Cold Forming

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.

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

Trimming, piercing and blanking

Cold forging

Deep drawing

Powder compaction

Stamping Form

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.

Forming roll

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 punch

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 - aluminum can nose punch

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 transp

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.

Premium coatings 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.

Forming & Molding
Deep drawing - aluminum can nose punch

Ionbond™ 01

Hardness, and wear resistance, makes it an ideal coating for blanking, trimming, and piercing tools as well as plastic injection molds for glass or fiber filled resins.

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Forming & Molding
Forming roll

Ionbond™ 10

Higher hardness, wear resistance and lower coefficient of friction than PVD TiN make it a more efficient coating for tools employed in blanking, trimming, piercing, and plastic injection molding applications involving glass or fiber filled resins.

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Forming & Molding
Extrusion Hot Forming Maximizer Color

Ionbond™ 22

Ionbond™ 22 is an AlTiCrN coating that possesses excellent toughness, wear resistance, and galling resistance.

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Forming & Molding
Microsection Ionbond 25

Ionbond™ 25

AlCrN coating that possesses high hardness and excellent wear resistance.

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Forming & Molding
Hot forming

Ionbond™ 30

Toughness, wear resistance, and galling resistance make it an excellent candidate for light to medium forming applications, including those involving carbon steels, austenitic stainless steels, galvanized, prepainted or coated steels and copper alloys.

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Forming & Molding
Ionbond 347 coated samples

Ionbond™ 347

A multi-layered CrN/CrON oxynitride coating which provides superior performance to traditional PVD TiN and CrN coatings in plastic molding applications.

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Forming & Molding
Ionbond 35 sample s

Ionbond™ 35

Ionbond™ 35 provides superior performance to PVD TiAlN and CrN coatings in aluminum die casting applications.

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Forming & Molding
Ionbond 347 coated samples

Ionbond™ 357

Oxynitride CrWN/(CrW)xOy coating for high-temperature forming applicationsIonbond™ 357 marks the next evolutionary step of our well-established Ionbond™ 35 (CrWN) coating wit…
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Forming & Molding
CD mold

Ionbond™ 40

Ionbond™ 40 is a DLC coating with excellent toughness, a low coefficient of friction, and good galling resistance. These characteristics make it a coating well suited for for…
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Forming & Molding
Plastic Mold DLC

Ionbond™ 41

Versatile PVD DLC coating for use in metal forming and plastic injection molding applicationsIonbond™ 41 is a DLC coating with excellent abrasive wear and good galling resist…
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Forming & Molding
Bottle cap mold shadow

Ionbond™ 42

PVD DLC Coating for premium performance in metalforming and plastic injection molding applicationsIonbond™ 42 is a DLC coating with superior fatigue resistance, excellent abr…
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Forming & Molding
Powder compaction transp

Ionbond™ 62

Premium PVD coating for use in metal forming applicationsIonbond™ 62 combines the hardness, toughness and wear resistance of PVD TiCN with the ultra low coefficient of fricti…
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Forming & Molding
Concept 90 7 shadow transp

Ionbond™ 90

Next generation PVD coating for use in demanding metalforming applicationsIonbond™ 90 Concept is a next generation PVD coating designed to provide superior performance in a w…
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Forming & Molding
Ionbond 95 hot forging transp

Ionbond™ 95

Next generation PVD coating for premium performance in forming metals and non-ferrous metals, particularly suitable for hot forging, aluminum extrusion and high-pressure die …
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Forming & Molding
Ionbond 962 Metal forming

Ionbond™ 962

Next generation self-lubricating PVD coating for use in demanding metal forming applicationsIonbond™ 962 is a multi-layered coating consisting of Ionbond™ 90 and a MoST (MoS2…
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Forming & Molding
Extrusion die

Ionbond™ CVD 02

Wear resistant and low friction CVD coatingThe combination of high hardness, toughness, wear resistance and the low coefficient of friction of Ionbond™ CVD 02 make it an idea…
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Forming & Molding
IB CVD 10 Ti CN transp

Ionbond™ CVD 10

Traditional CVD Coating for use in metal forming applicationsIonbond™ CVD 10 is a CVD TiCN coating with a high hardness, good toughness and wear resistance, and a lower coeff…
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Forming & Molding
Cold forging punch

Ionbond™ CVD 13

Traditional CVD Coating for use in metalforming applicationsHigh hardness, toughness, and wear resistance make Ionbond™ CVD 13 a versatile product for open tolerance tooling …
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Forming & Molding
Ionbond CVD 29 transp

Ionbond™ CVD 29

Aluminum oxide coating for high temperature forming applicationsIonbond™ CVD 29 Al2O3 is a multi-layered CVD coating engineered to be able to cope with the aggressive conditi…
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Forming & Molding
Orbital forming tool white

Ionbond™ CVD 62

Premium CVD coating for use in metalforming applicationsIonbond™ CVD 62 couples the high hardness, toughness and wear resistance of CVD deposited TiC with the ultra low coeff…
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Forming & Molding
FM Tetrabond sheet metal

Tetrabond™

Smooth Non-hydrogenated DLC CoatingTetrabond™ is a non-hydrogenated, tetrahedral amorphous carbon (ta-C) coating that belongs to the class of diamond-like carbon (DLC) coatin…
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Forming & Molding
Aluminium laser welding

Laser Welding

High productivity, high qualityLaser welding is a well established process and is integrated into a variety of applications worldwide. Through the use of this technique, the …
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Forming & Molding
LQ Laserstrahlhaerten 1

Laser Beam Hardening

Increased wear resistance, longer lifeLaser beam hardening is employed to locally improve the surface properties of components and tools. Use of this treatment can increase w…
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Forming & Molding
Plasma Nitriding

Plasma Nitriding / Duplex Coatings

Plasma Nitriding for Duplex CoatingsTools in metal forming and other challenging forming applications are highly susceptible to abrasive and adhesive wear and fatigue. That i…
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Get in touch

Discuss your challenges with Tobias Brögelmann

Tobias Brögelmann, Global Segment Manager Forming and Molding Tools, will be glad to support you.

We will get in contact with you as soon as possible

Tobias Broegelmann

Dr. Ing. Tobias Brögelmann

Global Segment Manager Forming and Molding