More accurate machining of graphite with the new coating material CCDia® CarbonSpeed

Diamond coatings offer unparalleled advantages when processing a wide variety of materials: CemeCon's newly developed coating materials now promise better performance and wear protection in the graphite electrode manufacturing process. For example, carbon fiber reinforced plastic processing benefits from the stability of the surface finish grade of diamond coated tools.
CemeCon has always been a world leader in the market for crystalline and multi-layer diamond coatings. This is why many well-known tool manufacturers trust the innovative coating development of Würselen. CemeCon coating materials, which always optimizes the customer's application. They are the basis for personalised coating solutions for special applications with users. The focus has always been on the economic processing of a wide range of high-tech materials such as carbon fiber reinforced plastics, other composite materials or graphite.

Photo: Bonn Technology Center SGL Carbon

Even the best contours are possible during graphite processing using diamond coated tools.

For graphite processing
In recent months, customers have been discussing again and again with CemeCon, noting that, especially for graphite processing, multi-layer diamond coatings have a huge advantage over crystalline diamond coatings. The first thing that should be mentioned is that it usually has a good surface quality. In addition, the operating life can be greatly increased, even tighter tolerances can be met. This reason is enough to enable CemeCon engineers to conduct a more in-depth study of this issue. The purpose of this is to develop a product that meets the above-mentioned graphite processing standards. It should be suitable for all common types of cemented carbides and maintain the same price level as traditional crystalline diamond coatings.

CemeCon's product managers, Fabian Küthe and Manfred Weigand, described the new development as follows: "Our goal is to be able to apply new coating materials to all common cemented carbides containing up to 10% cobalt. The wear characteristics should be ideal, and at the same time, it should meet very tight tolerances. Crystalline diamond coatings tend to form super-large crystals. Therefore, it is important to prevent unnecessary growth of individual crystals during the coating process. "Because it is these "clusters" that leave grooves in the graphite during milling. Worst of all, this may make the complete electrode unusable. In addition, the coating should be completely homogenous throughout the length of the coating, and all of this price is equivalent to a crystalline diamond coating. Fabian Küthe said: "This is indeed a huge challenge. However, this work has also paid off very well: as a result, we have developed a new coating material called 'CCDia? CarbonSpeed'."

New coating material for optimal performance of the tool CCDia® CarbonSpeed

Its technical specifications are very different from other products on the market. CCDia® Carbon Speed ​​is particularly resistant because the multi-layer diamond coating has “anti-cracking” properties: in crystal or nanocrystalline coatings, the cracks generated in this process can quickly reach the bottom layer due to the special CCDia® CarbonSpeed The microstructure, which eliminates the risk of such damage. At the same time, its reduced heat transfer protects the cemented carbide.

CemeCon customers are able to coat many carbide substrates. This makes special pre-treatment possible, which also makes it possible to coat coatings with higher cobalt content. Manfred Weigand said: "For carbon fiber reinforced plastics, aluminum, metal matrix composites (MMC) and similar materials, the existing coating materials CCDia® CarbonSpeed ​​and CCDia® MultiSpeed ​​can maintain a proper underlayer for the coating. CCDia® CarbonSpeed ​​only Limited to the treatment of graphite.

The new coating material achieves the best results in graphite processing: when milling EK 82 graphite, the comparative service life shows that CCDia® CarbonSpeed ​​has a better coating score than CCDia® HiCo coating, and the milling parameters are identical. Durability to wear increases by 32%.

It takes only a few steps to make a separate layer
With CCDia® CarbonSpeed, CemeCon provides the ideal foundation for precision-finished coating solutions for graphite, ceramics, blank parts and similar materials. All of this is at the current price level of crystalline diamond coatings. Of course, with just four steps, it is possible to develop a personalized customer solution that can target any coating material. This is possible with CemeCon's modular system:
The first step is to define the user's requirements for tools and coatings in the specification. Then, the specifications of the layers that have been determined are designed according to the coating properties. Sample coating and testing can then be performed to determine the final optimized specification.
This production process is stored in each customer's individual work plan, and a detailed description of the coating process is maintained in this work plan as a basis for the coating material and even the final quality control. This allows accurate replication of the unique composition of the coating specification even after many years. If the situation changes, it can also be used as a basis for improving the coating or finding a solution for other processing operations.

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