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FEATURE MATERIALS IN DESIGN & PROTOTYPING
PVD COATINGS: WHAT ARE THE BENEFITS FOR AUTOMOTIVE MANUFACTURERS?
Alongside pressures to improve the sustainability of production processes and the vehicles rolling off the line, automotive manufacturers are also looking to push the limits of performance and aesthetics. Innovative approaches, such as Physical Vapour Deposition (PVD) coatings, can make this possible. Dr Yuen-Ling Kong of Vestatec, comments
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n recent years, traditionalmethods ofmetal coating – such as painting and electroplating – have become less favourable due to
potentially harmful waste products and questions around safety. Hexavalent chrome, for example, is banned under the EU’s 2017 REACH directive due to its high toxicity. In response to the shifting industry
landscape, while focussing on performance, innovation and sustainability, carmakers must look to new techniques, such as PVD coatings.
HOW DO PVD COATINGS WORK? PVD is an advanced technique used in the process of metal finishing to achieve a durable, high-quality and aesthetically pleasing coating for decorative metal components. Presenting an alternative to traditional processes, PVD coating delivers a superior finish, which maintains the substrate surface finish – for example, polished, brushed grit and bead blast surface finishes. At the heart of the process is a cathodic
arc PVD machine which houses a vacuum chamber. It is here where an electrical arc is created which vaporises a conductive metal target source (known as a cathode target). This vaporised metal is combined with a unique combination of gases to create a compound, which is deposited atom by atom onto the substrate, forming a highly adhesive, strong and thin coating. Once the coating is applied, testing is carried
out on every bach to ensure consistency. An X-ray fluorescent (XRF) machine is used to determine the composition and thickness of the applied coating, while a spectrophotometer
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is used to measure its colour through lighting, chroma and hue.
WHAT ARE THE BENEFITS? With a high deposition rate, manufacturers can benefit from more time-efficient production and improved cost efficiency. Alongside this, the specialist process results in a highly uniform coating, creating greater consistency across batches. Once coated, components will begin to add
value to the final vehicle. Despite measuring just one micron thick (25 times thinner than a human hair), the coating delivers high hardness and great scratch resistance. This improves long-term durability and enables PVD coated components to stand up to the demands of everyday use. In addition, the thin coating achieved with
the PVD process heightens aesthetic appeal. By allowing the texture of the substrate metal to remain visible, the process enables carmakers to showcase the design detail of individual components. A range of colours – including black, graphite, blue, rose gold, gold, silver and nickel – can also be achieved consistently and repeatably, giving carmakers greater design freedom and the ability to appeal to a broader customer base. Alongside strengthening product development
and innovation with PVD coatings, the process can also enhance sustainability efforts. With increased pressures onmanufacturers to reduce the environmental impact of their processes and those of the wider supply chain, this is a significant factor for carmakers. Unlike
alternative methods, PVD coatings do not use substances which are hazardous to humans and there are no harmful waste products.
INVESTING IN SUSTAINABLE METAL FORMING AND FINISHING To support carmakers in leveraging the full potential of PVD coatings, Vestatec has made a significant investment to bring PVD coatings in-house. In practice, this strengthens the supply chain while enabling manufacturers to accelerate innovation through supplier expertise. With the full spectrumof expertise sitting with
one supplier, from metal forming through to coating and component assembly, carmakers can push the boundaries of what is possible and make their design visions a reality. The specialist knowledge of PVD experts ensures a complete understanding of the tolerances of different metals, the properties of substrates and how everything works together. In practice, this means thatmanufacturer-specific requirements can be achieved, without the need for costly and time-consuming trial and error. As a trusted supplier of formed metal
components, Vestatec has been supporting customers every step of the way for more than 40 years, from concept design through to production. The addition of PVD coatingsmeans thatmetal components can now be designed, formed, coated and assembled under one roof, streamlining production and reducing complexity for the world’s leading car brands.
Vestatec
www.vestatec.co.uk
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