Forming & Molding

Ionbond™ 40

Versatile PVD DLC coating for use in metal forming and plastic injection molding applications

CD mold
Microsection Ionbond 40

Technical data

Material a-C:H:W
Technology PVD Arc
Thickness range [µm] 4 - 6 µm
Microhardness, HV 1600
Friction vs. Steel 0.20
Service Temperature 350°C
Process Temperature 160 - 250°C
Color Black
Forming & Molding
Deep drawing - aluminum can nose punch

Ionbond™ 01

PVD coating for use in stamping, cold forging and plastic injection molding applications

Ionbond™ 01’s 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. These properties along with the excellent impact resistance make Ionbond™ 01 also one of the most common coatings for cold forging tools. Ionbond™ 01 is often used as a wear indicator in can making and plastic injection molding applications because of its golden color. Ionbond™ 01 can be deposited over a wide range of temperatures. The process allows a variety of tool materials to be coated below the respective tempering temperature which ensures that no softening or dimensional changes occur.

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Forming & Molding
Forming roll

Ionbond™ 10

PVD coating for use in metalforming and plastic injection molding applications

Ionbond™ 10’s 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. Ionbond™ 10 exhibits excellent performance in ferritic and austenitic stainless steels, high strength low alloy (HSLA) and advanced high strength steels (AHSS), aluminum alloys, nickel alloys and titanium.

The high hardness, toughness, and low coefficient of friction of Ionbond™ 10 make it a good candidate for tight dimensional tolerance, high pressure forming applications of ferritic stainless steel alloys, HSLA alloys and AHSS alloys. Deposition as a duplex coating by combining Ionbond™ 10 with nitriding of the tool material will significantly improve the tool performance.

Ionbond™ 10 is deposited at 425°C. It is recommended that tool materials are tempered above >450°C in order to avoid softening or cause dimensional changes during coating.

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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
Die casting hot forming

Ionbond™ 30

Versatile PVD coating for use in metalforming and plastic injection molding applications

Ionbond™ 30’s 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. The ability to combine Ionbond™ 30 with nitriding expands its range of successful applications to including higher strength materials such as ferritic stainless steels, high strength low alloy steels (HSLA), and advanced high strength steels (AHSS). In addition, hot forging applications pose no challenges to Ionbond™ 30 combined with nitriding.

Furthermore, Ionbond™ 30 exhibits excellent resistance to corrosive attack, which makes it a superior alternative to chrome plating in plastic film extrusion applications. The same corrosion resistance, along with its thermal stability and abrasive wear resistance, enable Ionbond™ 30 to perform well in aluminum die casting and hot extrusion applications. Deposition as a duplex coating by combining Ionbond™ 30 with nitriding of the tool material will significantly improve the tool performance.

Ionbond™ 30 can be deposited across a wide range of temperatures. This versatile process allows a variety of tool materials to be successfully coated below the respective tempering temperature, which guarantees that no softening or dimensional changes 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 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™ 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
Plastic Mold DLC

Ionbond™ 41

Versatile PVD DLC coating for use in metal forming and plastic injection molding applications

Ionbond™ 41 is a DLC coating with excellent abrasive wear and good galling resistance and a low friction properties, This combination makes it an ideal coating for forming of nonferrous metals and applications with galvanized, prepainted or aluminized sheet steels with low to medium impact levels. Ionbond™ 41 is particularly well suited for applications where static friction contributes to tool failure.

The low friction and wear characteristic combined with the superb surface quality promotes Ionbond™ 41 to be used in plastic injection molding. The increased hardness protects tools from damage during routine handling. Ejector pins, slide cores, bottle closures and video disc molds are typical examples of where Ionbond™ 41 is used.

Ionbond™ 41 is deposited between 160 and 200°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.

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Forming & Molding
Bottle cap mold shadow

Ionbond™ 42

PVD DLC Coating for premium performance in metalforming and plastic injection molding applications

Ionbond™ 42 is a DLC coating with superior fatigue resistance, excellent abrasive wear and galling resistance and a low coefficient of friction. This combination makes it the preferred coating over other DLC coatings for forming of nonferrous metals in demanding applications, such as trimming aluminum sheets. Ionbond™ 42 is particularly well suited for applications where limited lubrication is employed.

The low friction and wear characteristic combined with the superb fatigue properties promotes Ionbond™ 42  to be used over other DLC coatings in plastic injection molding. The increased hardness protects tools from
damage during routine handling. Ejector pins, slide cores, bottle closures and video disc molds are typical examples of where Ionbond™ 42 is used.

