PVD Coating Technology

PVD coating is a surface treatment that protects tools or components from wear, corrosion, and extreme temperatures while adding an attractive appearance to the object.

PVD coating technology (Physical Vapor Deposition) is a process where metals are transformed into a gaseous state and then transferred onto an object to create a thin coating. This coating, which is just a few microns thick (about one-tenth the width of a human hair), can significantly enhance the properties of the coated object. Wear resistance can be increased by up to twenty times. Objects are shielded from wear, corrosion, high temperatures, and additionally, they look great.

Our Technology

We utilize PVD (Physical Vapor Deposition) methods for coating application, including sputtering and magnetron sputtering, employing both DC and pulsed, as well as HiPIMS magnetron sputtering.

Our coating capabilities extend to all cleaned metallic materials except zinc, as well as glass, plastics, and ceramics. For coating machine parts and tools, we are limited by the size of the vacuum chamber, with a maximum part size of 450 mm in diameter and 700 mm in height. For certain decorative applications, we can coat parts up to the dimensions of a cylinder with a diameter of 1300 mm and a height of 1500 mm.

We can deposit coatings at low temperatures (up to 150°C) to prevent thermal damage to the material onto which the layer is applied (e.g., aluminum, hardened steel).

How does PVD technology work?

Chamber vacuuming

10 – 30 min

The object is placed inside a vacuum chamber, which is then evacuated to a very low pressure. This step ensures that the coating process takes place in an environment free from the presence of air or other undesirable gases that could affect the quality of the coating.

Warm up

90 min

The vacuum chamber is heated to improve adhesion and coating density. The temperature and heating time depend on the material of the object and the desired properties of the coating, typically ranging between 180-450°C.

Ion Etching

30 – 90 min

Ion etching removes the thin oxide layer that forms on the surface of metal parts in the presence of air, thereby increasing the durability of the coating against peeling and wear. Ion etching activates the surface of the parts.

Coating

2 – 10 hr

The coating material (titanium, zirconium, aluminum, etc.) is transformed from a solid state to a gaseous phase within the vacuum chamber. Then, atom by atom, it gradually deposits onto the object, where it reacts and forms a thin film. The process parameters are carefully controlled to achieve the desired thickness and properties of the coating.

Quality Control

12 hr

Upon completion of the process, the chamber is returned to atmospheric pressure, and the coated part is cooled to a safe handling temperature. Subsequently, quality control of the coating is performed, including thickness measurement, adhesion tests, and other relevant tests, to verify the desired properties and quality.

There are numerous coatings available, and we're here to help you select the right technology for your needs. For clients who prioritize product aesthetics, we offer decorative coatings using HiPIMS technology. Clients seeking to reduce friction in their manufacturing process will appreciate DLC coatings or MoSC for vacuum applications. If you're primarily focused on increasing the durability of production tools, you may consider one of our nitride-based PVD coatings. We're here to advise and propose solutions tailored specifically to you.

Do you need to increase efficiency and optimize your production process?

We offer free consultation and cost-benefit analysis.

As one of the few in the Czech Republic, we possess the HiPIMS method (High Power Impulse Magnetron Sputtering), which is an advanced version of magnetron sputtering technology utilizing high-power pulses to create plasma with high ion density. While arc evaporation and magnetron sputtering are basic PVD techniques, HiPIMS represents an advanced version of magnetron sputtering, combining the advantages of both technologies. This enables the creation of coatings with superior microstructure, resulting in smoother, denser coatings with enhanced properties.

Comparison of PVD Technologies

PVD TECHNOLOGY

∴

Advantages

.

