PVD duplex coating for use in aluminum high pressure die casting

Aluminum high pressure die casting is a high-volume manufacturing process which is becoming increasingly popular for the mass production of complex-shaped parts due to its high material utilization and high degree of automation. The short cycle times and the thermal cycling through the molten aluminum alloy and the use of release agents impose high demands on the die.

Technology mood whitepaper duplex coating high pressure die casting

The complex tribological system is responsible for the following damage and wear mechanisms:

  • 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.

AI HPDC Field performance duplex IB 35

The figure 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.

  • Product: parts for commercial air brakes
  • Tool material: H13 (core hardness 46-48HRC)
  • Alloy: aluminum alloy A380 (7.5 – 9.5 at.% Si)
  • Lubrication: atomized spray
  • Primary failure mechanism: soldering
  • Solution: Duplex Ionbond™ 35 (CrWN

Superior performance of Duplex Ionbond™ 35

Productivity increase by +50%

Compared to competitor’s duplex coating

Aluminum sticking significantly decreased

No marks from heat checking


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

Coating solutions for forming and molding tools | Ionbond

You might be interested...

Tetrabond 48 trimming dies

Performance boost in aluminum forming: enabling cost-effective trimming of aluminum with Tetrabond™ (ta-C)

For companies in sheet metal forming, the generation of burrs and slivers is an ongoing challenge, especially when it comes to forming aluminum alloys. Burrs and slivers can reduce the final product quality and are costly to remove, which drives the search for solutions that prevent them from forming. Ionbond’s solution for this challenge is our Tetrabond tetrahedral amorphous carbon (ta-C) coating – a thin, extremely hard coating with a smooth surface and low sticking.

Read more
Dulliken charge

Ionbond: high-tech coatings for luxury accessories available throughout Europe

Ionbond has been a leader in high-performance coatings for decades, for both technical applications and the luxury segment. In luxury products, we have especially earned a name for ourselves in beautiful, durable and high-quality coatings for watches, serving top brands. Today, this know-how has been extended to high-end accessories.

Read more
Cutting Tools coating solutions | Ionbond

Ionbond’s coating solution for machining of non-ferrous materials for EU manufacturing industry

Are you looking to increase the performance of your cutting tools for machining non-ferrous materials? Ionbond has a coating solution that helps combat built-up edges, abrasive wear and more. It was designed specifically to allow you to make use of the great material properties of these materials, while increasing manufacturing efficiency.

Read more
Service Centers
Decorative automotive coating solutions | Ionbond

Major capacity increases at Ionbond Greensboro

Good news for customers in the USA and Canada: Ionbond has invested in its facility in Greensboro, doubling its capacity for decorative PVD coatings. The new machines not only increased the plant's overall coating capacity, but also its coating portfolio, including the color selection of decorative coatings.

Read more
Service Centers
Tetrabond Plus Tools

Ionbond Germany now offers Tetrabond™ Plus

Tetrabond® Plus is now offered at Ionbond Germany's Saxony facility. This tool coating is ideal for machining non-ferrous materials, including aluminum alloys, copper alloys, plastics, and composite materials, making it particularly valuable for applications in the aerospace and automotive industries.

Read more
Rockaway Team DLC Hybrid Machine

Ionbond Rockaway enhances DLC coating capacity to support growing medical instrument industry

With the addition of a cutting-edge Hauzer 1200 PVD/PACVD hybrid tool, we're geared up to meet the soaring demand for quick turnaround times from our surgical instrument clients.

Read more
Industrial components coating solutions | Ionbond

Tribobond™ 51/52/54 – Wear resistance for highly corrosive environments

Modern machinery, with its intricate demands for precision and reliability amid cost pressures, faces challenges. Coatings that provide both corrosion and wear protection are scarce. Read on for insights into innovative solutions addressing this critical gap.

Read more
Decorative automotive coating solutions | Ionbond

Ionbond PVD coatings for automotive interior applications

Are you looking to stand out in automotive interior design with novel colors and increased wear resistance of design elements? Check out Ionbond’s expertise in PVD coatings at the Automotive Interiors Expo Novi from 24-26 October and find out more in below article.

Read more
H2 Hydrogen Charge Station

Ionbond joins Hydrogen Engine Alliance to advance the hydrogen internal combustion engine

Ionbond is proud to join the Hydrogen Engine Alliance! We’re looking forward to lending our expertise to the further development of this interesting technology for carbon-neutral mobility.

Read more
Aurora X Plus Composition 2 c

AuroraX Plus: new versatile coating for a wide range of cutting applications

Have you been looking for a superior tool coating for difficult-to-cut materials? Look no further! Ionbond's new AuroraX Plus coating offers the performance you need in both wet and dry conditions, making it a great all-round tool coating.

Read more
Decorative sanitary coating solutions

NEW Whitepaper: Decorative surfaces that withstand extreme environments

Are you looking for a coating to help your products keep their high performance in extreme environments?

Read more
Decorative coating solutions for automotive interior | Ionbond

Ionbond’s high-quality decorative coatings for extreme environments

Curious about the magic behind long-lasting, beautiful items? Dive into the latest developments in Physical Vapor Deposition (PVD) coatings, revealing the secrets of our decorative finishes.

Read more
Coating solutions for forming and molding tools | Ionbond

New Whitepaper on Duplex Coating Solutions for High-Pressure Die Casting

Read along to find out why high-pressure die casting is becoming increasingly popular for high-volume mass production of complex-shaped parts.

Read more
Scientist XPS special coatings

Tribobond™ 55 – new coating for vacuum and dry gas environments

Ionbond presents Tribobond™ 55, developed specifically for vacuum and dry gas environments!

Read more
Ionbond Duplex Coatings Plasma Nitriding parts

Ready to learn more about Ionbond’s duplex coating solutions?

Download our comprehensive technical presentation, including fundamentals, illustrative examples and real case studies of our duplex coatings in use at Ionbond’s clients.

Read more