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    Henkel PDF

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    mangal deo pathak
    This document discusses new nanotechnology developments for corrosion protection using "nanoceramics" as an alternative to traditional metal pretreatments like iron- and zinc-phosphating. It introduces two nanoceramic products, Bonderite NT-1 and TecTalis, that can replace phosphating and provide a phosphate-free pretreatment forming a thin ceramic conversion layer. The nanoceramic coatings offer superior corrosion protection compared to iron-phosphating and equivalent protection to zinc-phosphating. They also provide process efficiency through operation at ambient temperatures, shorter contact times, simpler monitoring, and elimination of toxic heavy metals and sludge.

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    © All Rights Reserved
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    Henkel PDF

    Uploaded by

    mangal deo pathak
    339 views20 pages
    This document discusses new nanotechnology developments for corrosion protection using "nanoceramics" as an alternative to traditional metal pretreatments like iron- and zinc-phosphating. It introduces two nanoceramic products, Bonderite NT-1 and TecTalis, that can replace phosphating and provide a phosphate-free pretreatment forming a thin ceramic conversion layer. The nanoceramic coatings offer superior corrosion protection compared to iron-phosphating and equivalent protection to zinc-phosphating. They also provide process efficiency through operation at ambient temperatures, shorter contact times, simpler monitoring, and elimination of toxic heavy metals and sludge.

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    This document discusses new nanotechnology developments for corrosion protection using "nanoceramics" as an alternative to traditional metal pretreatments like iron- and zinc-phosphating. It introduces two nanoceramic products, Bonderite NT-1 and TecTalis, that can replace phosphating and provide a phosphate-free pretreatment forming a thin ceramic conversion layer. The nanoceramic coatings offer superior corrosion protection compared to iron-phosphating and equivalent protection to zinc-phosphating. They also provide process efficiency through operation at ambient temperatures, shorter contact times, simpler monitoring, and elimination of toxic heavy metals and sludge.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    339 views20 pages

    Henkel PDF

    Uploaded by

    mangal deo pathak
    This document discusses new nanotechnology developments for corrosion protection using "nanoceramics" as an alternative to traditional metal pretreatments like iron- and zinc-phosphating. It introduces two nanoceramic products, Bonderite NT-1 and TecTalis, that can replace phosphating and provide a phosphate-free pretreatment forming a thin ceramic conversion layer. The nanoceramic coatings offer superior corrosion protection compared to iron-phosphating and equivalent protection to zinc-phosphating. They also provide process efficiency through operation at ambient temperatures, shorter contact times, simpler monitoring, and elimination of toxic heavy metals and sludge.

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    of 20

    New Nanotechnology Developments

    for Corrosion Protection


    NanoEngeneering - Hannover Messe, 21.04.2010
    Dr. Thomas John-Schillings

    Content
    Tasks of metal pretreatment
    Traditional metal pretreatment: Iron- and Zincphosphating
    Question about Phosphating
    Presentation of Nanoceramics Bonderite NT-1 & TecTalis
    Process
    Benefits
    Corrosion protection in comparison with traditional processes

    Why metal pretreatment?

    Prior to painting substrates are often:


    Dusty
    Oily (forming oils, temporary corrosion protection)
    Corroded (rust, welding scale)

    Pretreatment provides:
    Cleaning
    Paint Adhesion
    Better Corrosion Protection

    Traditional Metal Pretreatments

    Zincphosphating
    best corrosion protection
    excellent paint adhesion
    process difficult to monitor
    very cost intensive
    Ironphosphating
    simple, flexible process
    moderate process costs
    Low corrosion protection

    Why should Phosphatings being


    replaced?
    Question: Which aspects of Zinc-/Fe-Phosphating are mostly
    unsatisfying?

    very high sludge formation


    very narrow process operation window lot of parameter
    difficult multi metal pretreatment
    many process steps lot of active bathes
    high amount of heavy metals (Zn, Mn, Ni)
    environmental unfriendly process (energy, phosphate, COD,
    heavy metals)
    5

