FAQs on FortiPhySM Wear Resistant Metal Surface Tool Coatings
Here are some frequently asked questions about Phygen's
UltraEnduranceSM coatings:
Why
do some coatings fail?
Coating failure usually can be traced to two major problems
areas: poor substrate and deficiencies in the coating process
itself.
Substrate problems include improper preparation
(poor surface finish, incomplete cleaning), weak or soft
substrate (wrong material selection or insufficient heat
treatment).
Coating process problems include uniformity
problems (inconsistent or inadequate thickness; porosity;
macro particles, impurities, or columnar structures within
the coating), and adhesion problems (peeling or wearing
off due to substandard or extremely hot application processes).
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What makes FortiPhySM coatings different?
As an engineer from a Detroit automaker told us, "There are A LOT of good coatings, but none of them stick."
Hot coating processesexist to try to solve this problem. Unfortunately, using a hot process may require making several extra tools to get one that meets tolerance requirements after coating. That adds cost and uncertainty to the development process. In the Phygen process, we have extremely good process control and management of coating thickness, while applying at a lower temperature. Phygen's patented process delivers a more energetic plasma, capable of creating nano-sized particles. The resulting tool coatings have vastly superior adhesion, structure, uniformity, density, and coating thickness control.
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What makes Phygen different?
The Phygen team is made up of physicists, engineers, and
machinists dedicated to the custom application of ultra-performance
coatings. The patented FortiPhy process goes well beyond
the technical capabilities of other coating shops. But,
technology is only part of the Phygen difference. Our commitment
to customer service makes Phygen stand alone in providing
personalized service. Unlike other shops, we provide a truly
customized product, fine-tuned to specific applications
and customer needs. One of our customers commented that
his satisfaction and high confidence level were due in part
to his daily communication with Phygen. He stated that,
in addition to feeling that he had a personal Phygen coatings
expert dedicated to his project, “The founders are on the
floor,” ensuring that each part gets custom treatment. To
that we might add, “The patent holders are on the floor”
as well, monitoring and optimizing each step of the coating
process.
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What applications are the best fit
for coatings?
Phygen coatings can help wherever engineered components
need better wear, stress, corrosion, or friction characteristics.
Look at the current lifespan of individual components and
at your production numbers. You might be surprised to find
that simple items such as pierce punches are causing most
of your downtime. Coating those items could improve productivity,
eliminate unnecessary setup costs, and lead to a dramatic
reduction in your need to manufacture and stock redundant
tools. In other cases, you might be spending too much on
specialized material for one high-stress component, where
a FortiPhy coating on a more conventional material would
actually perform better.
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What is the best substrate for coating?
While FortiPhy coatings can improve the toughness of nearly
any metal, critical applications call for better materials.
High-performance tool steels or carbides, with a fine surface
finish, are the best choice for extreme applications. In
addition, the ideal material would have a final tempering
temperature higher than 975ºF to prevent annealing during
the coating process. The ultimate hardness and toughness
of FortiPhy coatings are related to the hardness of the
substrate.
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How does surface finish affect coatings?
Metal surface finish also will affect coating performance. A finer surface finish will allow a more uniform layer of coating to be applied. In general, you should specify a slightly better surface finish than usual. This will ensure maximal coating adhesion, toughness, and lubricity. An exception to this would be applications that require friction, such as thread rolling dies. In these cases, talk to a Phygen coating expert about strategies for increasing friction while improving toughness.
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 Are
there substrate materials to avoid with the Phygen process?
For extreme stress applications such as metal forming
or stamping, tool steels with an annealing temperature lower
than 975ºF should be avoided to ensure that hardness and
grain structure are not compromised during the coating process.
In other applications, such as components subjected only
to abrasive wear, substrate hardness is less critical.
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How are ultra-endurance coatings
applied?
Phygen's patented, proprietary process uses very energetic
plasma to deposit extremely uniform, nanocrystalline coatings.
After a multiple stage cleaning process, your parts are
attached to appropriate, electrically insulated fixtures.
When necessary, special masks are fabricated to prevent
the coating of selected areas. Parts are placed in a vacuum
chamber along with a small quantity of inert or reactive
gas. The parts inside the chamber are slowly heated to a
precise temperature. Next, an electrical charge is supplied
to the coating material, and a highly charged stream of
ions begins to flow to the negatively charged component.
In this way, the coating is “grown” on the surface of the
part, one ion at a time. Phygen's skilled technicians and
meticulous process controls ensure that coatings are applied
to the precise thickness and locations specified.
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What is the coating thickness?
