New trends in metal pretreatment

Peter Kuhm and Manuel Cortés

Barcelona, October 2nd , 2014

EUROCAR 2014

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

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

Convergence of OEM approachesSubstrate evolution and trends

1980 1990 2000 2010 2013 2020

GA GA 1200 MPaGA 590 MPa

(A) HSS

ZnMg

HDG (EG) HDG, EG

EG (HDG, ZnNi) EG (HDG)

EGph, Granocoat New thin coatings

Organic coated

Trend JP

Trend NA

Trend EU

Corrosion

E-coatability

Corrosion

Formability

• 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 coating @ 5-10 mg/m²

• Significantly improved corrosion protection compared to HDG

Magnesium content does not interfere with Zincphosphate

• Moderate etch rate of 200 – 300 mg /m² ZnMg

• No influence on wettability / water break

Magnesium content does not interfere with MPT Cleaners

Pretreatment systemsZinc / Magnesium Coatings

0.0

1.0

2.0

3.0

4.0

5.0

C/Zn N/Zn O/Zn M g/Zn AI/Zn P/Zn

Code “ 0”

Code “ 1”

Code “ 2”

Code “ 3”

Cleaned raw panels

• 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

Adhesive [ Crash resistant ] Bonding of ZnMg

• Excellent corrosion- and adhesion performance

No compatibility issues of ZnMg with TecTalis

Pretreatment systemsZinc / Magnesium Coatings

• Past: Lightweighting driven by

EU OEMs

• Global trend today: NA- and J

OEMs catching up fast

Convergence of OEM approachesAluminum

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

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

Evolution of Average Aluminum Content per Car

Produced in EuropeKg Aluminum per Car

50

78

99

125

150160

140

180

0

50

100

150

200

1985 1990 1995 2000 2005 2010 2015 2020

Year

EAA

2012

Profiles, Castings, Extrusion Parts Panels

pretreated with

Bonderite M-NT 2040Mounted parts

Storage

(Space frame)

Alu-Car-body

Phosphating or TecTalis

Chrome free passivation

Welding

Car-manufacturer Automotive supplier

Surface treatement of Aluminium

Creating a defined surface for bonding or welding

References: Audi, BMW, Volvo, VW, Jaguar - Land Rover, Porsche, Mercedes

Evolution of Multi Metal Pretreatment SystemsMixed Metal applications including Aluminum

1998 2006 2007 2010 2013 2014-2016

Bonderite M-NT 2840

For All – Alu Bodies

Zirconoxid

TecTalis

1. Generation

Zinkphosphate

Nickel, Nitrite, HAS

For CRS HDG

Two Step

Nickel, Nitrite

For CRS HDG Al

Two Step

+ Nickel,

Nitrite – free

Fe Deposition

Two Step

- Nickel-,

Nitrite- free

TecTalis

„1.5. Generation“

Fe Deposition

TecTalis

„2. Generation“

On line

Positive line trials

The Two Step (Flex) ProcessMixed Metal applications including Aluminum

Phosphating Rinse Passivation Rinse

Free Fluoride

40 - 60 mg/l

Deoxylyte 54 NC

SEM Steel SEM HDG/EG/ZnMg SEM Aluminum

Two Step Process: Nanoceramic Coating on Aluminum,

Closed / conventional Phosphate coating on Fe, Zn

• 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 30 – 50 % less sludge and waste, reduced chemicals

consumption, reduced heating requirements (lower operating temperature),

lower maintenance cost (sludge), less surface roughness

• Next Step: Nickel - free

The two Step Process

The Two Step (Flex) ProcessMixed Metal applications including Aluminum

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

Nickel Elimination OEM approaches

Strong driving force in EU [ REACh]

Lower concerns in JP, NA

First Nickel – free body line Daimler

Rastatt 1996 - 2002

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 2010 – 2013, increasing

conversion targets 2015 and beyond

Zinkphosphatier – Prozess

TecTalis – Prozess

Reinigung Spüle Aktivierung Phospha-

tierung

Spüle Passi-

vierung

VE-Spüle

50ºC

Angepasste

Reinigung

Spüle TecTalis Spüle

RT

VE-Spüle

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 e.g. @ 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.