Ionbond™ 42 is deposited between 200°C and 250°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.

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Forming & Molding
Powder compaction transp

Ionbond™ 62

Premium PVD coating for use in metal forming applications

Ionbond™ 62 combines the hardness, toughness and wear resistance of PVD TiCN with the ultra low coefficient of friction of a solid lubricant coating to produce a more efficient product in metal forming applications where sliding friction is the root cause of tool failure. Ionbond™ 62 provides excellent performance in forming applications involving ferritic and austenitic stainless steels, high strength low alloy (HSLA) and advanced high strength steels (AHSS), galvanized, pre-painted, or coated materials, copper alloys, nickel alloys and titanium. Depending on the application or the tool material, Ionbond™ 62 may need to be combined with nitriding in order to achieve maximum performance.

The characteristics of Ionbond™ 62 make it ideal for applications where high friction results in high extraction forces for tools. It is ideally used for piercing, particularly in thick gauge or high strength material, powdered metal compaction and plastic molding ejector pin applications.

The TiCN component included in Ionbond™ 62 is deposited at 425°C. Therefore it is recommended that tool materials be tempered above 500°C in order to avoid softening or dimensional changes.

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Forming & Molding
Concept 90 7 shadow transp

Ionbond™ 90 Concept

Next generation PVD coating for use in demanding metalforming applications

Ionbond™ 90 Concept is a next generation PVD coating designed to provide superior performance in a wide variety of metal forming applications, especially the most demanding cold forming applications. The combination of high hardness, low coefficient of friction, and excellent resistance to cracking under mechanical fatigue conditions enables Ionbond™ 90 Concept to provide superior performance to traditional PVD coatings such as TiN, TiCN, TiAlN, CrN, and TiCrN. It also is a viable alternative to CVD or TD coatings considering that Ionbond™ Concept 90 can provide comparable or superiour performance to these solutions.

Ionbond™ 90 Concept is targeted for the most demanding metalforming applications. Included in these applications are piercing and forming of AHSS and austenitc stainless steel alloys, cold forging, fineblanking powder metal compaction and forming of low carbon steel alloys with thicknesses greater than 2 mm. Deposition as a duplex coating by combining Ionbond™ 90 with nitriding of the tool material will significantly improve the tool performance.

Ionbond™ 90 Concept is generally deposited between 300-400°C. These processing temperatures require tool materials to be tempered at higher temperatures in order to avoid softening or dimensional changes. It can easily be combined with ion or low pressure nitriding in applications requiring added mechanical support.

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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
Ionbond 962 Metal forming

Ionbond™ 962

Next generation self-lubricating PVD coating for use in demanding metal forming applications

Ionbond™ 962 is a multi-layered coating consisting of Ionbond™ 90 and a MoST (MoS2 + Ti) top layer. It combines the high hardness and unrivaled resistance to cracking under mechanical fatigue conditions of Ionbond™ 90 with the ultra-low coefficient of friction of the solid lubricant MoST coating to produce a more efficient coating solution in metal forming applications where sliding friction is the root cause for tool failure.

Ionbond™ 962 provides excellent performance in fine blanking, deep drawing, piercing, extrusion, punching and forming applications involving ferritic and austenitic stainless steels, high strength low alloy (HSLA) steels and advanced high strength steels (AHSS) from 1st generation AHSS covering dual phase DP580, DP780, DP980, and DP1180 steels to 3rd generation AHSS. Additional materials that can be successfully processed with Ionbond™ 962 are galvanized and pre-painted steels. The main benefits of Ionbond™ 962 include reduced frictional forces during metal forming resulting in an extended tool life and minimized adhesion tendency to improve productivity, part surface finish and reduced need for lubrication. The superior performance of Ionbond™ 90 with a proven track record in metal forming applications makes Ionbond™ 962 a viable alternative to CVD or TD coatings. Ionbond™ 962 is also available as duplex coating with a plasma nitriding of the tool prior to PVD coating. This will significantly increase the impact fatigue resistance and improve the performance of the coated 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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Forming & Molding
Ionbond CVD 29 transp

Ionbond™ CVD 29

Aluminum oxide coating for high temperature forming applications

Ionbond™ CVD 29 Al2O3 is a multi-layered CVD coating engineered to be able to cope with the aggressive conditions present in high temperature forming applications. Ionbond™ CVD 29 Al2O3 exhibits excellent thermal stability, chemical inertness, and high wear resistance, which makes it the leading solution for hot extrusion applications for both ferrous and non-ferrous alloys.
Additionally, the thermal stability, density, and corrosion resistance of Ionbond™ CVD 29 makes it an ideal solution for open tolerance tools used in aluminum casting applications where sticking of aluminum is the primary cause of downtime.

