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Typical production flow
The route from in-coming inspection of the tools and precision components to be coated up to the point where they are returned to the customer is a specialised production process with many individual steps that are matched to the required coating with its special properties.
In-coming inspection
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The parts to be coated are checked for quantity, material and surface condition. The production sequence is determined on the basis of customer specifications. |
Cleaning
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Clean surfaces are essential for the coating adhesion. For this reason, Oerlikon Balzers invests a great deal of effort in surface preparation for PVD. Cleaning takes place in a multi-stage ultrasonic cleaning line using aqueous alkaline baths without environmentally damaging additives. Cleaning is simplified by delivery in special baskets respectively by automated loading of the cleaning line. |
Pre-treatment
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If additional pre-treatment is required, Oerlikon Balzers uses the appropriate technologies. Degassing in a vacuum oven, for example, eliminates material residues in narrow bore holes, microblasting removes porous surface layers. |
Loading
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Before coating, the parts are loaded into interchangeable substrate holders and then inserted into the coating system. In the case of large production runs, the substrate holders are loaded automatically. A defined arrangement of the parts ensures reproducible precision. |
Coating
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The coating is carried out with a sequence of automatically controlled and documented processes. The following process sequence typifies the special Oerlikon Balzers coating technology: |
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pump down the process chamber to a residual pressure of about 10-6 mbar |
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systems and process check |
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heat the tools or components to the required temperature |
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ion etch the tools/components to produce atomically clean surfaces |
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coat using the PVD-/PACVD process |
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cool |
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systems and safety check
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Oerlikon Balzers' coating know-how comes to the fore between the etching and coating phases. Precisely controlled application of suitable intermediate layers ensures optimum adhesion of the functional coating. The coating can be applied using mono-layer or multi-layer processes and in nano-structures. The plasma parameter settings determine the coating properties, and the proven system technology guarantees the required process reliability.
Outgoing inspection
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This includes the testing of properties such as hardness, coating thickness and adhesion and visual inspection. In long coating runs, with an agreed number of test parts a statistical process monitoring of agreed parameters is carried out. The automated testing of mass production components is always carried out where this is economically possible. |
Post-treatment / conservation
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IIn many cases, Oerlikon Balzers carries out a post-treatment if, for example, the coated tools or components are to be demagnetised or conserved. |
Packaging / shipping
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The coated parts are usually returned in the packaging in which they were delivered. Considerable savings are achievable if the parts are delivered packed in suitable cleaning baskets. |
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