Combining excellence in corrosion protection arsmote 2017/2017 03 09...Technology for tomorrow's...
Transcript of Combining excellence in corrosion protection arsmote 2017/2017 03 09...Technology for tomorrow's...
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Technology for tomorrow's solutions
Combining excellence in corrosion protection
Kjell Ahlin – SYF annual meeting 9.3.2017
Utökat korrosionsskydd med kombinerade skikt
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Combining excellence Agenda
1 Comparison of technologies
2 Process sequence
3 Examples and advantages
4 Summary
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Electrolytic plating process sequence Typical coating layer setup
Base Material
(Substrate)
Basecoat
Base material (Metal substrate)
Electroplated zinc / zinc alloy layer
Passivate
Sealer
Typically 8 – 20 μm
Typically 0.1 – 0.3 μm
Typically ~1 μm
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Pre treatment
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Zinc flake coating systems Typical coating layer setup
Base Material (Substrate)
Basecoat
Base material (Metal substrate)
Degreasing / shot-blasting or degreasing / phosphating
Base coat
Top coat Typically 1 – 6 μm
typically 8 – 10 μm (2 layers base coat)
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1 Comparison of technologies
2 Process sequence
3 Examples and advantages
4 Summary
Combining Excellence Directory of contents
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Process sequence Two technologies for cathodic corrosion protection
Dip-spin/spray appl.
base coats
Electrolytically plated
zinc and zinc alloys
Passivates
Sealers
Top coats
Coatings for cathodic corrosion protection
Electroless zinc flakes
Electrolytic coatings
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Process sequence Two technologies for corrosion protection
Coatings for corrosion protection
Electroless Zn flake coatings Electrolytic coatings
Top coats Sealers
Base Coat
Electrolytically plated zinc and zinc alloys
Passivates
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Process sequence Two technologies for corrosion protection
Coatings for corrosion protection
Electroless
zinc flakes
Electrolytic
coatings
Base coat
Top coat
5 µm
topcoat
zinc flake
basecoat
Sealer
0.2 µm passivate
1 µm sealer
zinc / zinc alloy
Passivate
Electroplated zinc / zinc
alloy layer
Electroless
zinc flakes
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Electroless
zinc flakes
Process sequence Two technologies for corrosion protection
Coatings for corrosion protection
Base coat
Top coat
5 µm
topcoat
zinc flake
basecoat
Electrolytic
coatings
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Process sequence Two technologies for corrosion protection
Electroplated
zinc or zinc alloy
Passivate
Top coat
Combined layer!
10
5µm Top Coat 0,2µm Passivate Electroplated Zn/Zn alloy
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Zinc or zinc alloy
Passivate
Zinc or zinc alloy
Passivate
Sealer
0.2 µm passivate
0.2 µm passivate
1 µm sealer
8 – 15 µm zinc or zinc-alloy 8 – 15 µm zinc or zinc-alloy
0.2 µm passivate
5 µm top coat
8 – 15 µm zinc or zinc-alloy
Zinc or zinc alloy
Passivate
Top coat Corrosive environment
Process sequence Different technologies for corrosion protection
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Combined layer!
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Possible combinations
Acid Zn
Alkaline Zn
ZnFe
Acid ZnNi
Alkaline ZnNi
Silver top coat
Black top coat
Blue / iridescent passivation
Black passivation
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Combining Excellence Directory of contents
1 Comparison of technologies
2 Process sequence
3 Examples and advantages
4 Summary
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Examples and advantages
ZnNi Silver system
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Example and advantages Zinni® AL 450 + EcoTri® HC 2 + Techseal® Bright Silver SL
0 h
96 h
216 h
504 h
1,000 h
ISO 9227 NSS result > 1,000 h minor visual change only
Mild steel door lock parts
Treatment:
Zinni® AL 450: Barrel alkaline zinc nickel process EcoTri® HC 2: Barrel Cr(III) thick film passivation Techseal® Bright Silver SL: Basket dip-spin coating organic top coat
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Example and advantages Alkaline zinc-nickel + passivation + top coat
Alk. ZnNi + passivate + 1x Zintek Top XT
ACT II test results
1 cycle
Start
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Example and advantages Alkaline zinc-nickel + passivation + top coat
Alk. ZnNi + passivate + 1x Zintek Top XT
6 cycles 12 cycles
ACT II test results
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Examples and advantages
Zn silver system
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Example and advantages Alkaline zinc + passivation + top coat
Coating sequence
Protolux® 3000 + EcoTri® NF + Zintek® Top XT
Excellent white and red rust resistance in NSST ISO 9227
240 h 480 h
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Example and advantages Alkaline zinc + passivation + top coat