For standard applications, Phygen coating will add between
1 and 1.5 ten thousandths (0.0001” - 0.00015”) to the most
critical surfaces to be coated. We also can adjust the thickness
to suit your particular needs. In the patented Phygen process,
we have extremely good process control and management of
coating thickness. Customers who send us very expensive
plastic injection molds tell us that we are the only coating-service
company that can deliver the precise and uniform coating
thickness they require. Overall, coatings you get from Phygen
will be uniform, and have the specified thickness.
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What is the coating application
temperature?
Phygen coatings are applied at 950º F, helping to ensure
that your heat treatment, dimensions, and other physical
characteristics remain “as designed.” Some commercial coating
processes can subject your engineered components to temperatures
of 1,800º F and beyond.
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How will the coating process affect
part tolerances?
Many coatings require temperatures in excess of 1,800ºF
for extended periods. This can anneal tool steel, compromise
physical properties, and cause components to warp. Some
customers have told us they previously had to make several
parts in order to ensure that they would have one usable
item after coating. The patented FortiPhy coating process
goes on at 950º F, very low compared to most high-performance
coating processes. This typically eliminates the need for
rework after coating.
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Is there a minimum or maximum
surface area for coating?
Any surface that must remain uncoated will be masked off.
Therefore, the minimum surface that can receive coating
is extremely small. Phygen's in-house machining capabilities
allow us to quickly produce any necessary masking or fixtures.
The maximum coated area is limited by the fixturing requirements
for a particular component, and the maximum size of the
coating chamber. Phygen has applied FortiPhy coatings to
a variety of parts and profiles, with great success. Contact
your Phygen representative for details.
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What type of contours are right
for coating?
FortiPhy coatings are applied using a modified line-of-sight
operation. Generally, this means that all working surfaces
can be coated, including holes to a depth up to two times
the diameter. For more radical profiles and complex features,
contact a Phygen coating expert.
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How should component details be
prepared for coating?
The three main elements of success for details that will
receive coating are substrate, surface finish, and heat
treatment. Talk to your Phygen representative about our
sharpening, polishing (both pre- and post-coating), and
tool restoration services.
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What is the maximum part size
that can be coated?
Phygen has successfully coated very large parts, including
a 325-pound ring used to form automotive transmission torque
converters for a Detroit automaker. The ring had a 25” diameter
(with 21" diameter maximum being standard) and a 12”
depth. If in doubt, call a Phygen coatings expert for advice
on your larger components.
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What about rework? Can the coatings
be removed?
Phygen can safely and completely remove FortiPhy coatings
and various other commercial coatings through a proprietary
process whenever rework needs to be done. We can polish
and recoat immediately, or we can send your components back
to you for more extensive rework. Talk to your Phygen representative
about our coating removal and tool restoration services.
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Can Phygen strip all other types
of coatings and then recoat?
Phygen has successfully removed all other commercial coatings,
including CVD. Talk to your Phygen representative about
our coating removal and tool restoration services.
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What are the physical properties
after recoating?
Unlike hot-processed CVD coatings, which combine with
carbon molecules from the substrate to form a hard layer,
FortiPhy CrN is a chemically complete coating, applied to
a surface using a special high-adhesion process.
Typical CVD coatings are applied above 1800°F in order
to increase diffusional activity within the substrate. During
the CVD coating process, carbon atoms move to the surface
and combine with the coating material to form a third compound.
This can produce a hard coating, but there are drawbacks:
only some of the substrate's carbon is available to migrate
to the surface, and it can only travel a short distance.
This means that as tools and coatings wear, the second application
of a CVD coating usually lasts about 70 percent as long
as the first application. A third application generally
has a life of only 30 percent of the original tool. The
free carbon molecules are all “used up” after that. When
no more carbon can be leached to the surface, the process
ceases to provide any benefits.
FortiPhy coating does not require diffusional action within
the substrate to build a hard coating. Instead, the patented
Phygen process, with its unprecedented level of process
control, applies a chemically complete layer of nano-sized
particles onto the surface. The FortiPhy coating does not
require any carbon or other molecules from the substrate.
This means that every re-coat of FortiPhy has the same toughness,
and lasts as long, as the first. Tool life is extended,
and the chemical composition of the substrate remains the
same, regardless of rework.
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In aluminum die casting applications,
how should coated pins be cleaned?
Do not use abrasive stones. A 4-micrometer thick coating
is easily removed on polishing with abrasive stones. There
is a need to use a new die cleaning practice that involves
cleaning the surface of the die (coating) with a dilute
sodium hydroxide solution applied with paintbrush.
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 How
does FortiPhy coating affect hardness?
FortiPhy has both extreme hardness and good toughness.
