The specialists in physical vapour deposition (PVD) processes

Tools and components are increasingly exposed to extreme conditions, imposing ever greater demands on their surfaces. In innovative production processes (those designed to achieve greater productivity, for example), higher material removal rates – but with simultaneously better workpiece-surface quality - are a vital necessity. Developments in integrated industry, the "cyberphysical" fourth industrial revolution, ("Industrie 4.0" in German parlance) therefore necessitate optimised tools which achieve a high performance level with absolute dependability and calculable minimum service-lives. Tool development must meet these requirements and, in particular, the need for surface enhancement. Surcoatec are the experts in PVD technology and in all peripheral processes for performance-optimised modification of tool and component surfaces.

It is necessary, to achieve functionally optimised tools, to identify the primary, application-specific wear and failure mechanisms and then counteract them systematically. Hardcoatings are an excellent way of reducing wear, friction and proneness to interaction (e.g. formation of built-up edges).

Coating technology for precision tools: Vacuum arc deposition (the arc process)

The arc process (vacuum arc deposition) is the most widely used industrial PVD technology for deposition of high-performance wear-resistant coatings. Surcoatec has good reasons for utilising this process: it accounts for 85% of the global market in PVD coatings for precision tools. Unceasing further development, combined with arc technology's reliability, will continue to make it the first-choice process in the future, too.

Enormous coating variety:

• Metal coatings (Ti, Cu, Cr, Nb, etc.)
• Nitrides, carbides, oxides and mixtures of these (TiN, TiCN, AlTiN, CrN, CrCN, CrON, Cr2O3, AlCrSiN, ZrN, etc.)
• Hard carbon coatings (ta-C) (ta-C)

Coating combinations of any desired complexity are possible (single-layer coatings = monolayers, gradient layers, multi-layer coatings or nano-composites).

The arc process is used for the coating of

• Tools of all types (chip-removing, forming, primary-shaping and plastics-processing)
• Automotive components (including bucket tappets, power-train parts, etc.)
• Hydraulic components (e.g. pistons)
• Compressor blades
• General mechanical-engineering components
• Piping fittings - for decorative purposes, for instance
• Medical components and instruments

The performance of arc coatings can be optimised by selecting a preparation procedure ideally matched to the specific application. As in all modern high-performance coatings, after-treatment of the surfaces achieves further significant improvements in surface quality, since the process incorporates micro particles (droplets) into the coating. Arc-coated surfaces can be excellently smoothed and polished.

The secrets of success are: continuous further development, process-engineering know-how based on many years of experience, correct selection of the fluids and other media used for preparation and finishing, and exactly the right coating materials.

Surcoatec = Coating Excellence (CoEx) in PVD

Modern high-performance PVD coating systems are, without exception, nowadays applied in batch-type coating units. Surcoatec uses state of the art coating technology for the generation of application-optimised coatings in the context of its s-performance service package. The technology is successfully used around the globe in customised configurations by independent coating companies and tool manufacturers for the coating of precision tools (cutting, shaping and forming tools). In the scope of CoEx (Coating Excellence) and supported by extensive experiences in technology, coating, process and product innovation the Surcoatec Experts develop novel micro-alloyed and nano-structured PVD layers, the MpC excellence coatings.

MpC is a synonym for multipurpose and multi-functional use. The combination of tool and application-specific surface integrity with the unique Surcoatec process management, MpC excellence coatings are universally suitable for precision tools. As a part of this system solution MpC excellence coatings are offered exclusively from Surcoatec.

Fast, flexible, reliable and fully automated. All coatings can be applied cost-efficiently both in small and large production series.

One coating - many applications

MpC excellence coatings: a new class of coating material with self-adapting and thus multi-functional properties.

The only true original, always better than any copy.

The MpC layers are multipurpose coatings for universal use, multi-alloyed and nano-structured. MpC thin films are the latest development in the context of Surcoatec´s Coating Excellence (CoEx) in PVD. Based on various alloying elements inside the coatings and a specifically developed process design for the layer synthesis properties, morphology, generally the crystal structure can be fine-tuned and adapted best to the purpose. The different MpC films are designed to build on one another by multiple micro-alloying to cover a wide range of different applications. Precondition for the multi-functional use of these films is the optimized cutting edge and surface preparation and structuring.

The MpC thin films come along with all ingredients required for each application. This and the coating structure design makes the MpC excellence coatings self-adapting, self-adapting best to the purpose. All films are distinguished by high temperature resistance, high phase stability and low thermal conductivity. Are specific micro-alloying elements required for instance for the dry or hard machining, the conditions let them come to the fore by diffusion towards the surface and reaction in the contact zone between MpC coating and workpiece material. So MpC´s hold a certain amount of different alloying elements dissolved in the mixed crystal. Due to this unique concept of a multi-phase mixture of phases with a more ceramic character, e.g. nitridic or carbidic phases and phases of more metallic character the MpC thin films become adaptive and thus multi-functionally applicable. Together with an optimal edge and surface preparation and a coating finish MpC´s can be used to full potential.

Within the framework of the compact solution consisting of optimized preparation, coating and surface structuring the Surcoatec MpC layers are unique due to their characteristics and universally applicable where previously various layers had to be used.

One coating, many applications!