Alodine EC 2 The Principle of Protection

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1 White Paper Alodine EC 2 The Principle of Protection Providing cost effective protection and improvement for aluminum parts used in extreme environments Contact American Trim, LLC 1005 W. Grand Ave. Lima, Ohio Phone: Fax: WEB: Copyright 2008 American Trim, LLC

2 Executive Summary Alodine EC 2 Electro Ceramic Coating was developed by the Henkel Corporation as a protective pretreatment system for aluminum substrates exposed to extreme environments. Aluminum-based castings, stampings and structures offer many advantages for manufacturers due to the potential for weight reduction and the further enhanced manufacturing opportunities aluminum affords. Aluminum castings have not been suited to high corrosion and heat environments until now. The corrosion resistance and scuff protection of Alodine EC 2 coated parts can make those applications possible. The Alodine EC 2 coating process has the dual benefit of requiring fewer steps while providing superior corrosion and wear protection. Alodine EC 2 can eliminate the need for priming and curing by electrodepositing oxides on the aluminum part in one step, and can reduce the need for repeated layers of paint through its adhesion properties. The coating process (left) prepares the part for a final painting. Alodine EC 2 simply raises the bar for the use of aluminum parts that historically failed prematurely due to corrosion and/or heat stresses. American Trim s Alodine EC 2 line in our Cullman, Alabama facility will be used to coat parts for the following industries: Marine Fasteners Aerospace HVAC Automobile Outdoor furniture Cooking Small engine The above industries all require special coatings that can withstand a variety of extreme conditions. The Alodine EC 2 process can bring OEM s and manufacturers new opportunities in protection resulting in a competitive advantage. In the time that the Alodine EC 2 coating line has been operational, we have been able to help companies in various industries: Improve corrosion and wear resistance Accomplish better paint adhesion Achieve more uniform coating thickness Eliminate coating layers and process steps Discover the potential for increased horsepower and fuel economy performance based on the ability to incorporate new manufacturing methods and materials that are now possible because of the Alodine EC2 process. 2 of 8

3 Introduction One marine manufacturer chose Alodine EC2 for their outdrives to improve warranty performance and enhance customer satisfaction. The Alodine EC 2 process can dramatically improve corrosion resistance, wear resistance, and performance over the lifetime of the product. But the even more important aspect is that it allows aluminum structures to be used where historically they have not been permitted. The Technology Alodine EC 2 is a high performance coating developed by the Henkel Corporation The coating application is targeted at severe use environments where exponential improvements in corrosion, heat and abrasion resistance will improve product performance, longevity and customer satisfaction on aluminum tube, extrusions and castings Benefits Alodine EC 2 has 4 primary benefits: Dramatic improvements in corrosion resistance Improves wear resistance Results in a uniform coating layer with strong adhesion properties Enables the use of lower cost materials (e.g., aluminum instead of stainless steel) Performance Surface Properties (Hardness of Vickers) Corrosion Resistance (see chart for alloy) Abrasion Resistance Improved bonding capability with most paints, adhesives, Teflon, Kynar and thermal spray coatings Useful coating thickness of 3 12 microns Targeted Applications Marine Engine Components, Pistons, Intake Manifolds, Valves, Electronic Modules, Compressors, Marine Hardware, Lawn Furniture, Wheels, Pumps, Heat Exchangers, Building Exteriors 3 of 8

4 Improved Corrosion Resistance Henkel s Alodine EC2 protects against the extreme, corrosive nature of salt water in marine engines, which can cause destruction or catastrophic failure. Corrosion of coated metal castings is an issue for any manufacturer that produces parts that operate in extreme environment with exposure to salt water, drastic temperature change, and/or corrosive chemicals or gases. Extreme environments can dramatically affect a part aesthetically and functionally. Alodine EC 2 can prolong the life of the part in such environments, justifying a better price, decreasing replacements and reducing warranty claims. Challenge A marine customer came to American Trim to solve a corrosion issue in their drive systems (outboards, stern drives and components). Their issue was specifically for their salt water application. Salt water is an extremely corrosive mixture that can wreak havoc on boat engines in a very short time. Marine engine companies are constantly striving to improve the life of their product- giving their customers the best performance possible. Our customer s goal was a solution that would greatly extend component life while simultaneously reducing the warranty cost. Solution Alodine EC 2 Electro Ceramic Coating was applied to the aluminum drive system components and then benchmarked against the current process. What they found was a dramatic improvement in corrosion resistance as illustrated in the chart. 4 of 8

