BuckCote/IonFusion was a great project. The issue we had was that the process itself tended to soften the blade steel...hence the rolling of the edges. When we got into other knife steels like BG-42, 154CM and S30V we decided those were more "bullet proof". If folks used their Ionfusion knives carefully they truly would hold an edge longer but if they impacted their edges it would ding or roll. The other bit was getting folks to sharpen them properly.
My favorite combination was the titanium/zirconium which we called Champagne. I still have a few of those in my hunting bag.
The company that did the vapor deposition was Molecular Metallurgy Inc. It was a fascinating process involving putting in targets, slabs of titanium, aluminum, zirconium etc and bombarding them electrically in a chamber charged with nitrogen. The targets throw off atoms which bond with the nitrogen and slam into the blade penetrating the surface and then building up over time creating a new hardened skin. You would not call it a coating anymore then you would call your own skin a coating and that was why we changed the name. You could put in multiple targets of more then one material and get the combos like titanium/aluminum nitride or titanium/zirconium etc...
MMI was trying to break into the medical field with ionfused scalpels where the theory was that if the doctors did not have to change blades as often they would have less chance of cutting themselves (aids was a big scare at the time). Not sure how that all worked out.