Ionbond™ CVD 29 is deposited at 1000 °C. Therefore it is only recommended for tool materials compatible with the CVD process. Dimensional change will occur on tool steel materials coated with Ionbond™ CVD 29, so sufficient dimensional tolerances are required to accommodate the expected dimensional change.

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Forming & Molding
Orbital forming tool white

Ionbond™ CVD 62

Premium CVD coating for use in metalforming applications

Ionbond™ CVD 62 couples the high hardness, toughness and wear resistance of CVD deposited TiC with the ultra low coefficient of friction of MoS2 solid lubricant coating. The result is a more efficient product for open tolerance tooling used in metal forming applications where sliding friction is the root cause of tool failure. Ionbond™ CVD 62 provides excellent performance in the forming of ferritic and austenitic stainless steels, high strength low alloy (HSLA) and advanced high strength steels (AHSS), steel alloy work pieces with thicknesses of more than 2mm, nickel alloys and titanium.

The high toughness and ultra low coefficient of friction of Ionbond™ CVD 62 make it an excellent solution for open tolerance tools used in piercing applications. Ionbond™ CVD 62 is particularly tailored to materials with high work hardening or spring back properties.

The TiC component of Ionbond™ CVD 62 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
FM Tetrabond sheet metal

Tetrabond™

Smooth Non-hydrogenated DLC Coating

Tetrabond™ 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 that is tailored to the specific needs of forming and molding tools with an enhanced temperature stability of 500°C.

The thin, smooth and hard coating is designed to accurately reproduce the geometry of complex shaped dies and maintain maximum edge sharpness. Due to its high adhesion resistance against strongly adherent workpiece materials such as non-ferrous metals, Tetrabond™ is highly suited for forming aluminum. It has a proven track-record in stamping, trimming, blanking, and piercing as well as extrusion of aluminum alloys where it avoids the build-up of material on the tool.

Its very low coefficient of friction makes Tetrabond™ an economical solution to ensure excellent product quality and improving productivity by reducing the scrap rate on dies for forming non-ferrous metals and on ejector pins, heater blocks and heater tips for plastic molding.

Tetrabond™ can be deposited on a broad range of tooling materials including cold work and hot work steels as well as high speed steels (HSS) and cemented carbide regardless of the tool geometry. It can be applied again after stripping making the best use of expensive forming tools.

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Forming & Molding
Aluminium laser welding

Laser Welding

High productivity, high quality

Laser 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 improved in terms of mechanical strength, speed
and economics. Laser welding has many advantages over conventional welding techniques.

Properties

The main target of laser welding is the optimisation of the joining metals through:

  • Improved weld properties
  • Reduction in component distortion
  • Increased automation

Process

Laser welding belongs to the group of liquid-phase joining. The necessary energy is obtained from a focussed laser beam which locally creates
a melt pool that is moved along a joint resulting in a weld seam.
Through the use of a local gas shield, the laser beam absorption can be increased and the oxidation of the workpiece reduced. The resulting
joint often has a higher strength than the base material.

Applications

Examples of welded components are found in the fields of automobile, engineering, medical and aerospace. An important application is the welding of car bodies and tailored blanks, where examples are found in both steel and aluminium, and in the welding of transmission parts where the shorter cycle time compared to electron beam is a significant advantage. Especially important is the aspect of low distortion which due to the low heat input offers a distinct advantage when welding sensitive components.

Advantages

  • High depth:width ratio compared to conventional processes.
  • Typical values 2:1 to 5:1
  • Low energy input creates low distortion reducing post-treatment costs
  • High welding speeds result in low process times and part price
  • High heating and cooling rates produce fine microstructures which improve the mechanical properties and reduce the heat-affected zone
  • Good control of welding parameters increases reproducibility and readily allows process automation
  • A wide variety of weld forms are possible, increasing freedom of design

Laser-weldable materials

Weldable materials range from normal and high-strength constructional steels through to high-alloyed stainless steels. Titanium, aluminium and nickel base materials can also be welded without an issue.

Equipment

Ionbond Lasertechnik in Nürnberg employs various laser systems in the power range 300 to 6000 W and robotized beam / workpiece handling with large capacities.

Our service

Ionbond offers a long experience in the field of laser welding.
Our experts are ready with their knowledge to offer you concrete solutions to your welding problems, from evaluation studies through to series production.

