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PVD stands for Physical Vapor Deposition. It is a thin-film coating process applied in a vacuum chamber to deposit thin-film coatings on component surfaces.

PVD coating occurs in a vacuum chamber at extremely low pressure (10⁻³ to 10⁻⁹ Torr, compared to standard atmospheric pressure of 760 Torr). Components are placed before a high-purity target source in a plasma environment. Three critical steps occur:

1. Evaporation: Removal of material (atom-by-atom) from the target source using sputtering, cathodic arc, electron-beam or other methods.
2. Transportation: Transfer of material from the target source to the component surface under plasma due to potential difference between the target and substrate.
3. Condensation: Nucleation and growth of the coating on the component surface by combining the transferred target source atoms with reactive gases to form the ceramic (non-metallic) coating compound.

Yes. There are different types of PVD coatings that can be offered depending on the application requirements. Titanium Nitride (TiN), Chromium Nitride (CrN), Titanium Aluminum Nitride (TiAlN), Titanium Boron Nitride (TiBN) are some examples of PVD coatings.

• High hardness
• Excellent wear resistance
• Reduced frictional properties
• Low deposition temperatures (120°C–350°C)
• Maintaining dimensional tolerances for precision components
• Excellent adhesion to substrates

In general, PVD coatings are thin film and are in the range of 1 to 5 microns. For reference, 25 microns equals 0.001 inches. Red blood cells are around 8 microns in diameter, while human hair is around 80 microns in diameter. Thus, PVD coatings are extremely thin-film coatings with thickness specification defined within this 1 to 5-micron range depending on the application requirement.

PVD coatings have a hardness value around 1500–4500 HV (Vickers) depending on the type of coating offered. For reference, 900 HV corresponds to 67 HRC (Rockwell C) hardness. Generally, carbon steels have a hardness range around 250 HV (25 HRC), nitrided or nickel and chrome plated steels fall in the range of 600–1000 HV surface hardness. Thus, PVD coatings are extremely hard and hence, very durable and wear resistant.

CERTESS® NITRO is a tradename of HEF Group for Nitrogen based PVD coatings. Options include:

• CERTESS Ti (TiN)
• CERTESS X (CrN)
• CERTESS T (TiAlN)

Yes. PVD is a line-of-sight process. Only the surfaces of the components exposed to the target source can be coated. Depending on the size and shape of the components, they are subjected to a planetary motion (part rotation along an axis for uniform exposure to the target source) within the vacuum chamber to ensure uniformity of the coating across external, exposed surfaces.

A general rule of thumb with this line-of-sight process is 1:1 in terms of coating penetration to the diameter of the opening. This ratio can vary depending on the orientation of the component in the vacuum chamber and the critical surfaces requiring the coating. HEF can evaluate this case-by-case based on component geometry.

Yes. It is possible to mask certain surfaces that do not require PVD coating. Customers should specify surfaces requiring coating (critical surfaces), surfaces where coating is prohibited, and surfaces where coating is optional (non-critical surfaces used for fixturing).

Absolutely. Pre-cleaning is essential and an important step of this process in order to ensure good adhesion of the PVD coating on the component surface. HEF offers cleaning solutions for parts shipped with light rust preventative oils or machining coolants as part of the process.

Yes. PVD coatings (depending on the type) can be offered in different colors such as gold, silver, gray and black to list a few.

Yes. PVD coatings can be removed or stripped if required. This requires components to be immersed in a special chemical solution for a certain time period to ensure the entire coating thickness has been removed. Special attention needs to be given to ensure these de-coating chemicals do not affect the substrate material. The components may require additional polishing before recoating. This is generally discussed with the customer on a case-by-case basis.

DLC stands for Diamond-Like Carbon. This is a special family of thin-film coatings that provide the high hardness like diamond (due to its tetragonal structure) and low lubricity like graphite (due to its hexagonal structure). DLC is amorphous in nature — it does not have a crystal structure — however, it offers combined advantages in spite of its overall random arrangement of carbon atoms.

DLC coatings are deposited using a Plasma Enhanced Chemical Vapor Deposition (PECVD) method. Unlike PVD which involves physically depositing the solid target material source on the component surface, PECVD involves a precursor gas source (hydrocarbon) that is broken down into carbon and hydrogen atoms in plasma, deposited as DLC on the component surface in an amorphous fashion.

