1. 6000 North Bailey Avenue Suite 9 Amherst, NY 14226 Phone: 716-270-2228 Fax: 716-270-2230
Sulzer Metco
Diamond-Like Coatings for Plastic
Molding
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2. DLC vs Other Surface Treatments
Sulzer Metco
Properties of DLC Coatings Properties of Other Surface
® ®
COATING Dylyn®/DLC Dylyn Cavidur B4 C Chrome Nickel Teflon WCC
TiN
MATERIAL DLN N * * *
Electroless
*
DIAMOND DIAMOND LIKE Tungsten
TITANIUM Diamond Electroplated Nickel
NAME LIKE NANOCOMPOSITE Carbide
NITRIDE Black CHROME Teflon®
COATING COATING Carbon
Composite
MICROHARDNESS
25 18 30 23 35 8 - 12 4-8 10 - 12
(GPa)
ROCKWELL C 85 78 90 80 95 64 - 70 40 - 60 66 - 70
COEFFICIENT OF
FRICTION AGAINST 0.12 0.07 0.1 0.4 - 0.5 0.4 - 0.5 0.2 - 0.4 0.1 - 0.3 0.2 - 0.3
STEEL (DRY)
COATING
1-4 1-4 2-4 1-4 1-4 Up to 50 5 - 50 2-4
THICKNESS (µM)
MAX. WORKING 570 °F 750 °F 840 °F 1000 °F 1800 °F 600 °F 750 °F 570 °F
TEMPERATURE 300 °C 400 °C 450 °C 600 °C 980 °C 325 °C 400 °C 300 °C
COATING 350 - 430 °F 350 - 430 °F 480 - 660 °F 500 - 950 °F 500 - 950 °F 120 - 175 °F 120 - 175 °F 440 - 480 °F
TEMPERATURE 180 - 220 °C 180 - 220 °C 250 - 350 °C 260 - 500 °C 260 - 500 °C 50 - 80 °C 50 - 80 °C 225 - 250 °C
WEAR FACTOR 1-5 5 - 10 1-5 250 41
(x 10-8 mm3/Nm) +++ +++ +++ ++ ++ + + ++
SURFACE ENERGY
40 - 50 20 - 40 40 - 50 40 - 42 20 - 30 46 - 53
(mN/m)
PVD / Galvanic Electroless
COATING METHOD PACVD PACVD PVD PVD PVD
PACVD Plating Plating
* Not a Sulzer Product listed for comparison purposes only.
| slide 1
3. Traditional Methods of Surface Treatment Sulzer Metco
Electrolysis Nickel Teflon Composite
• Excellent Lubricity (20 - 25% Teflon in deposit)
• Excellent release properties
• Lowest coefficient of friction
• Hardness: 62 Rc
• Weak adhesion to the surface
Chrome Plating
• Finishing necessary on wear parts to eliminate chrome
nodules.
• For optimized frictional and lubricating properties surface
finish must be taken below 15 micro inches Rp
400 X • Hardness: 68 Rc
• Edge build up a problem
Dicronite® Dry Lube
• deposition of 0.000020 inch (0.5 microns) “maximum”
• Not a line-of-sight process
• only corrosion hindering
• Composition - modified (WS2) Tungsten Disulfide in lamellar form.
• Hardness - 1.0 - 1.5 Moh’s scale.
• Co-efficient of Friction - 0.030 inclined plane method, against itself.
