Hot forming

Improve tool life and product quality by increasing high hot hardness, thermal stability and galling resistance

Ionbond Forming Molding Portrait
Die casting hot forming

Hot Forming of ferrous and non-ferrous alloys

During hot forming of ferrous and non-ferrous alloys, higher temperatures and limited lubrication options can result in severe adhesive, abrasive and erosive wear of the tools, not to mention poor product quality. A protective coating that provides high hot hardness, thermal stability and galling resistance can significantly improve tool life and product quality.

Hot Forming coating applications

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

Hot Stamping & Press Hardening

Die Casting

Hot Forging

Extrusion

Hot Stamping PVD coatings

Hot Stamping & Press Hardening

One of the fastest-growing trends in metal forming is the stamping and press hardening of AHSS and generation-3 steels. The tools used in these applications are subject to abrasive and adhesive wear and demanding thermal conditions. Ionbond™ PVD coatings provide the thermal fatigue and galling resistance to significantly improve tool productivity and enhance product quality.

IB 35 freigestellt hoch mirror 2023 12 20 124542 sqha

Die Casting

Heat-checking, soldering, and wash-out issues are very common in die casting of aluminum, magnesium and zinc alloys, because die cavities, cores and inserts for those processes are subject to severe thermal, corrosive and erosive conditions. To overcome these issues and improve tool productivity, Ionbond™ PVD coatings provide thermal stability, abrasion resistance and corrosion resistance.

Whitepaper

Duplex Coating Solutions for High- Pressure Die Casting

Download the whitepaper to get an insight and discover the power of Ionbond's duplex coating solutions for high pressure die casting to improve the performance and productivity of your forming and molding tool

12 pages | 25 minutes well spent

Ionbond Forming Molding Portrait
Hot forging Ionbond 95 accordion

Hot Forging

Tools used in hot forging applications need to function in demanding thermal conditions where they are subject to high forming pressures and severe abrasive and adhesive wear conditions. Together, this can severely limit the tool life and overall productivity. Ionbond™ PVD coatings improve tool productivity and product quality by providing the tools with increased thermal stability and resistance to thermal fatigue and galling.

Whitepaper

Designed for Impact: Ionbond™ 95 Duplex Coating for Hot Forging

Download the whitepaper to get an insight and learn about Ionbond 95 for hot forging and its benefits for your forming tool applications.

10 pages | 20 minutes well spent

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Extrusion hot forming coatings

Extrusion

The tools used in hot extrusion applications of both ferrous and non-ferrous alloys are subject to high forming pressures, severe abrasive wear, adhesive wear driven by corrosion, and very high temperatures. For these challenging applications, especially for tools with complex geometries and large aspect ratios, Ionbond™ CVD coatings provide excellent thermal stability, chemical inertness, hot hardness and corrosion resistance properties.

Our coating solutions

Forming & Molding
Extrusion Hot Forming Maximizer Color

Ionbond™ 22

Versatile PVD coating for use in metal forming, die casting and plastic injection molding applications

Ionbond™ 22 is an AlTiCrN coating that possesses excellent toughness, wear resistance, and galling resistance. This combination of properties makes Ionbond™ 22 a good coating candidate for light to medium forming applications, including those involving carbon steels, austenitic stainless steels, galvanized, prepainted or coated steels, and copper alloys. The ability to combine Ionbond™ 22 with nitriding expands its successful application to include higher strength materials such as ferritic stainless steels, high strength low alloy steels (HSLA), and advanced high strength steel (AHSS) applications.

Furthermore, Ionbond™ 22 has an excellent thermal stability and corrosion resistance, which, when combined with nitriding, enables it to be used in high temperature forming applications such as die casting, hot extrusion, hot stamping, and hot forging. For aluminum die casting applications, Ionbond™ 22 is particularly effective in reducing both the erosive wear and the sticking of aluminum that are so prevalent in these applications. Deposition as a duplex coating by combining Ionbond™ 22 with nitriding of the tool material will significantly improve the tool performance.

Ionbond™ 22 is generally deposited between 450-550 °C. These processing temperatures require tool materials to be tempered at higher temperatures in order to avoid softening or dimensional changes.

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Forming & Molding
Microsection Ionbond 25

Ionbond™ 25

PVD Coating for use in metal forming applications

Ionbond™ 25 is an AlCrN coating that possesses high hardness and excellent wear resistance. This combination of properties makes Ionbond™ 25 a good coating candidate for piercing, blanking, and trimming applications involving carbon steels, austenitic stainless steels, galvanized, prepainted or coated steels and advanced high strength steels (AHSS).

