Precision engineered components and tooling are designed to perform under strenuous operating conditions with speed, precision, and reliability. Over time, however, tiny imperfections and defects in the tooling's surfaces can develop and will begin to cause decreases in operating performance. These defects are the result of abrasive wear of the surface caused by friction, contact with corrosive materials, and many other operating conditions.

Cleaning, buffing and polishing are simple steps that can be taken to remove the corrosive particles and re-finish the surface. However, the manufacturing operations must be shut down every time the tooling needs to be polished, which can result in huge losses in productivity. Additionally, repeated use of polishing and buffing chemicals can strip away layers of the surface, altering the precision dimensions necessary for optimal performance.

A more effective long term solution is the application of coatings to maintain and/or enhance operating performance. Precision coatings are able to increase tools' resistance to abrasive wear and maintain the original surface integrity.

Conventional processes such as electroplating and physical vapor deposition (PVD) are often used to deposit metallic (Chromium or Nickel) or other hard-coatings (TiN, CrN). But these conventional processes both require pre-coating and post-coating treatments that add complexity and cost to the process. Additionally, these conventional coating and plating processes operate at elevated temperatures that can distort dimensions and bulk properties of the components being coated.

Ion Beam Enhanced Deposition is a PVD and chrome plating alternative process that is entirely physical in nature, rather than chemical or thermal. The IBED process does not require pre-coating treatments or post-coating grinding or polishing. IBED coatings are applied at temperatures that do not exceed 200 degrees Fahrenheit, and no toxic chemicals are used or wastes produced. The end result is a high performance coating that maximizes tooling performance without compromising the original precision dimensions, surface finishes, or bulk material properties.

Below is a comparison of conventional plating / coating processes and the IBED coating process:

CHROME / METAL PLATING -

PRE-TREATMENT REQUIREMENTS: Mechanical or chemical roughening

TEMPERATURE RANGE: Plating < 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: Degreasing 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: Degreasing & 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