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    19 views10 pages

    Surface Protection - PDF

    Uploaded by

    Regaieg Houssem

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    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 10
    = WURTH Pe tail | 5.1 Corrosion 5.2 Corresion types About 4% of the gross national product of « western industriel nation is destroyed by corrosion About 25% of ths could be avoided by applying existing knowledge. Corrosion is the reaction of « metallic materiel with its environment thal causes a measurable change fo the material and may lead fo an impairment ofthe function cof a component or of a complete system. This reaction is usually of on electrochemical nature, but in some cases if may also be of o chemical or meick physical nature. We can clo observe corrosion in our daly lives + Rust on vohicles, railings and fences * Creeping destruction of road structures, bridges, build ings * Leaks in woter pipelines and heating pipes made of steel Crevice corresion Corrosion is unavoidable ~ bu! tho domage caused by corrosion can be avoided through the correct planning — of suitable corrosion protection measures ecole The corrosion system of a screw assembly should, under operating conditions, be ot lecs! os corrosion-sistant os the paris that are to be connected The design engineer's job is to decide on the necessary corrosion protection measures. Here, the wear reserve of |Contact corrosion «corrosion protection system and the ambient conditions have fo be taken into account The ways in which corrosion monfests itself con vory greatly. (See DIN 50900 for corrosion types) 777 Corrosion rates, reference values in um per year ww WURTH Medium Zinenomchromated | Brass Unalleyed =teel M363 unpretected County ow 13 24 280 Urban air <6 <4 £270 Indusval aie 6-20 <8 5170 Sea ci 2.15 =6 =170 Tab. 1 5.3 Frequently used types of coatings for fasteners 5.3.1 Nonmetallic coatings Designation Procedure Application Corrosion resistances Rubbing with ol Workpieces ore immersed in oll | Bnght steel parts Undefned Suitable for shori4etm corrosion Proiection eg. dunng transport Bumishing Werkpieces are immersed in acid | Ports of weapons Sa spray fest approx 0.5 h or alkaline solutions. ‘Gouges and measuring technology | Corrosion protection oil can Oxide bayers with a (brown) black inerease resistance colour are created through reaction No layer development Purpose: formation of a weak protective layer on the suriace No hydrogen embritiement Phosphats Steel component in metal Col forming of steel Sal spray fest approx 3h phosphate bath or chamber with metal phosphate solution 5-15 ym layer connected wih the mmoterial lron/manganese /nicksl/2ine phosphate ‘Combination with corrosion protection medic Reduction of wear on manganese phosphatising Prmer for coat of lacquer (prevents rust creep) Corretion protection oll can increase resistance Tob. 2 3.2 Metallic coatings Procedure Application Corrosion resistance Elec gohansed ‘Metal depositon in he galvanic bath After reotmert through passivation Optionally wih sealing In areas with low to overage ‘cortosion exposure, e.g. general mechanical engineenng, electrical ‘engineering - systom dependent thermal londabiity 80° C= 120°C Corrosion resistance 16 120h against backing metal cotrosion (ced rust inthe sob spray tes in ‘accordance with DIN 56021 SS (ISO 9227) {layer thicknesses and dependent on the syst) Galvanic zine alloy layer ‘Metal depositon nthe galvanic bain In areas with extreme corrosion ‘exposure - eg. components in Greatest cathodic corrosion prove tion ~ even with layer thicknessas (zircon) After reotment through passivation | the engine compariment - or on | om 5 pm (important orf] (eine nickel) Opiionally wih sealing brakes, where normal elocro- | No voluminous corrosion