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New Nanotechnology Developments

for Corrosion Protection


NanoEngeneering - Hannover Messe, 21.04.2010
Dr. Thomas John-Schillings

Content
Tasks of metal pretreatment
Traditional metal pretreatment: Iron- and Zincphosphating
Question about Phosphating
Presentation of Nanoceramics Bonderite NT-1 & TecTalis
Process
Benefits
Corrosion protection in comparison with traditional processes

Why metal pretreatment?

Prior to painting substrates are often:


Dusty
Oily (forming oils, temporary corrosion protection)
Corroded (rust, welding scale)

Pretreatment provides:
Cleaning
Paint Adhesion
Better Corrosion Protection

Traditional Metal Pretreatments

Zincphosphating
best corrosion protection
excellent paint adhesion
process difficult to monitor
very cost intensive
Ironphosphating
simple, flexible process
moderate process costs
Low corrosion protection

Why should Phosphatings being


replaced?
Question: Which aspects of Zinc-/Fe-Phosphating are mostly
unsatisfying?

very high sludge formation


very narrow process operation window lot of parameter
difficult multi metal pretreatment
many process steps lot of active bathes
high amount of heavy metals (Zn, Mn, Ni)
environmental unfriendly process (energy, phosphate, COD,
heavy metals)
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Nanoceramics replace phosphating

Ironphosphating

Zincphosphating

Eisenphosphatierung

Bonderite NT-1

TecTalis

Nanoceramics replace phosphating

Which benefits provide Nanoceramics with respect to

What are Nanoceramics

phosphate free metal pretreatment process


provides excellent paint adhesion and corrosion protection
replacement of iron- or zincphosphating
multimetal pretreatment process (steel, zinc, aluminium)
forming a thin ceramic conversionlayer (Nanoceramics)
application in existing lines (dip or spray)

Nanocearmic coatings
Chemical Reaction
H2ZrF6

ZnO

Zn+2

ZrOXFy

Zn
Steel

H2ZrF6 + M + 2H2O

M = treated substrate; Fe, Zn, Al, Mg

ZrO2 + M2+ + 4H+ + 6F- + H2


pH = 3.8 5.0
T = 10 - 50 C
time = 30 - 180 s

Nanoceramic Coating
Dimensions
[nm]
10000
5000

Zincphosphate

1000
250

Ironphosphate

100

Chromates

50
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SEM (Scanning Electron Microscopy)


Phosphate Coating

Nanoceramics
bigger Molecules
AFM (Atomic Force Microscopy)
TecTalis Coating

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Typical Bonderite NT-1 process

Cleaning

Rinse

DIRinse

NT-1

DIRinse

Paint

Alkaline cleaning the only heated step


DI-Rinse prior to Bonderite NT-1
Conversion coating with Bonderite NT-1
(20 sec. or more)

DI-Rinse after Bonderite NT-1


Optional: Dryer after Bonderite NT-1
Powder coat, wet paint, CED/AEDC
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TecTalis process layout

typical Zincphosphate line

230 m

55C
Cleaning

Rinse

Activation

Phosphate.

Rinse

Passivation

D-Rinse

typical TecTalis process


180 m

Cleaning

Rinse

TecTalis

Rinse

DI-Rinse
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Corrosion protection and


paint adhesion
Corrosions tests
judgement of the area and the creep at the cut

Constant climate test


Neutral Salt spary
Cycling climate test
Outdoor exposure

DIN EN ISO 6270-2


DIN EN ISO 9227 AASS
VDA 621 415
VDA 621 414

Adhesion-tests
judgement before and after corrosion test
cross hatch
stone chip -test
Erichsen-Tiefung

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Perfomance:
Bonderite NT-1 vs FePhos
Bonderite NT-1

Fe-Phosphate

Customer sampes
Creep after 500h NSS
Bonderite NT-1 (left)

2.2 mm creep
Ironphosphate (right)

6,5 mm creep

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Performance: Comparison
Tectalis vs ZnPhos
70 cycles VDA Steel + CDP

4,0

TecTalis
Creep at cut [U/2 in mm]

3,5

Granodine 958

3,0
2,5

spec

2,0
1,5
1,0
0,5
0,0
E-coat 1

E-coat 2

E-coat 3

E-coat 4

E-coat 5

E-coat 6
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Comparison of process costs


example:

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Performance comparison
ZnPhos vs TecTalis
performance, e.g.
corrosion protection
area i.O. results ZnPhos
area i.O. results TecTalis
Specification

ZnPhos

TecTalis

Procesparameter
Process window ZnPhos
Process window TecTalis

automatical processcontrole (Lineguard Supervisor) for critical parameter possible!!


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Benefits of Nanoceramics vs
Phosphating
Efficiency

Process

A lot of savings, e.g.


Maintenance and Cleaning
Water consumption
Heating ( ambient temperature)
Sludge disposal
Result in: Process costs decrease

conversion at ambient temperature


short contact time
simple bath monitoring (pH)
real multimetal process

Environment

Quality

low energy consumption


no toxic heavy metals
phosphate free conversion
no contribution to COD
less disposal (sludge)
no hazardous substances

enhancement of corrosion
protection vs FePhos
replacement of Zincphosphating in
often possible
Compatible with Al, Zn, steel and
most available paint systems
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Nanoceramics - References

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Thanks for your attention!

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