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Leading Zinc Flake Technology for Automotive Applications

^ ATOTECH

02 Zinc Flake Technology for Highest Corrosion Protection within Automobiles

High corrosion resistance is one of the prime quality criteria for cars. Zinc Flake coatings provide a high grade of corrosion protection. Compared to electrolytic zinc plating, the zinc flake technology is applied in a dip-spin or spray technique and therefore has the advantage that hydrogen embrittlement is irrelevant. The spectrum of automotive parts to be coated is versatile, ranging from hose clamps, fasteners and brake discs to side impact protection or other stamping parts. For the different applications Atotech offers a comprehensive range of processes including silver and black base coats, organic and inorganic top coats as well as a large variety of lubricants.

Base Coats Zintek base coats are systems that contain Zn and Al flakes. The metal particles and reactive mineral resins react on steel base material to form an adhesive bonding. During baking a conductive, zinc aluminium coating with cathodic protection effect is formed. The dry film is Pb-, Hg-, Cd- and Cr(VI)-free. The typical curing temperature is 200 - 230 °C and therefore softening of the hardened steel parts will be prevented.

Product

Zintek 200

Zintek 200/30

Color

silver

silver

Features

> 2-coat application 6-10 urn > Combinable with all Zintek

> For high strength steel > Coating is weldable

Top and Techseal

Zintek 300 (B) black

Zintek 400 silver

Zintek 500 silver

> Unique black base coat > Avoids issues of „silver spots" after handling

> Zinc flake system containing special binder > Bendable coating for e.g. springs > Paintable and powder coatable > Good cathodic corrosion protection > Protection against corrosion creep > In combination with the cross linker Zintek CL very low drying

temperature (30 to 150 °C) > (Zintek CL is a hardener for the base coat)

> Specially developed product for brake discs > Color equals RAL 9006 (Al silver) > Low curing temperature (object temp. 75 °C) > Significant energy savings for the applicator compared to

standard zinc flake products > Suitable especially for after market applications > Fulfills further requirements of brake disc manufacturers

such as soot and odor development at first braking

Top Coats Zintek base coats can be combined with inorganic and organic top coats to form multifunctional coatings, which provide highest corrosion protection and fulfill torque tension requirements.

03

| Product

Zintek Top (L)

Techseal Silver W(L), S(L)

Techseal Black W(L), S(L)

Color

silver

silver

black

Features [

inorganic » Cr-free » Solvent free » Water based with transparent silicate » Reactive sealing additive » Improves corrosion resistance and mechanical properties

of the base coat » Very thin coating (0.5 - 1 urn) » Low drying temperature: 50 - 200 °C

organic » Cr(VI)-free » Water based, W-versions or solvent based S-versions >> Suitable for zinc-flake coatings as well as Zn and Zn

alloy electrodeposits » Includes internal lubricant to adjust torque tension

requirements » Other colors are also available including white, red, blue,

green, etc.

• (L): Including internal lubricant for torque tension adjustments (CoF 0.10 to 0.16)

Coatings - Recommended Process Sequence The following process combinations are recommended to achieve a certain corrosion protection to red rust.

Base Coat

Zintek 200

Zintek 200/30

Zintek 200

Top Coat

Zintek Top (L)

Color

silver

silver

silver

Corrosion Performance

up to 720 h to RR

up to 480 h to RR

up to 2000 h to RR

up to 1000htoRR

Zintek 300 (B)

Zintek 400

Zintek 500

no base coat

no base coat

no base coat

Techseal Black S(L)

Techseal Silver WL

Techseal Black SL

no base coat

black

silver

silver

silver

black

Zn Di

up to 1500htoRR

up to 1000 h to RR

up to 480 h to RR

up to 96 h to RR

up to 96 h to RR

Zn Die Casting with up to 720 h to WR EcoTri HC2 (30 °C)

04 Appl icat ions

The following list shows different automotive applications with exemplary coatings. Products and corrosion protection results, however, are depending on coating thickness, part size, geometry, equipment, customer requirements etc.:

Application

Fasteners

Clips & Clamps (e.g. Hose Clamps)

Springs

Brake Disc

Weldable Parts (e.g. Side Impact Protection) Locking Systems

Assembly Brackets

Angle Sheets, Sheet-Metal Bending Parts

Chassis Parts (e.g. Wheel Axle) Eyelet Bolts, Tow Lugs Fluid Delivery Tubes

Zn Die Casting Parts

Anti Vibration Components

Color silver

silver black black silver silver silver silver silver

silver

silver silver black silver silver silver silver black

silver

silver

silver

black

silver

black silver black blue silver

Base Coat Zintek 200 Zintek 200 Zintek 300 В Zintek 300 В Zintek 200 Zintek 200 Zintek 400

Zintek 200 Zintek 500

Zintek 200/30

Zintek 200 Zintek 200 Zintek 300 В Zintek 200 Zintek 200 Zintek 200

Zintek 200 Zintek 300 В

Zintek 200

Zintek 200 electrolytic Zn and ZnX plating electrolytic Zn and ZnX plating

Zintek 200 Zintek 200

Zintek 200

Top Coat Zintek Top (L)

Techseal Silver W(L) Techseal Black S(L) Techseal Black S Techseal Silver W

Zintek Top Techseal Silver WL Techseal Black S(L) Zintek Top Techseal Silver WL Zintek Top

Techseal Silver W Techseal Black S(L)