Ionbond™ 25’s excellent wear resistance also enables it to enhance the performance of tools used in powdered metal compaction applications. Ionbond™ 25 has excellent thermal stability, which, when combined with nitriding, enables it to be used successfully in high temperature forming applications. One particular high temperature application well suited for Ionbond™ 25 is the hot stamping of AHSS materials where both thermal stability and high wear resistance are indispensable.

Ionbond™ 25 is generally deposited between 450-550 °C. These processing temperatures require tool materials to be tempered at higher temperatures in order to avoid softening or dimensional changes.

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Forming & Molding
Ionbond 35 sample s

Ionbond™ 35

PVD coating for use in aluminum die casting, hot stamping & plastic injection molding applications

Ionbond™ 35 provides superior performance to PVD TiAlN and CrN coatings in aluminum die casting applications. Ionbond™ 35 exhibits excellent resistance to penetration by molten aluminum, high abrasive wear resistance to the silicon common in die casting alloys, and superior thermal fatigue resistance. These properties lead to improved resistance to soldering (aluminum sticking) and erosion that are the common tool failure modes in aluminum die casting applications.

Its high thermal stability, resistance to aluminum corrosive attack and mechanical fatigue resistance make Ionbond™ 35 a superior candidte for aluminum extrusion, and hot stamping or press hardening applications, particularly those where the steel material is coated with an aluminum alloy. Due to its excellent properties, nitriding of the tool material can be dispensed with in many cases without affecting the tool performance. Further, the equiaxed grain structure of Ionbond™ 35 produces superior corrosion resistance allowing it to perform well in plastic molding applications utilizing resins that produce corrosive vapors during the process.

Ionbond™ 35 can be deposited over a wide range of temperatures. This versatile process allows a variety of tool materials  to be successfully coated below the respective tempering temperature which ensures that no softening or dimensional changes will occur.

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Forming & Molding
Ionbond 347 coated samples

Ionbond™ 347

Next generation oxynitride CrN/CrON coating for use in plastic molding applications

Ionbond™ 347 is a multi-layered CrN/CrON oxynitride coating. It provides superior performance to traditional PVD TiN and CrN coatings in plastic molding applications. Ionbond™ 347 exhibits excellent resistance to adhesive wear and abrasive wear during processing of technical plastics and a superior mechanical and thermal fatigue resistance. These properties lead to increased productivity, machine availability and minimized scrap rate.

The low adhesion tendency of its CrON top layer towards all common thermoplastics and elastomers minimizes adhesive wear and sticking of the injected plastic parts to the mold. The excellent wear and impact fatigue resistance of the supporting CrN multilayer structure avoid abrasive wear of the mold by the technical plastics and its additives, such as glass fibers and hard particles to maintain surface appearance and ensure excellent product quality. The CrN multilayer structure in combination with the dense amorphous CrON top layer contributes to an increased corrosion resistance compared to a monolayer TiN or CrN coating.

Ionbond™ 347 is also available as duplex coating with a plasma nitriding of the mold prior to PVD coating. This can additionally help to increase the impact fatigue and corrosion resistance of the coating. Ionbond™ 347 can be deposited over a wide range of temperatures. This versatile process allows a variety of tool materials to be successfully coated below the respective tempering temperature which ensures that no softening or dimensional changes will occur.

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Forming & Molding
Ionbond 347 coated samples

Ionbond™ 357

Oxynitride CrWN/(CrW)xOy coating for high-temperature forming applications

Ionbond™ 357 marks the next evolutionary step of our well-established Ionbond™ 35 (CrWN) coating with a proven track record in high-temperature forming applications, such as aluminum high pressure die casting. Ionbond™ 357 combines the superior mechanical and thermal fatigue resistance of Ionbond™ 35 under complex thermo-mechanical loads with an excellent resistance to abrasive wear and crack formation. Another unique feature of the top layer is its low coefficient of friction against steel and aluminum at high temperatures. This pays off in increased productivity and machine availability as well as improved product quality and minimized scrap rate in high-temperature forming applications.

The low adhesion tendency of the (CrW)xOy top layer towards common thermoplastics and elastomers minimizes adhesive wear and sticking of the plastic parts to the die and makes Ionbond™ 357 a viable alternative to traditional PVD TiN and CrN coatings in plastic molding applications. The excellent wear resistance of the supporting CrWN layer prevents abrasive wear of the die by the technical plastics and its additives, such as glass fibers and hard particles. The CrWN base layer in combination with the dense, amorphous (CrW)xOy top layer provides increased corrosion resistance compared to a monolayer TiN or CrN coating.

