Accuracy engineered components and tooling are designed to perform under intense operating conditions with pace, precision, and reliability. With time, however , tiny imperfections as well as defects in the tooling's areas can develop and will begin to trigger decreases in operating overall performance. These defects are the consequence of abrasive wear of the surface area caused by friction, contact with hazardous materials, and many other operating circumstances.
Cleaning, buffing and perfecting are simple steps that can be delivered to remove the corrosive particles and also re-finish the surface. However , the actual manufacturing operations must be turn off every time the tooling must be polished, which can result in massive losses in productivity. In addition , repeated use of polishing along with buffing chemicals can remove layers of the surface, changing the precision dimensions essential for optimal performance.
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A more efficient long term solution is the application of films to maintain and/or enhance working performance. Precision coatings can increase tools' resistance to harsh wear and maintain the original area integrity.
Conventional processes for example electroplating and physical water vapor deposition (PVD) are often used to down payment metallic (Chromium or Nickel) or other hard-coatings (TiN, CrN). But these conventional procedures both require pre-coating in addition to post-coating treatments that include complexity and cost towards the process. Additionally , these traditional coating and plating functions operate at elevated temps that can distort dimensions as well as bulk properties of the elements being coated.
Ion Ray Enhanced Deposition is a PVD and chrome plating option process that is entirely actual physical in nature, rather than chemical substance or thermal. The IBED process does not require pre-coating treatments or post-coating milling or polishing. IBED topcoats are applied at temperature ranges that do not exceed two hundred degrees Fahrenheit, and no toxic compounds are used or wastes created. The end result is a high performance covering that maximizes tooling efficiency without compromising the original accuracy dimensions, surface finishes, or even bulk material properties.
Beneath is a comparison of conventional plating / coating processes and also the IBED coating process:
CHROME / METAL PLATING -
PRE-TREATMENT REQUIREMENTS: Mechanical or chemical roughening TEMPERATURE RANGE: Plating, less than 300 degrees Fahrenheit | Baking 300-900 degrees Fahrenheit POST-COATING GRIND/POLISH: Required ADHESION MECHANISM: Mechanical AVAILABLE COATING MATERIAL: Ni, Cr, Ni(B), Ni(PTFE) TOXIC WASTE: Yes
PVD COATING -
PRE-TREATMENT REQUIREMENTS: Decreasing and cleaning TEMPERATURE RANGE: 900-1200 degrees Fahrenheit POST-COATING GRIND/POLISH: Sometimes required ADHESION MECHANISM: Chemical AVAILABLE COATING MATERIALS: TiN, CrN, DLC TOXIC WASTE: Yes
IBED COATING -
PRE-TREATMENT REQUIREMENTS: Decreasing & Cleaning TEMPERATURE RANGE: Less than 200 degrees Fahrenheit POST-COATING GRIND/POLISH: Not required ADHESION MECHANISM: Metallurgical AVAILABLE COATING MATERIAL: Ni, Cr, TiN, Cr2N, Al2O3 TOXIC WASTE: No