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Technology for tomorrow's solutions
Responding to your needs
The right system for all types of fasteners
Ernesto Ibarra – Corrosion Protection Conference Fastener Fair 2017
© Atotech | confidential |
Contents
1. Overview fastener market 2. Fastener variety and requirements 3. Coefficient of friction 4. Process control 5. Key processes 6. Summary
2 Fastener Fair – Key Process - Mexico City| 21-Jun-2017
© Atotech | confidential |
Fastener market
Industrial fasteners in the automotive sector
3
Introduction
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
Screws
Nuts
Bolts
Washer
Rivets
Up to 2,500 different types fix an average car with vast number of applications and finishes
© Atotech | confidential |
Fastener market
Industrial fasteners in the automotive sector
4
Introduction
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
$ 20 billions sales in 2016 ww
4.6% annual growth rate, constantly growing
© Atotech | confidential |
Phosphating
Hot-dip galvanize
Zinc flake
Mechanical plating
Electroplated
Zn, ZnNi, ZnFe
Black Oxide
Introduction
5
Corrosion protection for steel fasteners
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
Thin iron oxide layer (Fe3O4), application by dip coating into
acidic or alkaline solution to form a thin oxide layer -> weak
corrosion protection
Chemical or electro chemical formed phosphate layer, basic corrosion performance, adhesion promoter for construction purposes like self tapping screws, screws for concrete,...
Coating iron and steel with a layer of zinc by immersing the metal in a bath of molten zinc at a temperature of around 450 °C
Placing steel into an enclosure surrounded by metallic zinc dust at elevated
temperatures, produces clear, thin zinc coatings, limited to relatively small objects,
Mechanical application of zinc flakes, mostly solvent based systems without hydrogen embrittlement -> suitaable for hardened fastener (p.c. 10.9 and higher).
Electrolytic deposition of Zn / Zn alloys for highest corrosion
demands with adjustable friction behavior, risk of hydrogen
embrittlement for hardened fasteners
© Atotech | confidential |
Introduction
Highest corrosion resistance demands for assembly parts are still fulfilled with zinc nickel & zinc flake systems.
6
Corrosion protection – state of the art for automotive industry
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
Example Golf VII
~ 16 kg of assembly parts
2,000 – 3,000 pieces (depending on configuration)
Zinc flake
Zinc nickel
Zinc
Phosphating
Rest
40 %
40 %
4 %
6 %
10 %
© Atotech | confidential |
Key processes for fastener application
7 Fastener Fair – Key Process - Mexico City| 21-Jun-2017
Corrosion protection
Decorative aspect
Profitability
Heat resistance Isolation / conductivity
Contact corrosion
Wear resistance /abrasion
Compatibility with threatlocker
Enviromental compatibility
Process control
Coefficient of friction
Impact resistance
Adhesion
Paintability
Chemical resistance
Assembly & loosening control
Cleanliness
Typical requirements in the automotive industry
Coefficient of friction
Requirements
Testing
© Atotech | confidential |
Coefficient of friction
Selected examples of coefficient of friction values for µ
Typical values for CoF
Dragster tyre against race track ≈ 4
Tyre against road ≈ 1
Steel vs. Steel ≈ 0.2-0.6
Car brake ≈ 0.4
Fastener lubrication ≈ 0.1-0.2
Skates (on ice) ≈ 0.005
Ball bearing ≈ 0.0015
Hydrostatic lubricated parts ≈ 0.0010
9
Amazing facts
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
WANTED! High friction
Slippery as ice – very low friction
© Atotech | confidential |
Coefficient of friction
10
Definition of sliding friction
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
The CoF gives the relation between the normal force FN and the tangential force FT
We are able to modify the surface to your needs !
© Atotech | confidential |
Fiat (general)Fiat (lubricated)Fiat (lubricated)
Ford (most popular)FordFordFordFord
GM (normal)GMW14100 (normal)
GM (Al, ELPO)GMW14100 (Al, ELPO)
Hyundai/Kia greenHyundai/Kia pink
Hyundai/Kia transp.PSA normal
PSA low frictionRenault
Scania STD 3950 (hex)Scania STD 3950 (flange)Toyota & other Japanese
Toyota flakesToyota TSH 7903-A1Toyota TSH 7903-D
VDA 235-101Volvo Car (dvlpmnt & QA)
Volvo Car (verification)Volvo Group (QA)
Volvo Group (dvlpmnt & vVW 01129
0,00 0,05 0,10 0,15 0,20 0,25 0,30 0,35 0,40
tot
K = 0.3 ... 0.4
target
Coefficient of friction
11
OEM requirements
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
2 main CoF windows: µ= 0.08 – 0.14 µ= 0.12 – 0.18
© Atotech | confidential |
Coefficient of friction
12
Requirements
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
German OEM‘s follow VDA window µtot: 0.08 – 0.014 (multiple mounting requested) - Daimler - Volkswagen - ...
