Chrome Electroplating Replacement With PVD Process

Applications

Chrome plating is a film surface treatment, which has been commonly used in many industrial sectors, to provide excellent shiny decoration, which prevented corrosion and abrasion.

However, the hexavalent Chrome electroplating (Cr6+) damaged the health of operators and ruined our environment. Therefore, trivalent Chrome electroplating (Cr3+) replaced the Cr6+ plating.

But with higher quality requirements by clients and lower production cost demands by manufactures, an alternative low-cost solution needed to be found, while preventing negative health impacts and damages to our environment.

PVD treatment has been identified as the perfect solution to these issues.

Royal Technology has developed standardized PVD coating equipment, which can be applied with various materials:

• ABS, ABS + PC, PA, PBT, Brass, Brass alloy, Metal steel, Zinc alloy, Aluminum alloy.
  PVD revolutionized chrome processing in industries such as:
  Automotive (e.g. Interior trims, Logo, etc.)
• Fashion
• Consumer electronics
• Tooling instruments
• Lighting
• Packaging
  Bathroom fixtures
• Home appliance

And in many other industries, parts need protective layers and aesthetic coatings.

Advantages

• Durable Manufacturing
• Robust Design
• Large Capacity
• Mass Productivity
• Environmentally Friendly Reproducible Coating
• User-Friendly

Besides, the PVD chrome coating benefits are:

1. Environmentally friendly: the whole process is clean, totally free of chemical CO2 emissions
2. High aesthetic finishing with a brilliant metallic look
3. High hardness, abrasion and corrosion resistant, durable; high uniformity; adjustable thickness through proper coating recipes and operating processes
4. High repeatability, fast cycle time, more cost-efficient products
5. Wide range of finishes: reflective, glossy and matte; brightness from see-through to semi-transparent, from full coverage to reflective finishing
6. Large variety of substrates, greater flexibility and choice in product design
7. Saver for operators
8. Reliability, being able to operate the machine 24/7
9. High yield
10. Recyclability

    
    PVD chrome coating process
    
    
    

    TOP COATING
    It provides protection to the PVD metal layer and increases its performance

    PVD METAL LAYER
    Metal or alloy: Chromium, Titanium, Copper, Brass, Silver, Aluminum, Nickel-Chrome, Stainless Steel and others

    BASE COATING
    It levels substrate imperfection, improves adhesion, provides brightness to the surface and improves the substrates hardness.
    
    
    
    

    Technical Specifications

    The PVD-Cr1600 machine is exclusively designed to replace traditional Chrome electroplating.

    Combined with UV process, the coating application covers all materials: plastics, brass and zinc alloy and mild steel. There are multiple deposition sources: The cathodic arc evaporator and magnetron sputtering cathodes enable maximum flexibility and numerous finishing requirements with reduced cycle times.
    Cycle time: 20~30 minutes
    Capacity per shift (8 hours): approx. 15 cycles

    Model: PVD-Cr1600
    Deposition Chamber (mm): Stainless Steel with liners, φ1600 x H1600 (63” x 63”)
    Effective Coating Zone (mm): φ1350 x H1250
    Load Mass (kg): 500 ~ 1000
    Number of Satellites (mm): 6 x φ 350
    Pulsed Bias Power: 48KW
    Arc Cathode Power (KW) : 9* 5
    Pulsed Sputtering Power (KW): 2* 48
    Vacuum Pump: Mechanical, roots and diffusion pumping package
    Operation Control System: PLC controlled processing with Touch Screen HMI
    Electrical Enclosures (mm) L x W x H: PS : 1200 x 2000 x 600
    Power : 600 x 2000 x 1000

    Utility Requirement

    Installation Space (L x W x H) mm: 5000 x 4000 x 4000

    Power Working Environment:l 3 Phase, 380V, 50Hz,

    Compressed Air Pressure: 0.5MPa ~0.7MPa, 5~8kg/cm2

    Cooling Water Flow rate: 120liter/min or more for Arc, sputtering sources and vacuum pumps;

    Water temperature (inlet): 20~25℃

    Water pressure (inlet): 0.3MPa ~ 0.4 MPa

    Water pressure (outlet): less than 0.1MPa, difference between inlet and outlet about 0.3MPa.

    Water quality: resistance no less than 5kΩcm
    
    Machine configuration according to customer requirements, the fixture design and workshop layout plan can be supplied on demand by Royal Technology.

