Cold Forming

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

Placeholder for Coating solutions for Cold FormingCoating solutions for Cold Forming
Placeholder for Cold FormingCold 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

Placeholder for Stamping FormStamping 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.

Placeholder for Forming rollForming 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.

Placeholder for Cold forging punchCold 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.

Placeholder for Deep drawing - aluminum can nose punchDeep 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.

Placeholder for Powder compaction transpPowder 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
Placeholder for Deep drawing - aluminum can nose punchDeep drawing - aluminum can nose punch

Ionbond™ 01

PVD coating for use in stamping, cold forging and plastic injection molding applicationsIonbond™ 01’s hardness, and wear resistance, makes it an ideal coating for blanking, trimming, and piercing too…

Read more
Forming & Molding
Placeholder for Forming rollForming roll

Ionbond™ 10

PVD coating for use in metalforming and plastic injection molding applicationsIonbond™ 10’s higher hardness, wear resistance and lower coefficient of friction than PVD TiN make it a more efficient co…

Read more
Forming & Molding
Placeholder for Extrusion Hot Forming Maximizer ColorExtrusion Hot Forming Maximizer Color

Ionbond™ 22

Versatile PVD coating for use in metal forming, die casting and plastic injection molding applicationsIonbond™ 22 is an AlTiCrN coating that possesses excellent toughness, wear resistance, and gallin…

Read more
Forming & Molding
Placeholder for Microsection Ionbond 25Microsection Ionbond 25

Ionbond™ 25

PVD Coating for use in metal forming applicationsIonbond™ 25 is an AlCrN coating that possesses high hardness and excellent wear resistance. This combination of properties makes Ionbond™ 25 a good co…

Read more
Forming & Molding
Placeholder for Die casting hot formingDie casting hot forming

Ionbond™ 30

Versatile PVD coating for use in metalforming and plastic injection molding applicationsIonbond™ 30’s toughness, wear resistance, and galling resistance make it an excellent candidate for light to me…

Read more
Forming & Molding
Placeholder for Ionbond 347 coated samplesIonbond 347 coated samples

Ionbond™ 347

Next generation oxynitride CrN/CrON coating for use in plastic molding applicationsIonbond™ 347 is a multi-layered CrN/CrON oxynitride coating. It provides superior performance to traditional PVD TiN…

Read more
Forming & Molding
Placeholder for Ionbond 35 sample sIonbond 35 sample s

Ionbond™ 35

PVD coating for use in aluminum die casting, hot stamping & plastic injection molding applicationsIonbond™ 35 provides superior performance to PVD TiAlN and CrN coatings in aluminum die casting a…

Read more
Forming & Molding
Placeholder for Ionbond 347 coated samplesIonbond 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 with a proven track record i…

Read more
Forming & Molding
Placeholder for CD moldCD mold

Ionbond™ 40

Versatile PVD DLC coating for use in metal forming and plastic injection molding applicationsIonbond™ 40 is a DLC coating with excellent toughness, a low coefficient of friction, and good galling res…

Read more
Forming & Molding
Placeholder for Plastic Mold DLCPlastic 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 resistance and a low friction p…

Read more
Forming & Molding
Placeholder for Bottle cap mold shadowBottle 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 abrasive wear and galling re…

Read more
Forming & Molding
Placeholder for Powder compaction transpPowder 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 friction of a solid lubricant c…

Read more
Forming & Molding
Placeholder for Concept 90 7 shadow transpConcept 90 7 shadow transp

Ionbond™ 90 Concept

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 wide variety of metal form…

Read more
Forming & Molding
Placeholder for Ionbond 95 hot forging transpIonbond 95 hot forging transp

Ionbond™ 95 Concept

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 casting applicationsIonbo…

Read more
Forming & Molding
Placeholder for Ionbond 962 Metal formingIonbond 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 + Ti) top layer. It comb…

Read more
Forming & Molding
Placeholder for Extrusion dieExtrusion 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 ideal coating for open tolera…

Read more
Forming & Molding
Placeholder for IB CVD 10 Ti CN transpIB 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 coefficient of friction than o…

Read more
Forming & Molding
Placeholder for Cold forging punchCold 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 used in light to medium m…

Read more
Forming & Molding
Placeholder for Ionbond CVD 29 transpIonbond 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 conditions present in high tempe…

Read more
Forming & Molding
Placeholder for Orbital forming tool whiteOrbital 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 coefficient of friction of MoS…

Read more
Forming & Molding
Placeholder for FM Tetrabond sheet metalFM 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) coatings. It is a ta-C coating …

Read more
Forming & Molding
Placeholder for Aluminium laser weldingAluminium 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 joining of parts can be i…

Read more
Forming & Molding
Placeholder for LQ Laserstrahlhaerten 1LQ 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 wear and fatigue resistanc…

Read more

Get in touch

Discuss your challenges with Tobias Brögelmann

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

We will get back to you as soon as possible.

Placeholder for Broegelmann Tobias 2021Broegelmann Tobias 2021

Dr. Ing. Tobias Brögelmann

Global Segment Manager Forming and Molding