| slide 2
4. DLC Coatings
Sulzer Metco
Hard amorphous carbon thin film
very hard DLC
electrically insulating
wear resistant
Comprises C, H
Carbon in sp3 bonding => "Diamond-like" properties
There are a few variants of DLC coatings
Engineered interface layer for low film stress
a-C:H
Hard amorphous carbon thin film
very hard
electrically insulating
wear resistant
Dylyn®
lower friction
low film stress
Comprises C, H, Si, O
a-C:H ~ "Diamond-like" properties
a-Si:O ~ enhances high temperature stability
Dylyn® is a family of coatings
Low intrinsic stress a- C:H; a- Si:O
This is a Sulzer exclusive coating - Several US patents issued
| slide 3
5. Coatings Reduce Abrasive Wear
Sulzer Metco
8000
7000
Hardness Comparison
6000 Soft Hard Particle
5000
4000 DLC
Hard
3000
Vickers (HV)
2000
1000
0
Diamond DLC Dylyn® Metal Carbon Nickel Teflon
Cavidur® N TiN CrN Hard Chrome 52100
PART
TOOL
ABRASION:
The high hardness of Diamond-Like Coatings reduce the likelihood of hard particle penetration into the tool or part.
| slide 4
6. Coatings Reduce Friction / Material Pickup Sulzer Metco
0.8
0.7
0.6
0.5
Coefficient of Friction
0.4
0.3
0.2
0.1
0
PTFE DLC Diamond Metal Carbon TiN 52100
Dylyn® Cavidur® N Nickel Teflon Hard Chrome CrN
τ1 F=τ x A
τ1 > τ2
τ2 PART
TOOL
RESISTANCE TO ADHESION:
The chemically inert characteristics of diamond-like coatings dramatically reduce possibility of cold
welding and material pickup on the surface of the tool
| slide 5
7. Surface Engery & Wetting Behavior of Different Coatings Sulzer Metco
Close-up of a series of
liquid droplets on a
Dylyn® sample
•Surface energy is a
lubricant fluid drop measure of the
wetting angle
with constant volume, affinity of a
here water of contact
substance to stick to
fluid spreads
over the surface the material.
•The lower the value,
Metal the less likely a
DLC TiN TiAlN material will weld or
Carbide
Dylyn®
stick to a surface.
•PFTE has a surface
20 - 40 40 - 42 42 - 46 46 - 53 energy of 18 mN/m
Surface Energy
Better Wetting Behavior (mN/m)
Better Release Behavior
| slide 6
8. Corrosion Test
Sulzer Metco
Dylyn® Corrosive Attack
DLC
PART
TOOL
The high density and
amorphous structure of
Diamond-Like Coatings
inhibit the corrosive by-
products from
penetrating into the
TiN tool.
ASTM B 117-97 Salt Spray Test
| slide 7
9. Plasma Assisted Chemical Vapor Deposition Process
Sulzer Metco
Sulzer Deposition System
Vacuum Pump
Substrates Reactive Plasma
Gas Supply
such as CH4
Plasma Generator
Equipment designed & constructed by Sulzer Metco
Plasma Assisted Chemical Vapor Deposition (PACVD)
process
In-situ substrate cleaning via plasma etching
Substrate temperature does not exceed 220°C
Maximum part dimensions must fit within a 32” diagonal,
be less than 12” in height and weigh less than 100Kg
| slide 8
10. Coating Penetration in Close Spaces Sulzer Metco
PACVD coating process is DLC Coating
non-line of sight
Shadowing occurs in holes or + + + + + + + + + + + +
thin slots + + +
+ + + + + + +
+ + + + +
+ +
During the process there is a + + + + + +
+ +
+ + + + + +
relative gas ion density. +
+
+
As the gas ions travels into the + + X
+ +
restricted pathway; the + +
charged part walls attracts the +
+ +
oppositely charged gas ions +
forming the coating. +
+ (-)
As the gas ions go deeper into +
the restricted pathway, there Taper +
are less available until no
coating is formed. +
This reduction of coating is
called Shadowing and the X
coating forms only as deep as
the width of the opening of the
restricted pathway.
| slide 9
11. Sulzer Stripping Process
Sulzer Metco
Stripped Masked Steel Sample
Stripped
2 Ra Away from edge
As Coated 2.5 Ra
3 Ra
Near Edge
Sulzer uses an Reactive Ion Etching
process to decoat diamond-like and
other carbon based coating types
Stripped finish on 8620 steel typically
changes about 1 to 2 Ra
This process can be used on titanium,
beryllium copper and aluminum parts in
addition to steels and ceramics
Note: Chrome plated parts and small geometries may not be advisable to strip.