Disadvantages

Typical product

Reason for Suitability

ARC EVAPORATION

∴

Greater Coating Hardness
High Adhesion and Density

Produces Droplets (Macro Particles)
Low Corrosion Protection
High Internal Stress

Cutting Tools (Drills, End Mills)
Metal Forming Tools

Ideal for applications requiring highly hard and durable coatings, such as AlCrN or AlTiN coatings
It can create coatings with high adhesion to the surface, which is crucial for improving the lifespan and performance of cutting tools

MAGNETRON SPUTTERING

∴

Low Internal Stress
Smooth Surface
Precise Control of Coating Thickness and Composition

Lower Coating Adhesion Compared to Arc or HiPIMS

Forming Tools
Machine Parts Requiring Low Friction
Parts with Specific Optical Properties
Decorative Applications

Enables the creation of very uniform and homogeneous coatings with very low roughness over large surfaces, ideal for manufacturing thin films for electronic displays
Creation of extremely dense coatings and diffusion barriers

HiPIMS

High Power Impulse Magnetron Sputtering

High Hardness, Wear and Corrosion Resistance
Low Internal Stress
Smooth Surface without Droplets

Approx. 20% Lower Deposition Rate

Cutting and Forming Tools
Aerospace Components
Medical Instruments and Implants
Decorative Coatings

Excellent adhesive properties, low friction coefficient, and high corrosion resistance
Creation of dense and hard coatings
Excellent mechanical and chemical properties

How does HiPIMS work?

HiPIMS stands for High Power Impulse Magnetron Sputtering. HiPIMS is like a super-modern spray. Unlike a regular spray, which can leave a rough and uneven surface, HiPIMS uses electrical discharges to "spray" the material onto the part so finely that the resulting surface is as smooth as a mirror and extremely strong.

How does HiPIMS work? Unlike conventional sputtering, where the material is deposited continuously, HiPIMS deposition transfers material in microsecond pulses with power in the megawatt range. This energy is then capable of not only dislodging atoms but also ionizing and subsequently implanting them into the surface of the coated part. This way, the coated material bonds so well with the surface that it's almost as if they were always one.

PVD Coatings

PVD coatings are widely used in various industries including tools and cutting instruments, where they extend lifespan and increase resistance to wear and tear, in the automotive industry to enhance component durability against corrosion and wear, in electronics where they improve conductivity and protect against corrosion, as well as in medicine where they offer biocompatible surfaces for implants and tools, and also in the watch and jewelry industry where they provide aesthetic surface finishes and increase scratch resistance. Additionally, PVD coatings are more environmentally friendly compared to some traditional processes, making them an ideal choice for a wide range of applications.

The hardest (HV 1000 - 4000) known synthetic materials. High resistance to abrasion, wear, and erosion

Thin ( 1 - 10 micrometers) - minimal impact on dimensions and tolerances of parts and tools

Very low friction (0.01 - 0.6) reduces friction losses and minimizes part wear

Non-stick surfaces (against plastics) - high variability in changing chemical and physical properties of the surface

Low coating temperatures (150° - 450°C) - do not change the geometry of parts due to expansion and maintain material strength

High adhesion to materials - excellent coating adhesion to various materials - metals, glass, and plastic

Growth of PVD Coating

The video shows the growth of a multilayer Nb and Zr simulated using standard molecular dynamics method. In the first part of the video, colors represent atoms of individual elements. In the second part, colors represent the number of neighboring atoms. The number of neighboring atoms indicates the crystalline structure (bcc for Nb and fcc for Zr) as well as the emerging defects due to shadowing and interdiffusion.

DLC Coatings

DLC "Diamond-Like Carbon" combines some of the best properties of diamonds - their incredible hardness and scratch resistance - but is much more affordable and versatile in use.

With these diamond-like coatings, you can coat almost anything, from components in cars to surgical instruments and even your watches, giving them extra resistance to wear and extending their lifespan. In addition to increasing the durability of your belongings, DLC coatings also significantly reduce friction, meaning that moving parts can move smoother and more efficiently without overheating. This is great for anything that rotates, slides, or otherwise moves - from engines and manufacturing equipment to sports gear.

Our specialization

COATING OF MOULDS, DIES AND NON-FERROUS METALS

Unlike other PVD processes, our mould and die coatings are characterised by a very smooth surface without droplets (arc sputtering) and coarse columnar structures (DC magnetron sputtering). As a result, it is possible to achieve a surface that achieves reliable performance and optimum efficiency.

Coating forming tools extends their service life and thus reduces production costs. Proper coating prevents abrasive wear (for example, in fiberglass composite plastics), adhesive wear and sticking in complex shapes and problems with deburring.

