New Developments in Surface Finishing

Transcription

1 New Developments in Surface Finishing Dr. Klaus Wojczykowski, CTO COVENTYA Group 2016

2 Content Drivers for Innovation in Surface Finishing REACH Increased Quality and Performance Requirements New Applications Innovation Management from a Process Supplier s View Technology Monitoring and Benchmarking Strategic R&D Project Selection and Management Innovation Pipeline Current R&D Focus at COVENTYA (PROTECTIVE) Radical Innovations in Other Fields New Developments 2016 Page 2

3 Content Drivers for Innovation in Surface Finishing REACH Increased Quality and Performance Requirements New Applications Innovation Management from a Process Supplier s View Technology Monitoring and Benchmarking Strategic R&D Project Selection and Management Innovation Pipeline Current R&D Focus at COVENTYA (PROTECTIVE) Radical Innovations in Other Fields New Developments 2016 Page 3

4 Drivers for Innovation: REACH SVHC Last Update: December 17 th, 2015 Now 168 Substances Member States propose new Additions Proposal needs Dossier for Justification SVHC ANNEX XIV or XVII New Developments 2016 Page 4

5 Drivers for Innovation: REACH SVHC New Developments 2016 Page 5

6 Drivers for Innovation: Performance Quality requirements were partly defined by warranty durations given by car manufacturers (liability mostly limited to functional aspects for longer durations) 10 Years warranty against corrosion perforation A big amount of new vehicle registrations are commercial through OEM s leasing company Re-sell value of car after lease ends becomes an important factor Young Stars As Mercedes as on the first day New Developments 2016 Page 6

7 Drivers for Innovation: New Applications New materials and components with new requirements come from major trends in the energy and mobility sector but also from changes in demographics and consumer behaviour New Developments 2016 Page 7

8 Drivers for Innovation New Developments 2016 Page 8

9 Content Drivers for Innovation in Surface Finishing REACH Increased Quality and Performance Requirements New Applications Innovation Management from a Process Supplier s View Technology Monitoring and Benchmarking Strategic R&D Project Selection and Management Innovation Pipeline Current R&D Focus at COVENTYA (PROTECTIVE) Radical Innovations in Other Fields New Developments 2016 Page 9

10 Investment in R&D Investment in Personnel and CAPEX in the COVENTYA Group Investment in different areas Employees by department 25% Administration 24% R&D 6% Sales/Service 50% 75% F&E others Manufacturing 20% The R&D group expanded by 500% since the year New Developments 2016 Page 10

11 Areas of Research COVENTYA drives Innovation in all areas of our business ALUMINIUM DATA STORAGE DECORATIVE FUNCTIONAL ORGANIC COATINGS POP PRECIOUS METALS PROTECTIVE WATERCARE New Developments 2016 Page 11

12 Strategic R&D Project Selection and Management Initiation of R&D projects follows a clear process with mandatory input of product management and sales During the run of a project its value to the company is constantly monitored and benchmarked New Developments 2016 Page 12

13 The House of Quality New Developments 2016 Page 13

14 Example: A new Black Top-Coat How does it correllate? e.g. more black less corrosion resistance How to measure? e.g. L-value How does the competition perform? What does the customer want? e.g. black What s the target? e.g. L < 20 using BYK Colorimeter XY New Developments 2016 Page 14

15 Example: A new Black Top-Coat The targets, probabilities and competitive environment is well defined at the very beginning of the development per the best available knowledge The progress can be constantly benchmarked during the development Whenever new approaches are taken (e.g. basic formulation changes) the potential consequences on the outcome can be forseen New Developments 2016 Page 15

16 Content Drivers for Innovation in Surface Finishing REACH Increased Quality and Performance Requirements New Applications Innovation Management from a Process Supplier s View Technology Monitoring and Benchmarking Strategic R&D Project Selection and Management Innovation Pipeline Current R&D Focus at COVENTYA (PROTECTIVE) Radical Innovations in Other Fields New Developments 2016 Page 16

