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KTL technology from Dörken MKS:Bulk parts - with or without cathodic protection

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Cathodic dip coating under the DELTA-eLACK® system name: areas of use

Beautifully fastened: KTL-coated bolts with character

KTL coatings are an established part of the surface coatings scene, but they remain the exception as far as bolts and screws are concerned. With our new DELTA-eLACK® KTL-system we are now addressing this area of application - and even going a step further. In addition to the highly-aesthetic, deep-black appearance the new system also boasts a VDA coefficient of friction (0.09-0.14µtot) and cathodic protection with the use of a zinc flake or zinc-based basecoat. Naturally, the topcoat can also be applied directly to a phosphate coat. Regardless of which surface you choose: you will receive a highly competitive system.

These characteristics are offered by KTL-coated screws in all cases: an aesthetic, deep-black appearance!

Bulk product component group:• screws ( M4-M14 )• corrosion protection according to requirement• VDA coefficient of friction set to

0.09–0.14µtot as per ISO 16047

Areas of use can be found everywhere: KTL-coated screws are used in areas ranging from the furniture industry, for example fittings screws, to other sectors including the au-tomobile industry.

Bulk parts: stamped parts from the rack into the barrel

Stamped and bent components are typically coated as racked goods. This is no longer necessary. The innovative plant technology in use enables coating within the barrel. This generally leads to significantly lower costs.

More on plant technology can be found on pages 6 - 7

Stamped and bent components component group:• stamped and bent components from very small to

180 grams or 15 cm in length• various geometries possible

Areas of use: machines, agriculture, steel construction and automobile – there are many possibilities.

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The black appearance and corrosion protection score points all along the line.

Complex bulk goods such as door hinges are also suitable for the barrel procedure.

Shiny and flexible: KTL clips and hose clamps keep together without sticking.

Bulk parts such as springs and clips are especially well-suited to the barrel procedure. The results of coating with DELTA-eLACK® are impressive: a deep black appearance with maximum ductility.

Springy clips: shiny and flexible

Clips and clamps component group• corrosion protection according to requirement• impeccable appearance, despite deformation• all geometries possible

Areas of use: machines, agriculture,furniture industry and automobile.

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KTL with cathodic protection – no contradiction

KTL technology DELTA-eLACK® from Dörken MKS:Function and characteristics

The high acceptance of Dörken MKS systems amongst our customers and our extensive technologi-cal experience convinced us to offer a further technological segment in addition to zinc flake. DELTA-eLACK® is the system name of our cathodic dip coating (KTL; also known as „cataphoresis“). This is an electro-chemical process in which objects are coated in a dip bath. It was developed specifically for complex geometries and bulk parts and is used as a standard procedure for corrosion protection coa-ting, e.g. for vehicle bodies.

Standard KTL technology comes up against its limits with regard to remote protective action: an active cathodic corrosion protection like the one of the zinc flake can therefore not be provided. If damage to the coating penetrates down to the base metal, the substrate will corrode rapidly.The combination of the new KTL coating DELTA-eLACK® 800 with a zinc or zinc flake base from the DELTA-MKS® series or another cathodic protecting base coat generates high-performance cathodic pro-tection without further undermining.

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The characteristics of our DELTA-eLACK® KTL system at a glance:

• high (cathodic) corrosion protection through combination of our products• coating in the barrel as bulk products• thin, even coats• VDA-compatible coefficients of friction for fastening elements• deep black appearance• high chemical resistance• depending on substrate: high resistance to white rust• anti-squeak properties for stamped and bent components• recoatability• environmentally-friendly and resource-saving• threaded parts without reworking / recutting• no recess filling

Visit our homepage

www.doerken-mks.com/en/ktl.html and find out more about our products and approvals in the product fact files.

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Are you still hanging or have you already started drumming?Our innovative plant technology: the „Twin Line“ tandem unit

Take advantage of the innovative plant engineering of Dörken MKS–Systeme. Where in the past stam-ped and bent components could only be coated when time-consumingly hung on racks, coating now takes place in the barrel as bulk products – with a throughput of up to 2 tonnes or 1,400 litres per hour. This means significant savings of time and money.

The Twin Line consists of two barrels: whilst one is being loa-ded and coated, the other is unloading. During the loading process the parts that are to be coated are also fed in at the same time.The benefits of this plant are clear - on the one hand the use of two barrels halves the time required per batch; on the other hand there is no need to hang the parts up as in the conventional method.

The surface is a key quality factor in the coating process. Various surfaces can be selected, dependent of the proper-ties and requirements of the part that is to be coated: phos-phating, zinc and zinc flake are all conceivable alternatives. Further base coats are possible following testing and appro-val. After the application of the respective base coat the part is coated with DELTA-eLACK®.

The innovative barrel geometry enables simple forwarding to the oven on the conveyor belt. Curing binds the coating and ensures good adhesion to the component – the result is a deep black appearance and optimal functionality.

Technical Data Twin Line

Capacity: 100 kg or 70 l (per barrel)

Cycle time: 3 minutes

Filling: automated via loading station with scale

Other: Parameter adjustable according to requirements

Further information can be found in our technical data sheet.