| slide 10
12. Diamond-Like Carbon Coatings (DLC) Sulzer Metco
Characteristics
Multi-Layer Coating
All DLC coating have an adhesion layer
Adhesion layer influences important coating properties
Dylyn®, Me-Dylyn® or DLC
Amount of hydrogen controls the hardness
Ti or Dylyn® Adhesion Layer
Multi-layer structures
DLN interlayer acts as buffer layer, reducing stress. Dylyn®, Me-Dylyn® or DLC
Allows for thicker total coating Ti or Dylyn® Adhesion Layer
Thicker coating Longer wear life
Substrate
Multilayer coatings resist Hertzian stresses due to
their higher modulus of elasticity Standard Coating
Stress Fracture
Dylyn®, Me-Dylyn® or DLC
Ti or Dylyn® Adhesion Layer
Substrate
Single Layer Mulit-layer
| slide 11
13. Matching the Coating & Applications / Cavidur®
Sulzer Metco
Sorevi Coatings (Cavidur®)
Benefits of Multiple Layers
• Better Adhesion
• High Fracture Toughness
• Higher Modulus
1 to 2 µm DLC Zone
1 to 3 µm
Adhesion Zone
2 to
5 µm
Base Material
| slide 12
15. SEM-Comparison
Sulzer Metco
2.5 µm
5,000 X
1,000 X
Amorphous coating
structure
without change in
surface finish
Dylyn®/DLC (PACVD) TiAlN (PVD)
| slide 14
16. Comparison of Wear Sulzer Metco
Force (F): 20 N
v
Velocity (V): 200 RPM
Sliding Distance: 10,000
Revolutions
F Wear Factor
Coating (x 10-8 mm3/Nm)
1.40E-05
1.20E-05
DLC 1-5
®
1.00E-05
Dylyn 5 - 10
Wear (mm3/Nm)
8.00E-06 WC/C 41
6.00E-06
TiCN 60
4.00E-06
TiN 250
2.00E-06
0.00E+00
TiAlN 790 - 1000
TiN Cr Dylyn®/DLC
Coating Wear Wear on Steel Ball (52100) | slide 15
17. Dry Running Properties of Materials
Sulzer Metco
Coefficient of friction
Wear tracks of materials after dry running
0.
8 AISI 52100 (DIN 1.3505)
bearing steel, uncoated
0.
AISI 4140 (DIN 1.7225)
7 alloy steel, nitrided Cold
Hard chrome plating Welding
0. Electroless nickel
6
AISI 4135 (DIN 1.7707)
alloy steel, oxynitrocarburised
0. AISI 52100 (DIN 1.3505) uncoated
5 CuSnPb-bronze
Scratches
Nickel-Teflon
0. WC/C-PVD
4 BALINIT C Nearly
DLC No Wear
0. Dylyn®
30
0 10 20 Test time [min]
AISI 4140 (DIN 1.7225) nitrided
0.
2
0.
1
Dylyn® DLC AISI 52100 + BALINIT® C (WC/C) Cu Sn Pb - bronze| slide 16
18. Summary Sulzer Metco
Dylyn®/DLC is able to offer a wide variety of
properties with only ONE coating:
• lowest available coefficient of friction…
• …which is maintained by the high hardness
• no surface roughness changes … that could
influence galling and release properties
• 100% corrosion protection
• Coating temperature below 200°C
• Removable!!
• Biocompatible
| slide 17
19. General Application Guidelines for Diamond-Like Coating Sulzer Metco
For molding surfaces: Use the Dylyn® family of
coatings
For sliding surfaces: Use the DLC family of
coatings
Both coatings can work for molding or sliding
applications, but we typically look at the primary
need to determine which coating is the primary
choice
There are multiple recipes available and if the
first coating recipe did not fully satisfy; we can
determine by analyzing the results what the
optimum coating recipe should be | slide 18