COATINGS FOR TOKAMAKS AND FUSION DEVICESCOATING OF MOULDS, DIES AND NON-FERROUS METALS

We have developed coating technology for use in nuclear fusion and advanced scientific experiments. Our services include the application of tungsten, molybdenum, chromium and zirconium coatings specifically designed for Tokamaks. Using state-of-the-art methods, we are able to apply layers up to 20 microns thick, which is ideal for equipment requiring maximum resistance to the extreme temperatures and corrosive environments typical of nuclear fusion experiments. This technology not only increases the efficiency and durability of the components, but also contributes significantly to the safety of the entire system. We offer individual consultation and customization of the technology to your specific needs and project specifications.

Tribological coatings - DLC, WS2, WSC/WSN

Tribological coatings are utilized wherever it is necessary to reduce friction coefficient, prevent cold welding, and ensure good lubricating properties.

The basic principle of tribological layers involves the formation of a tribological layer, which occurs through the transformation of several top atomic layers of the material. A common example is DLC coatings. DLC coatings consist of carbon in diamond and graphite configuration (roughly 50:50), where the diamond configuration ensures high hardness and the graphite configuration low friction. Under pressure, the diamond bonds in the friction contact transform into graphite, and the resulting 2D graphene flakes mediate low friction and thus low wear.

Similarly, our uniquely developed WSC/WSN coatings based on transition metal dichalcogenides operate on the same principle.

Coating of plastics

Thanks to a special technology developed by AdvaMat s.r.o., it is possible to coat plastic parts in small and large series with decorative metallic coatings in gold, silver, or bronze colors.

During the process, the parts are subjected to only a small amount of heat, T <50°C, so even thin-walled parts are not affected. It is possible to coat all materials that can be exposed to vacuum, such as ABS, PP, PE, PA, or PEEK. The maximum size of the parts is 1500 x 1500 x 300 mm.

This coating process is environmentally friendly, replacing chemical chroming, and is compliant with REACH legislation.

Coating at Low Temperatures

We perform the deposition of hard nitride and metallic layers at low temperatures, <150°C. Thanks to a pulsed power source, we are able to coat very hard layers with perfect adhesion even at such low temperatures.

We coat steel 19 312, nitrided steels, aluminum alloys, and other thermally unstable materials to prevent damage to the substrate material. At low temperatures, we predominantly apply coatings such as CrN, TiN, TiAlN, (CrAl)203, and DLC, and other materials can also be arranged upon request.

We are capable of coating plastics and prints from 3D printers (PLA, ABS, and others). For these materials, the coating mainly serves aesthetic purposes or to increase the electrical conductivity of the material.

Optimizing Your Coatings

At AdvaMat Ltd., our primary focus lies in the development and optimization of coatings to precisely meet the needs of our customers. To efficiently and cost-effectively optimize coatings, we employ not only trial-and-error methods but also extensive measurement equipment. In addition to typical mechanical properties of coatings, we are capable of measuring and adjusting the internal stress of the coating, measuring the friction of the coating against any materials (according to ISO and ANSI standards), and precisely measuring surface roughness and geometry (for instance, after edge grinding or polishing).

Coating of Aluminum Alloys

Coating components and tools made of aluminum, or various types of duralumin, is an application that optimally demonstrates the fundamental purpose of coating. It allows for the creation of components from a material that is lightweight, inexpensive, and easy to process, and applying a coating to it that provides sufficient hardness and other necessary properties.

Coating of Non-conductive Surfaces

Non-conductive PVD coatings mainly include DLC layers and oxide coatings. DLC coatings have extensive applications primarily as tribological coatings reducing friction in mechanical mechanisms, as coatings with excellent corrosion resistance, and as luxurious decorative coatings.

Oxides have not been used in industrial practice for tools and components for a long time due to the challenging deposition process. With their ability for good electrical insulation, they complicate the formation and duration of a stable coating process. Special control mechanisms are required for managing the growth of oxide coatings.

Oxide coatings (Al2O3, (AlCr)2O3, and Cr2O3) are mainly used as protection against oxidation at high temperatures and as excellent anti-adhesive coatings against plastics, aluminum alloys, and other colored metals.