The special barrel geometry facilitates unloading.Loading the barrel

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Technical characteristics: corrosion resistance

The performance characteristics of the new system are manifested via various quality tests. One standard procedure is the salt spray test (SST) in accordance with DIN EN ISO 9227.

The screws illustrated on the right have been coated with a DELTA-PROTEKT® zinc flake basecoat (left) or with a galvanic DELTA-PROZINC® base (right) and each sealed with the DELTA-eLACK® 800 topcoat. This coat is characterised by a deep black surface and long-lasting durability. After 1,600 hours in the SST, the results are impressive.

KTL top coat DELTA-eLACK® 800 on DELTA-PROTEKT® zinc flake (left) and DELTA-PROZINC® (right) after 1,600 hours in the SST

Salt spray test (SST) in accordance with DIN EN ISO 9227

Alternating climate test (as per PV 1210 / Volkswagen)

In order to achieve as realistic an assessment as possible of test results we also conduct further corrosion tests in addition to the SST. We set ourselves the hurdle of test specification 1210 from Volkswagen - and cleared that hurdle. In the process, we tested various zinc flake basecoats of the DELTA-MKS® family.

One cycle consists of four hours SST (DIN EN ISO 9227), four hours storage in a normal climate (ISO 554) and 16 hours of warm and humid storage in the CH test climate (DIN EN ISO 6270-2). After five cycles there is a two-day rest period in the normal climate. 15 cycles take a total of three weeks.

As underlying surface: phosphating after 30 cycles As underlying surface: zinc flake basecoatDELTA-PROTEKT® after 30 cycles

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Technical characteristics:coatability/bonding and ductility Standard superstructural components in the automotive field use KTL as a base coat. As a conse-quence, automobile or industrial coatings are often used for the further system structure. Particu-larly important in this is the bonding between the coats (cohesion) and bonding of the base coat to the substrate (adhesion).The bonding/coatability and ductility of a coating may be tested in various ways. We have tested our system in two of these: with the cross-cut (1mm) and bending test. Both reveal the same re-sult: it bonds!

Our systems perform, all cross cuts display Gt-0.The tested topcoats are from the DELTA-MKS® zinc flake series and were tested on DELTA-eLACK® 800

Standard automobile superstructural components in silver and black on DELTA-eLACK® demonstrate superb bonding with Gt-0.

Similarly, in the industrial field with 2K-EP systems bonding is also graded Gt-0.

In a number of areas and with a number of parts there is a need to coat parts that have already been KTL coated and installed. This is the case, for example, where a door hinge is protected against corrosion via a KTL coating before being coated again in the car colour for optical reasons.

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Noteworthy: the high performance of our DELTA-eLACK® is evident here, although the material tears, the KTL remains bonded.

Technical characteristics: coefficients of friction (torque/pre-load testing as per ISO 16047)

The diagram depicts ten measurements of screws, coated with a system comprising zinc flake plus DELTA-eLACK® 800.Tightening is effected against steel or an HH disc with defined hardness and roughness. The diagram shows that only a minimal spread of coefficient of friction occurs.

Total coefficient of friction: min. 0.110 - max. 0.122Average value: 0.117Average value head: 0.115Average value thread: 0.121

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Not just a solution - but one with a system:DELTA-eLACK® at a glance

Base Topcoat Thickness Base

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00 - 8-12 μm up to 240 **Zinc-Nickel 8-12 µm 8-12 μm up to 1.000 ** Zinc: DELTA-PROZINC® 8-12 µm 8-12 μm 1.000Zinc flake: DELTA-PROTEKT® 8-12 µm 8-12 μm 1.200Other bases are possible, but need to be approved by us. A constant quality is achievable with DELTA-MKS® systems at the best.

DELTA-eLACK® is a KTL system comprising various base coats oriented towards the requirements of OEMs and parts manufacturers. Differentiation is generally made between cathodic protecting substra-tes on a zinc basis, such as zinc flake or a galvanic coating, and passive coating such as phosphate.

*SST DIN EN ISO 9227. Depends on geometry and base including coating technology. Results are carried out at the pilot plant and technical center.

**Result depends on base quality / depends on manufacturer.

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Qualified coaters - our calling card on the market

Only selected coaters with the aforementioned plant technology are able to apply the DELTA-eLACK® system. We ensure a globally-consistent standard of quality via annual audits. The basis for this is a global licensing system that has been established in the zinc flake field for over 30 years and acts as a guarantee for the participants in the value chain.

The coating network is currently in the process of being established. Initial prototype plants are in use in Europe.

Only via the licensing system do customers gain access to our complete technical support and the net-work in which we operate.

Dörken MKS-Systeme GmbH & Co. KGWetterstraße 58D-58313 Herdecke/RuhrTelephone: +49 (0) 2330 63-243Fax: +49 (0) 2330 63-354Email: mks@doerken.deWeb: www.doerken-mks.com/en

A member of the Dörken-Group.