The CemeCon Coating Equipment
We are the Tool Coating People
We have developed the right technology, built the appropriate
production plants and thereby made the best PVD and CVD diamond
coatings in the world a reality. In CemeCon’s own job coating centre,
which is one of the biggest in the world, tens of thousands precision
tools are coated for our customers every day. For 30 years,
the experience and know-how gained here have been feedback
into the ongoing development of our PVD and CVD diamond
coating machines. This also enables our customers to benefit
in terms of productivity, ergonomics, processing quality and
cost-effectiveness.
2
We coat according to your order
in our job coating center
You coat with our coating
equipment within your own
production line
You are the customer.
The choice is yours.
Whether you take advantage of our job
coating service, or integrate our coating
equipment into your production, you will
always achieve a premium result.
We simplify things for you. We offer any
desired level of support for developing
your own individual coating solution.
You may test at our coating service center
and transfer the whole process into your
own facility if you wish to do so.
Would you like to develop your own
processes independently? The fully open
recipe editor included in our machines
gives you a fully featured tool and all
the opportunities to do so.
While being assisted by our experts,
you will notice the benefit of harmonised
processes and have access to our knowhow of Best Practices to achieve the
optimal PVD- and CVD diamond coatings.
The choice is yours!
3
PVD Sputter Coatings from CemeCon
Smooth, droplet-free coatings for cutting tools and components
unbeatable advantage in all applications
with a great demand for wear volume.
Integrated Plasma Booster and pulsed
substrate BIAS technology in all PVD
systems make for very high plasma
ionization. The results are thorough but
gentle cleaning, activation of surfaces
and outstanding coating adhesion.
Scratch test adhesion values of 100
Newtons are standard for CemeCon
DC Sputter systems.
HiPIMS is the evolution of the Sputter
technology. With the CC800® HiPIMS
CemeCon is offering the cost-effective
production of pure HiPIMS coatings as
the only company worldwide.
Since 1986, CemeCon has been a pioneer
in developing hard-material coatings
using PVD Sputter technology. During
Sputtering, the material is vaporized for
producing the coating and turns from a
solid state directly into the gaseous phase.
In traditional processes, the coating
material must be melted. This inevitably
creates droplets that form defects in
the coating structure and lead to a very
rough surface. During Sputtering, these
droplets do not appear. A valuable
advantage of Sputter technology, which
ensures a perfect coating and extremely
smooth, defect-free surfaces.
Another advantage of Sputter technology
is a significant reduction in the film’s internal stress. This allows AITiN coatings to
be deposited to a thickness of 15 µm. An
Extremely smooth: In contrast to processes that leave droplets on the surface (left),
surfaces from the PVD Sputter process (right) are extremely smooth.
i
Sputtering is enormously flexible. It can
be used to produce all known coatings.
Whether it is metals, oxides, nitrides,
borides or carbides – with Sputtering,
almost any coating material can be
deposited. Sputtering knows no limits –
from the smallest micro-tool with less
than a 0.1 millimeter diameter to hob
4
PVD Sputter Coatings from CemeCon
cutters or very heavy components. Both
electrically conductive and non-conductive coatings can be produced – on
both electrically conductive and nonconductive substrates. Most coatings
are produced at temperatures of 250°C
to 500°C. The Sputtering process also
allows temperatures below 150°C.
DC Sputter
Coating System
CemeCon coating systems with DC Sputter
technology are especially flexible and
applicable universally. For decades they
have been the backbone of many tool
coatings around the world.
Depending on the quantities required,
the ML and XL versions are available.
Both of them coat quickly and easily
with all nitride-, boride- and carbonbased materials. Add-on modules
allow further individual adjustments.
The CC800®/9 ML is the economical
system for medium lot quantities and
frequent changes in batch and coating
6
DC Sputter Coating System
material. With the optional flex module,
your capacity can be further enlarged and
quickly adapted to current order volume.
Due to its high flexibility, the CC800®/9
ML line has proved its worth in research
and development. The system‘s open,
modular design allows it to be equipped
with many extensions and options, such
as measuring devices.
