Injection Mold Coating Technology / Ruben Schlutter.

Format:

Book

Author/Creator:

Schlutter, Ruben, author.

Language:

English

Subjects (All):

Plastics--Conservation.

Plastics.

Physical Description:

1 online resource (375 pages)

Edition:

First edition.

Place of Publication:

München : Hanser, [2024]

Summary:

This book closes a fundamental gap in the field of mold design. The use of injection molding coatings extends the technical possibilities in the field of plastics production, such as the achievable flow path length, the use of abrasive and corrosive plastics, and the achievable tool life. This possibility of functionalization has so far been somewhat neglected due to a lack of available information on the state of the art and possible applications. This book therefore brings together the available knowledge of various experts in a way that is understandable for engineering students and tool and mold makers. The book covers the individual steps of coating technologies. First, the steel materials that are mainly used for the construction of tools in plastics processing are presented. This is followed by the current status of the various coating technologies. The existing coating technologies are presented and characterized with regard to their suitability for use in tool technology in the plastics processing environment. The third part deals with the characterization of the deposited coatings. On the one hand, the focus is on the characterization of the actual coating, such as chemical composition, coating layout and coating thickness. Secondly, the measurement methods for determining the functional properties of the deposited coatings, such as hardness and wear resistance, thermal properties, thermal conductivity and tribological properties, are presented. Finally, the use of appropriate coatings is illustrated using practical examples from plastics technology.

Contents:

