insights from enterprise
market supervisor, Tribological Divison
Mustang Vacuum structures, Florida
Mustang Vacuum systems‘ revolutionary PVD systems have taken the arena by means of storm, with over three hundred new structures mounted into existing production lines over the past 10 years. AZoM spoke to Dan Downey, of Mustang Vac, approximately how they’ve optimized the PVD procedure, thebenefits it grants to manufacturers and the way simple it’s far to integrate into production techniques.
JW: firstly, please may want to you in short describe the method of bodily vapour deposition (PVD) to our readers?
DD: PVD is an environmentally pleasant technique of depositing metal skinny movies coatings directly toa substrate. The coating is vaporized in a vacuum and is then deposited at the substrates surface to form a thin defensive and or decorative layer.
Mustang Vacuum structures have several exceptional options for vaporizing the coating material, designed for industrial, automotive, scientific and distinctiveness markets.
the first of those is magnetron sputtering which entails ionizing the coating fabric, which we call the ‘goal’, in one of these manner that is ejected as a plasma over the substrate to shape a film layer. we’ve our very own particular designs for magnetron sputtering resources at Mustang Vac which presents a advancedend and control over the features of the coating.
Our 2d vicinity of knowledge is the technique of cathodic arc deposition. This approach involvesvaporizing the cathode of a circuit the use of an electric powered arc, the vapor is then deposited at thesubstrate. Cathodic arc deposition has a tendency to result in a denser movie high-quality making it themost advantageous approach for packages wherein corrosion and wear will be an difficulty.
Evaporative processes, which includes PVD, are an efficient and environmentally friendly way of coating a surface with a skinny metal movie. PVD is used widely in the automotive enterprise in which the metallization of many small components is a nessecity. Shutterstock | Demeshko Alexandr
JW: Why is PVD, among different evaporative techniques, the selected approach for generating the LEDlighting fixtures observed within the headlights of automobiles?
DD: It comes down to 3 predominant matters; pace, throughput and consistency.
PVD supplies the capability to unexpectedly coat a first-rate thin film onto substrates, together withplastics, without detrimental the cloth, in a completely controlled, very predictable style. This capacity is the reason most LED element producers have adopted PVD as their desired technique rather than theconventional strategies of plating on plastic (POP) or the usage of polymer films.
LED producers have seen the benefit of PVD because it allows them to govern the colour and reflectivity of a completely thin movie the usage of a extraordinarily fast system. also, there aren’t anyenvironmental issues; no unsafe materials are worried inside the process and there’s no waste water todeal with. PVD is a device that can be engaged in nearly any facility that has electricity, water and air.
JW: How do Mustang Vac optimize the PVD process?
DD: The major manner that we optimize optimise PVD is through our particular technique to the hardwareand also the software program that manages the technique itself. We installation fast cyclelayout/construct features which are precise to the Mustang Vacuum generation.
We design for a excessive uptime and excessive quantity. We configure our gadget with magnificence Ahardware and we don’t scrimp on any of the controls or strength/pumping functions. Our PVD structuresare designed to run 24/7, as required. The architecture of the systems also are designed with excessivethroughput in mind. We’ve made positive that each one of the character additives are easy to access and the connections among them are ‘quick–match’ so repairs and troubleshooting take a minimal amount of time, that means the uptime is optimized.
We additionally add an in-chamber topcoat, Plascoat™, which reduces oxidation of the coating andprovides protection from condensation and ultraviolet mild for the substrate. Plascoat is introduced as a part of the PVD technique that means it does not require a secondary operation which assists in offeringthe throughput and consistency required for high quantity applications. This secondary coating protectscomponents from the environment, thereby increasing the pleasant and durability of componentswhich might be metallized the use of the Mustang Vac system.
Mustang Vacuum systems‘ Plascoat™ technology prevents additives, which includes the onesdiscovered in LED lights, from deteriorating from publicity to environmental moisture and UV light. Shutterstock | Alexandru Nika
JW: Can PVD be used to reduce the wear and corrosion of automobile components?
DD: it can, however it also depends on the character of the substrate. If the substrate is vulnerable, aaggregate movie structure may be required. skinny movies can be modified, either through alloying their chemistry or handling the structure of the movie itself, to provide movies which can be inherently anti-corrosive and anti-put on. this can be in addition enhanced by the use of PVD inside a complementary top coat/base coat paint structure in what we name a “paint steel paint” (PMP) approach.
the base coat gives a good floor (levelling)on top of the substrate itself which acts as an amazing platform for the metallic to be deposited by using PVD. The topcoat gives safety from the surroundings and can beeither clear or tinted relying on what aesthetic is desired. As you may see for protection PVD works fine aspart of a paint steel paint system.
