New trends in metal pretreatment. Peter Kuhm and Manuel Cortés Barcelona, October 2 nd, 2014 EUROCAR 2014

Transcription

1 New trends in metal pretreatment Peter Kuhm and Manuel Cortés Barcelona, October 2 nd, 2014 EUROCAR 2014

2 Content 1. Lightweighting New metal mix 2. Nickel free Zinc Phosphating 3. Thin Film Conversion Coating 4. Process Cost Reduction 5. Cleaner - Coater 6. Autophoretic coatings for Cast Iron 7. Summary and Next Steps

4 Convergence of OEM approaches Substrate evolution and trends E-coatability GA GA 590 MPa GA 1200 MPa Trend JP Organic coated Corrosion HDG (EG) HDG, EG (A) HSS Trend NA Corrosion EG (HDG, ZnNi) EG (HDG) ZnMg Trend EU Formability EGph, Granocoat New thin coatings

5 Pretreatment systems Zinc / Magnesium Coatings Magnesium content does not interfere with MPT Cleaners Moderate etch rate of mg /m² ZnMg No influence on wettability / water break Cleaned raw panels C/Zn N/Zn O/Zn M g/zn AI/Zn P/Zn Code 0 Code 1 Code 2 Code 3 Magnesium content does not interfere with Zincphosphate Minimum phosphating temperature: 40 C Minimum Spray time: 60 sec Magnesium etch rate is higher than Zinc etch rate Slightly reduced coating weights Magnesium is incorporated into the Phosphate 5-10 mg/m² Significantly improved corrosion protection compared to HDG

6 Pretreatment systems Zinc / Magnesium Coatings No compatibility issues of ZnMg with TecTalis Excellent corrosion- and adhesion performance Adhesive [ Crash resistant ] Bonding of ZnMg Initial concerns are overcome due to A special Bonderite Chrome-free coil coating product Applied on ZnMg in the steel mill No negative effects on automotive MPT and corrosions / paint adhesion performance

7 Convergence of OEM approaches Aluminum Past: Lightweighting driven by EU OEMs Global trend today: NA- and J OEMs catching up fast Honda Develops New Technology to Join Steel and Aluminum with World s First Application to the Door Panel of Mass Production Vehicles To reduce vehicle weight to improve fuel economy and dynamic performance Toyota, Honda, Mazda, Subaru, Mitsubishi Daihatsu: Preferably Hoods, Trunk Lids; Doors Evolution of Average Aluminum Content per Car Produced in Europe Kg Aluminum per Car EAA Year Alcoa expects to triple its automotive aluminum sales by 2015 Automotive News Ford Motor Co. Is exploring wider use of aluminum On its next-generation F-150 pickup to trim 700 pounds The Wall Street Journal

8 Surface treatement of Aluminium Creating a defined surface for bonding or welding Car-manufacturer Profiles, Castings, Extrusion Parts (Space frame) pretreated with Bonderite M-NT 2040 Welding Automotive supplier Panels Mounted parts Storage Alu-Car-body Phosphating or TecTalis Chrome free passivation References: Audi, BMW, Volvo, VW, Jaguar - Land Rover, Porsche, Mercedes

9 Evolution of Multi Metal Pretreatment Systems Mixed Metal applications including Aluminum Fe Deposition Bonderite M-NT 2840 For All Alu Bodies Zirconoxid TecTalis 1. Generation TecTalis 1.5. Generation TecTalis 2. Generation Fe Deposition Zinkphosphate Nickel, Nitrite, HAS For CRS HDG Two Step Nickel, Nitrite For CRS HDG Al Two Step + Nickel, Nitrite free Two Step - Nickel-, Nitrite- free On line Positive line trials

10 The Two Step (Flex) Process Mixed Metal applications including Aluminum Two Step Process: Nanoceramic Coating on Aluminum, Closed / conventional Phosphate coating on Fe, Zn Phosphating Rinse Passivation Rinse Free Fluoride mg/l Deoxylyte 54 NC SEM Steel SEM HDG/EG/ZnMg SEM Aluminum

11 The Two Step (Flex) Process Mixed Metal applications including Aluminum The two Step Process Performance equal to a Trication Zinkphosphating process with improved performance on Aluminum Fits into every existing brownfield line Line experience up to > 80 % Aluminum throughput Global Standard for Mixed Metall Bodies: AUDI, VW, SEAT, Jaguar, LandRover, FORD, Chrysler, Mercedes, Opel (Nitrite free), Volvo, more to come Process Cost Reduction 1 5 / body depending on %age Al Caused by % less sludge and waste, reduced chemicals consumption, reduced heating requirements (lower operating temperature), lower maintenance cost (sludge), less surface roughness Next Step: Nickel - free

13 Nickel Elimination OEM approaches Strong driving force in EU [ REACh] Lower concerns in JP, NA Zinkphosphatier Prozess 50ºC Spüle Reinigung Spüle Aktivierung Phosphatierung Passivierung VE-Spüle TecTalis Prozess First Nickel free body line Daimler Rastatt Angepasste Reinigung RT Spüle TecTalis Spüle VE-Spüle Nickel free thin film body lines 2007 FORD NA 2008 GM AUS, BRA, NA, 2009 PSA EU 2011 Daimler 2012 Toyota Speed of conversion slowed down , increasing conversion targets 2015 and beyond

14 Nickel Elimination: Nickel Free Phosphating OEM approaches Nickel Free Phosphating systems are bearing one risk: Paint adhesion failures on HDG and, to a lesser extend, EG Nickel free Phosphating on CRS, AL and some EG worked out very well Daimler in Rastatt Cost was an issue, as Hydroxyl Amine was the only suitable accelerator Today, MOON / hydrogen Peroxide accelerated processes are state of the art, cost equal to Nitrite accelerated systems.

