Easy multi-color tool-bit reconditioning with the cascade e-ion family of machines.
Less machine chatter reduces galling, enhances life, and creates a smoother cut, which is always a good outcome.
Users report over a 40% reduction in the coefficient of friction.
MHI offers a GoldenBlue® thermal plasma reconditioning and nitride coating service whereby GoldenBlue® coating is applied to tooling, parts and surfaces. This application will provide greater hardness, increase wear resistance and extend surface life for a variety of materials and alloys. The GoldenBlue® service is available through MHI as well as from approved vendors.
Is there a simple way to tell if the Cascade e-Ion Plume treated part is smoother? Less noise indicates smoothness for a ball bearing, roller bearing, or other part.
How do you know that the surface is harder (or has a higher modulus)? Bounce the ball bearing and watch if it bounces higher than the non-coated.
What is GoldenBlue®?
The in situ-growth coating that forms on exposure to the cascade e-Ion beam very often has low lubricity and high surface hardness. Saves the energy of machining. It saves tool resources and offers many more benefits. Please have your prototype tested free at MHI, and if convinced, please consider purchasing the cascade e-ion or sending it to MHI for paid service. Improved coatings on high-speed machine tools, cutting knives, blades, and even recoating thin razor blades when appropriately coated. Transform and reuse (recoat) at will, re-sharpening when possible. First, to prolong tool life, identify the signs of wear like abrasion, fracture, chipping, etc.. Both thermal and mechanical stresses cause tool wear, with heat and abrasion being the primary culprits. Reducing heat generation by lowering the friction adds considerably to life.
GoldenBlue® is the trade name for service and multi-color high-value coatings. The composition depends on the substrate. It is sometimes a Fe-Ti-Al-N-W-C type coating for HSS. One which is ultra-hard and ultra-smooth. Low coefficient of friction ~0.1 ( number depends on surface). The hardness and lubricity depend on the substrate and coating thickness. A hardness of about 13GPa is equivalent to a Rockwell C of about 75 Rc; however, the Rockwell C scale is not meant for such high hardness or coatings. The Cascade e-Ion machines offer easy nitriding/oxynitride of tungsten cobalt, stainless, and titanium alloys (almost all transition metal alloys). High hardness, good lubricity, and multi-element stable coatings are made in situ by the cascade e-Ion plume impingement.
An extensive surface area treatment, when required, does not present a problem. For example, if rails were GoldenBlue® treated, it does not present a problem for size. Consider for automobile parts, from engine parts to shafts and gears. When you purchase a machine, you are freely enrolled in the expanding cascade e-ion group knowledge base. The coatings may be beneficial for bolts and nuts that seize during operations, i.e., for making non-seizing surfaces for automobiles, aircraft, and other high-temperature engine parts like bolts, even for corrosive outboards. Each situation may be different. However, MHI will happily do limited free parts for your verification while this offer lasts. Please contact MHI for details. It is a new type of heat treatment with vast possibilities. MHI has introductory prices that are well below lasers, very large vacuum and gas furnaces, or vacuum ion nitriders
|Oxynitride or Carbo-oxynitride variations
|GoldenBlue® – this is a trademark to signify the multi-color hard in situ coating.
|>3000 Vickers (nano) as an example.
|It is one of the best for high hardness, low coefficient of friction, improved drilling speeds, and other benefits like less heat and less chatter depending on the substrate. Use for stainless steel, hardened die steel, and even ceramics.
Try GoldenBlue®. The process is simple. Immerse or move the part in or under the special CleanElectricFlame™ that is produced by the Cascade e-Ion™.
Process for about ten to fifteen seconds (for a inch or so thick part) to build up a four or five-micron coating thickness of the type A or type B GoldenBlue® coating. One should expect about a 15% tool life speed improvement per hole over the uncoated (such an improvement is in the same range as the regular TiN commercial coatings, at least as noted in our limited trials). The total life improvement could almost double (depending on part size and type). The GoldenBlue® – B offers even better expectations of about a 25% improvement in speed over a regular HSS-uncoated. These results are not guaranteed as they depend on specific tool types and use.
Improve carbide bits: Yes – coating is feasible on end-mill carbide inserts. In situ-coat many types of punches dies, and other surface.
Please do not hesitate to send us your specific tool or typical surface for trials so that your specific tool or surface can be coated for you. We can also determine if your tool bit may be reconditioned to GoldenBlue® grade.
Early stage, first-time use customer testimonial: “We ran one of the inserts on 17-4 stainless steel on our CNC lathe……..The coating did seem to make a difference. I would say at least 15 to 20% better than without it. I ran the small insert on 1045 steel. Bored 40pc with two passes for each bore. One thing I noticed right off the bat was the coating gave an improved finish over a standard insert finish. I did not have to change the insert and finished all 40 pcs without the tool breaking down!”
MHI to Customer: Thank you so much for sharing the result. Please allow us to express our gratitude and permit us to use more of your tools at no charge.
The available technology for surfaces and tool bits is changing rapidly. How does one compare drills and other such tools? The following checklist may assist your evaluation.
(1) For the same sharpness (radius of the edge), compare drill or cutting time; (2) For the same sharpness, compare the life of the tool before it begins to screech or leave behind burns; (3) compare the overall cost of the value addition, i.e., compare the improvement per unit cost including the cost of the of tool, cost of operations, cost of change/wait period, (4) determine whether the tool may be reused after coating and or after re-sharpening, and (5) if applicable, whether a sharpened tool may be recoated.
With the cascade e-Ion processed tools, we saw better drill speed (we could double the speed in a drilling experiment), improved sphericity of holes, cleaner breakthroughs, and smoother tapping control for tapping tools. All this results in more energy efficiency during manufacture and drilling/tapping because of the Goldenblue® treatment/coating.
With the Cascade e-Ion processed surfaces, we saw improved smoothness as measured by the chatter quality of the cut, with no seizing and less heat generation. Thus giving confident and longer-lasting tool expectations.
Common high-speed steel HSS composition grades (by %wt. nominal)