Cold Forming

Stable, reliable processes, low scrap rates and superb product integrity

Coating solutions for Cold Forming

The high forming pressures and resulting friction present in cold forming operations pose unique challenges for tools for ferrous and non-ferrous working materials. Optimized tool design and the right coating solutions can help overcome such challenges.

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Cold Forming coating applications

Ionbond’s coatings, which are also available in combination with nitriding as a duplex option, have a proven track record in the following cold forming applications:

Stamping

Stamping processes for ferrous and non-ferrous alloys frequently encounter issues such as split and wrinkled product or galling on the tool surfaces. These issues can be further exacerbated when thicker coils, high-strength materials and inadequate lubrication are used. Ionbond^™ PVD and PACVD coatings, with their favorable frictional properties, excellent wear resistance and high impact fatigue resistance, help improve product quality and extend tool life even in the most challenging applications involving AHSS, stainless steel and aluminum alloys.

Trimming, piercing and blanking

Tools for trimming, piercing and blanking of ferrous and non-ferrous alloys need to be able to shear through the cross-section of the coil and retract through the sheared edges with limited to no lubrication at the contact surfaces. The resulting abrasive and adhesive wear can severely decrease tool life and increase scrap rates, especially in applications where AHSS and aluminum alloys are involved. In these applications, spring-back is an increasing concern. Ionbond^™ PVD and PACVD coatings improve tool life and reduce scrap rates by providing the necessary resistance to wear and galling without affecting the tool tolerances.

Cold forging

The benefits of cold forging processes are substantial. They enable higher processing speeds, reduce the use of raw material and result in a better surface finish of the product. However, the tools used in these processes are subject to high contact stresses applied at speed, which can decrease tool life and productivity. Ionbond^™ PVD coatings, with their high impact fatigue and galling resistance properties, can significantly improve tool life and productivity.

Deep drawing

Deep drawing of ferrous and non-ferrous alloys is one of the most challenging forming processes, because of the complexity of controlling the flow of the sheet metal between binder, die and punch. In most cases, even an optimized tool design cannot guarantee a product free of splits, fractures and wrinkles. Ionbond^™ PVD and PACVD coatings, with their low coefficient of friction and high wear resistance, can significantly improve the flow characteristics of the sheet metal. That limits draw ratios, protects tool surfaces and increases product yield.

Powder compaction

Abrasive wear of powder compaction tools can be an issue depending on the powder’s physical characteristics (particle size, hardness, etc.). The chemical composition of such powders can also introduce sticking or adhesive wear and corrosion. During ejection of the compacted parts, frictional forces can introduce wear of the tool. Ionbond’s PVD and PACVD coatings, with their superior adhesion, wear resistance and corrosion resistance, can improve tool life and product quality, ensuring perfect-looking products with a flawless finish.

Coating Portfolio for Forming & Molding Tools

Ionbond’s coating portfolio for Forming & Molding Tools is highly diverse, including some perennial market favorites, allowing for the perfect combination of the base material and surface properties.

Coating portfolio