against abrasive and adhesive wear, fatigue, oxidation and fretting.

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Industrial Components
Microsection Tribobond 31

Tribobond™ 31 Industrial Components

Low stress wear resistant coating with smooth surface

Sub-stoichiometric Tribobond™ 31 Cr2N  features  lower  residual  stress  than  many  other  coatings from the Tribobond™ portfolio,  including CrN. Since the coating is produced by sputtering it generally features lower roughness than cathodic arc coatings. Crystalline structure of this coating allows for excellent polishing properties. Tribobond™ 31 Cr2N  also exhibits lower surface energy, making this coating more hydrophobic.

In general, Tribobond™ 31 Cr2N protects against abrasive and adhesive wear, impact fatigue, oxidation and fretting.

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Industrial Components
Industrial components coating solutions | Ionbond

Tribobond™ 34

Wear resistant coating with a top oxide layer

Tribobond™ 34 CrON features standard CrN coating with a top layer of CrON. Presence of the oxide film on the surface adds additional functionalities to the coating. Among those are decreased affinity to non-metallic materials, like elastomeric seals and components, lower friction in certain lubricating conditions, anti-sticking and improved resistance to stick-slip phenomenon and certain corrosive environments.  
The main and oxide layers are produced in a single coating cycle, so there is no need for additional processing.

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Industrial Components
Microsection Tribobond 40

Tribobond™ 40 Industrial Components

DLC-based coating for highly loaded industrial and automotive components

Ionbond’s Tribobond™ 40 DLC, also designated as a-C:H:W, is one of the widely used coatings for industrial and automotive components. It is essentially a DLC coating with dispersed nanoparticles of tungsten carbide (WC). The coating is specifically designed for applications with high contact loads in rolling and sliding contacts, such as gears and bearings. It combines excellent running-in properties with a good wear resistance and low friction. In addition, this coating reduces negative impacts of contact fatigue, common in cyclically loaded contacts.
For these reasons, Tribobond™ 40 DLC is a coating of choice on many transmission components in automotive and industrial applications.

Performance

Apart from high wear resistance and low friction, , Tribobond™ 40 DLC exhibits high load bearing capacity and the highest ductility in the Tribobond family of the DLC coatings. It also offers an excellent protection of the counterparts, which extends the lifetime of both components of the friction pair.

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Industrial Components
Piston Pin coating

Tribobond™ 41 Industrial Components

DLC coating with superior sliding properties

Ionbond’s Tribobond™ 41 DLC a-C:H:W + a-C:H coating has been used for high volume automotive production for many years. It combines good running-in properties with a high wear resistance and very low friction. The coating is very well suited for pure sliding conditions in tribological contacts. Tribobond™ 41 exhibits excellent  performance on valve train (e.g. tappets) and crank train components (e.g. piston pin/ ring). State of the art common rail and unit injector components are protected with Tribobond™ 41 DLC in order to improve the robustness and lifetime of fuel pump and fuel injection systems. Apart from automotive, multiple components of industrial machinery benefit from Tribobond™ 41 DLC through reduction of wear and friction, thus extending their lifetime and maintenance intervals. The coating shines in particular in applications with marginal lubrication and high loads.

Performance

Ionbond’s Tribobond™ 41 DLC is applied on components in order to minimize friction losses in engines and engine subsystems, such as oil/water pumps, compressors, and power steering, in order to increase the efficiency and  reduce  the  fuel  consumption  in  transportation.  In industrial applications Tribobond™ 41 is widely used for wear applications in aerospace, oil and gas, power generation, racing and other industries.

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Industrial Components
Microsection Tribobond 42

Tribobond™ 42 Industrial Components

DLC coating for highly loaded industrial components and high volume automotive applications

Ionbond’s Tribobond™ 42 DLC, CrN + a-C:H, coating is engineered for very highly loaded components. It combines a high load carrying capacity and fatigue  resistance  with  a  high  wear  resistance  and  still  exhibits  very  low  friction properties. Tribobond™ 42 DLC presents an excellent performance on valve train (e.g. tappets) and crank train components (e.g. piston pin/ring). State of the art common rail and unit injector components are protected with Tribobond™ 42 in order to improve the robustness and lifetime of fuel pump and fuel injection system. Apart from automotive, multiple components of industrial machinery benefit from Tribobond™ 42 through reduction of wear and friction, thus extending their lifetime and maintenance intervals. The coating shines in particular in applications with marginal lubrication and high loads.

Performance

Ionbond’s Tribobond™ 42 DLC is especially designed to run under combined rolling  and  sliding  situations.  It  combines  properties  of  extreme  fatigue  resistance, a very low coefficient of friction, and high wear resistance within one  coating  system.  In  operation,  this  coating  architecture  provides  ext-reme protection of the coated part, as well as the counterpart. In industrial applications Tribobond™ 42 is widely used for wear applications in aerospace, oil and gas, power generation, racing and other industries.

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Questions?

Discuss your challenges with Val Lieberman

Dr. Val Lieberman, Global Segment Manager Industrial Components, will be glad to support you.

We will get back to you as soon as possible.

Val Lieberman

Dr. Val Lieberman

Global Segment Manager Industrial Components