5 Improved Corrosion Resistance Challenge Another application in the marine environment brought to American Trim is the corrosion of transom mounts used for a variety of boating accessories. Many of these mounts are manufactured using a premium grade alloy that needs additional post process coating steps. Using this coated premium grade aluminum alloy allows the manufacturer to increase the warranty allowance for the part, but also increases the production cost of the part. Due to the high processing cost, use of the premium grade alloy is not a permanent solution to their problem. It is only a temporary fix for an immediate need. Manufacturers in the marine industry are now able to provide their customers with products that require less maintenance and last longer than ever before. Solution The manufacturer is researching the ability to coat and paint a lower grade alloy using Alodine EC 2 Electro Ceramic Coating, and still increase the corrosion performance over their product s current warranty. Alodine EC2 Electro Ceramic Coating has the potential to address a long term solution with a decreased total system cost. Challenge Like marine companies, coastal land areas are affected by the damaging properties of salt water. There are many instances where replacement costs of metal products are high because of corrosion and rusting which leads to product failure. Gas meter housings that are placed on homes near the coast are corroding and rusting too quickly. Currently these housings are aluminum parts coated with hexavalent chrome. In the highly corrosive coastal regions of the United States, the replacement rate and cost of gas meter housings is high. Solution The Alodine EC 2 Electro Ceramic Coating can be used as a replacement for hexavalent chromium and dramatically improve component performance. This results in not only a longer lasting product, but a more environmentally friendly coating than hexavalent chromium. The Alodine EC 2 is a completely chrome free process. 5 of 8

6 Improved Performance/Fuel Economy Challenge The recent increase in fuel costs have made all transportation product manufacturers take another look at their design and fuel economy. It is a battle for companies to find ways to improve upon their existing designs, which is when looking to a new technology like Alodine EC2 becomes essential to further advance product performance. Solution Alodine EC 2 coated products result in a very thin, uniform coating. A thinner coating is especially important when coating engine components. These components can be very complex and compact. By decreasing the thickness of the coating, there can be an increased space available for air flow. Alodine EC 2 has allowed the company to use new materials and new manufacturing methods. Initial customer results indicate an improvement in airflow which can increase the overall product performance. As companies look for ways to improve their coating performance capabilities and/or total cost structure, we believe that the Alodine EC2 process offers an attractive value proposition, - Vince DeFazio, Director of Operations in Cullman, Alabama. 6 of 8

7 Resistance to High Heat/Corrosion Environment Challenge Brazing is a joining process where a filler metal or alloy is heated to melting temperature above 800 F. Due to the nature of the various materials involved in this process, the brazing environment is highly corrosive and damaging to furnace and conveyor parts. One of our new customers needed a solution to this hazardous and damaging situation. Every day, we see new applications for this technology and how it can protect parts in the most extreme environments. Solution Alodine EC 2 coated products result in a very thin, uniform coating. The combination of high heat and acidic combustion products causes severe corrosion to aluminum machine and conveyor components. The company is using Alodine EC 2 to extend the life of conveyor and furnace components which leads to higher productivity and lower downtime. If you are using aluminum in your process or would like to, Alodine EC2 can add significant protection to your application. Dave Vanleuven, Sales Engineer Technical Coatings Products American Trim Coatings Products American Trim 7 of 8

8 About American Trim As a family-owned business, our success will not be a matter of chance, but of commitment to the core values that distinguish us. Jeffery Hawk Owner American Trim is a family-owned manufacturing company that began in 1951 as a small tool and die shop in Lima, OH. The company has grown organically and through strategic acquisitions to become an organization with over 1,300 employees in facilities across the United States and Mexico. American Trim specializes in the forming, decorating, and coating of metal and composite substrates. We are dedicated to providing value for our customers through innovative product design and development, efficient processes, quality products, and development of global logistical solutions to meet on-time delivery commitments. We develop and market breakthrough ideas and product concepts that improve aesthetics, performance, and enjoyment of products found in many businesses, households and vehicle systems. We welcome your inquiries about our variety of processes and capabilities. 8 of 8