    Nanoceramics replace phosphating

    Ironphosphating

    Zincphosphating

    Eisenphosphatierung

    Bonderite NT-1

    TecTalis

    Nanoceramics replace phosphating

    Which benefits provide Nanoceramics with respect to

    What are Nanoceramics

    phosphate free metal pretreatment process


    provides excellent paint adhesion and corrosion protection
    replacement of iron- or zincphosphating
    multimetal pretreatment process (steel, zinc, aluminium)
    forming a thin ceramic conversionlayer (Nanoceramics)
    application in existing lines (dip or spray)

    Nanocearmic coatings
    Chemical Reaction
    H2ZrF6

    ZnO

    Zn+2

    ZrOXFy

    Zn
    Steel

    H2ZrF6 + M + 2H2O

    M = treated substrate; Fe, Zn, Al, Mg

    ZrO2 + M2+ + 4H+ + 6F- + H2


    pH = 3.8 5.0
    T = 10 - 50 C
    time = 30 - 180 s

    Nanoceramic Coating
    Dimensions
    [nm]
    10000
    5000

    Zincphosphate

    1000
    250

    Ironphosphate

    100

    Chromates

    50
    5

    SEM (Scanning Electron Microscopy)


    Phosphate Coating

    Nanoceramics
    bigger Molecules
    AFM (Atomic Force Microscopy)
    TecTalis Coating

    10

    Typical Bonderite NT-1 process

    Cleaning

    Rinse

    DIRinse

    NT-1

    DIRinse

    Paint

    Alkaline cleaning the only heated step


    DI-Rinse prior to Bonderite NT-1
    Conversion coating with Bonderite NT-1
    (20 sec. or more)

    DI-Rinse after Bonderite NT-1


    Optional: Dryer after Bonderite NT-1
    Powder coat, wet paint, CED/AEDC
    11

    TecTalis process layout

    typical Zincphosphate line

    230 m

    55C
    Cleaning

    Rinse

    Activation

    Phosphate.

    Rinse

    Passivation

    D-Rinse

    typical TecTalis process


    180 m

    Cleaning

    Rinse

    TecTalis

    Rinse

    DI-Rinse
    12

    Corrosion protection and


    paint adhesion
    Corrosions tests
    judgement of the area and the creep at the cut

    Constant climate test


    Neutral Salt spary
    Cycling climate test
    Outdoor exposure

    DIN EN ISO 6270-2


    DIN EN ISO 9227 AASS
    VDA 621 415
    VDA 621 414

    Adhesion-tests
    judgement before and after corrosion test
    cross hatch
    stone chip -test
    Erichsen-Tiefung

    13

    Perfomance:
    Bonderite NT-1 vs FePhos
    Bonderite NT-1

    Fe-Phosphate

    Customer sampes
    Creep after 500h NSS
    Bonderite NT-1 (left)

    2.2 mm creep
    Ironphosphate (right)

    6,5 mm creep

    14

    Performance: Comparison
    Tectalis vs ZnPhos
    70 cycles VDA Steel + CDP

    4,0

    TecTalis
    Creep at cut [U/2 in mm]

    3,5

    Granodine 958

    3,0
    2,5

    spec

    2,0
    1,5
    1,0
    0,5
    0,0
    E-coat 1

    E-coat 2

    E-coat 3

    E-coat 4

    E-coat 5

    E-coat 6
    15

    Comparison of process costs


    example:

    16

    Performance comparison
    ZnPhos vs TecTalis
    performance, e.g.
    corrosion protection
    area i.O. results ZnPhos
    area i.O. results TecTalis
    Specification

    ZnPhos

    TecTalis

    Procesparameter
    Process window ZnPhos
    Process window TecTalis

    automatical processcontrole (Lineguard Supervisor) for critical parameter possible!!


    17

    Benefits of Nanoceramics vs
    Phosphating
    Efficiency

    Process

    A lot of savings, e.g.


    Maintenance and Cleaning
    Water consumption
    Heating ( ambient temperature)
    Sludge disposal
    Result in: Process costs decrease

    conversion at ambient temperature


    short contact time
    simple bath monitoring (pH)
    real multimetal process

    Environment

    Quality

    low energy consumption


    no toxic heavy metals
    phosphate free conversion
    no contribution to COD
    less disposal (sludge)
    no hazardous substances

    enhancement of corrosion
    protection vs FePhos
    replacement of Zincphosphating in
    often possible
    Compatible with Al, Zn, steel and
    most available paint systems
    18

    Nanoceramics - References

    19

    Thanks for your attention!

    20

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