VDA 235 – 101 µtot: 0.08 – 0.14
GMW 4700 : µtot: 0.13 +- 0.003 (CoF of 0,13 on Frankenbolts ~ µtot: 0,11 according ISO )
Low CoF values µtot: 0.08 – 0.14 Sealer 350 WL 8
Renault 01-50-005: µtot: 0.12 – 0.18 – steel µtot: 0.10 – 0.24 – Al + HDG µtot: 0.08 – 0.25 – E-coat
VOLVO STD 121-0013 µtot: 0.11 – 0.17 steel µtot: 0.12 – 0.20 aluminum
WX100: - S437: µtot: 0.15 +- 0.03 - S450: µtot: 0.14 +- 0.03
Mid CoF values µtot: 0.12 – 0.18 Corrosil® Plus 315L
2 main CoF windows
© Atotech | confidential |
Coefficient of friction
13
µtot for various black and silver passivates and sealers on alkaline ZnNi
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
0.160
0.150
0.140
0.130
0.120
0.110
0.100
0.090
0.080 µtot
CoF µtot against Steel ISO 16047 All figures depending on conditions of fasteners and line design
Sealer 350 WL 8
Mid CoF values µtot: 0.12 – 0.18
Corrosil® Plus 315L
Low CoF values µtot: 0.08 – 0.14
Ø µtot 0.14
Ø µtot 0.11
[45%] [50%]
Specific OEM request =
dedicated sealer:
One sealer does not fit all!
Process control
Influence on Corrosion results
and on CoF
© Atotech | confidential |
CP coating systems Process flow – Example for hardened steel (p.c. 10.9 – Vickerhardness 320-380 HV)
Activation
Uniclean
155
Plating & passivation
Pos.1 Pos.2 Pos.3
CRC post treatment CP post treatment
3 x Rinse
ex-proved (150°C – 210°C)
3 x Rinse
dried parts
(has to be handled in 48h)
Centrifuge (~ 80°C)
Electroplating (Zn , ZnNi, ZnFe, ZnZn)
Heat treatment (6h; 210°C)
0,3% HCl 3 x Rinse
Passivation Cr3+ 3 x Rinse
Heat treatment (6h; 210°C)
HT before passivation HT after passivation
HCl 35-50%
v/v%+ Uniclean 501 Part2 20-
30ml/l 3 x Rinse
Nonacid 701 (1-4 A/dm2) 3 x Rinse 3 x Rinse loading
HCl 5-10% v/v%
Soak cleaner
Pickling Acid
E-cleaner
oven oven
Sealer
oven
Pre treatment
Centrifuge
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
© Atotech | confidential |
Process control
16
Influences of different parameters
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
Zinni® 220 + Tridur® DB (Co-free) + Corrosil® Plus 315L
Variation of: • pH • dipping time
Variation of: • Concentration • centrifuge parameter
Wide working window with stable performance
© Atotech | confidential |
Process control
17
Influences of different parameters
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
pH 4.0
Color w/o sealer
pH 4.5 pH 4.2
Color
Zinni® 220 + Tridur® DB (Co-free)
© Atotech | confidential |
Process control
18
Corrosion performance
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
pH 4.0
NSST
ISO 9227
1,008 h
pH 4.5 pH 4.2
L-467/Act II
9 cycles
No red corrosion after 9 cycles L-467 or 1,000 hours
NSST
Zinni® 220 + Tridur® DB (Co-free) + Corrosil® Plus 315L
© Atotech | confidential |
Process control
19
Influences of different parameters
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
0.1
0.12
0.14
0.16
0.18
0.2
CP
315L
90
%
CP
315
L 7
5 %
CP
315
L 6
0 %
40% 35% 30%
Concentration
0.1
0.12
0.14
0.16
0.18
0.2
CP
315
L 9
0 %
( 2
00
rp
m)
CP
315
L 9
0 %
( 3
50
rp
m)
CP
315
L 9
0 %
( 5
00
rp
m)
200 rpm 350 rpm 500 rpm
Centrifuge parameter µtot µtot
No significant influence on CoF - Ø µtot:
0.14
Zinni® 220 + Tridur® DB (Co-free) + Corrosil® Plus 315L
*CoF according WZ102 on M8 ISO 4014 screws
© Atotech | confidential |
Process control
20
Corrosion performance
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
NSST
ISO 9227
1,008 h
L-467/ Act II
9 cycles
Zinni® 220 + Tridur® DB (Co-free) + Corrosil® Plus 315L
*40% MU 35% MU conc. 30% MU conc.
