PVD stands for Physical Vapor Deposition. It is a thin-film coating process. This is a process applied in a vacuum chamber to deposit thin-film coatings on component surfaces.

PVD coating is carried out in a vacuum chamber at an extremely low-pressure range (typically 10^-3 to 10^-9 Torr. Standard atmospheric pressure is 760 Torr) where in the component to be coated is placed in front of a high purity target source in a plasma environment (ionized gas). A target is the primary material source used for the coating (for example: Titanium for Titanium Nitride, Chromium for Chromium Nitride, etc.) This process involves three critical steps:

1. Evaporation: Removal of material (atom-by-atom) from the target source using sputtering, cathodic arc, electron-beam or other methods.
2. Transportation: Transfer of material from the target source to the component surface under plasma due to potential difference between the target and substrate.
3. Condensation: Nucleation and growth of the coating on the component surface by combining the transferred target source atoms with reactive gases to form the ceramic (non-metallic) coating compound.
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PVD coatings can be applied on components using different methods such as arc evaporation, magnetron sputtering to name a few. HEF specializes in plasma enhanced magnetron sputtering, CAM (coating assisted by microwaves) and modified arc evaporation coating technologies.

Yes. There are different types of PVD coatings that can be offered depending on the application requirements. Titanium Nitride (TiN), Chromium Nitride (CrN), Titanium Aluminum Nitride (TiAlN), Titanium Boron Nitride (TiBN) are some examples of PVD coatings.

PVD coatings offer the following benefits:

• High hardness
• Excellent wear resistance
• Reduced frictional properties
• Low deposition temperatures (120°C-350°C)
• Maintaining dimensional tolerances for precision components
• Excellent adhesion to substrates

In general, PVD coatings are thin film and are in the range of 1 to 5 microns. For reference, 25 microns equals 0.001 inches. Red blood cells are around 8 microns in diameter, while human hair is around 80 microns in diameter. Thus, PVD coatings are extremely thin-film coatings with thickness specification defined within this 1 to 5-micron range depending on the application requirement.

PVD coatings have a hardness value around 1500 – 4500 HV (Vickers) depending on the type of coating offered. Vickers (HV) is a microhardness unit for measuring thin film coatings. For reference, 900 HV corresponds to 67 HRC (Rockwell C) hardness. Generally, carbon steels have a hardness range around 250 HV (25 HRC), nitrided or nickel and chrome plated steels fall in the range of 600 HV to 1000 HV surface hardness. Thus, PVD coatings are extremely hard and hence, very durable and wear resistant.

CERTESS^® NITRO is a tradename of HEF Group for Nitrogen based PVD coatings. Depending on your application, there are different options that can be provided within the family of CERTESS^® NITRO coatings. Some of these include:

CERTESS NITRO FAMILY

• CERTESS Ti (TiN)
• CERTESS X (CrN)
• CERTESS T (TiAlN)

Yes. PVD is a line-of-sight process. Only the surfaces of the components exposed to the target source can be coated. Depending on the size and shape of the components, they are subjected to a planetary motion (part rotation along an axis for uniform exposure to the target source) within the vacuum chamber to ensure uniformity of the coating across external, exposed surfaces.

A general thumb rule or ratio with this line-of sight process is 1:1 in terms of coating penetration to the diameter of the opening. This ratio can vary depending on the orientation of the component in the vacuum chamber and the critical surfaces requiring the coating. HEF can evaluate this case-by-case based on component geometry.

Yes. It is possible to mask certain surfaces that do not require PVD coating. Components are also held on certain surfaces using special tools within the vacuum chamber that do not get exposed to the coating. Customers are requested to specify on part drawings the following:

• Surfaces that must have the coating – critical surfaces
• Surfaces where coating is not allowed – requirement for masking
• Surfaces where coating is optional – non-critical surfaces

Non-critical surfaces will be utilized to fixture the part for the coating process.

Yes. PVD coatings can be applied on steel, titanium, copper-beryllium, aluminum alloys as well as certain plastics, elastomers and glass.

Absolutely! Pre-cleaning is essential and an important step of this process in order to ensure a good adhesion of the PVD coating on the component surface. HEF offers cleaning solutions for parts shipped to us with light rust preventative oils or machining coolants as part of the process.

