Metal Forming Success Stories
NEW - Phygen Capacity Increase
Just What Pentaflex Ordered
 Pentaflex, Incorporated, in its 125,000-square-foot manufacturing operation in Springfield, OH, stamps and assembles components primarily for the tractor-trailer industry. New federal regulations governing air quality and emissions have brought new work for semi-tractor exhaust units.
— more story here
No Part Lube, No Problem Thanks to New Tool Coating
 Exedy America Corp., a Tier One automotive supplier, relies on lubrication built into the tooling by tool coatings to produce quality parts. The Mascot, TN stamper has tried various coatings and found success with a coating process using the patented physical vapor deposition coatings (PVD) technology. The PVD process has delivered three times the tool life as compared to an alternative coating process, like TD or CVD coatings, while maintaining part tolerances.— more story here
Cowles Stamping Relies on Phygen FortiPhySM
Coating to Eliminate Premature Punch Failure
and Increase Production Runs
 Cowles Stamping, Inc. of New Haven, CT, a Tier Two automotive supplier and subsidiary of C. Cowles & Company, experienced punch breakage on a progressive-die job after only a couple thousand hits as the punches caught in material. Severe galling on the sides of the punches also caused premature failure as the punch ends would rip off after welding to the press. After trying other coatings with little or no success, Cowles turned to Phygen Coatings’ FortiPhySM Ultra Endurance coatings for up to seven times longer punch life and greater productivity. — more story here
John Antenucci of Stamco Industries, Inc., a leading metal forming and stamping company, based in Euclid, Ohio makes some of the most difficult stamping jobs work, including forming thick .250 stainless steel end caps up to 4 ½ inch deep.
What does John say about Phygen’s turnaround?
“Service from Phygen Coatings is EXCELLENT! They consistently beat their promised delivery date. On our latest hot job, Paul the Phygen production coordinator, promised delivery on a Thursday and we actually received our order back on Wednesday. They must have done our job in ONE or TWO days to make that happen. I can depend on Phygen to meet my needs for the highest performance metal forming coatings for our difficult jobs and meet my short schedules for getting the FortiPhy coatings done. I strongly recommend Phygen.”
Tool and Die Shop Discovers Longer Tool Life
by Coating Tool Forms
 Vanguard Tool & Mfg. Co. Inc., Rancho Cucamonga, Calif., is a unique company. Although its owner, Robert Scudder, considers it a stamping house, it started off as a stamping and tool and die company. One of its first customers was a paper convertor that wanted Vanguard to produce fasteners used for file folders--the type that hold two-hole punched paper. Scudder felt that along with tool and die and stamping, it would be wise to have his own product, and these fasteners fit the bill.— more story here
Precision Metal Stamper Switches from Carbide
to Phygen FortiPhy Low-Temperature PVD Surface Coating on DC53
 Headquartered in Westland, MI, GT Technologies is a supplier of valve train component systems for automotive applications, commercial diesel engines,
and performance racing engines. Its stamping facility in Toledo, OH, Toledo Technologies, produces rocker arms and finger followers on high-speed transfer presses.— more story here
Glacier Vandervell Bearings Relies on Quick-Change Tooling and Phygen UltraEndurance PVD Coatings
 Glacier Vandervell Bearings, a division of Mahle Engine Components USA Inc., is located just off Interstate 77 in Caldwell, OH, a small town about 25 miles north of Marietta. Jim Pasquale, a dedicated member of the manufacturing team for 48 years, is supervisor of tools and design services. Ron Saling, who will celebrate 35 years at the plant in October 2007, is tooling supervisor. — more story here
Shiroki NA uses Phygen coating to eliminate major tool galling when stamping heavy gauge HSLA parts
 Shiroki North America, Smithville, TN experienced severe galling when stamping high strength, low alloy seat brackets. A special lubricant and a thermal dispersion (TD) coating provided some relief. Still, the coating broke down after only 12-15,000 parts and the tooling had to be recoated or replaced. — more story here
Stamper Gets Maximum Production, Minimum
Downtime With Phygen’s FortiPhy Coating
 Pentaflex, Incorporated, Springfield, OH is a medium to heavy gauge stamper. Their pressroom capacity ranges from 2,300 tons down to 75 tons and includes both hydraulic and mechanical presses. Pentaflex produces heavy duty components for the tractor and trailer industry including close tolerance brake systems.
— more story here
Tougher Dies Increase
Chain Maker's Productivity
Peerless Chain called for Phygen's patented FortiPhy coating to toughen chain-forming dies. This resulted in a phenomenal increase in hits per tool, even compared to industry-standard TiN PVD coating. They plan to use FortiPhy on their wire-forming dies next. — more story here
FortiPhy Coated Forming
Ring Survives without Lubrication
Phygen applied their patented plasma-accelerated FortiPhy coatings to one metal forming ring as a test case. P-K Tool nearly doubled their stamping rate. When lubrication pumps failed, only the FortiPhy-coated ring survived, without galling. The ring is still in use, with over 1 million parts produced.
— more story here
Measurable Success with
FortiPhy coatings by Phygen
Header Die and Tool Inc. (HDT) called for Phygen's patented FortiPhy coating to toughen critical forming pins. This resulted in a phenomenal increase in hits per tool, even compared to industry-standard TiN PVD coating. — more story here
Tougher Stamping Dies and Less Rework
 Beckett Gas, Inc. called for Phygen's patented FortiPhy coating to toughen stamping dies. This resulted in consistently more hits per tool with less distortion, compared to TiCN PVD coating. — more story here
High-Performance Coating
Helps Stamper Fight Downtime
 Progressive stampers invest a lot of time, money, and energy in finding ways to fight downtime and make their presses as productive as possible. Omni Manufacturing Inc. is one such stamper. A mentality of continuous improvement permeates the entire business, including the tool room that manages hundreds of dies used in 68 stamping presses. — more story here
PVD Coating Greatly
Increases Stamping Tool Life
LuK USA doesn’t use coatings on low runs of about 5,000 pieces. But a coating is used if a die does high-volume work, 50,000 pieces or more. “In high-pressure squeezing areas, we really need the coatings and PVD coatings are about the best for punching or blanking operations, as well as for trim dies,” says Paul Gray, section leader. — more story here
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