| The Ion beam enhanced deposition (IBED) process is a | | | | coating vapor flux, a high degree of control over |
| new metal coating process that can be used to | | | | coating nanostructure can be achieved. This allows |
| effectively coat tableting punches and dies with a | | | | optimization of coating properties such as adhesion |
| variety of hard, wear and corrosion resistant coatings. | | | | and composition, and guarantees that the properties |
| IBED coating technology is ideal for use on tableting | | | | can be duplicated repeatedly. Essentially a line of sight |
| tooling and has two main advantages over | | | | process, sources of the reactant fluxes are located so |
| conventional metal coating methods: | | | | that they simultaneously illuminate the components to |
| 1.) IBED coatings can be applied at temperatures that | | | | be coated. The components are mounted to an |
| do not exceed 150 degrees Fahrenheit, thus | | | | angling, rotating platen assembly that is used to |
| maintaining the original integrity of the tooling, including | | | | uniformly expose all surfaces of the components to |
| exact dimensions and bulk hardness. | | | | both reactant fluxes. The entirely physical nature of the |
| 2.) IBED coatings replicate the tooling's original surface | | | | coating process allows temperatures to be held under |
| finish exactly, thus eliminating the need for post-coating | | | | 150 degrees Fahrenheit. This removes the possibility of |
| repolishing. | | | | deforming structural integrity and altering the precise |
| Unlike conventional electro- chrome plating or | | | | dimensions critical to optimizing pharmaceutical tooling |
| high-temperature vacuum coating processes, IBED is | | | | performance. |
| entirely a physical process (chrome plating and | | | | A variety of types of metallic and hard ceramic |
| vacuum coating are chemical and thermal processes, | | | | coatings can be deposited on the working surfaces of |
| respectively). Ion beam enhanced deposition | | | | punches and dies. The metallic coatings include |
| processing combines the benefits of thermal diffusion | | | | chromium and nickel, and the ceramic coatings include |
| processing and conventional coating technologies | | | | metallic nitrides like titanium nitride and chromium nitride. |
| because the coating atoms first penetrate into the | | | | For most tableting applications the family of hard |
| substrate to form a case layer in the surface, and then | | | | ceramics is the coating of choice. They are much |
| are grown out from this case layer as a thick coating. | | | | harder and abrasion-resistant than nickel or even |
| Driven in kinetically instead of thermally, IBED coatings | | | | chrome plating, and provide a corrosion-resistant seal |
| are "ballistically bonded" to the substrate, thus forming | | | | on all coated surfaces. |
| a metallurgical bond that is much stronger than a | | | | Because of the hardness and durability of the coatings, |
| mechanical or chemical bond. | | | | the wear and corrosion experienced during normal |
| The IBED coating process is implemented by the | | | | tableting operations does not degrade and roughen the |
| simultaneous bombardment of a growing coating with | | | | tooling surface and the tableting tooling performs |
| an independently controllable beam of energetic atomic | | | | better and longer. If powders begin to stick because of |
| particles. The growing coating is generated either by | | | | physio-chemical adhesion, the coated surfaces can be |
| vacuum evaporation or ion beam sputtering. The | | | | cleaned with detergents, solvents, or mild abrasives |
| independent beam of particles consists primarily of | | | | without the risk of scratching or roughening the original |
| charged atoms (ions) extracted at high energy from a | | | | surface finish. The use of IBED performance coatings |
| broad beam ion source. Beams of either inert species | | | | offers an excellent way to preserve the critical |
| (Ne+, Ar+, or Kr+) or reactive species (N+ or O+) can | | | | surfaces of punches and dies thereby improving |
| be utilized for the process. | | | | tableting efficiency and manufacturing productivity. |
| Because control of the ion beam is independent of the | | | | |