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P. Kuhm and M. Cortes - Enabling Light Weight Car Body construction with innovative Light Metal Pretreatment
 

P. Kuhm and M. Cortes - Enabling Light Weight Car Body construction with innovative Light Metal Pretreatment

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Enabling Light Weight Car Body construction with innovative Light Metal Pretreatment

Enabling Light Weight Car Body construction with innovative Light Metal Pretreatment

By Peter Kuhm and Manuel Cortes

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    P. Kuhm and M. Cortes - Enabling Light Weight Car Body construction with innovative Light Metal Pretreatment P. Kuhm and M. Cortes - Enabling Light Weight Car Body construction with innovative Light Metal Pretreatment Presentation Transcript

    • Enabling Light Weight Car Body constructionwith innovative Light Metal PretreatmentPeter Kuhm, Manuel Cortes7th Eurocar BarcelonaNovember 16, 2011
    • Contents1. Introduction2. Two Step Process for mixed Metal Applications3. Magnesium and Aluminium component processes4. New plasma coatingsSlide 2 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Contents1. Introduction2. Two Step Process for mixed Metal Applications3. Magnesium and Aluminium component processes4. New plasma coatingsSlide 3 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • 50BY50 Actual average fleet fuel efficiency data through 2008 and nearest targets enacted or proposed thereafter by region Source: ICCTSlide 4 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Sustainability: driving force• Targets of car manufacturer: • Euro 5 & 6 regulation: CO2 and fuel consumption Dir. 80/1268/EC CO emission: 1900 mg/km• Vehicle weight is as critical as engine eficiency • New metal mix including increasing amount of light metals • Engines with more performances but downsizedSlide 5 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Sustainability is One of Our Core Values  All new products must contribute to sustainable development Slide 6 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Market Need:Pretreatment systems for increasing light metal contentIncreasing shares of light metals in car body construction in component construction in powertrain applicationsWere the motivation to develop and improve sustainable pretreatment systems supporting the goals of our customers.Slide 7 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Contents1. Introduction2. Two Step Process for mixed Metal Applications3. Magnesium and Aluminium component processes4. New plasma coatingsSlide 8 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Two Step Process for mixed Metal ApplicationsThe 2-step-process suppresses the formation of the phosphate coating on Aluminium in the phosphating zone whereas galvanized steel is phosphated conventionally. The conversion coating on the non-phosphated aluminium then has to be created in a second step by precipitation of zirconium oxide in the passivation zone. Pretreatment Pretreatment Cleaning Rinse Activation Rinse Rinse Rinse #1 #2The 2 step process is available with Nitrite – accelerated versions as well as Nitrite – free.Slide 9 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Two Step Process for mixed Metal Applications Traditional Process: Closed phosphate coating on all substrates Phosphat- Passi- Rinse Rinse ing vation Free Fluoride e.g. 0,25% 150 - 250 mg/l Deoxylyte 54 NC Two-Step-Process: No phosphate coating on aluminium Phosphat- Passi- Rinse Rinse ing vation Free Fluoride e.g. 0,4% 40 - 70 mg/l Deoxylyte 54 NCSlide 10 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Two Step Process for mixed Metal ApplicationsBenefits of the modified 2-Step-Processes• Reduction of process material consumption (less Sodium, less Fluoride, less phosphate- replenisher)• Reduction of aluminium phosphate sludge, consequently lower disposal costs, reduction of plant cleaning / maintanance• Reduction of energy input (reduction of phosphate bath temperature, throttling of circulating capacity)• Feasibility of mixed construction car bodies with theoretically unlimited share of aluminium in the metal mix in existing and new immersion phosphating zones.Slide 11 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Two Step Process for mixed Metal Applications Phosphat- Passi- Rinse Rinse ing vation Free Fluoride e.g. 0,4% 40 - 70 mg/l Deoxylyte 54 NC No phosphate coating on aluminium substrates SEM Steel, SEM HDG/EG, SEM Aluminium, CW: 2 - 4 g/m² CW: 2 - 4 g/m² CW: max. 0,2 g/m²Slide 12 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Two Step Process for mixed Metal ApplicationsPerformanceAs good as a standard phosphating processon steel and galvanized substratesImproved performance of Aluminium body panels and extrusion partsCompatible with all existing metal pretreatment linesReference ListAUDI, VW, Seat, Jaguar, LandRover, Opel, MercedesSlide 13 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Two Step Process for mixed Metal ApplicationsNext