Zinc-nickel for braking components

Alan Gardner

Global Marketing Manager

MacDermid

Environmentally Compliant Coatings

MacDermid – Part of the Platform Specialty Products Corporation

Paper # (if applicable) 2

MacDermid – Portfolio Overview


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Printing Solutions

Advanced Surface

Finishing

Autotype

Electronic Solutions

Industrial Solutions

Offshore

High quality precision hard coated

films for use in automotive and

electronics industries

Specialty chemical manufacturer and a key component of the surface

finishing supply chain for industries including aerospace, automotive,

electronics, plumbing and tubular furniture.

leading supplier of specialty

chemicals for fabricators,

assemblers, and original equipment

manufacturers.

Provider of products and services for the offshore industry. Our market leading Oceanic and

water-based fluids are used for hydraulic control of valves in offshore drilling and production

systems as well as for controlling oil and gas flow to processing.

Our End Use Markets


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Automotive

Sanitary

Consumer Electronics

Tubular / Wire Goods

Aerospace

Oil and Chemical Other

ZinKlad, the #1 Approved Applicator Program


• Specified by most global automotive manufacturers

• Coatings and Technology are compliant with legislation: ELV, ROHS, WEEE, REACH

• Approved applicators which are audited on a systematic rota

• Continuous improvement and development program

Sacrificial Coatings, the Current Status


Current prevailing coating

Zinc with cobalt containing passivation

New coating needs

• Higher performance

• Environmental compliance

Which technology

can deliver this new requirement?

Coatings which meet new directives / legislation are already in use

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Zinc-nickel

Passivation

Topcoat

Why the Need for Higher Performance Coatings?


• In 2011* about 50% of vehicles were produced with aluminum wheels

8 *European Aluminum Association

Open face • Aluminum wheels

have a more ‘open face’ (than steel)

• This makes the brake caliper more visible

Regional Environmental Directives often Lead to Global Adoption


• European REACH legislation may prohibit the use of cobalt in passivate coatings in this region

Example from

last decade

Our Recommendation is Zinc-Nickel


• Together with cobalt free passivation, the finish meets ELV and REACH directives

• Zinc coatings display voluminous white corrosion products

• Zinc-nickel coatings do not display these corrosion products to the same extent

• We estimate 10% of this market has already adopted the zinc-nickel coating

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Is Zinc-Nickel Reliable?


• The technology has been used in automotive applications for over 20 years now

• The dominant technology gives an alloy of some 12 – 15% nickel

• MacDermid’ s ZinKlad applicator program has over 30 zinc-nickel applicators world-wide

– ZinKlad 1000

– ZinKlad 1000 B

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Which OEM’s Specify Zinc-Nickel?


• BMW GS 90010

• Daimler DBL 8451

• Delphi DX5511330

• Ford WSS M21P51-A1, A2, A3, A4, A5

• FCA PS-12182

• General Motors GMW 16730, GMW 4700

• Navistar CEMS G-22 Class ZNi-B2

• PSA B2 B15 4140

• Renault 01-71-002, 01-50-005

• VW-Audi TL 244

What about the Performance of the Zinc-Nickel Coating ?


• Over 1200 hours to base metal corrosion*

• Over 240 hours to any corrosion of the zinc-nickel deposit*

• Deposit is harder (>400 HVN) than standard zinc

• Attractive silver / blue finish

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*In neutral salt spray test to ISO 9227 / ASTM B117

10% of Brake Manufacturers Have Changed to Zinc-Nickel*


*Internal market research

First adopters Second adopters Latest adopters

Typical country of origin of adopting brands

We Propose Acid Zinc-Nickel for this Application


• Kenlevel Ni acid zinc-nickel overcomes limitations of alkaline processes for caliper application:

– Rapid coverage of the cast iron

• Referred as ‘plating Initiation‘

– Single layer

• No deposit delamination

– Fast plating speeds

Deposit Delamination is a Concern with Duplex Plated Deposits


Zinc-nickel Layer*

Duplex - Layer can delaminate in use

Zinc Strike Layer*

*Example for illustration purposes only.

Cobalt-Free Passivates Provide the Perfect Conversion Coating


• TriPass ELV 3000 G

– Trivalent-chromium based

– Cobalt-free

– Attractive silver-blue color

– Exceptionally resistant to high temperature applications

• Brake calipers

• Engine bay

Cobalt Maybe Prohibited in Passivation Coatings


• ECHA recommended five cobalt salts for inclusion in the restriction list 2013

• Restriction can mean (restriction) for substances for specific applications or concentrations

• Transitional period or even a ban are possibilities

• Date of implementation is still unclear

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Zinc Produces Voluminous Corrosion Products


White Rust

• Voluminous zinc corrosion

Why is Corrosion Such and Issue?


• Once the corrosion has started, it will continue until red (base) metal corrosion commences

• The corrosion products ‘grow’ and look unsightly

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• They can make disassembly difficult due to the bolt and thread seizing

Is this a Problem to the Consumer*?


*A selection of quotes from customer discussion forums.

“My 2 ½ year old

‘brand’ got rust

brown front

calipers. It was

£50k new”!

“

“I've noticed that the front brake

calipers on my 2 year old car are

starting to show some slight rust.

Quite surprised by this, not sure if

I should speak to ‘brand’ about

taking action now, rather than wait

for it to get worse”.

“I noticed today that my brake calipers seem to

be developing a decent amount of corrosion,

more on one side than the other. Is this normal? I

bought the car 6 months ago. Thanks”!

Brake Fluid Compatible Topcoat Enhances Corrosion

Resistance


• To further enhance corrosion resistance, a brake fluid compatible, inorganic topcoat is often applied

• HydroKlad SI is specified by automotive OEM’s and Tier 1s

• Colorless and completely free of drip or run marks

– The silver-blue appearance is retained

• Film is only 0.5 - 1µm so does not interfere with dimensional tolerances

480 hours Neutral Salt Spray (Zinc Deposit)


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HydroKlad SI No Topcoat

No Topcoat

HydroKlad SI

So How Does Zinc-Nickel Compare?


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The silver-

blue color is

an excellent

match for the

aluminum

wheel finish

Cobalt-free

passivates

exceptional

corrosion

resistance,

even after heat

A harder

coating so

offers better

impact and

abrasion

resistance

Does not

corrode with

the same

voluminous

corrosion

products

Alan Gardner

Global Marketing Manager

MacDermid

Thank you. Any Questions?

Environmentally Compliant Coatings

MacDermid – We Are Represented Globally


Employees: 2,000

R&D Centers: 5

Manufacturing Sites: 13

Headquarters: Denver, USA

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Zinc-nickel for braking components

Engineering

Transcript of Zinc-nickel for braking components