Prevent flaking of DLC coatings – extend service life

The challenge

Layer spalling is caused by internal stresses or poor layer bonding

Flaking of hard coatings is often caused by high, thermally induced residual stresses or insufficient adhesive strength between the coating and substrate. The causes are often unsuitable or missing adhesion promoters, which should enable a stable bond to the base material.

If the shift system fails, the consequences are serious: unplanned tool failures, increased rejects, production downtime and therefore rising maintenance costs. In addition, the risk of critical interruptions in the entire production process increases.

Typical problem areas with Chipping of DLC and PVD coatings:

    • Automotive:
      Drive components, clamping technology, piston pins, shafts, bearings (air/radial bearings), components with boundary lubrication conditions, pumps, valves, electric motor bearings, gear wheels
    • Toolmaking:
       Pressing tools, roller burnishing tools, punching and forming tools, clamping technology & clamping systems, measuring equipment
    • Minting industry:
      Coin dies, textured dies, plating rollers, smooth and textured rollers, embossing rollers
    • Medical technology:
      Precision tools, mandrels, gripper fingers, special tools, structured components, system components, handling tools, biocompatible surfaces
    • Food industry:
      Production components, drive systems
    • Semiconductors:
      Wafer chucks, grinders, drive components, pick & place systems, gripper fingers, transport systems, valve seats, sealing surfaces, wafer handling components, precision bearings, transport rollers and guide elements

Our solution

Chipping-free DLC & PVD coating for tools and components

  • Layer relaxation through patented coating technology

  • Improved adhesion through coordinated process control and improved adhesion promoters

  • Production of extremely mechanically resilient coatings

  • Optimized substrate cleaning

Your advantages at a glance

  • Greater competitiveness: cost efficiency, stable processes and less downtime

  • Increased productivity: longer downtimes and fewer breakdowns increase the overall efficiency of production

  • Planning reliability: extended maintenance intervals and stable processes make production planning easier

  • Faster ROI due to lower reject rates and longer usage cycles

  • Sustainability: Longer service life reduces material and energy consumption

Specific cases and success stories

Hydraulic expansion mandrels, mandrels, centering tips, gripper fingers, structured surfaces, guide rails, tribologically highly stressed surfaces

Thanks to our stress-free DLC coating, a large-scale manufacturer of gears was able to massively increase the service life of its hydraulic mandrels. Instead of less than 1,000 clamping cycles, the customer now achieves several months of trouble-free operation – with greater process reliability and significantly reduced tool costs.

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