StepsA new, environmentally even more beneficial two step processIncluding a metallizing cleaner bath is under development.The first line trial was performance wise very promising.All corrosion- and adhesion data are indicating a performance levelof a standard tricationinc system.Slide 14 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Contents1. Introduction2. Two Step Process for mixed Metal Applications3. Magnesium and Aluminium component processes4. New plasma coatingsSlide 15 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Pretreatment before welding and adhesive bondingAlodine 2040• Alodine 2040 is an etch passivation process• The Aluminium surface is de-oxidized, a very thin passivation coating prevents the surface from re-oxidation• These defined surfaces allow consistent welding operations and are a reliable surface for adhesive bonding Alkaline Cleaning Temperature : 60 °C Time : 300 s Water pH : 9.5 Rinses Temperature : 30 °C Alodine Passivation Temperature : 40 °C Time : 90 s DI Water pH : 1.3 Rinses Temperature : RT• Alodine 2040 is also in use for corrosion protection of unpainted drivetrain componentsSlide 16 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • 100 % Aluminium Pretreatment processesAlodine 2840• First All Al car body pretreatment system Alodine 2840 Application Temp. (° C) Time (s) Alkaline Cleaning S/D 50 - 60 240 Water Rinses S/D < 50 100 Acid Deoxidation S 33 - 37 150 Water Rinses S/D < 35 60 Alodine Conversion S 25 - 30 60 Water Rinses S < 30 110Slide 17 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Coating Appearance Cleaning Cleaning Activation Deoxidizing Zinc Phosphating Non-chrome ProcessSlide 18 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Magnesium Pretreatment:The Alodine 5200-process • Chrome free one component titanium fluoride-process • Slightly visible layer • Treatment of magnesium and aluminium by spray and immersion • Approval of American OEMs • Successfully in production since several yearsSlide 19 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Magnesium and Aluminium component processes Alodine 160 • Alodine 160 is capable of simultaneously pretreating Aluminium and Magnesium in a single parts line • Approved by most EU OEMs • The only EU pretreatment system in use before E-coat for serial production body parts Clean Rinse Deoxidize I Deoxidize II Rinse DI Rinse Pretreatment DI Rinse DI RinseRidoline 1563/ Chemacid 3610 Alodine 2040 Alodine 160 / 161Ridoline 1568 Slide 20 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Contents1. Introduction2. Two Step Process for mixed Metal Applications3. Magnesium and Aluminium component processes4. New plasma coatings: Alodine EC²Slide 21 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • What is Alodine EC²? EC2 Ti 3m Aluminium Al• An electrochemically deposited Titanium Dioxide coating• Limited to Aluminium and ist alloys as substrate• A ceramic coating, yet more flexible and durable than Aluminium• Outstanding corrosion protection of several 1000h without any further top coat• Ceramic – like resistance against chemical attack• 3 times more abrasion resistant than Nickel, 5000 h 6063 600 Vickers harder than bare aluminum, with a coefficient of friction in the range of DLCSlide 22 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • What can Alodine EC² do for you?Corrosion Protection• Lightweighting: Replacing heavy steel parts through EC² - protected Aluminum in corrosion sensitive areas: Chassis components• EGR components: in use for Aluminium EGR components for diesel engines• First applications in marine engines exhaust systems• Corrosion- and soot protection for Turbo- and Super chargers• All kinds of Aluminum housings• As adhesion promoter for thermal spray coatingsSlide 23 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • What can Alodine EC² do for you?Emission reduction, improved wear and fuel economy• Catalytic EC² piston dome and cylinder head coatings In Diesel engines up to 30 % less NOx, HC, CO, fuel savings of 1 – 4 % possible combustion noise– 2 dB knock-free leaner combustion 5 – 10 % reduced emissions in gas engines• EC² skirt coatings as low in friction as state of the art coatings• EC² ring groove coatings are reducing blow by• Coated piston domes 10 x more durable in a racing environment• Improved efficiency of coated intake manifolds, chargersSlide 24 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Summary• Fuel economy targets and CO2 legislation are the main drivers for increased usage of Aluminium and Magnesium in automotive design• Today, pretreatment systems are available to cover all kinds manufacturing situations: from pure Magnesium- or Aluminium parts pretreatment to mixed metal car body designs with an Aluminium content up to 100 %• Plasma deposition processes are leading into a new level of corrosion protection. Engine efficiancy gains and emission reduction will become the main drivers for these technologies.Slide 25 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA
    • Thank you!