Over 80% of mould failures in plastic injection moulding are attributed to wear, corrosion, or friction-related damage. To combat these challenges, advanced surface treatments on the moulds have become essential for enhancing durability, precision, and efficiency. For companies that rely on high-quality moulds—whether for manufacturing intricate plastic parts or ensuring consistent production—mould durability and precision are critical.
As a leading plastic injection mould manufacturer in India, Vidhata Plastics leverages cutting-edge surface treatment technologies to extend mould life, reduce rework, and ensure flawless production of high-quality plastic components. By incorporating specialized coatings and hardening processes, Vidhata Plastics optimizes mould performance, enabling faster cycle times and superior part quality.
Advanced Surface Treatments Used by Vidhata Plastics
Vidhata Plastics employs advanced surface treatment technologies to enhance its plastic injection moulds' durability, precision, and performance. These treatments improve wear resistance, reduce friction, and extend mould life, ensuring high-quality production.
Plating Techniques
Hard Chrome Plating: Vidhata Plastics utilizes hard chrome plating to electroplate a thin layer of chromium onto mould surfaces. This coating provides a microhardness of approximately 850-1000 HV, significantly improving wear resistance. With a low coefficient of friction (around 0.1-0.2), it enables smoother part ejection and reduces cycle times. Additionally, its excellent corrosion resistance makes it ideal for moulds exposed to harsh processing environments.
Electroless Nickel Plating: Unlike traditional electroplating, Vidhata Plastics applies electroless nickel plating through an autocatalytic process, ensuring a uniform nickel-phosphorus alloy layer without requiring an external power source. This coating offers a hardness of 500 HV in its as-plated state and can reach approximately 950 HV after heat treatment. Its uniformity and hardness enhance wear and corrosion resistance, making it particularly beneficial for moulds with complex geometries and tight tolerances.
Nitriding Processes
Gas Nitriding: To improve surface hardness and fatigue strength, Vidhata Plastics uses gas nitriding, a thermochemical treatment that introduces nitrogen into the steel mould surface at temperatures between 500-550°C. This process forms hard nitrides (Fe₄N and Fe₂-₃N phases), achieving surface hardness levels of up to 1200 HV. Since it causes minimal dimensional changes, gas nitriding is ideal for precision moulds.
Plasma (Ion) Nitriding: By using plasma discharge to introduce nitrogen ions into the mould surface, Vidhata Plastics achieves precise control over case depth and surface composition. Operating at lower temperatures (400-550°C) than gas nitriding, this process enhances hardness and wear resistance while minimizing distortion, ensuring dimensional accuracy for high-precision moulds.
Physical Vapor Deposition (PVD) Coatings
Titanium Nitride (TiN) Coating: Vidhata Plastics applies TiN coatings via PVD to create a hard (approximately 2300 HV), gold-colored surface with a low coefficient of friction (~0.4). This coating improves wear resistance and reduces adhesive wear, particularly when moulding abrasive or filled polymers. With thermal stability up to 600°C, TiN ensures durability under high-temperature moulding conditions.
Chromium Nitride (CrN) Coating: Vidhata Plastics also uses CrN coatings, which provide a hardness of around 1750 HV and superior corrosion resistance. The lower coefficient of friction (~0.5) compared to uncoated steel minimizes frictional forces during part ejection, reducing wear and preventing surface defects. CrN coatings are especially useful for moulds processing PVC and other corrosive materials.
Chemical Vapor Deposition (CVD) Coatings
Diamond-Like Carbon (DLC) Coating: Vidhata Plastics utilizes DLC coatings for their exceptional hardness (up to 5000 HV) and ultra-low coefficient of friction (~0.1). Applied through CVD, DLC coatings provide superior wear resistance and anti-sticking properties, making them ideal for moulds used in high-precision, intricate component production. Their chemical inertness also ensures excellent corrosion resistance, extending mould life in aggressive processing environments.