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Forming & Molding
LQ Laserstrahlhaerten 1

Laser Beam Hardening

Increased wear resistance, longer life

Laser beam hardening is employed to locally improve the surface properties of components and tools. Use of this treatment can increase wear and fatigue resistance in parts of steel and cast iron. Through a locally restricted heat treatment arises a minimum heat input, thereby minimised distortion. The associated high heating and cooling rates result in fine microstructures with good mechanical properties.

Targets

Optimisation of surfaces through:

  • Increasing wear resistance
  • Improvement of the mechanical-dynamic properties

Process

As in conventional hardening, a hardness increase arises through martensitic transformation of the microstructure. The localised absorption of the laser beam creates a rapid increase in surface temperature to above the austenitisation temperature. A rapid cooling by conduction of heat into the relatively cool substrate generates the necessary transformation in appropriate steels. In addition, compressive stresses are generated in the hardened layer.

Applications

Laser beam hardening can be applied wherever localised improvement of hardness and fatigue life are required. Examples of successfully
hardened components are found in general engineering (cutting knives, shafts, pump parts, guideways, gears), power generation
(turbine blades, pistons), tool industry (press, forming and injection tools) etc. Laser beam hardening can offer distinct advantages in terms
of hardness, distortion, treatment speed and accuracy in comparison to many conventional processes.

Advantages

  • Fine microstructure with optimum mechanical properties
  • Increased wear resistance
  • Improved fatigue resistance
  • Minimal heat affected zone and distortion through reduced heat input
  • Economic treatments due to rapid process and CNC control
  • Localised treatments possible
  • Areas with difficult access often treatable

Laser-hardenable materials

The range of treatable materials extends from low alloy steels, through to high alloyed tool steels and hardenable stainless steels. Various cast irons can also be easily laser hardened providing the ferrite contents are low.

Equipment

Ionbond Lasertechnik in Nürnberg employs diverse laser systems (Nd:YAG-Laser) and Robot handling with a wide capacity and offers a wide range of treatments. Part weight up to 3t, hardened depth to 5mm and length to 3m is possible.

Our service

Ionbond offers a long experience in the field of laser hardening. Our experts are ready with their knowledge to offer you engineered solutions to your hardening problems.

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Forming & Molding
Plasma Nitriding

Plasma Nitriding / Duplex Coatings

Plasma Nitriding for Duplex Coatings

Tools in metal forming and other challenging forming applications are highly susceptible to abrasive and adhesive wear and fatigue. That is why the forming industry uses surface treatments and coatings to extend the lifetime of forming tools and increase their performance. Ionbond offers duplex coating solutions, which give excellent results close to chemical vapor 
deposition (CVD) coatings, but without affecting the dimensional accuracy by this high-temperature coating technology.

Ionbond duplex coatings consist of a plasma nitriding step followed by a physical vapor deposition (PVD) coating selected from Ionbond’s coating portfolio. Plasma nitriding creates a hard surface with a high resistance to abrasive wear and thermo-mechanical fatigue. It is a low-cost, thermo-chemical diffusion process that can be done at temperatures low enough to not require heat treatment afterwards.

Key features

  • Increased surface hardness in the range between 900 HV2 and 1,300 HV2 to support the PVD hard coating and enhance the load-carrying capability of the tool
  • Smooth hardness gradient between the coated functional surface and the substrate improves coating adhesion and tool durability
  • High thermal and mechanical fatigue strength increases the ability to withstand loads in challenging metal forming applications such as stamping advanced high strength steel (AHSS)
  • Precise process control allows for compound layer-free plasma nitriding with low surface roughness
  • Process temperature is kept below 500 °C to maintain dimensional accuracy and tight tolerances of the tools
  • No post-coat heat treatment is required
  • Dedicated plasma nitriding equipment permits nitriding with nitriding hardness depth (NHD) in the range between 50 µm and 200 µm (and beyond)
  • Tools are treatable up to a maximum size of 1,800 mm (70’’) height and 1,000 mm (39’’) diameter and a maximum weight of 5 tons (10,000 lbs)

Duplex coating combinations

  • Duplex Ionbond 30
  • Duplex Ionbond 35
  • Duplex Ionbond 357
  • Duplex Ionbond 90
  • Duplex Ionbond 95
  • Duplex Ionbond 962

Typical FMT applications for duplex coatings

  • Extrusion punches and dies
  • Forging die
  • Bending dies
  • Stamping dies
  • Draw punches and dies
  • High pressure die casting dies and cores
  • Plastic injection molds
  • Rubber molds

Ionbond is covering the complete manufacturing chain for coating your forming tool successfully and in the shortest possible time including mechanical pre-/post-coating treatment.

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