Forming represents one of the most delicate stages of all industrial production, especially when it comes to the processing of materials such as metals, glass and ceramics. This operation involves the transformation of a raw material into a precisely shaped object by applying external forces that determine its final profile. Fully understanding how the forming process works, its critical issues, and, most importantly, how to protect materials with the right coatings, can make the difference between an efficient production cycle and an expensive and ineffective one.
What is forming and why it is important
The term forming refers to the set of techniques and operations by which a desired shape is given to a material, starting from a raw state. It is a process that underlies a great many industries, from metallurgy to the glass industry, from ceramic production to the textile and printing sectors.
In the case of metal forming, the process takes on even greater significance, as the quality of the workmanship directly affects the mechanical properties, strength and durability of the final product. Achieving a surface free of imperfections, without defects due to wear or unwanted friction, is critical to ensuring the efficiency of the molds and the quality of the part produced.
Glass forming, on the other hand, involves high-temperature processes where the raw material, brought to a fluid or plastic state, is shaped in molds that determine its shape, thickness and surface finish. Here, too, the quality of mold and tool coatings plays a key role in preventing breakage, sticking, and visual defects.
The main types of forming
Cold forming
Cold metal forming is performed on materials that have not been preheated, taking advantage of the plasticity of the metals themselves at room temperature or slightly above. Techniques such as blanking, stamping, deep drawing and bending belong to this category. The advantage of these processes lies in the ability to obtain parts with close tolerances, smooth surfaces and excellent mechanical properties. However, mold wear resistance and surface quality depend largely on the presence of appropriate protective coatings.
Hot forming and foundry
In the field of high-temperature metal forming, such as in foundries, raw material is heated until it becomes malleable and cast inside a mold, which imparts its final shape. The choice of materials and coatings for molds is decisive: they must withstand extreme temperatures, thermal shock and abrasive processes. Without adequate protection, molds degrade quickly, causing scrap and plant downtime.
Glass forming
Glass forming is another highly specialized area: here the raw material is brought to a viscous state and shaped by blowing, pressing, casting or centrifuging. Mold linings must ensure perfect release of the part, prevent adhesion of molten glass, and ensure long tool life.
Critical issues in molding processes
Whatever the area of application, molding processes face a number of common issues: mold wear due to repeated production cycles, unwanted material adhesion, surface residue formation, increased friction between mold and raw material, and, in some cases, corrosion or oxidation phenomena. These critical issues result in frequent downtime, maintenance requirements, increased scrap and, ultimately, high production costs. Hence the need to employ specific protective coatings designed to reduce friction, prevent wear and extend the life of molds.
Boron nitride (BN) coatings in molding
Boron nitride coatings are distinguished by unique characteristics that make them ideal for both metal forming and glass forming. Hexagonal boron nitride (h-BN), in particular, offers a combination of properties that no other material can boast: extreme high temperature resistance, high lubricity even when dry, excellent chemical inertness and very low coefficient of friction.
Using a boron nitride coating means drastically reducing the adhesion of metals or glass to molds, facilitating the release of formed parts, minimizing the formation of surface residues, and extending tool life. This results not only in increased productivity, but also in consistent finished product quality and a significant reduction in maintenance and downtime costs.
The ATP R12 product: the ideal forming solution
The ATP R12 forming coating represents one of ATP Europe’s flagship products. It is a boron nitride-based protective paste specially developed to withstand the harshest conditions encountered during the machining of ferrous and nonferrous metals and in glass forming processes.
ATP R12 is distinguished by its outstanding properties:
- Extreme ease of application, even on complex surfaces
- Excellent adhesion to a wide range of metallic materials
- High resistance to high temperatures, without performance degradation
- Superior anti-adhesion and lubrication properties, which reduce friction and prevent premature mold wear
Thanks to these features, ATP R12 is the ideal solution for those in the metal forming and glass forming industries who want to ensure production continuity, quality and durability of equipment.
Protect your production, choose ATP Europe!
Choosing the right coating depends on the specific needs of your production: type of material, operating temperature, frequency of cycles, shape and size of molds. If you want to learn more about ATP Europe‘s metal forming solutions, contact us now: we are always ready to support you in choosing the right solution for your production needs!