PROCESS:The basic PVD Ion Sputter Plating Process (ISP) was developed by the Atomic Energy Authority of Great Britain for the application of extremely consistent ultra-thin film coatings in nuclear reactor applications. Daryl A. Blessing, using AGC modified ISP technology, developedthe deca-elemental, single layer coatingLaser-Cut 968® in 1993.Laser-Cut 968®, a patentable product, provides superior performance characteristics over that of other currently available single or multi-layered coatings using the conventional Evaporative Coating Process.These include coatings such as: TiN, TiCN, TiAlN, AlTiN, CrN or ZrN.

AGC ISP coatings do not materially affect the part’s structure, size, geometry or finish.The parts to be coated, after being thoroughly cleaned in ultrasonic baths, are positioned on special, non-reactive, stationery fixtures.The low vacuum and coating temperature ISP process is based upon the sputtering of single atoms from proprietary target material and then molecularly integrating them with the surface of the parts being coated.Gases are introduced into the vacuum chamber in precise amounts and intervals.The pieces to be coated are adjusted to a specific potential difference from that of the target material and a condition of ionization is affected.Ionized atoms of the gases bombard the target material and sputtering of the alloyed atoms occurs.The condition of the gases that are introduced into the coating chamber effect a molecular interaction that results in the unique multi-colored (rainbow) coating on the part being coated Markedly different sizes, geometric shapes and materials can be coated in the same operation, affording unequalled flexibility and maximum utilization of available coating space.

Shanghai AGC Co., Ltd. is presently producing the forth generation (G4) Laser-Cut 968®.The improvements provided broadened application range, consistency and performance.Expansion of the AGC Modified ISP process and Laser-Cut 968 G4 technology lead to the development of Super Tin® and Xtend-Cut 973® in 2001, AlTiMAX® and Xtend-Wear 971® in 2002.In our efforts for continuous improvement and value, other new coatings are on the drawing board by our R&D staff.

Coating

Hardness (HV)

Coefficient
of
Friction

Coating Thickness
Per Side

Temp.
Operating
Limits

• Speed and Feed compared to uncoated tools
• Applications

TiN

2300
+/-200

.650

.000065"
+/-
.000020"

7500F to
8500F

Good speed up to 20%.
Excellent choice for general machining applications where: tool life cannot be easily monitored; old or low horse powered or slow speed equipment is used or performance cannot be critically measured.

ZrN

2800
+/-200

.600

.000120"
+/-
.000080"

8500F to
11500F

Increase speed up to 20%.
Good choice for general machining applications in aluminum or other non-metals.

MolyS?
Multi-Layer

1750
+/-250

.025

.000160"
+/-
.000120"

6500F to
8500F

Increase speed up to 20%.
Good choice for general machining applications, punching or forming of most materials.Offers high degree of lubricity on surface layer with harder, more abrasion resistant under layer.

TiCN

4000
+/-400

.450

.000120"
+/-
.000080"

8500F to
10500F

Increase speed and feed by up to 25%.
Good choice for ferrous materials, hardened dies steels and other difficult to machine materials.

TiAlN

2600
+/-400

.700

.000120"
+/-
.000080"

10000F to
12000F

Increase speed and feed up to 25%.
Good choice for high temperature alloys and materials 35Rc and above.Elevated feeds and speeds are required to generate higher heat for the formation of the aluminum oxide (Al2O3) layer.

Super Tin?

2650
+/-250

.550

.000065"
+/-
000020"

10000F to
12000F

Increase speed and feed up to 25%.
Excellent choice for broad range of applications.Offers increased performance in most materials. Effective from low to high speeds and feeds.Ideal choice when machining low to medium carbon steel less than 35 Rc and/or low spindle speed.

AlTiMAX?

3500
+/- 500

.400

.000120"
+/-
.000080"

10000F to
12000F

Increase speed and feed 30% or more.
Excellent choice for high temperature alloys and materials 35Rc and above.Higher hardness, density and lubricity than TiAlN or AlTiN.Increased speeds and feeds not required for improved performance.Can be applied to HSS, Carbide or Carbide tipped tools.

Laser-Cut? 968

4825
+/-100

.027

.000065"
+/-
000020"

14000F to 18000F

Increase speed and feed by up to 50% or more.
Best overall coating for most machining applications.Low carbon steels require significant elevations in speed (begin at 50% and increase feed when possible) to maintain chip control.

Xtend-Cut? 973
Multi-Layer

4825*
+/-100

.027*

.000130"
+/-
.000080"

14000F to 18000F*

Good overall coating for wear parts, molds and dies requiring high abrasion resistance, lubricity and minimal change in geometry, surface or size change due to coating thickness.Provides increases in tool life and cycle time.(* Top Layer)

Xtend-Wear? 971
Multi-Layer

4825*
+/-100

.027*

.000250"
+/-
.000080"

14000F to 18000F*

Best overall coating for wear parts, forming tools, molds and dies requiring high abrasion resistance, lubricity and ability to operate at high temperatures.Significant increases in tool life, cycle time and scrap reduction.(*Top Layer)