CemeCon has developed the CC800®/9 XL
for large batch quantities or large components. With the same external dimensions as the ML model, it has considerably
larger coating volume. It coats 4.500 drills
or 16.400 cutting inserts and tools up
to a length of 800 milimeters and
650 millimeters in diameter in just one
operation. The electro-hydraulically
driven quick-change table allows fast
loading and unloading of tool batches.
CC800®/9
ML 6 (10)
CC800®/9
XL
Ø400 x 400
(Ø650 x 400)
Ø400 x Ø130 x 6
[mm]
number (Ø650 x Ø130 x 10)
Mechanical or
electro-hydraulic
Coating area Ø x h
[mm]
Substrate table,
Ø x Ø satellites x number of satellites
Table for quick batch change
Ø650 x 700
Ø650 x Ø130
x 10
Electrohydraulic
Sputter cathodes
items
[mm]
4 x 500
4 x 800
Maximum substrate dimensions Ø x h
[mm]
Ø400 x 800
(Ø650 x 800)
Ø650 x 800
Drill capacity Ø6 mm x 60 mm
item
1,800 (3,000)
4,500
Insert capacity 12.7 mm x 3.5 mm
item
4,920 (8,200)
16,400
Maximum substrate weight
[kg]
250 (500)
500
Cycle time for 3 µm Hyperlox®*
[h]
5
6
Processes
Sputtering
with Booster
Technology
Sputtering
with Booster
Technology
Substrate pre-treatment
(plasma etching)
Booster and MF
etching
Booster and
MF etching
Electrically conductive coatings
Yes
Yes
Electrically non-conductive coatings
No
No
Electrically non-conductive substrates
No
No
Rated power
[kW]
60
80
Power consumption per batch for 3µm
Hyperlox®*
[kWh]
120
200
Outer dimensions (w x l x h)
[mm3]
1,050 x 3,350 x
2,200
1,050 x 3,350
x 2,200
3,000 – 3,300
~ 3,300
Weight (empty)
* On a 10 mm milling cutter
DC-MAGNETRON-SPUTTERING
Cathode
DC
BIAS
DC
Puls
ALOX® SN2 coating with 12.5 µm coating
thickness
COATING VOLUME
700 mm
400 mm
400 mm
400 mm
650 mm
ML 6
ML 10
CC800®/9 ML
130 mm
130 mm
130 mm
650 mm
XL
CC800®/9 XL
DC Sputter Coating System
7
HiPIMS – the Future of
PVD Coating Technology
Featuring denser coatings, improved hardness/toughness and enhanced
cutting results – all with a deposition rate of 2 µm/h
HiPIMS (High Power Impulse Magnetron
Sputtering) is the next evolutionary step
in Sputter technology. It combines all
the advantages of common coating technologies and methods currently on the
market. Like the DC Sputtering process,
HiPIMS deposits smooth, droplet-free
and low stress coatings in an almost
unlimited variety. HiPIMS is characterised
by an outstandingly high ionization of
the Sputtered metal. Scratch loads up
to 130 Newton prove the superb coating
adhesion which is directly related to the
high ionization level. HiPIMS coatings
are both hard and tough at the same
time thanks to the dense and nearly
amorphous film structure. A consistent
and homogeneous distribution of coating
thickness all around three-dimensional
objects like the cutting edge of a tool,
facilitates optimal wear protection.
CemeCon has systematically refined the
HiPIMS technology to the point of being
ready for industrial coating production.
In terms of technology this means maximum flexibility and highest productivity
with a deposition rate of 2 µm/h.
Nearly 100% metal ionization
Highest adhesion
Homogeneous coating all around
the cutting edge
The power peaks of HiPIMS result in an
enormously dense plasma which provides
an unrivalled degree of ionization to the
deposited materials. The high flux of highly
ionized species results in very dense and
nearly amorphous coating structures.
The high metal ionization ensures the best
possible coating adhesion.
A scratch load of 120 Newton is an outstanding result for InoCon® as a silicon doped and
thereby very hard coating. FerroCon®, based
on AlTiN, results in a scratch value of up to
130 Newton. This enables to machine the
most difficult to cut materials.
The high ionization makes the coating structure very dense and compact. Such a fine
grain morphology is likewise hard and tough.
Coatings grow extremely homogeneous when
HiPIMS is used for the deposition.
Also, very complex tool geometries will receive
approximately the same coating thickness all
around the cutting edge.