Intro

Contents

Preface

The Authors

The Editor

The Co-Authors

1 Introduction

Dr. Ruben Schlutter

1.1 Defect Patterns in Injection Molding

1.2 Preparation of a Specification Sheet and Functional Specification Sheets

2 Tool Steels and Their Coatability

Markus Pothmann

2.1 Introduction

2.1.1 Definition of Tool Steels

2.1.2 Development of Tool Steels

2.1.3 Types of Tool Steels

2.2 Injection Molding Tool Steels

2.2.1 Introduction

2.2.2 Properties of Injection Molding Tool Steels

2.2.3 Composition of Injection Molding Tool Steels

2.2.4 Heat Treatment of Injection Molding Tool Steels

2.2.5 Surface Treatment of Injection Molding Tool Steels

2.2.6 Maintenance and Care of Injection Molding Tool Steels

2.3 Selection of Injection Molding Tool Steels

2.3.1 Factors that Influence the Choice of Material for Injection Molding Tool Steels

2.3.2 Challenges in the Selection of Injection Molding Tool Steels

2.3.3 Selecting Materials for Injection Molding Tool Steels

2.3.4 Future Development of Injection Molding Tool Steels

3 Fundamentals of Coating Technologies

3.1 Electrolytically Deposited Metallic Layers and Hybrid Systems

Dr. Orlaw Massler

3.1.1 Background and Challenges

3.1.2 Galvanic Layers

3.1.2.1 Challenges and Actions

3.1.3 Electroless Separation

3.1.3.1 Electroless Nickel Plating

3.1.3.2 Principle of Electroless Nickel Plating

3.1.3.3 Electroless Nickel Coatings with Solid Additives (Dispersion)

3.1.3.4 Dispersion Layers as a Special Case

3.1.3.5 Friction-Increasing Layers

3.1.3.6 Sensor- and Indicator Layers

3.1.4 Loading Types

3.1.5 Coating-Compatible Design

3.2 Physical Vapor Deposition

3.2.1 Introduction

3.2.2 Process Variants

3.2.2.1 Evaporation

3.2.2.2 Sputtering

3.2.2.3 Ion Plating.

3.2.3 Layer Growth and Adhesion Mechanisms for PVD Coatings

3.2.4 Multilayer Coating Systems

3.3 Chemical Vapor Deposition

3.3.1 Metalorganic Chemical Vapor Deposition

Vanessa Frettlöh

3.3.1.1 Classification of the Technology

3.3.1.2 Processes during MOCVD-coating

3.3.1.3 Requirements for Organometallic Precursors

3.3.1.4 Structure of an MOCVD System

3.3.1.5 Gap mobility and 3D capability of the coatings

3.3.2 Solid-Based Chemical Vapor Deposition

3.3.2.1 Basics of CVD with Solid Precursors

3.3.2.2 Transport of the Solid Precursor

3.3.3 Plasma-Based Chemical Vapor Deposition

Patrick Engemann

3.3.3.1 Plasmas

3.3.3.2 Plasma-Activated Chemical Vapor Deposition

3.3.4 Precursors - Molecular Sources for Functional Materials

Prof. Dr. Sanjay Mathur, Dr. Veronika Brune, and Dr. Thomas Fischer

3.3.4.1 Chemical Strategies in Material Synthesis

3.3.4.2 Outlook

3.4 Simulation of Layer Deposition

Ameya Kulkarni

3.4.1 Introduction

3.4.2 Theoretical Principles and Experimental Setup

3.4.3 The Equations of State

3.4.4 Experimental Procedure and Results

3.4.5 Results of the Simulations

3.4.6 Conclusion

4 Measurement Technology for Coating Characterization

4.1 Crater Grinding Method

4.1.1 Determination of the Coating Thickness

4.1.2 Determination of Wear Resistance

4.2 Scanning Electron Microscopy

4.2.1 Introduction

4.2.2 Instrument Setup

4.2.3 Preparation of the Sample

4.2.4 Sensors in a Scanning Electron Microscope

4.2.4.1 SE Sensor

4.2.4.2 UVD Sensor

4.2.4.3 BSE Sensor

4.2.4.4 EDX Sensor

4.3 Laser Microscopy

Dr. Stefan Svoboda

4.3.1 Basic Principle

4.3.2 Taking a Picture

4.3.3 Application Examples

4.3.3.1 Crack Network in Sol-Gel Coating.

4.3.3.2 Representation and Evaluation of Crater Grinding

4.3.3.3 Roughness Measurement on a Plastic Sample

4.3.3.4 Evaluation of a Wear Test

4.4 White Light Interferometry

Dr. Andreas Balster

4.4.1 Introduction

4.4.2 Roughness as a Measured Variable

4.4.3 White Light Interferometry method

4.4.3.1 Measuring Principle of White Light Interferometry

4.4.3.2 Applications of White Light Interferometry

4.4.3.3 Limitations of White Light Interferometry

4.5 Infrared Spectroscopy

4.5.1 Introduction

4.5.2 Physical Basics

4.5.3 The Application of FTIR Spectroscopy to Polymers: Material Identification

4.5.4 Identification and Structure Clarification

4.5.5 Quantification of Components

4.5.6 Metrological Aspects of FTIR Spectroscopy

4.5.7 ATR-FTIR Spectroscopy

4.5.8 Application in Molding Tool Technology

4.6 X-Ray Fluorescence Analysis

Dr. Martin Ciaston

4.6.1 Introduction

4.6.2 Physical Principles of X-Ray Fluorescence