*recommended value
No red corrosion after 9 cycles
L-467 or 1,000 hours
NSST
© Atotech | confidential |
Process control
21
Corrosion performance
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
200 rpm/min 500 rpm/min *350 rpm/min
No red corrosion after 9 cycles
L-467 or 1,000 hours
NSST
L-467/ Act II
9 cycles
NSST
ISO 9227
1,008 h
Zinni® 220 + Tridur® DB (Co-free) + Corrosil® Plus 315L
*recommended value
Key processes
Acid and alkaline zinc nickel
Acid and alkaline zinc
© Atotech | confidential |
Key processes for fastener application Main categories
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
Performance Coating Plating Passivation Finish
Supreme performance CP combination Zn / ZnNi Cr3+ Top coat
High performance Corrosion resistant coatings
ZnNi Cr3+ Sealer
Medium performance Corrosion resistant coatings
Zn Cr3+ Sealer
23
© Atotech | confidential |
Key processes for fastener application
Plating sequence
24
High performance – acid and alkaline ZnNi products achived more than 1,000 hr
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
Plating Passivate Sealer
Acid zinc nickel
Alkaline zinc nickel
Zinni® AL 450
Zinni® 220 Tridur® DB Tridur® DB (Co-free)
Unifix® Ni 3-34L
Tridur® DB Tridur® DB (Co-free)
Unifix® Ni 3-30 L
(H3BO3 & Co-free)
Sealer 350 WL8
Corrosil® Plus 315L
Low CoF window (0.08 – 0.14)*
Med. CoF window (0.12 – 0.18)*
*measured according ISO 16047
Sealer 350 WL8
Corrosil® Plus 315L
Low CoF window (0.08 – 0.14)*
Med. CoF window (0.12 – 0.18)*
© Atotech | confidential |
Key processes for fastener application
Plating sequence
25
Medium performance – acid and alkaline zinc products achived more than 360 hr.
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
Plating Passivate Sealer
Acid zinc
Alkaline zinc
Protolux® 8000
Zylite® HT Plus EcoTri® NF
EcoTri® NoCo 2.0 (Co-free)
Tridur® Zn H2
EcoTri® NF EcoTri® NoCo 2.0 (Co-free)
Tridur® Zn H11
Sealer 350 WL8
Corrosil® Plus 315L
Low CoF window (0.08 – 0.14)*
Med. CoF window (0.12 – 0.18)*
*measured according ISO 16047
Sealer 350 WL8
Corrosil® Plus 315L
Low CoF window (0.08 – 0.14)*
Med. CoF window (0.12 – 0.18)*
© Atotech | confidential |
Low CoF: Zinni® AL 450 + Tridur® DB + Sealer 350 WL8
Corrosion protection
26
Results of main corrosion tests, key processes zinc nickel silver
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
Medium CoF: Zinni® AL 450 + Tridur® DB + Corrosil® Plus 315L
NSST DIN EN ISO 9227 1,008h
Ford L-467 // ACT-2 9 cycles (9 weeks)
VOLVO Group ACT-1 6 cycles (6 weeks)
VW PV 1209 4 cycles (4weeks)
© Atotech | confidential |
Low CoF: Zinni® AL 450 + Unifix® Ni 3-30 L (bo-free) + Sealer 350 WL8
Corrosion protection
27
Results of main corrosion tests, key processes zinc nickel black
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
Medium CoF: Zinni® AL 450 + Unifix® Ni 3-30 L (bo-free) + Corrosil® Plus 315L
NSST DIN EN ISO 9227 1,008h
Ford L-467 // ACT-2 9 cycles (9 weeks)
VOLVO Group ACT-1 6 cycles (6 weeks)
VW PV 1209 4 cycles (4weeks)
Summary
© Atotech | confidential |
The key for fastener application
29
Summary
Fastener Fair – Key Process - Mexico City| 21-Jun-2017
Fasteners just appear as simple – but...
Up to 2,500 different types fix an average car with vast number of applications and finishes
Coefficient of friction is key to keep the fasteners where they are supposed to be
Each OEM follows his own assembly strategy: Application of dedicated sealers
Our systems are robust to ensure corrosion performance and correct CoF in all situations
Sealer 350 WL8 and Corrosil® Plus 315L fulfill most of the OEM requirements
Contact
Technology for tomorrow's solutions Technology for tomorrow's solutions Technology for tomorrow's solutions
Thank you
for your attention!
Atotech de Mexico, S. A. de C. V. Booth 605
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