9 Teamwork Alodine EC² Innovation Finish Design Integrity High Performance TiO2 Electro Ceramic Coating The First and Only Multifunctional Coating for Light Metals Form Titanium Ceramic Toughness and Durability for Aluminum and Aluminized Substrates Process Description American Trim is excited to present an Electro Ceramic Coating Technology that will change the game for coating technology. Alodine EC2 is a coating based on Titanium Metal Oxide (TiO2) electrodeposited from the electrical assisted hydrolysis of metal complexes. The TiO2 Coating provides superior corrosion and wear resistance for harsh and demanding applications such as marine and high temperature engine environments. Product Benefits Alodine EC2 has exciting potential: A new electrolytic process provides a 3-12 micron thick layer of TiO2 Virtually eliminates corrosion Drastically improves wear resistance Enables the use of lower cost materials (e.g., aluminum instead of stainless steel) Excellent bonding capability when combined with Loctite, Hysol and Teroson brand adhesives Provides superior wear, corrosion, and thermal protection over aluminum, titanium, and aluminized surfaces Thousands of times harder and more flexible than paint Impervious to fuel and fuel vapor, powertrain lubricants, oil, and ethylene glycol Withstands temperatures up to 600 C (1112 F) without corrosion performance loss Substrate Requirements Alodine EC2 readily bonds to the following materials: Aluminum and aluminum alloys Titanium and titanium alloys Aluminized ferrous substrates Targeted Applications Marine Engine Components, Pistons, Intake Manifolds, Valves, Electronic Modules, Compressors, Marine Hardware, Lawn Furniture, Wheels, Pumps, Heat Exchangers, Building Exteriors Cullman Alabama Facility

10 Teamwork Alodine EC² Innovation Finish Corrosion Protection ASTM B117 Neutral Salt Spray Design Form Integrity High Performance TiO2 Electro Ceramic Coating 500 Hours Salt Spray 2000 Hours Salt Spray 7000 Hours Salt Spray 6063 Aluminum 356 Cast Aluminum 356 Cast Aluminum with Powder Paint Aluminum Alloy Hours Scribe Creep 356 Cast >2000 Nil 356 Cast Painted >7000 Nil 6063 >5000 Nil 7075 >1000 Nil 2024 Clad >3000 Nil Physical Properties on Aluminum Surface Properties Hardness: vickers (nanoindenter) Roughness: <0.07 microns Flexibility: Pass 1-2 "T" bend (ASTM D 4145) Chemical Resistance: Acids and Alkali Thermal Cycle: 5 to 600 C Adhesion to Coating: 3-5K psi Lap Shear Strength Corrosion Resistance hours for most wrought aluminum alloys (unsealed) hours for cast aluminum alloys (unsealed) Abrasion Resistance 2000 Taber cycles (C-17 Wheel); no wear through coating thickness of 12 microns Bonding Compatibility Most paints Adhesives Teflon, Kynar Thermal spray coatings Other Useful coating thickness is 3-12 microns Chemical Resistance Ethylene Glycol/Water Mixture (30/70%) 12 microns (0.0005") 21 Days 10% Solution Sulfuric Acid 12 microns (0.0005") 2 Days 10% Solution Acetic Acid 12 microns (0.0005") 30 Days Hot & Cold Solvent-Borne Paint Strippers 12 microns (0.0005") 30 Days No Effect of Attack No Effect of Attack & No Adhesion Loss No Effect of Attack & No Adhesion Loss No Effect of Attack Hard and Flexible Coating hardness of 800 vickers, yet extremely flexible Cross-hatch followed by impact to metal fracture Contact Us American Trim, LLC 1005 W. Grand Ave. Lima, Ohio Phone: Fax: WEB: *American Trim is a licensed product center of the Alodine EC2 Process produced by the Henkel Corporation. Alodine & EC² designate trademarks of Henkel Corporation or its affiliates. = registered in the U.S. Patent & Trademark Office. Henkel Corporation, All rights reserved (11/2007) Copyright American Trim LLC, November 2007, Printed in USA