Techseal Silver WL

Zintek Top Techseal Silver WL

Techseal Black S(L)

Techseal Silver WL Techseal Black S(L) Techseal Silver WL Techseal Black S(L)

Techseal Blue WL

Lubricant yes/

yes/ yes / no no no no no no

no

no yes yes / no yes no

no yes/

yes

no yes

yes /

yes yes/

yes yes/

yes no

no

no no

no

no

no

no

no

Clips & Clamps (Hose Clamps) Fluid Delivery Tubes

Brake Disc Weldable Parts (e.g. Side Impact Protection)

Springs Lock Systems

Angle Sheets, Sheet-Metal Bending Parts Eyelet Bolts, Tow Lugs

Fasteners Application 07

For fastener applications special requirements are necessary. To ensure a precise bolt-nuts connection and to get the required clamping force, the choice of suitable processes as well as constant and consistent friction properties of the coatings are important. Various test methods are available. All methods give a ratio of applied torque and accessible clamping force. As an indicator the coefficient of total friction (ulol), the coefficient of friction between bearing surfaces (ub) and the coefficient in the thread (uth) can be used.

Exemplary Coefficient of Friction Measurement Fastener: M 10 x 1.5 x 70 - 8.8 Flange Head Coating: Zintek 200 + Techseal WL 14 silver Nut: M 10 zinc plated Steel bearing surface

N1 Step 1 MbStep 1 Mth Step F . Step 1 ulot Step 1 ub Step 1 u,h Step 1

1 2 3 4 5

Subseries #8

n = 5 X

s min max

R

Nm 59.85 57.19

60.17 63.06 61.88

Mto,Step1

Nm 60.43

2.23 57.19

63.06 5.87

Nm 35.37

33.24 33.30 33.55 36.98

Mb Step 1

Nm 34.49

1.65 33.24 36.98

3.74

Nm 24.48 23.94 26.87 29.51 24.90

M„, Step

Nm 25.94

2.28 23.94 29.51

5.56

kN 28.31

28.30 28.32 28.33 28.31

0.140

0.133 0.141 0.148 0.145

Fc,Step1 MlotStep1

kN 28.31

0.01 28.30 28.33

0.02

0.141 0.006

0.133 0.148

0.015

0.152

0.143 0.143 0.144 0.159

Mb Step 1

0.149 0.007 0.143 0.159 0.016

0.120 0.117 0.136 0.154 0.123

ulh Step 1

0.130 0.015 0.117 0.154

0.038

Tension In kN

Fig. 1: Coefficient of friction measurement

Zinc Flake Coatings approved by the Automotive Industry

OEM / Tier 1 1 Specification

BMW GS 90010

Bosch 0 204Y82 119

Brembo BDS-11.22

Comments

approved for non-threaded parts

Zintek

Zintek 200, Techseal Black WL, Techseal Silver WL, Zintek Top, Zintek Top L

Brose 590295-105 Part 1

Continental Automotive ATE N106 61.00

Daimler

Fiat

GE

GM

Nissan

PSA

Renault

Renault Trucks

Schneider Electric

TRW

vw

VW Brazil

DBL 9440.40

957.513

GME 00255

GMW3359

NES M4601

B15 3320

01-71-002/-Q

01.71.4002/H

155881701A06

TS 2-25-060

TL245

TL245

TL233

Zintek 200, Zintek 200/30

Zintek 200, Zintek 300 B, Techseal Black WL, Techseal Silver WL, Zintek Top, Zintek Top L

Zintek, Zintek Top and Techseal

Zintek 200, Zintek 200 BS, Techseal Silver WL, Zintek Top, Zintek Top L

approved for wind generator application

Zintek 200, Techseal Silver WL

Zintek 200, Techseal Silver WL

Zintek 200 + Zintek Top

Zintek 200, Zintek Top LF

Zintek 200, Techseal Silver WL

Zintek 200, Techseal Silver WL

Zintek 200

Zintek 200, Zintek Top, Techseal Silver W, Techseal Silver WL

Zintek 200, Zintek Top, Zintek Top LV (Ofl-t601,Ofl-t602, Ofl-t647)

approved for Ofl-t602 and Ofl-t611

approved for Ofl-t330

W ДТ0ТЕСН Subsidiary of the Total Group

Home Atotech Main Office Erasmusstr. 20 D-10553 Berlin

Phone +49(0)30 349 85 0 Fax +49 (0)30 349 85 777

www.atotech.com Ф TOTAL

ГУРосНИИИТиАП Ассоциация МВТК

Федеральный информационный фонд отечественных и иностранных каталогов на промышленную продукцию

Каталог был представлен на выставке «Покрытие и обработка поверхности -

2008»

Каталог включен в базу данных «Федерального информационного фонда

отечественных и иностранных каталогов на промышленную продукцию»

Россия, 105679, Москва, Измайловское шоссе, 44, Тел./факс (095)366-5200, 366-7008, 365-5445. e-mail:; fkataIog@maiI.ru,

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Электронная копия издания изготовлена с целью её включения в базы данных Федерального информационного фонда отечественных и иностранных каталогов на промышленную продукцию, которые

формируются в соответствии с Постановлением Правительства РФ от 24 июля 1997 г. № 950 и Постановлением Правительства РФ от 31 декабря 1999

г. № 2172-р и зарегистрированы Комитетом по политике информатизации при Президенте РФ под №№ 39-50.

2008год