By incorporating these advanced surface treatments, Vidhata Plastics enhances mould performance, ensuring longevity, precision, and efficiency in plastic injection moulding applications.
Steps for Applying Advanced Surface Treatments on the Moulds to Reduce Rework
As a leading plastic injection mould manufacturer in India, Vidhata Plastics follows a precise, multi-step process to apply advanced surface treatments on the moulds, ensuring enhanced durability, reduced friction, and minimal rework.
Step 1. Surface Preparation
Cleaning & Degreasing: Removal of contaminants using ultrasonic cleaning, chemical baths, or abrasive blasting to ensure adhesion of coatings.
Surface Roughening: Techniques like sandblasting or chemical etching improve mechanical bonding for plating or coating applications.
Step 2. Heat Treatment (If Required)
Stress Relieving: Pre-treatment heating (450-650°C) reduces residual stresses from machining or welding, preventing deformation during coating.
Hardening & Tempering: Thermal cycles enhance core hardness, improving resistance to mechanical wear.
Step 3. Plating or Coating Application
Electroplating (Hard Chrome Plating): Electrochemical deposition of chromium onto the mould surface for high hardness and wear resistance.
Autocatalytic Deposition (Electroless Nickel Plating): A uniform nickel-phosphorus alloy layer is applied without external power for corrosion and wear resistance.
4. Nitriding Treatment
Gas Nitriding: Diffusion of nitrogen into steel at 500-550°C to form hard nitride layers (Fe₄N, Fe₂-₃N), enhancing wear and fatigue resistance.
Plasma (Ion) Nitriding: Plasma-assisted diffusion of nitrogen ions at 400-550°C for precise control over case depth, minimizing distortion.
5. PVD or CVD Coating Deposition
Physical Vapor Deposition (PVD): Vacuum-based deposition of TiN or CrN for high hardness (1750-2300 HV) and reduced friction.
Chemical Vapor Deposition (CVD): Formation of DLC coatings with extreme hardness (~5000 HV) and ultra-low friction for superior mould longevity.
6. Post-Treatment Finishing & Quality Control
Polishing & Buffing: Achieving required surface roughness (Ra < 0.1µm) to enhance part release and prevent defects.
Hardness & Adhesion Testing: Microhardness testing (Vickers method) and scratch tests ensure coating integrity.
Dimensional Inspection: Precision measurements confirm minimal deviations post-treatment, ensuring mould accuracy.
By implementing these advanced surface treatments on the moulds, Vidhata Plastics optimizes mould performance, reducing rework and enhancing productivity in plastic injection moulding applications.
Advantages of Surface Treatment Benefits
The implementation of these advanced surface treatments yields several technical advantages:
Enhanced Wear Resistance: The increased surface hardness resulting from treatments like nitriding and PVD coatings significantly reduces abrasive wear, a common issue in high-volume production.
Improved Corrosion Resistance: Coatings such as electroless nickel and CrN provide protective barriers against corrosive degradation, essential for moulds exposed to corrosive polymers or humid operating conditions.
Reduced Friction: Low-friction coatings like TiN and DLC minimize friction between the mould surface and the moulded part, facilitating easier ejection and reducing the risk of surface defects.
Dimensional Stability: Processes like plasma nitriding operate at lower temperatures, minimizing thermal distortion and preserving the dimensional integrity of precision moulds.
Conclusion
Vidhata Plastics' commitment to integrating advanced surface treatments into mould manufacturing underscores our dedication to producing high-quality, durable moulds. By leveraging techniques such as hard chrome plating, nitriding, and PVD/CVD coatings, we enhance mould performance, reduce maintenance requirements, and ensure the consistent production of superior plastic components.
For industry-leading solutions in plastic injection moulding, trust Vidhata Plastics—a premier plastic injection mould manufacturer in India—to deliver excellence through innovation and technical expertise.
Visit Our Website: https://www.vidhata.co.in/
Contact Us: https://www.vidhata.co.in/contact
Email Id: info@vidhata.co.in
WhatsApp No. : +919550665666
Comments