Surface finish primarily depends on the application and performance requirements of the component. Ra, Rpk and Rz are typical surface roughness parameters that are looked into depending on the application. However, it is important to ensure that the parts are provided in a good surface condition without any imperfections/defects and contamination (rust, scaling/oxides).

PVD coatings generally duplicate the incoming surface finish of the parts. However, HEF offers certain pre-blasting and pre-polishing capabilities for applications that require a specific finish.

Yes. PVD coatings (depending on the type) can be offered in different colors such as gold, silver, grey and black to list a few.

Yes. PVD coatings can be removed or stripped if required. This requires components to be immersed in a special chemical solution for a certain time period to ensure the entire coating thickness has been removed. However, special attention needs to be given to ensure these de-coating chemicals do not affect the substrate material. The components may require additional polishing before recoating. This is generally discussed with the customer on a case-by-case basis. HEF has the capabilities to offer these services, if required.

DLC stands for Diamond-Like Carbon. This is a special family of thin-film coatings that provide the high hardness like diamond (due to its tetragonal structure) and low lubricity like graphite (due to its hexagonal structure). DLC though, is amorphous in nature i.e. it does not have a crystal structure, however, offers combined advantages in spite of its overall random arrangement of carbon atoms.

DLC coatings are deposited using a Plasma Assisted Chemical Vapor Deposition (PACVD) method. Unlike PVD method that involves physically depositing the solid target material source on the component surface, PACVD on the other hand involves a precursor gas source (hydrocarbon) that is broken down into carbon and hydrogen atoms in plasma, deposited as DLC on the component surface in an amorphous fashion.

DLC coatings are generally applied after a PVD underlayer such as Ti, Cr, CrN or WCC or a combination of them has first been deposited on the component surface. The selection of the underlayer depends on various factors such as hardness of the component surface (substrate), bonding characteristics with the substrate, load bearing requirements of the application, etc. The choice of underlayer is determined case by case primarily based on the application and performance requirements.

DLC coatings are deposited at relatively low temperatures below 200°C. HEF’s specific deposition technology allows us to deposit these coatings at around 170°C. With our plasma enhancement technology, HEF is able to deposit at such low temperatures to ensure no distortion or change in core properties of the component being coated. Thus, precision components with tight dimensional tolerances can be DLC coated without any concerns.

Total coating thickness including the underlayer is uniform and generally in the range of 2 to 5 microns. The exact coating thickness within this range is determined based on the application and performance requirement.

DLC coating hardness can range from 2500 HV to 4500 HV depending on the type of DLC coating including the choice of underlayer.

DLC coatings offer the following benefits

1. High hardness (2500-4500 HV)
2. Excellent wear resistance
3. Friction reduction
4. Thin, uniform film (precision coating)
5. Excellent aesthetics

Coefficient of friction is a system property. It is generally the ratio of the frictional force to the normal force when two bodies interact with each other. Deposition of DLC coatings helps with friction reduction of the system for applications involving smooth, interacting surfaces. Lubrication plays a key role in this property as well. Typical friction coefficient range for such systems with DLC coated surfaces can be around 0.1 to 0.2 in a dry-condition and less than 0.1 in a lubricated condition.

Yes. DLC coating can be removed or stripped if required. While the DLC layer can be removed within the same coating chamber using a reactive plasma-based process, removal of the PVD underlayer(s) requires components to be immersed in a chemical solution for a certain time period. The components may require additional polishing before recoating. This is generally discussed with the customer on a case-by-case basis. HEF has the capabilities to offer these services, if required.

DLC is a family of ultra-hard, thin-film, carbon-based coatings that can be broadly classified into:

1. Hydrogenated DLC, represented as a-C:H (amorphous carbon, hydrogenated). In this category there are several coatings with different underlayers – but all of them have the same a-C:H top layer. The full range of hardness for coatings within this family is 1000-2800 HV, but the typical range is 2000-2200 HV. For further details, please refer to the DLC Coatings overview section on our website.
2. Non-Hydrogenated DLC, represented as ta-C (tetrahedral amorphous carbon). This coating is deposited from solid carbon sources, rather than a gaseous hydrocarbon (as for the a-C:H coatings) precursor. The specific arrangements of the carbon atoms within the ta-C coatings results in them being at least 20% harder than the standard a-C:H coatings and can withstand operating temperatures of up to 450° C – which is about 100° C higher than the maximum temperature resistance of a-C:H coatings.

