Responding to your needs

Transcription

1 Responding to your needs The right system for all types of fasteners Ernesto Ibarra Corrosion Protection Conference Fastener Fair 2017 Technology for tomorrow's solutions

2 Contents 1. Overview fastener market 2. Fastener variety and requirements 3. Coefficient of friction 4. Process control 5. Key processes 6. Summary 2

3 Fastener market Introduction Industrial fasteners in the automotive sector Screws Nuts Rivets Washer Bolts Up to 2,500 different types fix an average car with vast number of applications and finishes 3

4 Fastener market Introduction Industrial fasteners in the automotive sector $ 20 billions sales in 2016 ww 4.6% annual growth rate, constantly growing 4

5 Introduction Corrosion protection for steel fasteners Phosphating Chemical or electro chemical formed phosphate layer, basic corrosion performance, adhesion promoter for construction purposes like self tapping screws, screws for concrete,... Thin iron oxide layer (Fe 3 O 4 ), application by dip coating into acidic or alkaline solution to form a thin oxide layer -> weak corrosion protection Black Oxide Hot-dip galvanize Coating iron and steel with a layer of zinc by immersing the metal in a bath of molten zinc at a temperature of around 450 C Electrolytic deposition of Zn / Zn alloys for highest corrosion demands with adjustable friction behavior, risk of hydrogen embrittlement for hardened fasteners Electroplated Zn, ZnNi, ZnFe Placing steel into an enclosure surrounded by metallic zinc dust at elevated temperatures, produces clear, thin zinc coatings, limited to relatively small objects, Mechanical plating Zinc flake Mechanical application of zinc flakes, mostly solvent based systems without hydrogen embrittlement -> suitaable for hardened fastener (p.c and higher). 5

6 Introduction Corrosion protection state of the art for automotive industry Highest corrosion resistance demands for assembly parts are still fulfilled with zinc nickel & zinc flake systems. Zinc flake Zinc nickel Zinc Phosphating Rest 40 % 40 % 4 % 6 % 10 % Example Golf VII ~ 16 kg of assembly parts 2,000 3,000 pieces (depending on configuration) 6

7 Key processes for fastener application Typical requirements in the automotive industry Adhesion Impact resistance Cleanliness Coefficient of friction Process control Enviromental compatibility Compatibility with threatlocker Chemical resistance Corrosion protection Isolation / conductivity Contact corrosion Wear resistance /abrasion Assembly & loosening control Paintability Decorative aspect Profitability Heat resistance 7

8 Coefficient of friction Requirements Testing

9 Coefficient of friction Amazing facts Selected examples of coefficient of friction values for µ WANTED! High friction Typical values for CoF Dragster tyre against race track 4 Tyre against road 1 Steel vs. Steel Car brake 0.4 Fastener lubrication Skates (on ice) Ball bearing Hydrostatic lubricated parts Slippery as ice very low friction 9

10 Coefficient of friction Definition of sliding friction The CoF gives the relation between the normal force F N and the tangential force F T We are able to modify the surface to your needs! 10

11 Coefficient of friction OEM requirements VW Volvo Group (dvlpmnt & v Volvo Group (QA) Volvo Car (verification) Volvo Car (dvlpmnt & QA) VDA Toyota TSH 7903-D Toyota TSH 7903-A1 Toyota flakes Toyota & other Japanese Scania STD 3950 (flange) Scania STD 3950 (hex) Renault PSA low friction PSA normal Hyundai/Kia transp. Hyundai/Kia pink Hyundai/Kia green GMW14100 (Al, ELPO) GM (Al, ELPO) GMW14100 (normal) GM (normal) Ford Ford Ford Ford Ford (most popular) Fiat (lubricated) Fiat (lubricated) Fiat (general) K = target 2 main CoF windows: µ= µ= ,00 0,05 0,10 0,15 0,20 0,25 0,30 0,35 0,40 tot 11

12 Coefficient of friction Requirements 2 main CoF windows Low CoF values µ tot : Sealer 350 WL 8 GMW 4700 : µtot: (CoF of 0,13 on Frankenbolts ~ µtot: 0,11 according ISO ) German OEM s follow VDA window µtot: (multiple mounting requested) - Daimler - Volkswagen -... VDA µtot: Mid CoF values µ tot : Corrosil Plus 315L WX100: - S437: µtot: S450: µtot: Renault : µtot: steel µtot: Al + HDG µtot: E-coat VOLVO STD µtot: steel µtot: aluminum 12

13 Coefficient of friction µtot for various black and silver passivates and sealers on alkaline ZnNi Ø µtot 0.11 Sealer 350 WL 8 [50%] Ø µtot 0.14 Corrosil Plus 315L [45%] Low CoF values µ tot : Mid CoF values µ tot : µ tot Specific OEM request = dedicated sealer: One sealer does not fit all! CoF µtot against Steel ISO All figures depending on conditions of fasteners and line design 13

14 Process control Influence on Corrosion results and on CoF

15 CP coating systems Process flow Example for hardened steel (p.c Vickerhardness HV) loading Soak cleaner Uniclean 155 Pre treatment 3 x Rinse Pickling Acid HCl 35-50% v/v%+ Uniclean 501 Part ml/l Activation 3 x Rinse E-cleaner Nonacid 701 HCl 5-10% (1-4 A/dm2) 3 x Rinse v/v% 3 x Rinse Plating & passivation HT before passivation HT after passivation Pos.1 Pos.2 Pos.3 Electroplating (Zn, ZnNi, ZnFe, ZnZn) 3 x Rinse oven Heat treatment (6h; 210 C) 0,3% HCl 3 x Rinse Passivation Cr3+ 3 x Rinse oven Heat treatment (6h; 210 C) CRC post treatment CP post treatment Sealer Centrifuge (~ 80 C) dried parts (has to be handled in 48h) Centrifuge oven ex-proved (150 C 210 C)