products jating unable to cope not only | with zine-ickel) couse ofthe great heat but | Corrosion resistance to 720 hro also because of the & ect of sal! | bocking metal corrosion (red rus in winer in the sah spray test in accordance with DIN 50021 $$ (150 9227) (layer thicknesses and system dependent) Elecromickel plated — | Metal deposition inthe galvanic | In areas with very low corrosion | Because of is electrochemical bath Optionally wih impregnation exposure, eg. decoraive ‘opplications in interiors Component of a mulilayer system 9. Coppernickel chromium properties with regard fo steel ricksl cannot toke over the function of @ reactive anode = WURTH Designation Procedure Application Corrosion resistance Elecrechrome pled | Metal depostion inthe gokanic | In areas with very low corrosion | Because ofits elecrochemical bath exposure, eg decorative properties wih regard to steel Usually as ¢ coating on a nicksl- | applications in interiors hromium cannot ‘oks over the lated surface ‘Component ofa mulileyer system | function of a reactive anode Thickness of the chromim eg. coppernickelchromum layer usvally between 0.2 pm and 05 pm Mechanical ‘Metal powderis hammered onto [Retoining washers, ighatrengih | Comosion resistance to 144 h Scented” the components, gloss beads are |spingmoumed components | ogansi backing meal corsion used os “impact material (co rak of hydrogen induction | [fed rus inthe salt spray fest in Coating is cared out by means of | dunng the coating process) ccccordance with DIN 50021 SS © chemical medium, electricity is (ISO 9227} layer thicknesses and notused system dependent) Coating is carted out at room temperature Hotdip gakanising | Immersion in molten metal bath | Fasteners for steel consitction | Corrosion resistance between ‘Min. layer thicknesses approx. |For example, HV kis. Sand 25 years depending on the 40 pm Applicable lor fasteners ® M12 | environmental cordiions Process temperature approx. 450°C Greater corrosion protection Not suitable for small screws Cathodic corresion protection Tab 3 5.3.3 Other coatings Procedure Explanations temperature Veroisng ‘Special hard rickelplotng Brass coating Bross coatings are used mainly for decoralive purposes. Apart from this, steel parls re coated with brass to improve the adherence of rubber on steal Copperplating If necessary, as an intermediate layer before nickelplahng, chromeplating and siver plating. As a cover layer for decorative purposes. Sikerplating Siker coatings ore used for decorative and technical purposes. Timing Tinring is used mainly to achieve or mprove soldering copabily (soft solder). Serves of the same time as corrosion protection. Thermal aferireatment nor possible Anodising ‘A protecive layer is generated n aluminium through anodic oxidation that works os Contosion protection and prevents siining. Nearly all colour shades can be achieved for decorative purposes Ruspert Hiighgrade zinc-cluminium flake coating, con be produced in extremely df erent colours Depending onthe layer thickness 500 hor 1000 hn fog ist [IN 50021). Burishing (blackening) | Chemical procedure. Bath temperature approx. 140°C with subsequent ollng, For decorative purposes. Only sight conosion protection. Blackering (stainless) | Chemical procedure. The corrosion resistance of Al AS can be impoired by this 70°C For decorative purposes. Not suitable for external application Folyseal Following a comentional immersion procedure a zinc;phosphate layer is applied at frst. ‘An orgonic protecive layer is then opplied thats precpitahomhordened af approx 200°C. Following tis, ¢ ustprotecton ol is opplied as well. This protecve coating can bbe conned outn df erent colours (layer thickness apprex. 