Responding to your needs - Fastener Fair STD 121-0013 µtot: 0.11 – 0.17 steel µtot: 0.12 – 0.20 aluminum S437: µtot: 0.15 + 0.03 S450: µtot: 0.14 + 0.03 Mid CoF values µ :

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


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


Fastener market

Industrial fasteners in the automotive sector

4

Introduction


$ 20 billions sales in 2016 ww

4.6% annual growth rate, constantly growing


Phosphating

Hot-dip galvanize

Zinc flake

Mechanical plating

Electroplated

Zn, ZnNi, ZnFe

Black Oxide

Introduction

5

Corrosion protection for steel fasteners


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


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


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 %


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


Requirements

Testing



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


WANTED! High friction

Slippery as ice – very low friction



10

Definition of sliding friction


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 !


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


11

OEM requirements


2 main CoF windows: µ= 0.08 – 0.14 µ= 0.12 – 0.18



12

Requirements


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



13

µtot for various black and silver passivates and sealers on alkaline ZnNi


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


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



Process control

16

Influences of different parameters


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


Process control

17



pH 4.0

Color w/o sealer

pH 4.5 pH 4.2

Color

Zinni® 220 + Tridur® DB (Co-free)


Process control

18

Corrosion performance


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



Process control

19



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


*CoF according WZ102 on M8 ISO 4014 screws


Process control

20



NSST

ISO 9227

1,008 h

L-467/ Act II

9 cycles


*40% MU 35% MU conc. 30% MU conc.

*recommended value

No red corrosion after 9 cycles

L-467 or 1,000 hours

NSST


Process control

21



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


*recommended value

Key processes

Acid and alkaline zinc nickel

Acid and alkaline zinc


Key processes for fastener application Main categories


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



Plating sequence

24

High performance – acid and alkaline ZnNi products achived more than 1,000 hr


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


Low CoF window (0.08 – 0.14)*

Med. CoF window (0.12 – 0.18)*

*measured according ISO 16047

Sealer 350 WL8






Plating sequence

25

Medium performance – acid and alkaline zinc products achived more than 360 hr.


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




*measured according ISO 16047

Sealer 350 WL8





Low CoF: Zinni® AL 450 + Tridur® DB + Sealer 350 WL8


26

Results of main corrosion tests, key processes zinc nickel silver


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)


Low CoF: Zinni® AL 450 + Unifix® Ni 3-30 L (bo-free) + Sealer 350 WL8


27

Results of main corrosion tests, key processes zinc nickel black


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


The key for fastener application

29

Summary


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

Documents

Responding to your needs - Fastener Fair STD 121-0013 µtot: 0.11 – 0.17 steel µtot: 0.12 – 0.20 aluminum S437: µtot: 0.15 + 0.03 S450: µtot: 0.14 + 0.03 Mid CoF values µ :