Maximum flexibility
Perfect for micro tools
Maximum profitability for pure
HiPIMS coatings
HiPIMS is a Sputter process. Almost every
material can be sputtered. This means
an unlimited variety of coatings through
combinations of elements of the
periodic system.
Free of defects and without antenna effects.
The HiPIMS technology is also very useful for
very small geometries, as it works droplet-free
and without damaging or rounding the cutting
edge.
The CC800® HiPIMS achieves in pure
HiPIMS mode deposition rates of 2 µm/h
and process times of 4–5 hours. 3 µm/h
are possible when all 6 cathodes are used.
Magnetron
Me
Me
Me
HiPIMS Plasma
Me+
8
Me+
Ar+
Me+
HiPIMS – the Future of PVD Coating Technology
HiPIMS
Coating System
CC800® HiPIMS combines all the advantages of the classical DC Sputter coating
system with the capabilities of the latest
HiPIMS technology. The system is equipped
with a total of six Sputter cathodes,
four of which can be operated in either
HiPIMS or DC mode. The additional two
DC cathodes can be operated, for example,
to provide more complex multilayer coatings, to deliver color and top coatings,
or simply to increase deposition rates.
The absolutely free combination of these
technologies within one process gives an
unlimited range of coating designs at very
low production costs. Deposition rates of
2 µm/h and process times of 4–5 hours
10
HiPIMS Coating System
can be achieved in pure HiPIMS mode.
When simultaneously operating of all
6 cathodes, 3 µm/h are reached.
This was a so far unthinkably low
production time for a coating capacity
of 1.800 round shank tools or 5.000
indexable inserts before now.
The CC800® HIPIMS is able to deposit
all available CemeCon Sputter coatings
and almost all PVD coatings available
on the market. Furthermore, it is the
perfect machine for the development of
custom-built processes. The customerfriendly user interface „DataView“ and
the integrated planning tool „DataPlan“
facilitate the design of individual coating
solutions. Your coating will make your
product stand out on the market, allowing users to gain a competitive edge.
Other features such as user-friendly
remote control by tablet and phone,
the maintenance-friendly assembly, fully
automatic cathode shutters, automatic
door closing and the unit for a quick
exchange of the coating table complete
the picture of CC800® HiPIMS being the
optimum coating system for the production
and development of state-of-the-art high
performance coatings.
CC800® HiPIMS
Coating area, Ø x h
[mm]
Ø400 x 400
Substrate table,
Ø x Ø satellites x number of satellites
[mm],
number
Ø400 x Ø130 x 6
Table for quick batch change
Optional
Sputter cathodes
items
[mm]
6 x 500 (including 4 optional
HiPIMS/DC and another
2 DC; all cathodes equipped
with shutters)
Maximum substrate dimensions Ø x h
[mm]
Ø400 x 800
Drill capacity Ø6 mm x 60 mm
item
1,800
Insert capacity 12.7 mm x 3.5 mm
item
4,920
Maximum subtrate weight
[kg]
250
Deposition rate
µm/h
In pure HiPIMS mode 2 μm/h.
In DC or combi mode up to
3 µm/h.
Cycle time for FerroCon®*
[h]
4.5
Cathode
HiPIMS
DC
BIAS
HiPIMS
DC
Puls
HiPIMS and Sputtering using
booster technology.
All established CemeCon
coatings are possible.
Booster, MF and HiPIMS
etching
Processes
Substrate pre-treatment (plasma etching)
Electrically conductive coatings
Yes
Electrically non-conductive coatings
Yes
Electrically non-conductive substrates
Yes
Rated power
Power consumption per batch for 3 µm
FerroCon®*
Outer dimensions (b x l x h)
[kW]
80
[kWh]
120
[mm3]
1,450 x 3,350 x 2,200
Weight (empty)
[kg]
~ 3,500
Closing of chamber doors
HiPIMS
HIGH POWER IMPULSE
MAGNETRON SPUTTERING
Automatic closing
Intuitive touch control and pneumatic
actuators for chamber doors facilitate
daily operation of the unit.