Coating sequence
Protolux® 3000 + EcoTri® NF + Zintek® Top XT
7/10 parts had no white corrosion after 1,200h
720 h 1,200 h
Excellent white and red rust
resistance in NSST ISO 9227
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Example and advantages Alkaline zinc + passivation + top coat
Coating sequence
Protolux® 3000 + EcoTri® NF + Zintek® Top XT
2 cycles 6 cycles
Excellent white and red rust resistance in ACT
10 cycles
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Examples and advantages
ZnNi Black system
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Zinni® AL 450 + Unifix® Ni 3-30 L + Techseal® Black SL
Parts
Screws M8x50
Treatment
Zinni® AL 450:
Barrel alkaline zinc nickel process
Unifix® Ni 3-30 L:
Barrel black Cr(III)-passivation
Techseal® Black SL:
Dip spin coating organic top coat
NSST > 1000h minor visual change only
0 h
240 h
480 h
720 h
1,176 h
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Examples and advantages
ZnFe high alloy Black system
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Hiron® – for advanced corrosion protection
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Corrosion test result: NSST according ISO 9227
Coating Sequence: Hiron EcoTri NC Zintek Top Black S
Rack: 720 h
Rack: before NSS
Barrel: 1008h
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Examples and advantages
ZnNi Black system for GMW 16730
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Example and advantages GMW 16730
240 h 1000 h
240 h + HT
Zinni® 210 + Unifix® Ni 3-34 L + Tridur® Finish 300 + 1x Tech Dip Black WL 2 HV
1000 h + HT
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No visual change No base material corrosion
FULFILLS THE STANDARD!
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Example and advantages GMW 16730
240 h
1000 h + HT
1000 h
240 h + HT
Zinni® 210 + Unifix® Ni 3-34 L + Tridur® Finish 300 + 2x Tech Dip Black WL 2 HV
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No visual change No visual change
FULFILLS AND EXCEEDS THE STANDARD!
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Examples and advantages
ZnNi Black system
Customer success story
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Black systems - Customer success story
2,000 h only WR, no RR
NSST ISO 9227
Coating sequence
Zinni® 210 + Unifix® Ni 3-34 L + Tridur® Finish 300 + 2 x Techdip® Black SL
Example and advantages
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Example and advantages Customer success story
Production of tiny black screws for smart phones
Requirements
– High decorative appearance and high corrosion resistance
Zinni® 210 / Unifix® Ni 3-34 L / Zintek® Top Black SL
NSST results
1,000 h 1,200 h
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Example and advantages
Zinni® AL 450 S – Alkaline ZnNi, thickness 8 – 12 µm
EcoTri® NC
– Transparent / iridescent thickfilm passivate – Co-free – Excellent adhesion to top coats
– Zintek® Top Black S
– Inorganic top coat
Customer success story
Zinni® AL 450 S + EcoTri® NC + 2x Zintek® Top Black
Achievement: > 1000 h without WR > 1000 h without color change
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Example and advantages Customer success story
Process: Zinni® AL 450 + EcoTri® NC + Zintek® Top Black S
24 h
312 h
696 h
1,008 h
NSS DIN ISO 9227
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Achievement: > 1000 h without WR > 1000 h without color change
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3 Examples and advantages
Combining Excellence
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Directory of contents
1 Comparison of technologies
4 Summary
2 Process sequence
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Combining Excellence
Continuous requirement of the industry ... – Excellent results in ACT and NSS
– excellent appearance at the same time
– Further properties: – Temperature stability – Chemical resistance – Consistent CoF’s
Summary
Applicable to zinc and zinc alloy coatings
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Combined systems with Zinc/Zinc alloy,
passivation and top coat are capable to provide extraordinary corrosion protection, chemical
resistance and consistent CoF properties
with a very attractive appearance.
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Zinc or zinc alloy
Passivate
Zinc or zinc alloy
Passivate
Sealer
0.2 µm passivate
0.2 µm passivate
1 µm sealer
8 – 15 µm zinc or zinc-alloy 8 – 15 µm zinc or zinc-alloy
0.2 µm passivate
5 µm top coat
8 – 15 µm zinc or zinc-alloy
Zinc or zinc alloy
Passivate
Top coat Corrosive environment
Thicker barrier layer –
increased protection!
Combining Excellence Summary
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Combined layer!
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Contact
Technology for tomorrow's solutions Technology for tomorrow's solutions Technology for tomorrow's solutions
Thank you
for your attention!
Global head office
Atotech Deutschland GmbH Erasmusstraße 20 10553 Berlin – Germany
+ 49 (0) 30 349 85 0 [email protected] www.atotech.com