17 Corrosion Protection Concept Cathodic Lower Potential than base material (Zn, ZnX, Al) Barrier Isolate the base material from corrosive media (Nickel, Lacquer) Challenge Layer thickness Protect the sacrifical layer against corrosion Pore free Crevice corrosion Development Potential Lower corrosion rate by increased potential of the deposit Primer and Top-Coats for good adhesion and durable coatings New Developments 2016 Page 17

18 Cathodic Corrosion Protection Known Components and their Properties - Temporary isolation, Protect the passivate against dehydratation, Control surface properites like the coefficient of friction - Thick, compact conversion coating - Incorporation of inhibitors (SiO 2, Co, V, Zr etc.) - Sealing /Increase of layer weight by Post-Dip Sealer/ Top-Coat Passiviate Zinc (+X) Post-Dip - Alloy components for a lower corrosion rate (Sn, Ni, Fe) or better self passivation (Mg, Al, Mn) - Dispersion Coating Diffusion layer with base material (hot dip galvanizing, sheradizing) Base Material New Developments 2016 Page 18

19 Morphological Box * Application for problems of non-reducible complexity - Definition of main- and secondary goals - List all essential parameters and properties - Combination of properties to generate a new product Example of a morphological box for an innovative corrosion protection system Sacrificial Coating Barrier Coating Distribution of corrosion current Conversion Coating Dip-Spin Coating Monolayer Self Passivation Inhibitor Intrinsically noble layer Batch Coating Continuous Coating Coating of single Pieces Permanent Protection of Base Material Permanent Protection of entire Part Permanent Protection of Entire Part with changed Aspect CMR-Metal containing CMR-Metal free Metal free *F. Zwicky New Developments 2016 Page 19

20 Concepts of Innovation The S-Curve Concept Performance of the Technology Limit of new Technology Limit of old Technology Status Today Status Today Technological Potential Cumulated R&D Investment * Clayton M. Christensen, Harvard Business School sustaining Innovation disruptive Innovation New Developments 2016 Page 20

21 COVENTYA S PLAN FOR INNOVATIVE CORROSION PROTECTION Improved Performance of Established Processes (e.g. ZnNi, Co-free Passivates) through sustaining Innovation with parallel Development of Novel Processes using Harmless and Sustainable Materials (disruptive Innovation) New Developments 2016 Page 21

22 COVENTYA S PLAN FOR INNOVATIVE CORROSION PROTECTION PROTECTIVE (Zn & Zn Alloys) Duktile Alkaline ZnNi Drop -free Cr(III) Post-Dip Improved Flow Silicate Sealer Complete Replacement of Cobalt in Passivates High Performance (Boric-Free) Acid ZnNi Alloy to Replace ZnNi ORGANIC COATINGS Curable Top Coat Range for electroplated Fasteners Rheology modified Zinc Flake Process ALUMINIUM Cr(III) Conversion Processes for 7xxx Aluminium-Alloys REACH adapted Cleaning and Sealing processes Development Introduction Fully Implemented New Developments 2016 Page 22

23 Alkaline ZnNi for Bendable Parts PERFORMA 288 produces ZnNi deposits with high corrosion protection after bending or crimping due to a specific crystal structure. X-Ray Diffraction shows the preferred crystalline orientation of the ZnNi γ-phase Standard alk. ZnNi The Bending Test shows less damage of the coating and better corrosion protection PERFORMA 288 more (330) slip planes Standard alk. ZnNi more (600) planes PERFORMA New Developments 2016 Page 23

24 High Performance Acid ZnNi PERFORMA 560 BF gives superior aspect and corrosion protection through a burn free deposit with a very homogeneous alloy distribution. Simple bath control with only 3 fully analyzable organic additives Simple air agitation possible due to low foaming 2A, 5 min %Ni µm Standard Acid ZnNi PERFORMA 560 with new Additive System γ-phasen ZnNi New Developments 2016 Page PERFORMA 560 FINIDIP 129 FINIGARD 200A After 25 cycles GMW

25 Improved Flow Silicate Sealer SiO x SiO x x y SiO x z FINIGARD 503 is an inorganic sealer for high heat and chemical resistance. Dedicated organic functionalization gives a crack-free amorphous film. Dynamic Surface Tension FINIGARD 503 Std. Silicate Sealer Small amounts of a harmless solvent lead to superior film formation properties compared to competitive products, little residue at edges and corners and completely covered iridescence. New Developments 2016 Page 25