Nickel Elimination: Nickel – Free Phosphating OEM approaches

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

Nickel – Free PhosphatingMixed Metal applications including Aluminum

Pre - Cleaning

pH 11,0, 50°C

Degreasing

pH 11,0, 50°C

Iron deposition

pH 11.5, 60°C

Rinse Ni-free ZnPh Rinse

Bath Maintenance

Fe deposition

Elimination of Ions IEx

Cond. Pass. DI

Rinse

Nickel – Free PhosphatingMixed Metal applications including Aluminum

OEM, Body line trial

• Bonderite TP 2743 (Nickel-free ZnPhos, Cu-containing, MOON/Peroxide-

accelerated) with Zr post rinse; Metallizing last cleaner stage

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

DegreasingDegreasing

+ IronRinse Post Rinse

Phospha-

ting

Iron Deposition + TP 2743 (2 Step Process)

Nickel – Free PhosphatingMixed Metal applications including Aluminum

Iron / Iron Oxide Coating ZnPhos Coating

Nickel – Free PhosphatingMixed Metal applications including Aluminum

Lab approved @ 3 OEMs

Extended line trial in a body line in August 2014

Performance of panel programs and parts coated previous line trials:

No performance difference to traditional tricationic zinc phosphating processes

Line introduction for 2015 expected

DegreasingDegreasing

+ MetalRinse Post Rinse

Ni – free

Phospha-ting

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

Zinc Phosphating – Process

Thin Film Conversion CoatingMixed Metal applications including Aluminum

Bonderite TecTalis – Process Generation 1

Degreasing Rinse Conditioning Phospha-

ting

Rinse Passivation DI-Rinse

50ºC

Degreasing Rinse TecTalis Rinse

RT

DI-Rinse

Thin Film Conversion CoatingMixed Metal applications including Aluminum

Degreasing Rinse Rinse TecTalis

modified

DI RinseRinse

RT°C

• Dramatically reduced porosity

• Improvement mainly on CRS

TecTalis 1.5: Internal Accelerator + Coating Refinement: TecTalis 1820

Optimized Rinse – and overall process conditions: GM, PSA

Holes are evidence of gas evolution No evidence of gas evolution

Thin Film Conversion CoatingMixed Metal applications including Aluminum

TecTalis Generation 1.5: Iron Deposition

Degreasing,

Iron Deposition

Rinse Rinse TecTalis

Gen 1.5

DI RinseRinse

RT°C

• Left:

HDG + Iron Deposition

• Right:

HDG + Iron Deposition + TecTalis

Performance in many OEM panel programs as good as

tricationic ZnincPhosphate . Line trials ongoing.

Global Market References for Automotive Thin Film

GM San Jose Dos

Campos

GM Lake OrionMaxion Wheels

Spain

PSA Vesoul

Bajaj India

Qoros China

Dongfeng China

Holden Australia

More than 2.5 million vehicles on the road today with Henkel Thin Film

In production SOP 2014

GM ShanghaiFord Kentucky

Ford Dearborn

GM Fairfax

Honda Ohio

Maxion Wheels Königswinter

Thin Film Conversion CoatingNext 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

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

Process Cost Reduction

Cleaning Section Raw material cost

New Cleaner Concepts:Multi – Component, KOH – Substitution

Development ongoing

Zinc Phosphate based dispersions,Reducing Phosphate operating temperature and –time, improving phosphate coatings in box sections

2 Step Process: reduced energy consumption and maintenanceLow T phosphating: reduced energy consumption Ni-free phosphating: reduced environmental- health- and safety riskTecTalis: reduced energy- and water consumption,

reduced invest and maintenance

Conditioner Energy cost, volume increase

Conversion Coating Energy- and Maintenance, Water + Waste

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

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:

• 4 Steps:

• Advantages: WW treatment, P level, no heavy metals, no VOC’s

CC RinseDI-

RinsePaint

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

Autodeposition coating for Cast IronBONDERITE 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 E-coat controlM-PP 930C

240 hr NSS504 hr NSS

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

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

Thank You!