15 Nickel Free Phosphating Mixed Metal applications including Aluminum Idea: No paint adhesion issues with Ni-free ZnPhos on Galvannealed. Chemical Galvannealing in the last cleaner tank Deposition of Iron and Iron Oxide specifically on Zinc Pre - Cleaning ph 11,0, 50 C Degreasing ph 11,0, 50 C Iron deposition ph 11.5, 60 C Rinse Cond. Ni-free ZnPh Rinse Pass. DI Rinse Bath Maintenance Fe deposition Elimination of Ions IEx

16 Nickel Free Phosphating Mixed Metal applications including Aluminum OEM, Body line trial Bonderite TP 2743 (Nickel-free ZnPhos, Cu-containing, MOON/Peroxideaccelerated) with Zr post rinse; Metallizing last cleaner stage Degreasing Degreasing + Iron Phosphating Rinse Post Rinse SEM CRS, CTW 1,8 g/m² ZnPhos SEM HDG CTW 2,8 g/m² ZnPhos SEM Alu AA 6014, CTW max. 100 mg/m² Nanoceramic

17 Nickel Free Phosphating Mixed Metal applications including Aluminum Iron Deposition + TP 2743 (2 Step Process) Iron / Iron Oxide Coating ZnPhos Coating

18 Nickel Free Phosphating Mixed Metal applications including Aluminum Lab 3 OEMs Extended line trial in a body line in August 2014 Degreasing Degreasing + Metal Ni free Phospha-ting Rinse Post Rinse Performance of panel programs and parts coated previous line trials: No performance difference to traditional tricationic zinc phosphating processes Line introduction for 2015 expected

20 Thin Film Conversion Coating Mixed Metal applications including Aluminum Zinc Phosphating Process 50ºC Degreasing Rinse Conditioning Phosphating Rinse Passivation DI-Rinse Bonderite TecTalis Process Generation 1 RT Degreasing Rinse TecTalis Rinse DI-Rinse

21 Thin Film Conversion Coating Mixed Metal applications including Aluminum TecTalis 1.5: Internal Accelerator + Coating Refinement: TecTalis 1820 Optimized Rinse and overall process conditions: GM, PSA RT C Degreasing Rinse Rinse TecTalis modified Rinse DI Rinse Dramatically reduced porosity Improvement mainly on CRS Holes are evidence of gas evolution No evidence of gas evolution

22 Thin Film Conversion Coating Mixed Metal applications including Aluminum TecTalis Generation 1.5: Iron Deposition RT C Degreasing, Iron Deposition Rinse Rinse TecTalis Gen 1.5 Rinse DI Rinse Left: HDG + Iron Deposition Right: HDG + Iron Deposition + TecTalis Performance in many OEM panel programs as good as tricationic ZnincPhosphate. Line trials ongoing.

23 Global Market References for Automotive Thin Film Honda Ohio GM Lake Orion Ford Kentucky Ford Dearborn GM Fairfax Maxion Wheels Spain Maxion Wheels Königswinter PSA Vesoul GM Shanghai Bajaj India Dongfeng China Qoros China GM San Jose Dos Campos Holden Australia More than 2.5 million vehicles on the road today with Henkel Thin Film In production SOP 2014

24 Thin Film Conversion Coating Next Steps First panel programs with new Hybrid system or TecTalis generation 2.0 in June 2014 Improved corrosion protection for CRS, HSS Improved paint adhesion on HDG New F-Free technology expected for 2016

26 Process Cost Reduction Cleaning Section New Cleaner Concepts: Multi Component, KOH Substitution Development ongoing Conditioner Zinc Phosphate based dispersions, Reducing Phosphate operating temperature and time, improving phosphate coatings in box sections Raw material cost Energy cost, volume increase Conversion Coating Energy- and Maintenance, Water + Waste 2 Step Process: reduced energy consumption and maintenance Low T phosphating: reduced energy consumption Ni-free phosphating: reduced environmental- health- and safety risk TecTalis: reduced energy- and water consumption, reduced invest and maintenance

28 Cleaner - Coater Bonderite CC a simple process Cleans and produces a conversion coating at the same time. Technology fits for lines of 3 to 4 metal pretreatment steps Suitable as conversion coating in short lines (4 steps) 3 Steps: CC Rinse DI- Rinse Paint 4 Steps: Advantages: WW treatment, P level, no heavy metals, no VOC s

30 Autodeposition coating for Cast Iron BONDERITE M-PP 930C Cast iron, shot blasted hot rolled steel and machined surfaces have historically been a challenge for many paint applications. Out gassing, pin-holing during deposition and poor performance due to voids in the coating and poor edge coverage are a few examples of the problems. BONDERITE M-PP 930C Autodeposition Chemistry overcomes these issues. M-PP 930C E-coat control M-PP 930C E-coat control 504 hr NSS 240 hr NSS

32 Summary and Next Steps We are in a rapidly changing scenario due to legislation, process optimization needs and metal mix. Nickel Elimination picked up interest and speed at Western OEMs Next Generation TecTalis introduced at PSA and GM Hybrid version customer programs started already. Nickel Free Zinc Phosphate as option for more conservative customers. Based on MOON / H2O2 accelerator Cleaner Coater systems based on Zr available now New Autodeposition coatings: for cast iron, low T cure process available

33 Thank You!