DLC coatings are generally applied after a PVD underlayer such as Ti, Cr, CrN or WCC or a combination of them has first been deposited on the component surface. The selection of the underlayer depends on various factors such as hardness of the component surface (substrate), bonding characteristics with the substrate, load bearing requirements of the application, etc.

DLC coatings are deposited at relatively low temperatures below 200°C. HEF's specific deposition technology allows deposition at around 170°C. With our plasma enhancement technology, HEF is able to deposit at such low temperatures to ensure no distortion or change in core properties of the component being coated.

Total coating thickness including the underlayer is uniform and generally in the range of 2 to 5 microns. The exact coating thickness within this range is determined based on the application and performance requirement.

DLC coating hardness can range from 2500 HV to 4500 HV depending on the type of DLC coating including the choice of underlayer.

1. High hardness (2500–4500 HV)
2. Excellent wear resistance
3. Friction reduction
4. Thin, uniform film (precision coating)
5. Excellent aesthetics

Coefficient of friction is a system property. Deposition of DLC coatings helps with friction reduction of the system for applications involving smooth, interacting surfaces. Lubrication plays a key role in this property as well. Typical friction coefficient range for such systems with DLC coated surfaces can be around 0.1 to 0.2 in a dry-condition and less than 0.1 in a lubricated condition.

DLC coatings are classified into two categories:

1. Hydrogenated DLC (a-C:H): "amorphous carbon, hydrogenated" with hardness range 1000–2800 HV (typical 2000–2200 HV)
2. Non-Hydrogenated DLC (ta-C): "tetrahedral amorphous carbon" deposited from solid carbon sources. The specific arrangements of the carbon atoms within ta-C coatings results in them being at least 20% harder than standard a-C:H coatings and can withstand operating temperatures of up to 450°C — about 100°C higher than the maximum temperature resistance of a-C:H coatings.

CERTESS® CARBON is a tradename of HEF Group for DLC coatings. Options include: CERTESS DT (WCC), CERTESS DDT, CERTESS DCX, CERTESS DCY, CERTESS DCZ, and CERTESS TC.

Coatings provide added performance and protection, often solving issues at a reasonable cost. Calico also offers unmatched technical knowledge to help with the selection and application of your coatings needs, plus much more.

Calico's CT-1 dry film lubricant is 0.0002″ to 0.0004″ thick and generally does not require extra clearances. Benefits include allowance for tighter bearing clearances (.002″ to .003″ typical for high performance). CT-3 piston coating is 0.0005″ to 0.001″ thick and allows tighter piston-to-wall clearance resulting in faster sealing and longer ring life, with less loss of power due to blow-by. PVD/PECVD coatings are extremely thin (PVD: average 3 to 3.5 microns; PECVD: 2 to 2.5 microns), ensuring tolerances are maintained.

CT-2 ceramic thermal barrier coatings are virtually permanent. CT-1 and CT-3 dry film lubricants are sacrificial in nature and wear out, but rather than wearing out the engine part, the coating absorbs the wear. PVD/PECVD coatings are highly corrosion resistant and virtually permanent. It has been proven that the actual part will wear out long before the coating does.

Engine Parts: Engine bearings, pistons, oil pumps, combustion chambers, exhaust ports & valves, exhaust systems, transmissions & shifter, rear ends, wheel bearing races and many others.

Gun Parts: Gun barrels, bolt carrier groups, hammers, magazines and many others.

Industrial: Tire molds, vacuum plates, injection molds & components, along with various other industrial and fabrication parts.

Calico Coatings is a bearing warehouse as well as a performance coatings facility. Nearly all bearing orders are shipped same day. Most other coating operations take up to 8–12 days. For faster service please call first.

All of Calico's coatings are economically priced. In many instances, engine builders and car owners have saved considerably more by using coatings than the initial cost of having parts coated.

We do not stock bearings directly.

Yes. While we do not keep bearings in inventory, you may contact Calico, and we can assist by connecting you with trusted distributors for availability and ordering support.

Two coating thickness options are available (measured per shell):

• Standard Option: .00025″ – .0003″ per shell
• Heavy Option: .0004″ – .0005″ per shell

Three coating thickness options are available:

• Piston-S (Standard): .001″ total thickness
• Piston-SH (Heavy): .002″ total thickness
• Piston-SHX (Extra Heavy): .003″ total thickness