Novel Layers for Dies Used in Electromagnetic Sheet Metal Forming Processes * E. Vogli 1 , F. Hoffmann 1 , J. Nebel 1 , D. Risch 2 , A. Brosius 2 , W. Tillmann 1 , A. E. Tekkaya 2 1 Institute of Materials Engineering, Dortmund University of Technology, Germany 2 Institute of Forming Technology and Lightweight Construction, Dortmund University of Technology, Germany Abstract Due to the high forming velocities during electromagnetic sheet metal forming processes, a high impact force acts between workpiece and die. Here, the die surface sustains high damages shown by high wear and galling of the workpiece on the die surface. To enhance the die lifetime, a novel coating concept based on the PVD (physical vapour deposition) process was developed. In doing so, the hardness and the toughness of the designed layers were varied and adjusted to the demands of AlMg-sheet forming process. Keywords Electromagnetic sheet metal forming, Tool design, Physical Vapour Deposition (PVD) 1 Introduction The electromagnetic forming (EMF) process is a highly dynamic process using pulsed magnetic fields to form metals with a high electrical conductivity. A typical setup (see Figure 1) consists of a tool coil, a workpiece, and a form defining tool (die). In this case, a modular die consisting of a drawing ring and cover plate is applied. * This work is based on the results of the Research Unit FOR 443; the authors would like to thank the German Research Foundation (DFG) for its financial support. 301