Unlocking the Potential of Duplex Coatings: Insights from Ionbond's Experts

With our new duplex coating capabilities in Ionbond Madison Heights, we’re ready to help our customers in forming and molding make big improvements in their tool productivity. Read what our team of experts has to say about these game-changing coatings.

New plasma nitriding system Madison Heights

In a recent group interview, Ionbond's experts shed light on the technical and sales aspects of duplex coatings, highlighting the remarkable benefits and market demand. Adding this technology to Ionbond’s coating technology portfolio will help Ionbond revolutionize ther forming and molding tool industry.

Chris Flattery, Senior Process Engineer, explains the significance of duplex coatings. "Plasma nitriding combined with PVD coating offers a game-changing solution in the FMT market," he says. "The surface hardening provided by plasma nitriding significantly enhances the resistance to impact fatigue and crack formation, while the PVD coating adds an extra layer of wear protection. This not only extends tool life but also contributes to improved productivity and reduced machine downtime."

New plasma nitriding system Madison Heights installation

Mike Pogasic, Production Manager at Madison Heights, is proud of this new addition to the facility. "Our investment in state-of-the-art plasma nitriding equipment has elevated the services we can provide our customers," he says. "Because we can control the entire process, from plasma nitriding to pre- and post-coat treatments, we can deliver top-notch duplex coatings with the highest service quality standards."

Carol Malfroid, Sales Manager, is expecting the market demand for duplex coatings to grow and develop in the coming years. "Our customers are increasingly seeking solutions that maximize productivity and ensure excellent part quality," she explains. "The forming of demanding workpiece materials, such as advanced high strength steels, presents challenges that conventional coatings can no longer overcome. Duplex coatings offer a reliable solution for applications involving stamping DP980 and DP1180 dual phase steel, hot forging, and high-pressure die casting."

New plasma nitriding system Madison Heights forklift

Tobias Brögelmann, Global Segment Manager for Forming and Molding Tools, emphasizes the impact of duplex coatings on the automotive industry. "Since the automotive sector strives for optimized fuel efficiency through lightweight design, the demand for high-strength steels is on the rise. Ionbond's duplex coatings provide a crucial advantage by supporting forming of thicker sheet metals while maintaining tool integrity. This aligns perfectly with the industry's sustainability goals and ensures compliance with passenger safety standards."

Together, the experts emphasize Ionbond's technical prowess and comprehensive sales approach. "Ionbond Madison Heights is not just a coating provider; we are The Surface Engineers, offering end-to-end solutions," Carol adds. "Our team of experts assists customers in finding the perfect coating solution and ensures precise control of the plasma nitriding process, tailored to their specific tooling material and application requirements."

Coating solutions for forming and molding tools | Ionbond

Ionbond is taking a leading role in duplex coatings, and these insights from our technical and sales experts provide a glimpse into the innovative solutions and market trends that drive the industry forward. Are you interested in seeing what Ionbond’s duplex coatings can do for your application? Download our whitepapers on plasma nitriding for duplex coatings and on duplex coatings for high-pressure die casting. Or read our Ionbond™ Duplex Coating Portfolio: FMT Case Studies, download below.

Case Studies

Duplex Coatings for Forming & Molding Tools

Download the case studies to get an insight and discover the power of Ionbond's Duplex Coatings and improve the performance and productivity of your Forming & Molding Tools.

39 pages | 30 minutes well spent

Coating solutions for forming and molding tools | Ionbond
Ionbond Duplex Coatings Plasma Nitriding parts

What are Ionbond’s duplex coatings?

Ionbond's duplex coatings combine plasma nitriding and PVD coating, for enhanced resistance to impact fatigue, crack formation, and wear. Our plasma nitriding capabilities span a wide range of steel grades, including heat treatable, tool, hot work, cold work, high-speed, and stainless steels. The plasma nitriding process generally creates a surface layer that consists of a diffusion layer, compound layer (or "white layer"), and an oxide top layer. The diffusion layer gives the tools their improved impact fatigue strength, and higher resistance to thermal fatigue and crack formation. Ionbond's advanced technology allows us to minimize the formation of the compound layer, which is rather brittle, ensuring optimal adhesion between the PVD coating and the surface layer. Moreover, we offer pre- and post-coating treatments that further enhance the quality and performance of the duplex coatings.

Get in touch

Discuss your challenges with Tobias Brögelmann

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

We will get in contact with you as soon as possible

Tobias Broegelmann

Dr. Ing. Tobias Brögelmann

Global Segment Manager Forming and Molding

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