Technology Advancements for Select Key Hard Chrome Applications

Transcription

1 Technology Advancements for Select Key Hard Chrome Applications SUR/FIN June 4, 2018 Cleveland, OH Ron Cucuro N.A. Hard Chrome & Surface Finishing Product Manager

2 Global Key Market Segments in Hard Chrome Clear Focus 2

3 MDE Addressing the "T" T = Technical Risk Minimization Measures (TRM) Downstream User obligation (1)Foam Free Surfactants (2)Liquid Replenishment dust free replenishment, including foam free surfactant (3)Closed systems Zero Discharge Horizontal Continuous Plating for 6m Hydraulic Bars (4)Closed systems Zero Discharge, Rector Cell equipment for Shock Absorber Plating (5) more individual solutions are developed 3

4 REACh and OSHA Rules Dictate Risk Reduction Global Emission and Exposure Thresholds Open Tank plus ventilation Tanks with: Ventilation Surfactants Dust-free chemistry Closed Systems Surfactants Dust Free Chemistry Max 50 µgcr(vi)/m³ Max 5 µgcr(vi)/m³ µgcr(vi)/m³ past present future 4

5 Horizontal Continuous Plating Lines for Hydraulics 5

6 Hydraulics Conventional Open Tank vs. Horizontal Continuous Plating 6

7 Hydraulics Typical Application Issues With Conventional Open Tanks Poor chrome layer distribution results in dog boning, variation in mechanical post-treatment Low micro-crack count density, results in poor corrosion resistance Nodules and micro pores Requirement to achieve hours (salt spray test DIN EN ISO 9227) 7

8 Hydraulics Safe and Productive Processes Horizontal Continuous Plating: Addresses weaknesses with traditional approach Bars run horizontally through plating chamber and conforming anodes Rods turn as conveyed through cell Installations Europe, Asia, Americas 8

9 System Design #1 Safe and Productive Processes tank volume: 3,000 liters (790gal) (1 plating tank) Tracks: 4 line speed: 6 m/h Capacity: 24 m/h current densities: 50 A/dm² 9

10 System Design #1 Details of a Line 10

11 System Design #1

12 System Design #1

13 System Design #2 Safe and Productive Processes tank volume: ~ 14,000 liters (3,700gal) (5-6 plating tanks) line speed: m/h Tracks: 4 to 9 Capacity m/h current densities: A/dm² 13

14 Hydraulics Focused Chemistry Next Generation Chemistries Other Organic Catalyst Systems Plating rate vs. current density 100% Plating Rate Plating rate vs. current density 100% Plating Rate 0% 0% Anode Anode Bar Anode Anode V = 7.5 m/h V = 5.3 m/h Productivity gain: 20-30% vs. Other HEEF Systems, nodule free, high brightness Low plating rate between the anodes 14

15 Horizontal Continuous Plating with MacDermid Enthone Features and Benefits: Zero emission and exposure compliance with future regulations Plate to size no dog boning or overplate High Productivity MDE chemistry is 20 30% faster than competition Logistical Efficiency: Plant can be fully integrated between pre- and post grinding Fully Commercial: Becoming more and more dominant in the 6m bar market 15

16 Improved Automation - Shock Absorber Plating

17 Evolution Shocks and Struts Evolution Stages in HC Plating for Shocks and Struts < Conventional Rack Lines, Return Type Machines Open Tanks No integration logistics necessary Poor thickness distribution High plating costs 2. Enclosed Rack Lines w/ Conforming Pt/Ti Anodes Integrated in manufacturing Outside enclosure clean and safe Inside enclosure contaminated due to Cr(VI) aerosols open tanks Lower plating costs than previous generation 3. Emission Free Equipment Modular system, reactor cell under vacuum Zero discharge no contamination of air, water REACh ready Lower plating costs versus both 17

18 Shocks and Struts Features and Benefits of Emission Free Equipment Consistent quality one rectifier per part, eliminate part-to-part deviation Compliance with future regulations zero emission and exposure Lowest cost per part very exact plating thicknesses and logistical efficiencies Highest Productivity seamless changeover to different part dimensions Highest OEE (Overall Equipment Effectiveness) modular setup no downtime Industrialized: Coating approved by major automotive OEMs for NSS performance, micro-cracks and thickness 18

19 Automated Plating of Shocks and Struts 19

20 Conclusions -The Future of Hard Chrome In the global key market segments, there will be continued future demand for low cost, high performance, wear, and corrosion resistant coatings - like hard chrome Continued Zero Discharge Technology Growth: Can reduce the risk of Cr(VI) to zero Allow the applicator to meet even tighter regulations while staying competitive and even improving their bottom lines Benefits of HC coatings outweigh the risk of Cr(VI) 20

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22 Ron Cucuro Thank You N.A. Hard Chrome & Surface Finishing Product Manager 22