* Pure HiPIMS coating on 10 mm milling cutter
COATING VOLUME
400 mm
130 mm
400 mm
HiPIMS
High-energy
HiPIMS plasma
HiPIMS Coating System
11
CVD Diamond Coatings from CemeCon
Patented Multilayers for machining graphite, glass- or carbon-reinforced
plastics and composites
The world‘s hardest material used as
a coating for maximum wear protection
when machining graphites, fiber-reinforced plastics (composites) and abrasive
non-ferrous metals.
For many years, CemeCon has used CVD
technology to produce diamond coatings
for cutting tools and components – true
crystalline sp3 diamond with a hardness
of nearly 10,000 Vickers. More than 20
years ago, CemeCon developed the hot
filament process to market maturity and
is now the world leader in diamond
coatings and technologies.
In the hot filament process, diamond
is produced from gas. In a H2-CxHy gas
atmosphere, carbon is turned into pure,
crystalline diamond in vacuum. This can
produce up to four carat diamond per
hour. Depending on the application, it
can be deposited as a micro-crystalline,
nano-crystalline or Multilayer coating.
The fully automatic coating technology,
paired with optimal pretreatment of the
substrate, allows the deposition of
coatings with thicknesses of more than
20 µm and outstanding adhesion.
CemeCon‘s patented Multilayer technology ensures maximum stability by
interlocking the individual layers within
the coatings. If cracks arise, they cannot
spread beyond the layer boundaries.
source: Airbus
12
CVD Diamond Coatings from CemeCon
Thanks to their extreme hardness – with
up to 10,000 HV0.05 close to natural
diamond – all coatings in the CCDia®
product group are extremely wear resistant. Performance of shank tools and
indexable inserts made of solid carbide
is significantly increased with a CCDia®
coating. The diamond coating‘s high
heat conductivity makes for fast heat
dissipation. This is enormously important
when processing temperature-sensitive
materials such as carbon- and glass-fiberreinforced plastics, and allows higher
processing speed during machining. All
of these properties make the CCDia® line
of coating materials the first choice for
machining graphites, composites, nonferrous metals, green parts and ceramics
according to VDI standard 3323.
More and more components are enhanced with a diamond coating. Diamond is
extremely hard and barely deformable.
It is chemically inert to nearly all media,
has very low friction and high heat conductivity. These unique properties constantly open new fields of application for
diamond coatings in many industries.
S U B S T R AT E
Micro-Crystalline Diamond Coating
S U B S T R AT E
Nano-Crystalline Diamond Coating
S U B S T R AT E
Multilayer Diamond Coating
Diamond
Coating System
The CC800®/9 DIA coats tools for
processing fiber-reinforced plastics,
graphite and abrasive nonferrous
metals with the world‘s hardest coating
material – real diamond crystals.
Smooth, best adhesion and wear
resistant thanks to Multilayer coating
14
Diamond Coating System
With the CC800®/9 DIA, extremely
smooth, especially adhesive nanocrystalline, crystalline or Multilayer
diamond coatings can be deposited on
more than 80 different tungsten carbide
grades. Thanks to the hot filament process, even complex three-dimensional
tools and components receive very homogeneous coating thickness distribution
within tight tolerances.
Despite its compact external dimensions,
the CC800®/9 DIA is the largest-capacity
automatic diamond coating system on
the market. Three independently operating coating chambers make it especially
flexible and economical.
CC800®/9 DIA
Coating area, number x (b x t x h)
[mm]
1 x (740 x 360 x 30) or
3 x (50 x 560 x 70)
Maximum substrate dimensions Ø x h
[mm]
Tools 30 x 500
Maximum substrate weight
[kg]
250
Processes
Hot filament
Electrically conductive coatings
Yes
Electrically non-conductive coatings
Yes
Electrically non-conductive substrates
Yes
Rated power
[kW]
90
External dimensions (w x l x h)
[mm]
1,260 x 3,600 x 2,070
Weight (empty)
[kg]
4,000
HOT-FILAMENT
DIAMOND COATING
SYSTEM
Filaments
Horizontal
Vertical
Micro end mills with CCDia® Carbon Speed
for graphite machining
Composite airplane wings, drilling and reaming the rivet holes with diamond-coated tools
Router with CCDia® MultiSpeed Plus –
17 µm pure Diamond
Counter sink drill with CCDia® AeroSpeed®,
the benchmark in aircraft production
Diamond Coating System
15
Turnkey
In-house Coating Systems
In-house coating competence is a competitive advantage
CemeCon is doing coatings - every single
day. And it does it in one of the world‘s
largest coating centers for cutting tools.