16 Process control Influences of different parameters Zinni Tridur DB (Co-free) + Corrosil Plus 315L Variation of: ph dipping time Variation of: Concentration centrifuge parameter Wide working window with stable performance 16

17 Process control Influences of different parameters Zinni Tridur DB (Co-free) ph 4.0 ph 4.2 ph 4.5 Color w/o sealer Color 17

18 Process control Corrosion performance Zinni Tridur DB (Co-free) + Corrosil Plus 315L ph 4.0 ph 4.2 ph 4.5 L-467/Act II 9 cycles NSST ISO ,008 h No red corrosion after 9 cycles L-467 or 1,000 hours NSST 18

19 CP315L 90 % CP315L 75 % CP315L 60 % CP315L 90 % ( 200 rpm) CP315L 90 % ( 350 rpm) CP315L 90 % ( 500 rpm) Process control Influences of different parameters Zinni Tridur DB (Co-free) + Corrosil Plus 315L µtot Concentration 40% 35% 30% µtot No significant influence on CoF - Ø µtot: 0.14 Centrifuge parameter 200 rpm 350 rpm 500 rpm *CoF according WZ102 on M8 ISO 4014 screws 19

20 Process control Corrosion performance Zinni Tridur DB (Co-free) + Corrosil Plus 315L *40% MU 35% MU conc. 30% MU conc. L-467/ Act II 9 cycles NSST ISO ,008 h No red corrosion after 9 cycles L-467 or 1,000 hours NSST *recommended value 20

21 Process control Corrosion performance Zinni Tridur DB (Co-free) + Corrosil Plus 315L 200 rpm/min *350 rpm/min 500 rpm/min L-467/ Act II 9 cycles NSST ISO ,008 h No red corrosion after 9 cycles L-467 or 1,000 hours NSST *recommended value 21

22 Key processes Acid and alkaline zinc nickel Acid and alkaline zinc

23 Key processes for fastener application Main categories Performance Coating Plating Passivation Finish Supreme performance CP combination Zn / ZnNi Cr3+ Top coat High performance Medium performance Corrosion resistant coatings Corrosion resistant coatings ZnNi Cr3+ Sealer Zn Cr3+ Sealer 23

24 Key processes for fastener application High performance acid and alkaline ZnNi products achived more than 1,000 hr Plating sequence Plating Passivate Sealer Acid zinc nickel Zinni 220 Tridur DB Tridur DB (Co-free) Low CoF window ( )* Med. CoF window ( )* Unifix Ni 3-34L Sealer 350 WL8 Corrosil Plus 315L Alkaline zinc nickel Zinni AL 450 Tridur DB Tridur DB (Co-free) Low CoF window ( )* Med. CoF window ( )* Unifix Ni 3-30 L (H 3 BO 3 & Cofree) Sealer 350 WL8 Corrosil Plus 315L *measured according ISO

25 Key processes for fastener application Medium performance acid and alkaline zinc products achived more than 360 hr. Plating sequence Plating Passivate Sealer Acid zinc Zylite HT Plus EcoTri NF EcoTri NoCo 2.0 (Co-free) Low CoF window ( )* Med. CoF window ( )* Tridur Zn H2 Sealer 350 WL8 Corrosil Plus 315L Alkaline zinc Protolux 8000 EcoTri NF EcoTri NoCo 2.0 (Co-free) Low CoF window ( )* Med. CoF window ( )* Tridur Zn H11 Sealer 350 WL8 Corrosil Plus 315L *measured according ISO

26 Corrosion protection Results of main corrosion tests, key processes zinc nickel silver Medium CoF: Zinni AL Tridur DB + Corrosil Plus 315L NSST DIN EN ISO ,008h Ford L-467 // ACT-2 9 cycles (9 weeks) VOLVO Group ACT-1 6 cycles (6 weeks) VW PV cycles (4weeks) Low CoF: Zinni AL Tridur DB + Sealer 350 WL8 26

27 Corrosion protection Results of main corrosion tests, key processes zinc nickel black Medium CoF: Zinni AL Unifix Ni 3-30 L (bo-free) + Corrosil Plus 315L NSST DIN EN ISO ,008h Ford L-467 // ACT-2 9 cycles (9 weeks) VOLVO Group ACT-1 6 cycles (6 weeks) VW PV cycles (4weeks) Low CoF: Zinni AL Unifix Ni 3-30 L (bo-free) + Sealer 350 WL8 27

28 Summary

29 The key for fastener application Summary Fasteners just appear as simple but... Up to 2,500 different types fix an average car with vast number of applications and finishes Coefficient of friction is key to keep the fasteners where they are supposed to be Each OEM follows his own assembly strategy: Application of dedicated sealers Our systems are robust to ensure corrosion performance and correct CoF in all situations Sealer 350 WL8 and Corrosil Plus 315L fulfill most of the OEM requirements 29

30 Thank you for your attention! Contact Atotech de Mexico, S. A. de C. V. Booth 605 Technology for tomorrow's solutions