Finishing plasma hardening

The essence of finishing plasma hardening (FPH) refers to increasing service life of parts and tools by applying thin-film coatings at atmospheric pressure during tubeless chemical vapor deposition (PECVD process) using liquid organoelement compounds and activation by electric arc plasma. The coating is a product of reactions of reagent vapors passing through small plasma chemical reactor.

The purpose of FPH is production of parts, tools, stamps, molds, knives, dies, bearings and other products with special surface properties: wear resistance, antifriction, corrosion resistance, heat resistance, high resistance, anti-seizing, resistance to fretting corrosion, etc.

The effect of FPH is achieved by changing physical and mechanical properties of the surface layer: increasing microhardness, reducing coefficient of friction, creating compressive stresses, healing microdefects, forming dielectric and corrosion-resistant film coating on the surface with low coefficient of thermal conductivity, chemical inertness and specific topography of the surface.

Equipment for FPH comprises a specialized current source, a unit of equipment with liquid metering device, plasma jet with plasma chemical reactor. In addition, this equipment may be equipped with a robot, positioner. manipulator, autonomous cooling unit, mobile exhaust system, coating control device, coating thickness measuring device, surface preparation equipment prior to coating.

FPH technological process is performed at atmospheric pressure and comprises operations of pre-cleaning (by any known method) and directly hardening of the treated surface by mutual movement of the product and plasma jet with plasma chemical reactor. The speed of movement is 1-10 mm/sec, distance between plasma jet and product is 5-15 mm, diameter of hardening spot is 12-15 mm, coating thickness is 0.5-3 μm. Temperature of heating of parts with FPH does not exceed 100-150 °C. Surface roughness parameters do not change after FPH. As gases, argon and nitrogen are used, starting materials for passage of plasma chemical reactions and formation of coatings are liquid technological preparations of SETOL family. Total consumption of substances does not exceed 0.5 g/h (not more than 0.5 liters per year).

Examples of FPH application: hardening of cutting tools, stamps, knives, saws, molds, gages, dies, gears, bearings, machine parts such as rollers, cams, guides, latches, clamps, pushers etc.

FPH implementation at enterprises in Russia, CIS countries and abroad shows an increase in resistance of reinforced products by 2-10 times.

Distinctive features of FPH versus analogues - ion-plasma surfacing (PVD-processes), CVD-processes, laser and electric spark hardening, epilamation and others:

Production trials. The following types of coatings are used in FPH:

Coating Material Application
Pateks Х-SiOCN Tools, stamps, molds, knives, saws, gages, dies. Thread-rolling and nut-cutting tools, knives centerless grinding machines, parts of pipeline fittings, equipment for tobacco, sewing and canning industries. Excellent anti-adhesion properties, lubricity and dielectric characteristics.
SuperPateks B-SiOCN Cutting, bending, stamping, drawing dies, tools for cold setting, branding, packing, stamping, tablet machines, cold-cutting tools, knives for cutting paper, cardboard, leather, bread machines, tooth wheels and gears, extruder parts and screw pumps. Increased hardness and resistance to oxidation.
MultiPateks H-SiOCN Molds for pressing, equipment for glass forming machines, tools for threading, hot setting, treatment of hard-to-work materials, cylinder liners, piston rings, thermocouple covers. High-temperature resistance, heat and wear resistance. TriboPateks Y-SiOCN. Spools and sleeves, and plunger pairs, rolling bearings, parts such as rollers, cams, guides, locks, clamps, pushers, pins, operating under lubrication. Coating with low coefficient of friction, minimum running-in time, which ensures temperature reduction in friction zone.
TriboPateks Y-SiOCN Spools and sleeves, and plunger pairs, rolling bearings, parts such as rollers, cams, guides, locks, clamps, pushers, pins, operating under lubrication. Coating with low coefficient of friction, minimum running-in time, which ensures temperature reduction in friction zone.
BioPateks AgX-SiOCN Medical instruments, details of implantation of orthopedics, traumatology and dentistry. High biocompatibility, bactericidal, resistance to corrosion-electrochemical effects of biofluids.
DLCPateks a-C:H-SiOCN Rolling bearings, parts of face seals, worm gearboxes, labyrinth seals, protective bearings of sliding bearings, guide devices and impellers of submersible pumps, threads of tubing and couplings. Excellent tribological characteristics.
SilcoPateks a-Si:H-SiOCN Elements of chromatographs, systems for sampling, storage and transport of natural gas samples (cylinders, vessels, samplers), parts operating under fuel combustion conditions and high-temperature and oxidative effects of oil components, technological devices of vacuum systems for protection against chemically active compounds (sulfur and sulfur-containing compounds, mercury, ammonia, alcohols, acetates, hydrides, hydrochloric, nitric, sulfuric acids and other substances), passivation and enhancement of corrosion resistance, reduction of formation carbonaceous deposits (soot, varnish, sludge) minimize contamination of gaseous media in vacuum technology.

The economic efficiency of FPH parts, tools, tooling and other products is determined by increasing their resource, reducing required number for a given production program, saving tool steel, reducing scope of grinding operations, reducing time and costs related to setting presses and machine tools, possibility of intensification of operating modes.