12 pm) Impregnating Wit rickelploied paris above all, the micropores can be sealed with wax through fierireotment in dewatering Fuid with added wax. Significant mprovement of corrosion feabionce, The wax fim i dy nisl Tab. 4 ww WURTH 5.4 Standardisation of galvanic corrosion Coating metel/alloy Protection systems Abbreviation | Element 5.4.1 Designation system in accordance with Ag Silver L DIN EN ISO 4042 CuAg Coppersiver—_[N The most common system for the abbreviated designation [Za TZincickel P of golvonic surfaces on fasteners isthe standard DIN EN ZnCo Zinceobal ° 1SO 4042 In the fist ploce, this standard stipulates the ZF Zinciron ® dimensional requirements for fastonors made of stool ond Ta 5. Extract from ISO 4042 copper olloys that are to be given a galvanic coating. It stipulates layer thicknesses and provides recommenda- Table B layer thickness tions for reducing the rick oF hydrogen embrittlement in highstength or very herd fasteners, or with surface: Layer thicknezz In pm Coden hardened fasteners Onc coating motel DIN EN ISO 4042 does not df erentiate between sur Nola plows - ° foce coatings conteining chromium (Vij ond those without > j chromium (VI 5 2 2 3 a5 3 Designation example 1 6 9 12 28 4 secs bee : 15 5+10 5 surlace designation must ways consis ol ~ the code later table A+ code number table B + 20 ie é code lenor table C 25 1or15 z 30 1218 8 x x x Tab. 6: Extract from ISO 4042 Cnt ned ——] Table € Passivation/chromatin Minimum hicknose < Glezz level | Pazzivetion through | Code letter ‘Aferreatment cheomating Mane No colour A i \ Blich wo Bluth indescent | @ Table A Coating metal/alley Yellownsh shmmenng to yellow-brown tidescent Coating metal/alley Code letter Ohve gon toobm[D ‘Abbre Element brown Zn Zine A Bight No colour E cd Cadmium 8 Bich to Bluth irdescent | F & Copper ¢ Yellowish chmmering to |G am Coppene|B yellow-brown tidescent ND Nel Z Obie gone | NiCr Nickelchvoniom | F on os 5 cone Coppernickel_ |G Bich to Buch indescent | K GNI Ge Geppermickel | H Yellowish chmmering to | | chrom yellow-brown kidescent So Tin J Olive green to olive | M Cue Conperin « brown 1780 Glez: level Passivation through | Cede letter shremeting High gloss | No colour N ‘Any As 8, Cord P Matte Brown Blackto black | Bright Brown Black o black |S Glossy Browr-Black to black _[T All gloss levels | Without chromaiing __[U Tab, 7: Extract fram ISO 4042 = WURTH 5.4.2 Reference values for corrosion resistances in the salt spray test DIN 50021 SS (ISO 9227) Procedure [Chremating [Inherent colour | Designation Nominal | White rust |Red rust group: designation ite chromate layer oe h h Fonvaion A Tronsparnt AIAAIE AU (3 2 2 colouriess AQA, AE, A2) is 6 24 IAAI AM (a 6 40 Fasiaiion ——‘(B Blue widescen AIBAIEAIK [8 é 12 Ble AQB, AQF A2K 3 12 36 | KIBAIEAIK (8 24 72 Chromaing —_(C Yalow ndescent [AIC AIG AIL 3 2 24 yellow ‘AIC, APG, ADL 5 6 72 AICAIG,ASL (8 72 120 ‘Chromating D ‘Olive green AID, ATH, AIM 3 24 24 ove A2D, A2H, A2M_ is 72 96 20, AH, AIM | 96 aa Cheomaing [6K Sooty tw blk AIRAIS AIT [8 2 36 Black AQR, A2S, AQT 3 12 72 8 24 96 Tab. 8 5.4.3 Designation system in accordance with DIN 50979 This standard applies to electroplated and Cr(VI}ree possivated zine and zinc alloy coatings on ferrous mater ck The zine alloy coatings contain nickel or iron (zinc/ nickel, zine/iron) as the alloy components The main purpose of the coatings or cooting systems is the corrosion prolection of components made of ferrous materials This stondard defines the designations for the coating systems that are shown below and stipulates minimum corrosion resistances in the described test procedures as ‘well asthe minimum layer thicknesses required fo this 1781 5.4.4 Design: ings The galvanic coatings consist of zine or zinc alloys ion of the galvanic co Abbreviation | Definition Zn Tine cochng without added alloy partner ZnFe Zine alley coating with @ mass shove of 0.3% to 1.0% iron ZoNi Zine alley coating with a