JW: What structures do you provide to facilitate PVD processing?
DD: Mustang Vacuum structures provide standalone PVD equipment for self-contained procedures. Weadditionally offer integration of PVD into broader systems that might encompass base coat and topcoatgeneration.
we are able to combine PVD into an current coating machine or help layout a brand new machine andlayout manufacturing flow with our integration partners: paint providers, fabric dealing withcorporations, robotics, and many others.
Mustang Vacuum systems provide a variety of without difficulty included coating structures to fitdifferent industries of production line sizes.
JW: What are the advantages of the usage of PVD over conventional coating strategies which includeplastic on plastic?
DD: there may be a huge environmental gain to the usage of PVD. unlike other plating techniques, which use hazardous acids and caustic reagents, we do now not create unsafe waste so there’s no requirement for waste water treatment or air regulation. This lets in companies to have greener credentials and itmeans the collateral cost for environmental compliance is non-existent.
On top of this PVD, due to its low processing fees, is truly becoming more comparatively cheap than plating over plastic, which is turning into extra high-priced due to extended environmental rules and compliance expenses.
PVD also has a bonus on a chunk charge basis because the process is extra low-priced formanufacturing–kind volumes. In latest environment, the value to procedure components along the extra collateral costs mean PVD can be the best choice each economically and environmentally.
there’s also a yield benefit for correctly configured PVD techniques. We do not have the pleasantanomalies which are normal for most plating approaches that means much less faulty products are made to be wasted.
JW: How hard is it to integrate PVD into excessive–quantity manufacturing procedures?
DD: It’s loads easier than you will expect. Mustang presents a self-contained PVD chamber which may betransported complete to a purchaser’s website and integrated into their manufacturing line, coating theirmerchandise, within four hours.
Our skilled team assist in the preliminary set up of the gadget and supervise the initial production. Following this we’ve got a system trainer stay with the purchaser for five days to teach the operators the Mustang method. as soon as the recipes for successful PVD coatings has been optimized for the client,they may be embedded into the gadget to give a push button procedure.
Troubleshooting is made clean as our structures have internet connectivity allowing us to troubleshoot andprovide technical aid in real time on a 24/7 basis. This allows us to fix problems or help load a distinctivePVD recipe, and of course this is all supervised through the patron to ensure no modifications are made to their device with out their approval.
All of those benefits are to be had to our clients on a international scale. we have extra than 300systems installed worldwide. we’ve a committed aid community across North the us, Asia, Europe and Latin the united states.
JW: Has this functionality ended in PVD becoming the famous alternative for industrial plating?
DD: definitely, PVD is getting used frequently these days across many industries. There’s been an incredibly sturdy uptake of PVD inside the automotive space and ornamental business productsspace. I don’t think there’s a single major plumbing fixture business enterprise which hasn’t integratedPVD into their strategies.
There are markets where PVD is the dominant approach. automotive lights is typical, forward and rearlights, decorative plumbing, and excessive–stop cosmetic packaging. those are large industries thatadopted PVD for financial and environmental motives as both their general or the complementary move-toprocedure.
Evaporative technologies are quickly turning into the move-to method for ornamental completing for aextensive sort of programs starting from rings to plumbing. Shutterstock | Ensuper
JW: wherein can our readers discover more about Mustang Vacuum structures and your PVD structures?
DD: The quality region to begin would be our website, which contains statistics on how wide ourtechnology is, its packages, the products, our assist enterprise and the way to contact us.
in case you want to know some thing else about PVD and the structures we provide please get in touch. We’re centered in Sarasota, Florida and you may name us on +1 941-377-1440 and we’ll be extra than gladto help.
about Dan Downey
Dan Downey is a marketplace manager at Mustang Vacuum structures for their tribological departmentwhich incorporates markets which include automobile, aviation, business and medical.
Dan has worked for Mustang Vacuum structures for the past years but has a robust history in industrialcompleting, with a huge region of knowledge starting from powder coating and e-coating to wellknownplastic coating.
Disclaimer: The views expressed right here are those of the interviewee and do not always represent theviews of AZoM.com limited T/A AZoNetwork the proprietor and operator of this website. This disclaimerpaperwork part of the phrases and situations of use of this website.