CERTESS^® CARBON is a tradename of HEF Group for DLC coatings. Depending on your application, there are different options that can be provided within the family of CERTESS^® CARBON coatings. Some of these include:

1. CERTESS DT (WCC)
2. CERTESS DDT
3. CERTESS DCX
4. CERTESS DCY
5. CERTESS DCZ
6. CERTESS TC

Coatings provide added performance and protection, often solving issues at a reasonable cost. Calico also offers unmatched technical knowledge to help with the selection and application of your coatings needs, plus much more.

Calico’s CT-1 dry film lubricant used on engine bearings, valve springs, oil pump gears, timing and transmission gears is 0.0002″ to 0.0004″ thick and generally does not require extra clearances. A benefit of Calico coated bearings is the allowance for tighter clearances. Keeping in mind that bearing clearances of .002″ to .003″ are typical for high performance applications.

Calico’s CT-3 dry film lubricant used on pistons is 0.0005″ to 0.001′ thick. With many different piston materials on the market today, there are no typical clearances. However, CT-3 coated pistons can be installed with tighter clearances than uncoated pistons. Tighter piston-to-wall clearance will result in faster sealing and longer ring life, with less loss of power due to blow-by or for partially sealed rings.

PVD coatings are extremely thin, as they are applied to your parts on average 3 to 3.5 microns thick. PECVD coatings are applied on average of 2 to 2.5 microns. Applying these high performance coatings to precisely engineered parts ensures that tolerances and fits won’t be affected and that they will fit back together perfectly. Although these coatings are thin, they are not thin on performance.

Calico’s CT-2 ceramic thermal barrier coatings are virtually permanent.

Calico’s CT-1 and CT-3 dry film lubricants are “sacrificial” in nature and eventually wear out. But rather than wearing out the engine part, the coating absorbs the wear — saving you time and money on expensive engine parts. It is also possible to re-coat and further extend the life of the coated parts at a fraction of the replacement cost (i.e. pistons, etc.).

PVD/PECVD coatings are highly corrosion resistant and virtually permanent. It has been proven that the actual part will wear out long before the coating does. These coatings extend your tool/part life and can help your company realize significant savings in replacement costs and in helping your mean time between occurrences.

Engine Parts:
Engine bearings, pistons, oil pumps, combustion chambers, exhaust ports & valves, exhaust systems, transmissions & shifter, rear ends, wheel bearing races and many others.

Gun Parts:
Gun barrels, bolt carrier groups, hammers, magazines and many others.

Industrial:
Tire molds, vacuum plates, injection molds & components, along with various other industrial and fabrication parts.

There are many “hidden” benefits to using Calico Coatings. Engine builders using CT-1 coated engine bearings save time and effort during rebuilds by not having to change and refit new engine bearings. CT-1 coated engine bearings have greatly extended service life over uncoated bearings. Engine builders have also seen reduced damage in engines from heat and lubrication-related failures.

Coated transmission and rear end housings as well as gears and shafts reduce operating temperatures by 30 degrees or more. Coating heat shields, cowlings, air cleaner housings, and exhaust systems reduces under-hood temperatures. Coating brake pads, calipers, and caliper pistons extends pad life and reduces or eliminates boiling of the brake fluid. The list goes on and on.

Calico Coatings is a bearing warehouse as well as a performance coatings facility. Nearly all bearing orders are shipped same day. Most other coating operations take up to 8-12 days. For faster service please call first. Calico Coatings will be glad to help!

All of Calico’s coatings are economically priced. In many instances, engine builders and car owners have saved considerably more by using coatings than the initial cost of having parts coated.

We do not stock bearings directly.

Yes. While we do not keep bearings in inventory, you may contact Calico, and we can assist by connecting you with trusted distributors for availability and ordering support.

Calico offers two coating thickness options for bearings (measured per shell):

• Standard Option: .00025″ – .0003″ per shell
• Heavy Option: .0004″ – .0005″ per shell

This allows customers to choose the appropriate coating build based on clearance requirements and application demands.

Calico offers three different coating thickness options for piston skirts:

• Piston-S (Standard): .001″ total thickness
• Piston-SH (Heavy): .002″ total thickness
• Piston-SHX (Extra Heavy): .003″ total thickness

This allows customers to select the appropriate build-up depending on application requirements and piston-to-wall clearance considerations.