Enabling Light Weight Car Body construction with innovative Light Metal Pretreatment By Peter Kuhm and Manuel Cortes

1. Enabling Light Weight Car Body construction
with innovative Light Metal Pretreatment
Peter Kuhm, Manuel Cortes
7th Eurocar Barcelona
November 16, 2011

2. Contents
1. Introduction
2. Two Step Process for mixed Metal Applications
3. Magnesium and Aluminium component processes
4. New plasma coatings
Slide 2 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

3. Contents
1. Introduction
2. Two Step Process for mixed Metal Applications
3. Magnesium and Aluminium component processes
4. New plasma coatings
Slide 3 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

4. 50BY50
Actual average fleet fuel efficiency data through 2008 and nearest targets enacted or proposed
thereafter by region
Source: ICCT
Slide 4 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

5. Sustainability: driving force
• Targets of car manufacturer:
• Euro 5 & 6 regulation: CO2 and fuel consumption Dir. 80/1268/EC
CO emission: 1900 mg/km
• Vehicle weight is as critical as engine eficiency
• New metal mix including increasing amount of light metals
• Engines with more performances but downsized
Slide 5 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

6. Sustainability is One of Our Core Values
 All new products must contribute to sustainable development
Slide 6 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

7. Market Need:
Pretreatment systems for increasing light metal content
Increasing shares of light metals
in car body construction
in component construction
in powertrain applications
Were the motivation to develop and improve sustainable pretreatment
systems supporting the goals of our customers.
Slide 7 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

8. Contents
1. Introduction
2. Two Step Process for mixed Metal Applications
3. Magnesium and Aluminium component processes
4. New plasma coatings
Slide 8 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

9. Two Step Process for mixed Metal Applications
The 2-step-process suppresses the formation of the phosphate
coating on Aluminium in the phosphating zone whereas
galvanized steel is phosphated conventionally.
The conversion coating on the non-phosphated aluminium
then has to be created in a second step by precipitation of
zirconium oxide in the passivation zone.
Pretreatment Pretreatment
Cleaning Rinse Activation Rinse Rinse
Rinse
#1 #2
The 2 step process is available with Nitrite – accelerated
versions as well as Nitrite – free.
Slide 9 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

10. Two Step Process for mixed Metal Applications
Traditional Process: Closed phosphate coating on all substrates
Phosphat- Passi-
Rinse Rinse
ing vation
Free Fluoride e.g. 0,25%
150 - 250 mg/l Deoxylyte 54 NC
Two-Step-Process: No phosphate coating on aluminium
Phosphat- Passi-
Rinse Rinse
ing vation
Free Fluoride e.g. 0,4%
40 - 70 mg/l Deoxylyte 54 NC
Slide 10 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

11. Two Step Process for mixed Metal Applications
Benefits of the modified 2-Step-Processes
• Reduction of process material consumption (less Sodium, less
Fluoride, less phosphate- replenisher)
• Reduction of aluminium phosphate sludge, consequently lower
disposal costs, reduction of plant cleaning / maintanance
• Reduction of energy input (reduction of phosphate bath temperature,
throttling of circulating capacity)
• Feasibility of mixed construction car bodies with theoretically
unlimited share of aluminium in the metal mix in existing and new
immersion phosphating zones.
Slide 11 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

12. Two Step Process for mixed Metal Applications
Phosphat- Passi-
Rinse Rinse
ing vation
Free Fluoride e.g. 0,4%
40 - 70 mg/l Deoxylyte 54 NC
No phosphate coating on aluminium substrates
SEM Steel, SEM HDG/EG, SEM Aluminium,
CW: 2 - 4 g/m² CW: 2 - 4 g/m² CW: max. 0,2 g/m²
Slide 12 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

13. Two Step Process for mixed Metal Applications
Performance
As good as a standard phosphating process
on steel and galvanized substrates
Improved performance of Aluminium body panels and extrusion parts
Compatible with all existing metal pretreatment lines
Reference List
AUDI, VW, Seat, Jaguar, LandRover, Opel, Mercedes
Slide 13 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

14. Two Step Process for mixed Metal Applications
Next Steps
A new, environmentally even more beneficial two step process
Including a metallizing cleaner bath is under development.
The first line trial was performance wise very promising.
All corrosion- and adhesion data are indicating a performance level
of a standard tricationinc system.
Slide 14 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

15. Contents
1. Introduction
2. Two Step Process for mixed Metal Applications
3. Magnesium and Aluminium component processes
4. New plasma coatings
Slide 15 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

