Tool coating industries

Two maj or areas of application of CVD have rapidly developed in the last twenty years or so, namely in the semiconductor industry and in the so-called metallurgical-coating industry which includes cutting-tool fabrication. CVD technology isparticularly important in the production of semiconductors and related electronic components. Itisby far the most... 

In the coatings industry, emulsion polymerization, as a synthetic tool for the preparation of acrylic and vinyl polymers, allows the manufticturer access to a wide array of polymeric systems, simply based on the types and ratios of the monomers used [7]. However, coatings derived fi"om these emulsion polymers often are deficient in performance because of lack of an internal crosslinking mechanism. Silanes can remedy this deficiency. 

Grinding ). To further enhance performance and efficiency of expensive broaching tools, coatings were developed which clearly enhance tool life (see Coated Tools ). Especially, TiN coatings have established in industrial applications. High micro hardness leads to a minimization of wear, the chemical resistance reduces built-up edges as well as material adherence, and a small friction coefficient reduces the... 

Clavel, A. L., Tool Coatings for the Metal-Working Industry, in Thin Films 91, (jorham Advanced Materials Inst., Gorham, ME (1991)... 

Applications of Diamond Tools. Most industrial machining operations are performed with coated cemented-carbide tools, usually as indexable inserts. Diamond (and PCD) increasingly competes with these materials, in particular in the machining of non-ferrous metals such as aluminum, copper, magnesium, lead, and theiralloys since it does not react chemically with these materials. 

ToF-SIMS is a powerful tool to control the surface quality of industrial polymer products, as in the polymer coating industry [198,199]. Strengths of ToF-SIMS for analysis of coatings are overall sensitivity (lOx higher than XPS), molecular specificity, in situ analysis, mapping, analysis of mixtures. Each... 

MALDI and ESI have become important characterisation tools for polymers of interest to the coatings industry. The mass data obtained from these experiments can help determine the chemical structures of materials by providing information on the polymer repeat units, end groups, and MWD. By better understanding how these experiments are done and how the data can be analysed, these techniques can find even greater incorporation into the characterisation of materials. 

Other approaches include using optimal process parameters, different chemical compositions, appropriate lubricating strategies, and changing tool coatings. Food and glass manufacturing industries have successfully reduced the production of waste. 

Abrasive appHcations for industrial diamonds include thek use in rock drilling, as tools for dressing and tmeing abrasive wheels, in polishing and cutting operations (as a loose powder), and as abrasive grits in bonded wheels and coated abrasive products. 

Coated abrasive products, once limited to sandpaper in woodworking shops, are versatile and efficient industrial tools. Machines ranging from portable Sanders to giant slab conditioners and roU grinders utili2e coated abrasives. Abrasive belt machines now perform many of the operations that were once the exclusive province of grinding wheels. 

The gap between laboratory wear testing and industrial appHcation trials is extremely difficult to bridge, since there is often Httie or no control over testing in the industrial environment. Despite these limitations, several examples of industrial successes involving ion implanted tools have been reported and blind tests of nitrogen-implanted machine tools have been performed, including tool taps, dies, punches, and TiN coated WC cutting inserts (106). 

The third part identifies and describes the present and potential applications of CVD in semiconductors and electronics, in optics and optoelectronics, in the coating of tools, bearings and other wear- and corrosion-resistant products, and in the automobile, aerospace, and other major industries. 

In this book, the CVD applications are classified by product functions such as electrical, opto-electrical, optical, mechanical and chemical. This classification corresponds roughly to the various segments of industry such as the electronic industry, the optical industry, the tool industry, and the chemical industry. CVD applications are also classified by product forms such as coatings, powders, fibers, monoliths, and composites. 

CVD suffers these limitations to a lesser degree and, as a result, is being used increasingly in many industrial applications, particularly those operating in extreme conditions. It is often the best solution to severe problems of erosion, friction, or hot corrosion. A special case must be made forthe coating ofcutting tools, which is amaj or industrial application of CVD and is reviewed separately in Ch. 18. 

Coatings play a vital part in the cutting-tool industry and this is where CVD technology has made some of its most important gains. As an example, CVD films of titanium carbide on cemented carbide tools were first commercialized in the early 1960s and their use has continuously increased ever since. Today, the percentage of tools that are coated by either PVD or CVD depends on the type of tool as shown in Table 18.1 (in 1996). 

Horsfall, R. H., Role of Present and New PVD Coatings to Meet the Need of the Cutting-Tool Industry, 2d. Int. Conf. on Cutting Tools, Gorham Advance Materials Inst., Gorham, ME (1996)... 

The synthetic method used in preparing a particular boride phase depends primarily on its intended use. Whereas for basic research borides of high purity are desirable, for industrial applications, e.g., in coatings, tools and crucibles, as a refining agent in metallurgy or in control rods in nuclear energy plants, pure borides are unnecessary. 

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