    
    

    Key Components Introduction
    

    1. Satellites

11. Robust design and Laser precision machining
12. Magnetic fluid sealing device

• Mechanical bearings (optional ceramic bearings)
  
  

  2. Vacuum Pump Groups

  2.1 Efficient pump-down system contains 2 sets DP28” diffusion pump
  2.2 Cold-trap device to prevent oil vapour molecules from diffusion pump into chamber
  
  
  

  3. Deposition Sources

  3.1 cathodic arcs distributed in chambers with 2 line
  3.2 2 sets magnetron sputtering cathodes mounted on chamber wall
  3.3 Low temperature deposition
  3.4 Recommended substrate materials:
  Plastics: ABS, PC, PC/ABS, PC/PBT, PC/PRT, PA (fiber glass and mineral enforced)
  many other polymers; with lacquer spray painted substrates, glass.
  Metals: Stainless steel, Aluminum, Titanium alloys, Aluminum alloys, Zinc alloys, brass and many other metals.
  3.5 Recommended target metals
  Chromium, Titanium, Zirconium, Aluminum, Stainless Steel, Copper, Silver, Gold
  and many other non-feffomagnetic metals.
  
  
  

  4. Operation and Control System: Human Machine Interface (HMI)

  Custom-designed user interface can be programmed in your chosen languages
  The history of coating processes are saved automatically
  10 coating processes can be recalled and executed at any time. ( No. 0~ No.9)
  Cycle page: shows all parameters that have to be selected to create a process
  Troubleshooting and Alarm Pages
  Maintenance page
  Electronic components are : Wöhner, Schneider, Omron brands.
  
  
  
  The descriptions presented in the above are purely indicative, Royal Technology reserves the right to give precise details or make changes during machine manufacturing.
  

  Learn how our customer say about this total coating solutions:

  April 1st 2018

  To Royal Technology Team:

  I bought the PVD-machineRTAC-1416. After the start-up and commissioning of the equipment, ceramics, glass and stainless steel were coated. The quality of the coating is excellent.
  To cover Al-Zn alloys products, additional surface preparation of the parts to be coated is necessary. The best option is to pre-coat parts with nickel, and then topcoat the decorative coating. But since there are problems with galvanizing and nickel plating, you can do without it. The seller of this equipment can provide the technology of coating without the use of electroplating.
  The colors are varied and very beautiful, especially on glass and ceramics. It makes no sense to spend money on expensive targets of chromium, instead of them you can use titanium targets, which are five times cheaper, and the resulting color is practically the same.
  The company also provides services for the launch of equipment. At start-up, an interpreter is needed. We used the services of an interpreter who did not have a sufficient level of technical language knowledge. But, in principle, everything was clear, due to the very accessible and user-friendly interface of the software, and a convenient touch screen.
  When buying a PVD-machine you need to have a compressor and a chiller. We were recommended to have a compressor at 9-10 atm., but quite enough 5-6 atm. Also the company provides the necessary spare parts.
  Before buying a PVD-machine, all negotiations were conducted on the Internet. The end result: the PVD-machine is stands and works at my place.
  I want to express special gratitude to the highly skilled manager of the company Miss Zhou Xin, who helped bring the matter to its logical completion.

  TSykalo Sergey Alekseevich (Zaporozhye, Ukraine)
  
  

  Russian:

  
  

  Мною была куплена вакуумная установка для нанесения покрытий САС1416. После запуска и введения в эксплуатацию оборудования покрывали керамику, стекло и нержавейку. Качество покрытия превосходное.

  Для покрытия изделий из цинковых и алюминиевых сплавов необходима дополнительная подготовка поверхности покрываемых деталей. Самый лучший вариант, это предварительно покрывать детали никелем, а потом поверх наносить декоративное покрытие. Но т.к. существуют проблемы с гальванизацией и никелированием, можно обойтись и без него. Продавец данного оборудования может предоставить технологию нанесения покрытия без использования гальваники.

  Цвета получаются разнообразные и очень красивые, особенно на стекле и керамике. Нет смысла тратиться на дорогие мишени из хрома, вместо них можно использовать титановые мишени, которые в пять раз дешевле, а получаемый цвет практически не отличается.

  Также компания предоставляет услуги по запуску оборудования. При запуске необходим переводчик. Мы пользовались услугами переводчика, у которого не было достаточного уровня знания технического языка. Но, в принципе, было все понятно, за счет очень доступного и удобного интерфейса программного обеспечения, и удобного сенсорного экрана.

  При покупке машины необходимо иметь компрессор и чиллер. Нам рекомендовали иметь компрессор на 9-10 атм., но вполне достаточно 5-6 атм. Также компанией предоставляются в комплекте необходимые запасные части.

  Перед закупкой машины все переговоры велись по интернету. Конечный результат: машина стоит у нас и работает.