16. Pretreatment before welding and adhesive bonding
Alodine 2040
• Alodine 2040 is an etch passivation process
• The Aluminium surface is de-oxidized,
a very thin passivation coating prevents the surface from re-oxidation
• These defined surfaces allow consistent welding operations and are a
reliable surface for adhesive bonding
Alkaline
Cleaning Temperature : 60 °C
Time : 300 s
Water pH : 9.5
Rinses Temperature : 30 °C
Alodine
Passivation Temperature : 40 °C
Time : 90 s
DI Water pH : 1.3
Rinses Temperature : RT
• Alodine 2040 is also in use for corrosion protection of unpainted
drivetrain components
Slide 16 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

17. 100 % Aluminium Pretreatment processes
Alodine 2840
• First All Al car body pretreatment system Alodine 2840
Application Temp. (° C) Time (s)
Alkaline Cleaning S/D 50 - 60 240
Water Rinses S/D < 50 100
Acid Deoxidation S 33 - 37 150
Water Rinses S/D < 35 60
Alodine Conversion S 25 - 30 60
Water Rinses S < 30 110
Slide 17 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

18. Coating Appearance
Cleaning Cleaning
Activation Deoxidizing
Zinc Phosphating Non-chrome Process
Slide 18 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

19. Magnesium Pretreatment:
The Alodine 5200-process
• Chrome free one component titanium fluoride-process
• Slightly visible layer
• Treatment of magnesium and aluminium by spray and
immersion
• Approval of American OEMs
• Successfully in production since several years
Slide 19 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

20. Magnesium and Aluminium component processes
Alodine 160
• Alodine 160 is capable of simultaneously pretreating
Aluminium and Magnesium in a single parts line
• Approved by most EU OEMs
• The only EU pretreatment system in use before E-coat for serial
production body parts
Clean Rinse Deoxidize I Deoxidize II Rinse DI Rinse Pretreatment DI Rinse DI Rinse
Ridoline 1563/ Chemacid 3610 Alodine 2040 Alodine 160 / 161
Ridoline 1568
Slide 20 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

21. Contents
1. Introduction
2. Two Step Process for mixed Metal Applications
3. Magnesium and Aluminium component processes
4. New plasma coatings: Alodine EC²
Slide 21 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

22. What is Alodine EC²?
EC2 Ti
3m
Aluminium Al
• An electrochemically deposited Titanium Dioxide coating
• Limited to Aluminium and ist alloys as substrate
• A ceramic coating,
yet more flexible and durable than Aluminium
• Outstanding corrosion protection of several 1000h
without any further top coat
• Ceramic – like resistance against chemical attack
• 3 times more abrasion resistant than Nickel, 5000 h
6063
600 Vickers harder than bare aluminum,
with a coefficient of friction in the range of DLC
Slide 22 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

23. What can Alodine EC² do for you?
Corrosion Protection
• Lightweighting:
Replacing heavy steel parts through EC² - protected Aluminum in corrosion
sensitive areas: Chassis components
• EGR components:
in use for Aluminium EGR components for diesel engines
• First applications in marine engines exhaust systems
• Corrosion- and soot protection for Turbo- and Super chargers
• All kinds of Aluminum housings
• As adhesion promoter for thermal spray coatings
Slide 23 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

24. What can Alodine EC² do for you?
Emission reduction, improved wear and fuel economy
• Catalytic EC² piston dome and cylinder head coatings
In Diesel engines up to 30 % less NOx, HC, CO,
fuel savings of 1 – 4 % possible
combustion noise– 2 dB
knock-free leaner combustion
5 – 10 % reduced emissions in gas engines
• EC² skirt coatings as low in friction as state of the art coatings
• EC² ring groove coatings are reducing blow by
• Coated piston domes 10 x more durable in a racing environment
• Improved efficiency of coated intake manifolds, chargers
Slide 24 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

25. Summary
• Fuel economy targets and CO2 legislation are the main drivers for
increased usage of Aluminium and Magnesium in automotive design
• Today, pretreatment systems are available to cover all kinds
manufacturing situations:
from pure Magnesium- or Aluminium parts pretreatment to
mixed metal car body designs with an Aluminium content up to 100 %
• Plasma deposition processes are leading into a new level of corrosion
protection. Engine efficiancy gains and emission reduction will become
the main drivers for these technologies.
Slide 25 November 17, 2011 Eurocar 2011 Barcelona, November 16, 2011 Cortes / Kuhm, Henkel AG & Co KGaA

26. Thank you!