PVD duplex coating for use in aluminum high pressure die casting

• Abrasive wear due to the Si-containing Al alloy
• Erosion (“washout”) and the loss of die material from high velocity and/or turbulent melt flow of the Si-containing Al alloy
• Adhesive wear due to melt deposition on the die surface
• Soldering (“sticking”) being a corrosion mechanism due to chemical reactions of the Al alloy and the die material during filling and solidification
• Heat checking being a thermal fatigue phenomenon resulting from the alternative heating and cooling of the die surface during die casting

With the duplex Ionbond 35 Ionbond™ offers an optimized coating solution for high productivity, maximum machine availability and excellent product quality with minimized scrap rate in Al high pressure die casting. The pre- and post-coating treatment customized to the requirements of the application and the duplex treatment for setting the optimal surface hardness and nitriding hardness depth ensue the superior performance of duplex Ionbond™ 35. Figure 1 demonstrates the superior performance of duplex Ionbond™ 35 increasing the production yield by +50 % compared to the competitor’s duplex coating during the production of parts for commercial air brakes at one of our customers.