Tag Archive for: zplus coating

An In-Depth Look at Helical’s Tplus Coating for End Mills

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When working with difficult-to-machine materials, such as Inconel, stainless steel, or hardened steels, utilizing an effective coating is important for sustaining the life of your tool and perfecting the outcome of your part. While looking for the right coating, many machinists try out several before finding a solution that works – a process that wastes valuable time and money. One coating gaining popularity in applications involving tough materials is Helical Solutions’ Tplus coating. This post will explore what Tplus coating is (and isn’t), and when it might be best for your specific job.

tplus coating on helical end mill

What is Helical Solutions’ Tplus Coating?

Helical’s Tplus coating is a Titanium-based, multi-layered coating that is applied by a Physical Vapor Deposition (PVD) process. This method of coating takes place in a near-vacuum and distributes micron-thick layers evenly onto a properly prepared tool.  Tplus is a premium, multi-layered, titanium coating that increases edge strength, wear resistance, and tool life.

tplus coating specification chart

When Should a Machinist Use Tplus Coating?

When Working in Difficult to Machine Materials

Tplus coating works great in difficult-to-machine materials such as Inconel, stainless steel, hardened steels, and other alloyed steels with a hardness up to 65 Rc. It provides high hardness (44 GPa) for your tool, creating stronger cutting edges and resulting in extended tool life.

When Working in High Temperature Applications

When you are running an application in a ferrous material where extreme heat and work hardening are a possibility, Tplus is a great solution, as it’s designed to withstand high temperatures (up to 2,192°).

Helical Solutions’ 7 Flute Tplus End Mill

In Dry Machining Applications

In the absence of coolant, fear not! Tplus coating is a viable option since it can handle the heat of machining. The low coefficient of friction (0.35) guarantees great performance in dry machining and allows the coated tool to move throughout the part smoothly, creating less heat, which is extremely beneficial in applications without coolant.

In Large Production Runs

In high production runs is truly where this coating excels, as its properties allow your tool to remain in the spindle longer – creating more parts by avoiding time in swapping out a worn tool.

What to Know About Helical Solution’s Zplus Coating

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Non-ferrous and non-metallic materials are not usually considered difficult to machine, and therefore, machinists often overlook the use of tool coatings. But while these materials may not present the same machining difficulties as hardened steels and other ferrous materials, a coating can still vastly improve performance in non-ferrous applications. For instance, materials such as aluminum and graphite can cause machinists headaches because of the difficulty they often create from abrasion. To alleviate these issues in non-ferrous machining applications, a popular coating choice is Helical Solution’s Zplus coating.

zplus coating

What is Helical Solutions’ Zplus Coating?

Helical’s Zplus is a Zirconium Nitride-based coating, applied by a Physical Vapor Deposition (PVD) process. This method of coating takes place in a vacuum and forms layers only microns thick onto the properly prepared tool. Zirconium Nitride does not chemically react to a variety of non-ferrous metals, increasing the lubricity of the tool and aiding in chip evacuation.

zplus coating specification chart

When Should a Machinist Use Helical Solution’s Zplus?

Working with Abrasive Materials

While Zplus was created initially for working in aluminum, its hardness level and maximum working temperature of 1,110°F enables it to work well in abrasive forms of other non-ferrous materials, as well. This coating decreases the coefficient of friction between the tool and the part, allowing it to move easier through more abrasive materials. This abrasion resistance decreases the rate of tool wear, prolonging tool life.

Concerns with Efficient Chip Evacuation

One of the primary functions of this coating is to increase the smoothness of the flutes of the tool, which allows for more efficient chip removal. By decreasing the amount of friction between the tool and the material, chips will not stick to the tool, helping to prevent chip packing. The increased lubricity and smoothness provided by the coating allows for a higher level of performance from the cutting tool. Zplus is also recommended for use in softer, gummy alloys, as the smooth surface encourages maximum lubricity within the material – this decreases the likelihood of those gummier chips sticking to the tool while machining.

Large Production Runs

Uncoated tools can work well in many forms of non-ferrous applications. However, to get a genuinely cost-effective tool for your job, the proper coating is highly recommended. Large production runs are known for putting a lot of wear and tear on tools due to their increased use, and by utilizing an appropriate coating, there can be a significant improvement in the tools working life.

3 flute corner radius end mill for aluminum

When is Zplus Coating Not Beneficial to My Application?

Finishing Applications

When your parts finish is vital to its final application, a machinist may want to consider going with an uncoated tool. As with any coating, ZrN will leave a very minor rounded edge on the tip of the cutting edge. The best finish often requires an extremely sharp tool, and an uncoated tool will have a sharper cutting edge than its coated version.