26 Alloy as ZnNi Replacement Overview of known Zn alloys: ZnCo ZnNi ZnCr ZnSn ZnMn ZnFe + - Good corrosion resistance - Easy passivation (esp. black) - Excellent corrosion resistance - Established processes - Might be an interesting alternative - Very good corrosion resistance - Good ductility and solderability - Good corrosion resistance - Self-passivating property - Good corrosion resistance - Easy passivation (esp. black) - Alloys with high Fe content are potentially interesting - CMR!! - Price - Waste water treatment - Nickel is potentially CMR - Chrome is also a candidate to be potentially replaced - Price (!!) - Availability of Sn - Passivation - Aspect - Passivation (esp. black) - Aspect of corrosion products - Bath maintenance - Bath maintenance - Alloys with high Fe content are not well researched New Developments 2016 Page 26

27 Alloy as ZnNi Replacement Experiments regarding the ideal alloy composition: The Phase Diagram* shows a ZnFe Γ-phase like in ZnNi alloys. In ZnNi this is the phase with the highest corrosion resistance. * Adaniya et al., Zinc-Iron alloy electroplating on strip steel, Nippon Kokan KK, 1975 COVENTYA found a bath composition and plating parameters that allow to plate ZnFe alloys in a wide range of Fe contents. New Developments 2016 Page 27

28 X-Ray Diffraction at different Fe-contents With and without baking Fe T without Fe T without New Developments 2016 Page 28

29 X-Ray Diffraction at different Fe-contents With and without baking Fe T without Fe T without New Developments 2016 Page 29

30 X-Ray Diffraction at different Fe-contents It was shown, that a pure Γ-phase is only present at 30% Fe. The full phase equilibrium only takes place at baking temperatures higher then in the typical hydrogen relief bake. Which composition is really preferred for the layer properties and also without baking?? New Developments 2016 Page 30

31 Crystallite morphology at different Fe contents 9,3 % 15 % 19,6 % 19,4 % 22,2 % 24,8 % 25 % 26,7 % 28,1 % New Developments 2016 Page 31 31

32 Electrochemical Properties Chronopotentiometry j= 10 ma/cm² in NaCl 50 g/l less noble Potential noble [V] earlier Layer Dissolution later [min] The alloy with 13% Fe shows, like ZnNi, a delayed layer dissolution with steps. New Developments 2016 Page 32

33 Corrosion Test Finidip 128 CF + Finigard 150 NSST The alloy with 13% Fe shows the best aspect and the best corrosion resistance. New Developments 2016 Page 33

34 Comparison of zinc processes With cobalt-free passivation and top-coat 1200h NSST Zinc ZnFe 13% ZnNi 15% New Developments 2016 Page 34 34

35 Alloy as ZnNi Replacement ZnFe with 13% Fe is an interesting alternative for ZnNi The alloy and its protective properties are known for at least three decades and it can be deposited from known ZnFe electrolytes with slight modifications. Structure, aspect and passivate acceptance are comparable with current zinc processes. It has to be confirmed in the industrial test for which application the process is suitable regarding layer properties like ductility as well as bath maintenance. New Developments 2016 Page 35

36 Curable Top Coat Range for electroplated Fasteners In comparison to classical Sealers in electroplating, a new generation of top-coats will apply paint technology to get to the next level of performance In return, the new processes will offer longer un-changed optical appearance and even higher resistance to red corrosion New Developments 2016 Page 36

37 REACH adapted Cleaning and Sealing processes (Aluminium) Example: Cleaner for Aluminium: Borate, EDTA, NTA and Silicate-free before after New Developments 2016 Page 37

38 Radical Innovations in Other Fields Cr(VI)-free etch for POP pre-treatment New Developments 2016 Page 38

39 Radical Innovations in Other Fields Cr(III) Hard Chrome Results from IRT M2P Project (France) Up to 200 µm can be plated No adhesion failure ASM 2460 R&D Roadmap: Corrosion Protection New Developments 2016 Page 39

40 Thank You for your Attention! The future is already here, it is just not evenly distributed William Gibson New Developments 2016 Page 40