Well-established deposition technologies like ARC or materials like AlTi/TiAl deliver solid results, but it is hard to differentiate yourself substantially here anymore. "Luckily" there has been a lot of movement in both fields that enable individual, tailormade coatings with potential for differentiation and increased margins.
I. Differentiation in technology and process
𝗔𝗱𝘃𝗮𝗻𝗰𝗲𝗱 𝗗𝗲𝗽𝗼𝘀𝗶𝘁𝗶𝗼𝗻 𝗧𝗲𝗰𝗵𝗻𝗶𝗾𝘂𝗲𝘀: 𝗛𝗜𝗣𝗜𝗠𝗦-𝘀𝗽𝘂𝘁𝘁𝗲𝗿𝗶𝗻𝗴
It has been there for a while but is really gaining momentum now. The higher ionization and energy of the sputtered material contribute to many advantages:
✔ Improved hardness and wear resistance
✔ Films with consistent and desired properties
✔ Better machining performance of tools, higher corrosion resistance
All that can create added value. Industries that profit most are tooling, automotive (friction reduction) fuel cells, and optical coatings (corrosion and electrical properties).
𝗔𝗱𝘃𝗮𝗻𝗰𝗲𝗱 𝗽𝗿𝗼𝗰𝗲𝘀𝘀𝗲𝘀
Introducing a reactive gas (such as O or N) along with the sputtering gas delivers the possibility to create thin films with much higher value. Examples: TiON, TiAlCN, for tools and decorative applications, photocatalysis with TiO2, and antireflection (SiO2) in solar cells.
Advantages:
✅ Improved Product Performance: Thin films with specific electrical, optical, or mechanical properties >> Improved device performance and reliability.
✅ Enhanced Functionality: Tailored properties, such as optical coatings for lenses or mirrors with specific reflectance or transmittance characteristics >> enhanced functionality and performance.
✅ Customization and Differentiation: Precise control over properties such as color, hardness, and surface texture. >> Unique features and aesthetics.
𝗔𝗱𝘃𝗮𝗻𝗰𝗲𝗱 𝗰𝗼𝗻𝘁𝗿𝗼𝗹 𝗮𝗻𝗱 𝗺𝗼𝗻𝗶𝘁𝗼𝗿𝗶𝗻𝗴
Advanced coating technologies and -processes in themselves require much more sophisticated monitoring and control equipment:
🛰 Reactive processes: Controlling the composition requires controlling the reactive gases ratio to ensure good reliability of the process.
🛰 Reactive gas control in general: Less defects, better homogeneity >> Higher prices possible.
II 𝗛𝗘𝗔 𝗮𝗻𝗱 𝗗𝗢𝗣𝗜𝗡𝗚 - 𝗜𝗻𝗻𝗼𝘃𝗮𝘁𝗶𝘃𝗲 𝗣𝗩𝗗 𝗺𝗮𝘁𝗲𝗿𝗶𝗮𝗹𝘀
Innovative, tailor-made coatings are a major driver to creating innovative layers, differentiating yourself and getting better prices. There are two main approaches nowadays:
The classical method: Doping
𝗧𝗵𝗲 𝗺𝗼𝗿𝗲 "𝗰𝗹𝗮𝘀𝘀𝗶𝗰𝗮𝗹", 𝘄𝗲𝗹𝗹-𝗲𝘀𝘁𝗮𝗯𝗹𝗶𝘀𝗵𝗲𝗱 𝗺𝗲𝘁𝗵𝗼𝗱 𝗶𝘀 𝘂𝘀𝗶𝗻𝗴 𝗮 𝗺𝗮𝗶𝗻 𝗲𝗹𝗲𝗺𝗲𝗻𝘁 𝗮𝗻𝗱 𝗮𝗱𝗱𝗶𝗻𝗴 𝘀𝗼𝗺𝗲 𝗽𝗲𝗿𝗰𝗲𝗻𝘁𝗮𝗴𝗲𝘀 𝗼𝗳 𝗮 𝘀𝗲𝗰𝗼𝗻𝗱 𝗲𝗹𝗲𝗺𝗲𝗻𝘁 ("𝗱𝗼𝗽𝗶𝗻𝗴"). The second element can induce specific changes and deliver new, decisive properties, the possible individual variation of the second element (within the limits set by nature and production methods) makes it possible to "finetune" the wished characteristics quite well. In a more strict definition "doping" means the introduction of impurities into a material to modify its electrical or optical properties but in PVD materials the term is more widely used, with the second element comprising even 10% or more.
The "fancy" method: HEA
High Entropy Alloys, known as HEA, are relatively new class of materials characterized by having multiple principal elements, 4-5 mainly, in roughly equal proportions. Benefits:
✔ They offer a unique combination of properties, such as high strength, hardness, and corrosion resistance.
✔ The composition of HEAs can be adjusted to achieve desired properties. This flexibility allows for the customization of thin films based on the specific requirements of a given application, providing a high degree of tunability.
Both approaches can deliver thin films with improved or unique properties, i.e. tailoring the properties of thin films for various technological applications and are therefore a valuable base for innovative PVD coatings and high-value products.