mass share of 12% 10 16% nickel Tab. 9: Extract from DIN 50979 5.4.5 Passivation Possivating means making conversion layers by treating with suitable CrlVI] free solutions in order to improve the corrosion resistance of the coatings. Colouring is possible ww WURTH Abbreviction | Appeerance of the surface Notes Transparent passivated | An Colourless to coloured, iidescent Frequently referred to os thin layer passivation Coloured iridescent Block Iridescent passivated | Cr Black passivated Fr Frequently referred to os thick layer passivation Tab. 10. Extract from DIN 50979 5.4.6 Sealings Sealings increase corrosion resistance and usually have & layer thickness up to 2 ym. Sealings consist of CrlVIHree organic and/or inorganic compounds. Products that can be removed with cold cleaners, e.g. on an oil, grease, wax basis, are not considered as sealings in the context of this standard. The influence of sealings con the functional properties of the component, such as, for example, transition resistance, weldobily, companbilty with fuels, glued joints, is to be assessed on the basis of the component. In caso of the special roquiremonts for the surfoce functionality he use of the seoling ond the lype of sealant have to be agreed, because the band width of the possible surface modifications through seolings is large. 1782 In most cases the seclings also eliminate the interference colours [ridescences) formed by passvating Abbreviation Dezeri 10 Without sealing 2 With sealing Tab. 11. Extract from DIN 50979 = WURTH 5.4.7 Minimum layer thicknesses and test duration Type of Exceution type | Procedure surface protective layer type Zn alley layer thickness) Spm 8pm [12pm Gol zinc coating, ronsporent|Zn//An//10. | Drum 8 8 72 96 Psshated Frame 16 72 96 120 aly zine coating, descent | Zn//Ca//10 Drm 72 144 216 288 Passivated Frame 120 192 264 336 Gol zinc coating iridescent |Zn//Cn//12_——-| Drum 120 192 264 360 Passivoted and sealed Frame 168 264 360 480 Galv zinc on alloy cooing, | ZnFe//Cn//T0 | Drum 96 168 240 312 Wwidescent passivated Frame 168 240 312 384 Gal zinciron clloy coating, |ZnFe//Cn//I2__ [Dum 14a 216 288 364 indescent passivated and sealed Frame ne a2 408 528 Gol. zinc nickel alloy coating, |ZN//Cn//10— [Drum 120 480 720 720 ‘idescen passivated rane 172 600 720 720 Galv zinc nickel alley coating, [ZnN//Cn//T2__ [Drum 168 600 720 720 indescent passivated and sealed Frame 340 720 520 700 Gol zinciron olloy coating. |ZnFe//Fn//T2 | Drum 120 192 264 360 black passivated and sealed Frome 168 Dea 360 20 Galv zinc nickel alloy cooing, [ZaN//Fr//T2__ [Drum 168 280 720 720 black passivated and sealed Fame Dao cao 20 a0 Gol. zinc nickel alloy coating, |ZnNi//Fn//10 [Drum 48 480 720 720 black passrated Frame 72 600 720 720 Tab. 12: Extract from DIN 50979 Designation examples: Zinc/nickel alloy coating on © component made of steel (Fo), 0 thinnest local layer thickness of 8 ym (8) and iridescent passivated (Cn}, without sealing (TO) Fe// ZaNi8//Co//10 Zinc/iron alloy coating on a component made of steel (Fe), «thinnest local layer thickness of 5 ym (5) and black possivated (Fn), with sealing (T2) Fe//ZnFe5//Fn//T2 5.5 Standardisation of non-electralytically applied corrosion protection systems 5.5.1 Zine flake systems The ports that ore to be coated are placed in o centrifuge boske! ond immersed in the coating medium. Part of the coating substance is thrown & through contrifugation In this way « largely even layer is created. The coating is thon burnt ino continuous furnace at 150°C-300°C (depends on the system). To obtain an even and covering layer iis necessary thatthe pars to be cooted pass through two coating posses. Larger parts can cso be coated by spraying the coatng medium on This procedure is unsuitable for threaded parts

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