4.6.3 Instrumental Aspects of X-Ray Fluorescence Spectroscopy

4.6.4 Applications of X-Ray Fluorescence Spectroscopy in Material Analysis

4.6.5 Quantitative Aspects of X-Ray Fluorescence Spectroscopy

4.6.6 Summary and Outlook

4.7 Electrochemical Impedance Spectroscopy

Dr. Anatoliy Batmanov

4.7.1 Introduction

4.7.2 Basics of EIS

4.7.3 Presentation of EIS Measurement Results

4.7.4 EIS Investigation of Protective Coatings

4.7.5 The Test Setup for EIS Measurements

4.7.6 Conclusion

4.8 Nanoindentation

4.8.1 Introduction

4.8.2 Experimental Setup for Measurement using a Nanoindenter

4.8.3 Common Test Methods

4.8.3.1 Determination of the Indentation Hardness

4.8.3.2 Determination of the Indentation Modulus

4.8.3.3 Determination of the Penetration Creep.

4.8.3.4 Determination of the Penetration Relaxation

4.8.3.5 Determination of the Plastic and Elastic Part of the Indentation Work

4.8.4 Test Methods for Coatings

4.8.4.1 Penetration Modulus of the Coating

4.8.4.2 Penetration Hardness of the Coating

4.9 Determination of the Thermal Diffusivity of Coatings

4.9.1 Influence of the Mold Wall Temperature on the Injection Molding Process

4.9.2 Contact Temperature

4.9.3 Time-Domain Thermoreflectance (TDTR)

4.9.4 3-Omega

4.9.5 Test Setup for Measuring the Contact Temperature

4.9.6 Test Procedure for Measuring the Contact Temperature

4.10 Determining the Demolding Force during Injection Molding

4.10.1 Introduction

4.10.2 State of the Art

4.10.3 Experimental Setup for Analyzing Static and Dynamic Friction

4.10.3.1 Experimental Setup

4.10.3.2 Carrying out the Experiment

4.10.3.3 Qualification of the Injection Mold in the Long-Term Test

4.10.4 Summary

4.11 Determination of Emissions in Plastics Processing

Dr. Andreas Balster and Matthias Korres

4.11.1 Introduction

4.11.2 Gas Chromatography/Mass Spectrometry (GC/MS)

4.11.3 Emission Formation in Plastics Processing

4.11.4 Process-Dependent Emission Formation

4.11.4.1 Material Drying

4.11.4.2 Material Processing

4.11.5 Summary

4.12 Wear Tests in Plastics Processing

Marko Gehlen

4.12.1 Introduction

4.12.2 Definition of Wear

4.12.3 The Importance of Wear for the Industry

4.12.4 State of the Art and Measurement Methods

4.12.5 Wear during Injection Molding and in the Injection Molding Tool

4.12.6 Investigation of the Wear Behavior in Injection Molding

4.12.7 Outlook

4.12.8 Summary

4.13 Adhesion Assessment of Coatings

4.13.1 Rockwell Test (DIN 4856)

4.13.2 Thermal Shock Test.

4.13.3 File Test

4.13.4 Cross-Section Method

5 Application of Functional Coatings

5.1 Hard Coatings

5.1.1 Introduction

5.1.2 Definition and Properties of a Hard Coating

5.1.3 Areas of Application

5.1.4 Requirements and Coating Structure

5.1.5 Process for Applying Hard Coatings

5.1.6 Characteristic Values for Evaluating Wear Resistance

5.1.7 Achieved Abrasion Comparison Values and Hardness

5.1.8 Summary

5.2 Tribological Coatings and Wear Protection Coatings

5.2.1 Types of Wear

5.2.2 Friction Reduction

5.2.3 Galvanic Coatings

5.2.3.1 Hard Chrome Plating

5.2.3.2 Nickel Plating

5.2.4 Electroless Nickel and Dispersion Coatings

5.2.4.1 Dispersion Coating

5.2.4.2 SiC Dispersion Coatings

5.2.4.3 BC Dispersion Coatings

5.2.4.4 hBN Dispersion Coatings

5.2.5 Tribological PVD and PACVD Coatings

5.2.6 Hybrid Coatings

5.3 Corrosion-Protective Coatings

5.3.1 Definition of Corrosion

5.3.2 Basic Strategies for Preventing Corrosion

5.3.3 Requirements for Corrosion Protection Coatings

5.3.4 Development of a Corrosion-Protective Coating against Hot Gas Corrosion

5.3.5 Development of a Corrosion-Protective Coating against Aqueous Corrosion

5.4 Thermal Barrier Coatings

5.4.1 Understanding Thermal Barrier Coatings

5.4.2 Influence of Temperature in the Injection Molding Process

5.4.3 Application and Properties of Thermal Barrier Coatings

5.4.4 Functionality of Thermal Barrier Coatings

5.4.5 Application of Thermal Barrier Coatings in the Injection Molding Process

5.4.6 Use of Thermal Barrier Coatings in Thin-Wall Injection Molding

5.5 Coatings for Plaque Reduction

Mattias Korres

5.5.1 Introduction

5.5.2 Plaque in the Injection Molding Tool

5.5.3 Process Optimization.

5.5.4 Optimization of the Injection Molding Tool.

Notes:

Description based on publisher supplied metadata and other sources.

Description based on print version record.

ISBN:

1-56990-271-2