All-in Treatment CLIENT ADVANTAGES PROCESS CYCLE FOLLOWING AN EXAMPLE WITH HARD COATING RECOMMENDATIONS

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1 All-in Treatment ADVANTAGES n The production unit does not need any additional resources for tool conditioning n Coated tools are ready for use in due time n Manageable schedule and cost planning n Production reliability provided by our technical expertise PROCESS CYCLE FOLLOWING AN EXAMPLE WITH HARD COATING Documentation of actual state upon entry (by Dörrenberg) Tool pre-finish and optimisation in assembled state Disassembly of the tool segments and detailed documentation CLIENT CVD-, PVD- or PA-CVD-coating Documentation of actual state on delivery (by Dörrenberg) If necessary, heat treatment with dimensional check Spot-grinding and assembly of the segments n Take-over of segmented forming tools in the main casting for up to 20t load capacity RECOMMENDATIONS n Tool layout in view of future coating n Attention to construction notes and agreements, respectively n First heat treatment by Dörrenberg Edelstahl Final surface optimisation

2 All-in Treatment HEAT TREATMENT Take advantage of our capacities in vacuum heat treatment as perfect preconditions for a subsequent coating. On your request, we take care of the fitting work after heat treatment. Thereby, you discharge your tool shop and create new capacities. Take also advantage of our all-in treatment for case Hardening and Plasma Nitriding. SEGMENTED DIE POLISHING Your tools are being professionally polished fixed in the main casting. On your request, this service can also be provided on-site in your facilities. CVD-/PA-CVD-/PVD HARD COATING Our all-in treatment also includes the fitting of tool segments into the main casting after coating. OUR SPECIAL OFFER nt um atme cu Va at tre ng t he ai co rd Ha CONSULTING H E A T T R E A T M E N T SURFACE TREATMENT Con st ruc tion To ol sh op P ress ing p lant CONSULTING el ste S P E C I A L S T E E L C A S T I N G CONSULTING TTooooll S P E C I A L S T E E L D E V I S I O N ol To n Complete project support from construction to concluding hard coating Tool Steel casting

3 CVD/PVD WHICH PROCESS IS TO APPLY FOR WHICH PURPOSE? Whatever the coating process, we provide you with competent advice CVD Extreme hardness and performance PVD High hardness without dimensional change Coating process CVD (Chemical Vapour Deposition) Chemical deposition Coating suitability for drill-holes and undercuts Coating temperature of approx C Subsequent vacuum re-hardening treatment necessary Use of dimensional stable materials Excellent adhesion Coating process PVD (Physical Vapour Deposition) Physical deposition in a low temperature plasma Limited coating suitability for drill-holes and undercuts Coating temperatures from 200 up to 500 C Coating suitability below the final annealing temperature No dimensional change of the base material Good adhesion

4 CVD/PVD PROCESSES The CVD coating process defines the chemical vapor deposition of hard materials. At temperatures of approx C, the gaseous components circulate around the substrate. This involves a chemical reaction of the components at the tool surface which build adhesive layers. In opposition to the exclusively thermally acti vated CVD process, the PVD technology enables a physical deposition of thin layers. This allows reduced processing temperatures and thus to deposit hard coating layers at a temperature that is below the final annealing temperature. ADVANTAGES OF HARD COATING LAYERS n Increase in endurance n Reduction of downtimes n Lower unit costs We provide you with competent advice on the selection of a suitable coating system for your specific applications. n Prevention of wear due to abrasion or adhesion n Increase in number of strokes and cycle times n Reduction of lubricants PRECONDITIONS TO BE FULFILLED n Selection of suitable materials n Heat resistant materials n Preferably use of secondarily hardened materials n Use no oils or emulsions containing silicone

5 Heat Treatment OUR SERVICES n Modern vacuum furnaces n Multidirectional cooling n Quenching pressure up to 13bar n Heat treatment with dimensional check n Optimised heat treatment for special steels n Particular heat treatment adapted to special applications During our long experience in coating we have developed a special knowhow in heat treatment technology for heavily loaded tools. Building on confidence and challenging the justification by performance provide the basis for a successful cooperation. It generates reliability for both partners regarding order and order execution. CHARACTERISTICS n Heat treatment for segmented dies with following trimming into the main casting n Heat treatment for subsequent CVD-, PA-CVD-, PVD coating or plasma nitriding

6 Heat Treatment PROCESSING Vacuum heat treatment means creating cost-efficient advantages and competitiveness by a profitable production! Heat treatment is one of the most important parameters with regard to tool life time. Heat treatment enables optimal preconditions for subsequent surface processing. Scale-up 500:1 Example of microstructure and mechanical properties subject to the heat treatment of special steel CPR developed by Dörrenberg (reference sample) hardness hardness impact strength hardness impact strength 3x tempered 63 HRc 2x tempered 63 HRc 1x tempered 61 HRc hardened 58 HRc hardness impact strength ADVANTAGES OF HEAT TREATMENT n Reduction of material allowance n Cost savings for mechanical refinishing operations n Optimal microstructure conditions by means of controlled temperature control n High processing stability and reproductibility n No subsequent tool cleaning n High environment acceptability