A turnkey solution brings this wealth of
experience and proven CemeCon coatings
into your production.
With cutting tools, the coating is often
the crucial competitive advantage. The
skill gained through integrating your own
coating system ensures you full control
over your product and allows flexibility
and fast reaction.
The complete package, including the
coating system, substrate pretreatment
and peripherals, covers the entire work-
16
Turnkey In-house Coating Systems
flow. This entirety is the result of technology and a proven process, easing your
entry into in-house coating technology.
With experience from 300 completed
systems, and as your project partner,
CemeCon takes responsibility for creating an individual turnkey solution. The
service team draws up the time, space
and utility plan, handles country-specific
details, assists in cooperation with public
authorities and delivers a coating production ready to use.
You gain from CemeCon‘s continuous
development of coatings. Our development team will help you at any time
with future applications. Comprehensive
support and services ensures the system‘s
continuous operation.
CemeCon turnkey solutions for
maximum flexibility and highest
productivity.
The Wolf coating center for components and cutting tools in Bruchmühlbach
Three good reasons for
choosing a CemeCon turnkey
coating line
• Proven coating recipes from
CemeCon‘s job coating service
on proven coating systems.
• An individually adapted production
process that ensures fast and
efficient production runs.
• Service right from the start:
CemeCon handles complete advance
planning and sets up the system
and peripherals.
Coating, substrate and geometry
adjusted by one supplier makes for
the perfect tool.
Take advantage of having your own
coating technology!
CC800®: premium coating, simple
and efficient
CemeCon‘s CC800® system series includes modularly designed models for
smooth, droplet-free PVD Sputter and
HiPIMS coating, as well as for superhard CVD diamond coatings. All of them
combine premium quality with maximum
performance in a compact design.
•
•
•
•
fully automatic process control
graphical user interface
full internet connectivity
flexible design for all available
coatings
• open to future materials
CemeCon advises the individual customer
and offers solutions adapted to nearly
any component size or unit quantity.
Whether a tool manufacturer, contract
coater or in research and development,
every customer gets a complete turnkey
solution designed to their needs, including complete peripherals: Pre- and posttreatment technology, cleaning, cooling
and compressed air systems, as well as
quality inspection equipment. All components are integrated into their production
processes and infrastructure and existing
machines are used effectively.
CemeCon’s job coating service is the
ideal place to give your employees intensive training on the selected system
model and on coating processes specifically adapted to suit your applications.
Technicians will instruct you in the simple
operation of your new coating system
on site. So you can be sure that you can
deliver the first coated tools immediately
after your in-house system is installed.
i
24/7 support for machine customers
around the world
Turnkey In-house Coating Systems
17
Peripherals and accessories
integrated in the most optimal way
Coating quality depends on all of the
necessary steps in the process fitting
together perfectly. CemeCon offers all of
the components for a complete in-house
coating center from one source –
perfectly matched with one another.
The CemeCon advantage: Accessories
and all components, machines and processes for pre- and post-treatment and
quality control are always adapted to
customer requirements and existing
infrastructure.
Blasting and cleaning systems
Cooling systems
CemeCon blasting and cleaning systems provide the best possible substrate preparation. Blasting systems
free tools of burrs and grinding burn
and remove loose carbide grains
and cobalt smearing. If necessary,
preparation of cutting edges can be
optimized. Cleaning systems remove
impurities gently and completely.
The product line extends from manual systems for small or medium production quantities to fully automatic
systems for large coating centers. All
of the solutions are environmentally
friendly and economical, thanks to
the regeneration of blasting and
cleaning media.
During coating, cooling systems
dissipate heat and provide necessary
process reliability. CemeCon offers
compact, robust, energy-saving
cooling systems for every system
size and every coating technology.
Targets
Thanks to a special bonding process,
CemeCon Targets ensure the highest
quality and process reliability. They
are optimally adapted to the coating
process and, thanks to the plug
technology, are available in a wide
choice of materials.
Blasting system
Quality control
When it comes to quality control when
goods are received or dispatched,
CemeCon offers the right testing device
for every need. Tailor-made quality
assurance packages can be assembled
from ball cratering test devices, Rockwell testers, microscopes and impact
testers.
