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The PVD coating method is a process in which metals go through a cycle of vaporization and condensation to be transferred from their original solid state to the tool. The metal compounds that make up the coatings are often referred to as the “metal material” in this process. The metal material starts as a solid wafer and is vaporized into a plasma, which can then be put onto the tools in the chamber. In this process, the tools are referred to as the “substrate.”

Most tool manufacturers offer tool coatings, made up of a layer of metal compounds adhered to the surface of the tool to enhance its performance. The most common methods for adding coatings to a tool are Physical Vapor Deposition (PVD coating) and Chemical Vapor Deposition (CVD coating). This article will take a deep dive into PVD vs CVD to identify their unique and shared characteristics.

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Citation:[1] Ucun, İ., Aslantas, K., & Bedir, F. (2013). An experimental investigation of the effect of coating material on tool wear in micro milling of Inconel 718 super alloy. Wear, 300(1-2), 8–19. https://doi.org/10.1016/j.wear.2013.01.103

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Tool coatings are utilized by machinists every day to accomplish prolonged tool life, a more efficient machining operation, and an overall higher quality final part. Most manufacturers use two different types of application techniques, PVD coating and CVD coating. Stay on “In the Loupe” to learn more about tool coatings by reading the following blog posts: Overview of Harvey Tool Coatings: Maximizing Performance and 3 Ways Tool Coatings Increase Tool Life.

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Unlike PVD coating operations, which use high electrical charges and atomic collisions to deposit coatings onto a tool, the CVD method utilizes the chemical properties of the metals to transfer metallic compounds onto the tool. The following steps are required to carry out the CVD operation:

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The main difference between arc ion plating and sputtering is that arc ion plating uses high electrical currents to vaporize the metallic material, and the metal ions are steered onto the tool for coating. Sputtering, in contrast, uses the properties of magnetic fields to direct reactive gasses to collide with a target made up of metallic material. During these collisions, metallic surface ions fall from the target and land on the substrate, slowly bombarding it until it is sufficiently coated. Both arc ion plating and sputtering are high temperature, ultrahigh vacuum processes. The term “vacuum” refers to any pressure below atmospheric pressure at sea level.

Arc ion plating and sputtering are both effective methods of applying a PVD coating. So why use one over the other? Arc ion plating has a significantly higher ionization rate than sputtering, allowing for much faster deposition rates, shortening coating times. In turn, since sputtering is a slower process, it allows for more control when applying multi-metal compositions and ensuring that the stoichiometry of the coating is even throughout the tool. Finally, during the PVD coating process, micro-droplets are formed as the vaporized metals condense and solidify onto the tools. As these droplets impact the newly applied coating, they can cause defects and craters, producing residual stress points. In order to achieve a perfect coating, droplet size must be minimized. Arc ion plating produces droplets up to 3µm (micrometers) in diameter, while sputtering has droplets with diameters up to 0.3µm. With droplets up to ten times smaller, sputtering produces much smoother and defect-free surfaces which have been proven to slow corrosion rates.

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