In heavy cutting of ferrous materials, tool life is linearly dependent on layer thickness. With FerroConQuadro, CemeCon achieves layer thicknesses of up to 12 µm on indexable inserts, thus providing the thickest PVD-based coatings on the market. Compared to the CVD process, HiPIMS technology offers advantages such as smoother and tougher coatings, higher flexibility, more stable process control at lower temperatures, and the ability to precisely manage residual stresses.
Whether high-speed trains or several hundred tons of freight trains – the weights that railway tracks and switches are subjected to suggest the immense demands placed on indexable inserts during milling for track maintenance. This also applies to many other applications in heavy cutting, such as machining large components for shipbuilding, aerospace, or the energy sector: high material removal rates, changing cutting conditions, extreme mechanical loads. At the same time, expectations for tool life, quality of the machined surface, and process stability are increasing. A true test of the tool!
Extremely smooth, hard, and simultaneously tough coatings for tools with long tool life
A solution for competitive performance and quality in heavy cutting is provided by HiPIMS technology: With FerroConQuadro, layer thicknesses of up to 12 µm on indexable inserts can be achieved – significantly more than with other PVD processes. CemeCon thus creates a premium alternative to classic CVD coatings.
With the HiPIMS process developed by CemeCon from sputtering, extremely smooth coatings with a dense and fine-grained structure, as well as an unprecedentedly high toughness and homogeneity, can be produced. Residual stresses can also be precisely adjusted over the layer thickness. Thanks to HiPIMS, a higher machining speed is often possible, and the high machining quality remains consistent throughout the entire lifespan of the indexable inserts.
Technology that shows results
Moreover, process control through the process-safe deposition at moderate temperatures with HiPIMS is significantly easier and more stable than with the CVD process. Due to a process temperature of only about 500 °C, coating temperature-sensitive substrates is possible without them being damaged. At the same time, environmental regulations can be met more easily and cost-effectively, as no harmful waste products are generated in the process.
At the same time, HiPIMS technology offers the highest degree of flexibility and versatility in coating various types of tools. Almost all chemical elements can be used as coating materials on the same system – even extremely thin coatings of less than 1 µm can be applied to delicate geometries of shank tools.
A plus for tool manufacturers
For manufacturers of cutting tools, the great capabilities of HiPIMS technology open up significant potential. Heavy cutting is an excellent example: With FerroConQuadro, coating solutions for a wide range of applications and new business areas can be realized. The unique combination of maximum layer thickness, optimized toughness, and flawless surface smoothness creates opportunities for premium tools with clear positioning in numerous markets.
In navigating and tapping into these markets, customers can rely on a consultative collaboration with CemeCon. With decades of experience in its own coating center, CemeCon's engineering team collaborates with the customer to tailor coating materials and processes individually to the application, substrate, and geometry. This results in customized solutions for demanding applications in heavy cutting and beyond. Tool manufacturers secure a decisive advantage in performance, quality, and cost-effectiveness.
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