This article is the first in a series of features to cover a range of latest tool surfacing technologies for protecting sheet and bulk metal forming tools against the most severe conditions of high volume metal pressing production. The main intention of this series is to introduce the main mechanisms and surface failure modes that tools experience in high production manufacturing. We will look at some historical best practice tool protection which enabled manufacturing of basic geometric forms, to complex multi-stage forming of automotive and general engineering structures. The final section of the series will focus on tool and die protection of high strength alloys and composites in some detail using Thin Film Ceramic coating, duplex treated surfaces and laser cladded deposition layer protection; with some reference to tool reclamation features. In the later series sections some mention with be made of the advanced role of tool lubrication in combination with surface coatings and selection of tool steels via their respective heat treatment to effect optimum performance to achieve best metal forming process economics.
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