Aplicações da metalização de alumínio PVD na indústria automotiva

Applications of PVD aluminum metallization in the automotive industry

PVD aluminum metallized parts are quite familiar in cars, buses, trucks and even bicycles that travel on the road every day. These parts can be car logos, lenses, optics, touch screens, mirrors and other external and internal decorative parts. They look like aluminum, but when we pick them up we realize that they are not actually metal. Most of them are made of plastic.

In this article we talk about the applications of PVD aluminum metallization in the automotive industry.

First of all, what is PVD aluminum metallization?

PVD (Physical Vapor Deposition) are sputtering and evaporation processes in which materials such as aluminum or hard alloys pass from the condensed phase to the vapor phase and then condense as a thin film on the object to be coated, also known as metallizing. vacuum.

PVD Coating-Aluminum Finish-2

PVD aluminum metallization is the process of coating a non-metallic substrate with aluminum through evaporation. The substrate must be suitable for vacuum or must be manufactured. The most common materials are tool materials, steel, glass, brass, zinc, as well as ABS and polycarbonate plastic.

PVD aluminum coating is a good option for applications that require very thin functional coatings. The PVD coating process involves applying a layer of high-density material

which is just a few micrometers thick. Once applied, the coating is difficult to remove and does not wear off.

So what can PVD aluminum metallization do for vehicle parts?

In the automotive industry, the use of PVD aluminum metallization has increased in recent years for several reasons, including the following:

  • Provides the aesthetic appearance of metal parts and reduces costs.
  • It is safer than other procedures. Vacuum metallizing does not require a mixture of dangerous chemicals.
  • The cleaner process reduces the risk of chemicals in the part being harmful to people.
  • Offers greater resistance than metallic coating in other forms.
  • It gives the base material advantageous properties such as high wear resistance, high hardness at high operating temperatures, high oxidation resistance, low friction, non-stick effect, high scratch resistance, etc.

PVD Coating-Aluminum Finish-4

In the automotive industry, almost all manufacturers, especially car manufacturers, are racking their brains on how to achieve the ideal status between higher strength and lower weight for their vehicle products. Therefore, aluminum has become a good choice for them over other metals due to its properties such as high strength and light weight. Furthermore, with the development of technology and the advent of vacuum metallization, manufacturers quickly came up with the idea of ​​applying it to vehicles – PVD aluminum metallization on plastic parts replacing metallic versions.

An example of a car headlight reflector at the prototype stage

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Above is a pair of bright Wayken reflectors. They are prototypes for optical testing, CNC milled from PC/ABS and metallized PVD aluminum.

The optical functions can be achieved with the aluminum version or the PC/ABS + PVD metallized aluminum version. What are the advantages of the PC/ABS version?

  1. In terms of aesthetic effect, PVD-AL metallization on plastics can achieve a brighter mirror effect than handmade highly polished aluminum.
  2. In terms of weight, the density of PC/ABS is 1.160 g/cm^3, while the density of aluminum is 2.7 g/cm^3. With the same volume, the AL version is twice as heavy as the PC/ABS version. The PC/ABS version supports car manufacturers' drive to reduce weight.
  3. When it comes to cost, aluminum is certainly more expensive than PC/ABS plastic. Additionally, shipping costs are higher for heavier aluminum reflectors.

In addition to lamp reflectors, PVD aluminum metallization can also be useful for other areas, from luxury car dashboards to functional parts such as exhaust pipes. If you are very interested in our special surface treatment services, you can check out more custom prototype projects like this.

Five frequently asked questions

Question 1: What is the difference between PVD aluminum coating and other coating processes?

PVD is a dry coating process. Typically, the coating is transferred to the substrate using a medium such as a solvent. In PVD, aluminum vapor is generated, transferred to the gas phase and deposited directly on the substrate without the use of a coating medium. PVD only requires electricity and refrigeration equipment to function.

Question 2: Can I get different surfaces using PVD aluminum metallization? ?

The metallization of PVD aluminum closely follows the surface topology. No roughness is added or removed. The PVD surface therefore depends on the surface properties of the substrates. Polished or mirror finish provides polished PVD aluminum metallization surfaces; Brushed or satin finishes produce satin or matte PVD aluminum metallization surfaces. Polymer powder coating can be used as a pre-treatment to create a smooth, shiny surface.

Question 3: Is it possible to remove PVD aluminum coatings?

Yes, there are pickling processes to remove most aluminum PVD coatings. These processes only remove the coating layers and do not affect most application substrates.

Question 4: Does PVD aluminum metallization hide surface imperfections? ?

No. The process does not fill or level the surface. Surface defects remain visible even after applying PVD aluminum coating. Since PVD coatings are highly reflective in most cases, defects become even more visible.

Question 5: Is it possible to cover certain areas of the parts to prevent them from being coated?

Yes. PVD is a line of sight process. Therefore, it is possible to cover areas to prevent coatings from accumulating there. By covering and manipulating the substrate in the deposition process, only the desired areas can be coated.

Conclusion

PVD aluminum coating supports the trend towards more environmentally friendly and lighter production. It can even be said that PVD aluminum coating will have a place in the future of automobile manufacturing. No matter whether it is visual or functional requirements, we can adapt the surface fishing method to actual production on plastic and metal parts. If you would like to learn more about Wayken's PVD aluminum metallization prototyping projects, please contact us via email – (email protected). We look forward to all your questions, not just an offer.

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