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Forming & Molding
Ionbond 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 applications

Ionbond 95 is a new, revolutionary coating with superior fatigue resistance, excellent adhesive and abrasive wear resistance, and a high oxidation resistance. This combination makes it the preferred coating over other coatings for hot forging applications.

The high adhesive and abrasive wear resistance of Ionbond 95 at elevated temperatures makes it suited for challenging forming applications of non-ferrous metals like aluminum extrusion and high-pressure die casting where erosion is the primary failure mode of the tool.

The excellent fatigue and wear resistance characteristics of Ionbond 95 also make it an excellent solution for piercing, cold forming, and trimming of advanced high strength steel (AHSS).

Ionbond 95 is deposited between 400 °C and 450 °C. The process allows coating of a wide variety of tool materials below their respective tempering temperature. This ensures that no softening or dimensional changes will occur. Ionbond 95 is particularly recommended to be combined with nitriding to enhance the load-carrying capability and durability of the tool.

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Forming & Molding
Extrusion die

Ionbond™ CVD 02

Wear resistant and low friction CVD coating

The combination of high hardness, toughness, wear resistance and the low coefficient of friction of Ionbond™ CVD 02 make it an ideal coating for open tolerance tools used in metal forming applications. Ionbond™ CVD 02 provides excellent performance in forming ferritic and austenitic stainless steels, high strength low alloy (HSLA), advanced high strength steels (AHSS), and steel alloy work pieces with a thickness of more than 2 mm.

In addition, the inherent characteristics of Ionbond™ CVD 02 make it a better solution than traditional PVD coatings for open tolerance tools used in piercing applications.

Ionbond™ CVD 02 is deposited at 1000°C. Therefore, it is only recommended for tool materials compatible with the elevated temperatures. Due to the fact that tool steel will undergo dimensional changes, sufficient dimensional tolerances are required or dimensioning has to be adapted to compensate for the expected changes. Tempered tools need to be heat treated after coating in order to restore the desired hardness of the tool material.

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Forming & Molding
IB CVD 10 Ti CN transp

Ionbond™ CVD 10

Traditional CVD Coating for use in metal forming applications

Ionbond™ CVD 10 is a CVD TiCN coating with a high hardness, good toughness and wear resistance, and a lower coefficient of friction than other CVD coatings like Ionbond™ CVD 13. This combination of properties makes Ionbond™ CVD 10 a preferred product over Ionbond™ CVD 13 for open tolerance tooling used in light to medium metal forming applications involving stainless steels, steel alloys with thicknesses greater than 3 mm, and high strength low alloy (HSLA) materials.

Ionbond™ CVD 10 can be deposited between 800 and 1000°C. Therefore it is only recommended for tool materials compatible with the CVD process. In addition, dimensional change will occur on tool steel materials coated with Ionbond™ 10. Therefore, sufficient dimensional tolerances are required to accommodate the expected dimensional change. The broader deposition range for Ionbond™ CVD 10, as compared to that for Ionbond™ CVD 13 and Ionbond™ CVD 02, allow for it to be used on tool steels like S7 (1.2355) or A2 (1.2363), which are not compatible with the deposition process for Ionbond™ CVD 13 or Ionbond™ CVD 02.

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Forming & Molding
Cold forging punch

Ionbond™ CVD 13

Traditional CVD Coating for use in metalforming applications

High hardness, toughness, and wear resistance make Ionbond™ CVD 13 a versatile product for open tolerance tooling used in light to medium metal
forming applications. In addition, the toughness under impact loading makes Ionbond™ CVD 13 an excellent product for open tolerance tooling used in cold forging and fastener trim die applications.

Since Ionbond™ CVD 13 is deposited by means of the CVD process, they can be deposited onto tools with small openings, complex geometries and long aspect ratios (> 1:1). This capability makes it a viable solution for wire drawing, warm and hot extrusion, and some plastic molding injection nozzle applications. Ionbond™ CVD 13 is an excellent choice for ceramic or non steel tool materials in order to promote superior coating adhesion.

Ionbond™ CVD 13 is deposited at 1000 °C. Therefore it is only recommended for tool materials compatible with the CVD process. In addition, dimensional change will occur on tool steel materials coated with Ionbond™ CVD 13. Therefore, sufficient dimensional tolerances are required to accommodate the expected dimensional change.

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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.

Broegelmann Tobias 2021

Dr. Ing. Tobias Brögelmann

Global Segment Manager Forming and Molding