Also, it is less brittle than other similar coatings, due
in part to its uniform, nanocrystalline structure. Other
coating processes often produce very large macro particles,
pores, or columnar structures within the coating. These
act as stress concentrators, weakening the coating and decreasing
its useful life. Phygen’s patented application process produces
a more uniform coating structure with virtually no defects.
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What about overall strength and
toughness?
Critical load is a measure of toughness. In extreme-stress
machine tools, such as roll forming, forging, and heading
dies, FortiPhy extends tool life significantly by increasing
the allowable critical load. Surface hardness is increased
without brittleness, allowing components to withstand higher
mechanical loads and longer load cycles. Because of its
highly uniform structure, FortiPhy is actually more flexible
(less brittle) than other coatings—-more able to “roll with
the punches” without losing adhesion. Because it has more
"stretch" than other coatings, it has better ability
to withstand repeated impact.
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How will coatings affect friction
and lubricity?
A key benefit of FortiPhy’s nanocrystalline microstructure
is its low coefficient of friction. FortiPhy CrN has a COF
of less than 0.1 under properly lubricated conditions in
an oxidizing environment. FortiPhy coating users report
better release properties and fewer cosmetic rejects after
coating molds used for silicone rubber, aluminum casting
dies, and precision stamping dies. We also can help you
with applications in which you must increase toughness while
maintaining higher friction characteristics.
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How can FortiPhy improve abrasive
wear resistance?
FortiPhy coatings increase surface hardness and toughness,
and reduce friction. This combination, plus high hardness,
makes treated surfaces extremely resistant to abrasion.
FortiPhy coating reduces abrasive wear in machine tools
and engineered components used in harsh environments at
elevated temperatures.
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Will coatings improve corrosion
resistance?
Because of its dense, non-columnar structure, FortiPhy
is chemically inert and provides excellent corrosion resistance.
In one extreme example, acid burn was destroying the vents
in a thermoplastic injection mold after only 8 hours. After
treatment with FortiPhy coating, the mold was still in “like
new” condition after more than 50,000 shots.
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What is the operational temperature
range?
FortiPhy CrN is chemically and thermally stable in air
up to at least 1550°F (850°C). This high resistance against
oxidation gives ForitPhy-coated components higher temperature
resistance than uncoated or conventionally coated parts.
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Is the Phygen process environmentally
safe?
Phygen's patented process begins with a substrate cleaning
using an EPA- and OSHA-approved aqueous solvent bath. Parts
are cleaned in an efficient closed-loop cleaning line that
includes a hard-piped vapor recovery system to capture and
return vapor emissions. To reduce chemical use to an absolute
minimum, final substrate cleaning is performed electronically,
with no emissions. Finally, the FortiPhy coating is applied
electronically within a vacuum chamber, producing no toxic
byproducts and releasing nothing into the atmosphere. The
final product, a FortiPhy ultra-endurance coating, is inert,
safe, and approved for food contact.
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Is the Phygen process for one
or two parts at a time? Or can high volume production parts
be batched and processed?
Large parts will usually be treated individually, but
smaller, similar parts can be batch processed.
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What is the turnaround time?
Most parts are coated and returned to you within 4-6 business
days of receipt. In special cases we can provide faster
turnaround. Let us know your scheduling needs.
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What is the cost of FortiPhy coating?
Coating cost is a combination of many factors, including
component dimensions, surface finish, material, critical
surfaces to be coated, weight, heat treatment, and number
of parts. Contact Phygen with your specific requirements
for a timely quote. National testing labs and our many successful
customers have proven that FortiPhy coatings are tougher
and longer-lasting than traditional coatings. That makes
FortiPhy coating an investment that can pay for itself quickly.
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Can FortiPhy be used in food processing & packaging?
The Food and Drug Administration (FDA) has given approval for use of FortiPhy UltraEndurance™ super hard, wear resistant coating in contact with all food types. FortiPhy coating has been added to the FDA’s inventory list of effective food contact substances (FCN: 00823) for repeat-use in food processing and food packaging equipment to prevent metal-to-metal and abrasive wear to components. The coating is inert, creating a protective barrier between the working surface and food product.
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 What
is the chemical composition of FortiPhy metal surface coatings?
Finish also will affect metal surface coatings performance. A finer metal surface finish will allow a more uniform layer of coating to be applied. In general, you should specify a slightly better surface finish than usual. This will ensure maximal coating adhesion, toughness, and lubricity. An exception to this would be applications that require friction, such as thread rolling dies. In these cases, talk to a Phygen coating expert about strategies for increasing friction while improving toughness.
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