18
Peripherals and accessories
Coating Equipment
at a Glance
CC800®/9
ML 6 (10)
CC800®/9
XL
CC800® HiPIMS
CC800®/9 DIA
Coating area
Ø x h*
[mm]
Ø400 x 400
(Ø650 x 400)
Ø650 x 700
Ø400 x 400
1 x (740 x 360 x 30)
or
3 x (50 x 560 x 70)
Substrate table,
Ø x Ø satellites x
number of satellites
[mm]
number
Ø400 x Ø130 x 6
(Ø650 x Ø130 x 10)
Ø650 x Ø130 x 10
Ø400 x Ø130 x 6
Depending
on use
Mechanical or
electro-hydraulic
Electro-hydraulic
Optional
4 x 800
6 x 500 (including 4
optional HiPIMS/DC
and another 2 DC;
all cathodes equipped
with shutters)
Filaments
Table for quick
batch change
Sputter cathodes
items
4 x 500
[mm]
Maximum substrate
dimensions
Øxh
[mm]
Ø400 x 800
(Ø650 x 800)
Ø650 x 800
Ø400 x 800
Tools Ø30 x 500
Drill capacity
Ø6 mm x 60 mm
item
1,800 (3,000)
4,500
1,800
Depending
on process
Insert capacity
12.7 mm x 3.5 mm
item
4,920 (8,200)
16,400
4,920
Depending
on process
Maximum
substrate weight
[kg]
250 (500)
500
250
250
Cycle time for 3 µm
Hyperlox® SN2**
[h]
5
6
4.5 FerroCon®
Depending
on process
Processes
Sputtering with
Booster Technology
Sputtering with
Booster Technology
HiPIMS and Sputtering
with Booster Technology.
All established CemeCon
coatings may be used.
Hot filament
Substrate
pre-treatment
(plasma etching)
Booster and
MF etching
Booster and
MF etching
Booster, MF and
HiPIMS etching
Electrically
conductive coatings
Yes
Yes
Yes
Yes
Electrically non-conductive coatings
No
No
Yes
Yes
Electrically non-conductive substrates
No
No
Yes
Yes
60
80
80
90
200
120 FerroCon®
Depending
on process
manually
automatically
automatically
1,050 x 3,350 x 2,200
1,450 x 3,350 x 2,200
1,260 x 3,600 x 2,070
~ 3,300
~ 3,500
4,000
Rated power
[kW]
Power consumption
per batch for
3µm Hyperlox®**
[kWh] 120
Closing of chamber
doors
Outer dimensions
(w x l x h)
Weight (empty)
manually
[mm3] 1,050 x 3,350 x 2,200
3,000 – 3,300
*CC800 /9 DIA: Coating area, number x (b x t x h)
**On a 10 mm milling cutter
®
Coating Equipment at a Glance
19
CemeCon AG | Phone: +49 2405 4470 100 | [email protected]
USA
CemeCon Inc. | Phone: +1 607 562 2363 | [email protected]
CHINA
CemeCon Coating Technology Co., Ltd. Suzhou | Phone: +86 512 891 74919 | [email protected]
JAPAN
CemeCon K.K. | Contact: Alexander Marxer | Phone: +81 3 6459 4430 | [email protected]
CZECH REPUBLIC
CemeCon s.r.o. | Phone: +420 539 003 501 | [email protected]
DENMARK
CemeCon Scandinavia A/S | Phone: +45 7022 1161 | [email protected]
INDIA
M+V Marketing & Sales Pvt. Ltd. | Contact: Manish Adwani | Phone: +91 9158 99 99 56 | [email protected]
KOREA
Huakorea Ltd. | Contact: Hong-Silk Cho | Phone: +82 2 792 2430 | [email protected]
TAIWAN
DKSH Taiwan Ltd. | Contact: Vincent Chu | Phone: +886 963 495 396 | [email protected]
RUSSIA
ZAO Rosmark-Steel | Contact: Ilya Mozgov | Phone: +7 812 336 27 27 | [email protected]
Editor | CemeCon AG | Adenauerstr. 20 A 4 | 52146 Würselen | Germany
CC_EN_09 / 16
GERMANY
www.cemecon.com