7 Induction Hardening OUR SERVICES n Efficient heat treatment of forming tools by applying large inductor track width n Special hardening treatment for tool cutting edges n Optimised process parameters for different tool materials n Suitability for tool dimensions up to 4000 x 7500 mm n Repeatable performances by means of CNC-controlled equipment n 20t load capacity Competent know-how for the treatment of cutting and forming tools

8 Induction Hardening PROCESSING Induction Hardening defines the case hardening process whereby the tool surface is being locally hardened using inductive heat treatment. State-of-the-art equipment enables to select a defined harden ing depth. It is also possible to proceed according to individually regulated harden ing parameters which bring about reproductible results. So best precondi tions are set for case hardening, of cutting blades as well as big forming tools. ADVANTAGES n Generating of tough materials with wear resistant surfaces n Generation of inductor track widths up to 300 mm (without overlapping) n Adapted case hardening depths from 1,0 up to 5,0 mm n Low risk of distortion n Material allowance can be reduced compared to through-hardening processes State-of-the-art equipment enables cost-efficient, low-distortion heat treatment by means of modulated hardening depths

9 PA-CVD An ideal addition to the CVD and PVD technologies n Excellent coating adhesion n Processing temperature of approx. 500 C, thus no second hardening treatment is necessary n Coating without any dimensional change or distortion n Coating of complicated shapes (suitability for drill-holes and undercuts) n New coating systems for exceptional applications (highly heat resistant, high coating hardness) n Best surface by initial plasma cleaning n Cost-efficient coating process EXAMPLES OF APPLICATION

10 PA-CVD PROCESSING PA-CVD coating (Plasma AssistedChemical Vapour Deposition) is like CVD coating a process, where all components required for the layer construction are feeded in a gaseous state, generating most homogeneous layers. By means of the plasma the chemical reactions already occur at temperatures from 500 C upwards. Thus, suitable tool materials maintain their core hardness and no second hardening treatment is required. The process enables optimised coating systems apt to special applications. CHARACTERISTICS n Duplex-processing (nitriding and coating within one process) n Best surface quality without final polishing n Heat resistant coating systems n Economical coating of large tools ADVANTAGES n Prevention of wear due to abrasion, adhesion and erosion n Very low coefficient of friction n Enhanced demouldability n Reduction of lubricants n Suitability for complex shaped tools n Environment-friendly technique

11 Plasma Nitriding OUR SERVICES n Custom-designed plasma nitriding treatment n Special nitriding processing with subsequent PVD or PA-CVD coating n Plasma nitriding without compound/white layer n Nitriding with subsequent oxidation n Partial nitriding n State-of-the-art equipment technology n Tool treatment up to 20t load capacity PRECONDITIONS n Appropriate material selection n Adapted prior hardening treatment

12 Plasma Nitriding PROCESSING While thin layers are deposited on the surface by CVD and PVD processing, plasma nitriding, and nitrocarburisation, respectively, are diffusion processes. The diffusion of nitrogen (and carbon) into the surface near layer has a positive effect on the tools properties profile. In opposition to other nitriding treatments (i.e. gas nitriding or salt bath nitriding), plasma nitriding does not provide only the best environmental compatibility but it also offers reliable process control and high reproducibility. Due to a wide temperature range from 430 C up to 580 C hardness and dimension stability are guaranteed. ADVANTAGES n Enhancement of wear resistance n Considerably enhanced hardness of the surface near layer / case area n Optimised gliding properties n Enhanded corrosion resistance n Higher fatigue strength n Cost savings due to plasma nitriding of prior finish-machined quenched and tempered steels

13 Polishing OUR SERVICES SCOPE OF SERVICES n True-to-form optimisation of your cutting and forming tools n Polishing of tools and pre fabricated parts / components n Defined polishing according to the drawing specifications n Up-to-date treatment capabilities n Mirror finish for all types of application n Treatment of segments assembled in the main casting (max. 20t) n In situ polishing carried out by our specialists n Polishing in tool working direction n In situ polishing of your tools including disassembly and take-over of segments for further surface treatment n Defined optimisation of cutting edges IMPACT OF SURFACE TREATMENT ON THE PERFORMANCE OF FORMING TOOLS Cross-section polish of CVD-TiC coating on different surfaces (500:1) surface finish (schematic) turned grinded polished particular load illustration of particular load on the tool surface forming direction forming direction forming direction

14 Polishing PROCESSING Polishing means that the active tool surfaces are treated in order to obtain the required surface finish without damaging the microstructure. An optimised polishing process generates best preconditions for further surface treatment. Final finish treatment The CVD-coated drawing die as shown has been polished on the upper portion ADVANTAGES n Enhanced gliding properties for metal sheet forming n High surface quality of the finished parts n Reduced for cutting operations lateral friction coefficient n Reduction of lubricants n Enhanced demouldability of die casting components n Best preconditions for any further surface treatment