  Хочу выразить особую благодарность высококвалифицированному менеджеру компании мисс Чжоу Синь (Zhou Xin), которая помогла довести дело до логического завершения.

  Цыкало Сергей Алексеевич (г. Запорожье, Украина)

  
  

  Ukrainian:

  Мною була куплена вакуумна установка для нанесення покриттів САС1416. Після запуску і введення в експлуатацію обладнання покривали кераміку, скло і нержавійку. Якість покриття дуже чудова.
  Для покриття виробів з цинкових і алюмінієвих сплавів необхідна додаткова підготовка поверхні деталей. Найкращий варіант, це попередньо покривати деталі нікелем, а потім поверх наносити декоративне покриття. Але тому що існують проблеми з гальванізацією і нікелюванням, можна обійтися і без нього. Продавець даного обладнання може надати технологію нанесення покриття без використання гальваніки.
  Кольори виходять різноманітні і дуже красиві, особливо на склі та кераміці. Немає сенсу витрачатися на дорогі мішені з хрому, замість них можна використовувати титанові мішені, які в п’ять разів дешевше, а одержуваний колір практично не відрізняється.
  Також компанія надає послуги із запуску обладнання. При запуску необхідний перекладач. Ми користувалися послугами перекладача, у якого не було достатнього рівня знання технічної мови. Але, в принципі, було все зрозуміло, за рахунок дуже доступного і зручного інтерфейсу програмного забезпечення, і зручного сенсорного екрану.
  При покупці обладнання необхідно мати компресор і чиллер. Нам рекомендували мати компресор на 9-10 атм., але цілком достатньо 5-6 атм. Також компанією надаються в комплекті необхідні запасні частини.
  Перед закупівлею обладнання усі переговори велися по інтернету. Кінцевий результат: машина стоїть у нас і працює.
  Хочу висловити особливу подяку висококваліфікованому менеджеру компанії міс Чжоу Синь (Zhou Xin), яка допомогла довести справу до логічного завершення.

  Цикало Сергій Олексійович (м. Запоріжжя, Україна)

  
  
  ​

Shanghai Royal Technology Inc. was established in 2006, a worldwide supplier of high quality vacuum equipment with key locations around the globe. Research and Development technology are supported by specialized engineers in the United States and China. High-tech machine manufacturing facilities are located in Shanghai and our global network of service centers ensure fast customer service response in key locations.

 Shanghai Royal Technology has a strong drive for innovative design and high quality components selection, combined with an extra careful assembly process and a topnotch team of talented technicians and inventors, which enable us to offer turn-key coating solutions with high standard vacuum equipment, meeting and often exceeding Western standard. We are determined to serve the market worldwide in various industries such as:

Consumer electronics, automotive, renewable energy, architecture, Nano and bio-medical materials.

RTAS model,the arc and sputtering integrated series equipment can produce highly reflective black and bronze films specifically for high quality decorative coatings.

RTSP1200-FCEV, It is a sputtering system with PECVD process to deposit thin film on hydrogen fuel cell power modules. Fuel Cell Vehicles is the newest technology for the next generation of environmentally friendly cars. The main advantage and technological progress compared to commonly used batteries like dry cell need to undergo a recurring recharging process, but hydrogen fuel cell power modules only require Hydrogen and Oxygen reaction to generate power for driving.

RTSP1200-DPC,This coating system is exclusively used for the DPC (Direct Plating Copper) ceramic substrates process. The DPC ceramic substrates are widely used in various applications: for instance in high brightness LED to increase the longevity because of its high heat radiation performance, Semiconductor equipment, in microwave wireless communication, military electronics, various sensor substrates, aerospace, railway transportation, electricity power and much more.

RT-CsI950, Evaporation coating plant is applied to CsI film deposition for X-Ray Imaging devices. It is an advanced technique to evaporate CsI on the screen to create high quality images. The high-resolution performance allows this application to be extremely efficient and disruptive in the medical instrument, nuclear energy industry, security checking and inspection, high energy physics subjects and more.

Shanghai Royal Technology also successfully designed and developed Cube and Cylinder model large size Aluminum Vacuum Metalizing System which is used for Automotive Logo Board Coating.

     Live Locally, Think Globally is our Vision. We live our day to day business by the concept of “Integrity and Solidarity”, always striving for innovation to achieve win-win situations in our ecosystem of worldwide partners. As pioneers in the Vacuum Coating Equipment Industry, we never relied on previous accomplishments, but we continuously tried to explore the ever changing world of the Vacuum Coating Industry to always create optimal economic, social and environmental benefits for our customers.

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