Used Equipment

Compare the effectiveness of the wear resistance of coatings pharmaceutical equipment

A study to compare the performance of a series of coatings deposited wear resistant plates / electroplating, deposition physical vapor deposition (PVD) and Ion Beam Deposition (Enhanced IBES) process. Interest was to determine the effectiveness of these coatings "to extend the operating time pharmaceutical precision tools. coverings include: coating industrial hard chrome, PVD deposited on titanium nitride (TiN) and Diamond-like carbon (DLC) and IBES to deposit titanium nitride (TiN). The properties include adherence measures coating, durability and abrasion rate.

MEMBERS / DURABILITY COMPARISON –

A qualitative measure durability and grip hardcoating can be done with a Rockwell "C" test script (VDI 3198 Procedure). The coatings are deposited on a polished steel sample hardened (Rc> 60) with a thickness of between 1 and 3 microns. Rockwell diamond indenter standard script used to measure the surface at a "C" scale (150 kg). This coupon is similar in hardness of the steel and the type of equipment to the pharmaceutical precision tools that can benefit wear-resistant coatings such as punches and dies, pins, jam, and compaction roller.

The withdrawal from the area and examined under a 200X increase and the pattern of cracking in the coating is observed. With good cohesion Hardcoatings lines show little or no fracture extending radially from the center dash outside and beyond circular perimeter of the script. In addition, there are islands appear on the board of the crater broken or the perimeter of the crater. Hardcoatings show good adhesion without delamination the coating is in the crater near the perimeter of the coating.

The test results VDI-3198 of the four coatings tested were varied:

Hard chrome / ELECTROPLATING –

There were lines of radial fracture after the test, indicating failure plates cohesion / Plating in the conical surface of the board. Most radial fracture lines on the layer beyond the scope of the instruments. A series islands were formed cracks, but no delamination of the coating, either by retirement or by his side, indicating good adhesion under high stress.

PRESENTED PVD Diamond Like Carbon (DLC) -

There are many radial fracture lines and islands in the area of ​​tapered board cracked indicating low cohesion. Many of these islands were cracked and delaminated from the surface was filled with the DLC coating delamination beyond the conical script, which indicates poor adhesion under high stress.

PRESENTED PVD titanium nitride (TiN) -

It has a high density of radial fracture lines on the board of the cone and beyond the scope of the script, which indicates poor cohesion and embrittlement of coated surface. The presence of the surface of the islands of cracks in the dash and the perimeter of the cone upside down, many of which delamination, said membership of the substrate marginal hardened steel under high stress.

STRONG IBES titanium nitride (TiN) –

The lines of fracture presence was minimum radius, with a torn cone surface layer script, which indicates excellent cohesion within the coating. Some radial fracture lines slight tear in the wall were the race beyond their reach. The dark areas on the board are indicative of conical particles of dirt transferred from diamond indenter on the toothed surface. The absence of programs covering several islands cracks excellent adhesion to the substrate of mild steel under high stress.

The abrasive wear resistant high-performance coatings can be tested using a Taber abrasion. Out according to standard procedure, SAE/AMS-2438A (SAE International) coatings deposited on discs with a diameter of 3.75 inches (9.5 cm) that have become resistant against volumetric impregnated roller 50 microns in diameter alpha phase aluminum oxide grains. The coated discs were weighed, run for a fixed number of cycles and then reweighed. The thickness of the coating material used can be calculated. Since the standard test parameters are used – the governing grain size of the wheel RPM, and surface charge – the attrition rate are obtained directly comparable as measures of effectiveness would be covered in each of reducing the rate of pharmaceutical machinery wear.

The four surfaces in the study have been deposited 3.75 inches (9.5 cm) diameter, hardened (Rc 64-66) of high speed steel disks that have been honed to a polished end of 0025 micrometers AR (1-inch micro-AA). The coatings were deposited in the equivalent thickness, about 4 microns. The results of the abrasion test of the four layers were compared to the rate of wear of hardened S7 tool steel to 'C' Rockwell 60.

– The wear rate measured for hardened tool steel (S7) was 1.3 microns per 10 000 rpm.
– Industrial Chrome / Electroplating showed a wear rate of 0.6 microns per 10 000 laps – or less than twice the wear of the UN-coated steel.
– PVD deposited diamond-like carbon (DLC) coating showed a wear rate of 0.04 microns per 10 000 laps – or 32 times smaller than the wear of the United Nations with steel cover.
– Countries developing and titanium nitride is deposited IBED (TiN) coatings showed both the wear rate of 0.015 micron 10 000 laps – or 86 times smaller than the wear of the United Nations coated steel.

About the Author

Dr. Deutchman is currently Chairman and Director of Research and Development at Beamalloy Technologies, LLC where he is directly involved with the research, development, and application of the Beamalloy patented IBED coating process. He is the author of numerous articles published in a variety of scientific and trade journals, holds numerous patents, and lectures widely on surface engineering.

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