Post on 11-Feb-2017
transcript
New Developments in Surface Finishing Dr. Klaus Wojczykowski, CTO COVENTYA Group 2016 Beyond the Surface
Beyond the Surface www.coventya.com Page 2
Content
Drivers for Innovation in Surface Finishing REACH Increased Quality and Performance Requirements New Applications
Innovation Management from a Process Supplier’s View Technology Monitoring and Benchmarking Strategic R&D Project Selection and Management
Innovation Pipeline Current R&D Focus at COVENTYA (PROTECTIVE) Radical Innovations in Other Fields
New Developments – 2016
Beyond the Surface www.coventya.com Page 3
Content
Drivers for Innovation in Surface Finishing REACH Increased Quality and Performance Requirements New Applications
Innovation Management from a Process Supplier’s View Technology Monitoring and Benchmarking Strategic R&D Project Selection and Management
Innovation Pipeline Current R&D Focus at COVENTYA (PROTECTIVE) Radical Innovations in Other Fields
New Developments – 2016
Beyond the Surface www.coventya.com Page 4
Drivers for Innovation: REACH SVHC
New Developments – 2016
Last Update: December 17th, 2015 Now 168 Substances Member States propose new Additions Proposal needs Dossier for Justification
SVHC ANNEX XIV or XVII
Beyond the Surface www.coventya.com Page 5
Drivers for Innovation: REACH SVHC
New Developments – 2016
Beyond the Surface www.coventya.com Page 6
Drivers for Innovation: Performance
New Developments – 2016
Quality requirements were partly defined by warranty durations given by car manufacturers (liability mostly limited to functional aspects for longer durations) A big amount of new vehicle registrations are commercial through OEM’s leasing company Re-sell value of car after lease ends becomes an important factor
http://www.sternpartner.de
http://audi100.net
„10 Years warranty against corrosion perforation“
„Young Stars – As Mercedes as on the first day“
Beyond the Surface www.coventya.com Page 7
Drivers for Innovation: New Applications
New Developments – 2016
www.energy.siemens.com
www.sglgroup.com
New materials and components with new requirements come from major trends in the energy and mobility sector but also from changes in demographics and consumer behaviour…
www.rp-online.de
Beyond the Surface www.coventya.com Page 8
Drivers for Innovation
New Developments – 2016
Beyond the Surface www.coventya.com Page 9
Content
Drivers for Innovation in Surface Finishing REACH Increased Quality and Performance Requirements New Applications
Innovation Management from a Process Supplier’s View Technology Monitoring and Benchmarking Strategic R&D Project Selection and Management
Innovation Pipeline Current R&D Focus at COVENTYA (PROTECTIVE) Radical Innovations in Other Fields
New Developments – 2016
Beyond the Surface www.coventya.com Page 10
25%
75%F&E
others
Investment in R&D Investment in Personnel and CAPEX in the COVENTYA Group
Employees by department
The R&D group expanded by 500% since the year 2000.
Sales/Service 50%
Manufacturing 20%
R&D 6%
Administration 24%
Investment in different areas
New Developments – 2016
Beyond the Surface www.coventya.com Page 11
Areas of Research COVENTYA drives Innovation in all areas of our business…
ALUMINIUM DECORATIVE ORGANIC COATINGS PRECIOUS METALS WATERCARE
DATA STORAGE
FUNCTIONAL POP
PROTECTIVE
New Developments – 2016
Beyond the Surface www.coventya.com Page 12
Strategic R&D Project Selection and Management Initiation of R&D projects follows a clear process with mandatory input of
product management and sales During the run of a project its value to the company is constantly monitored and benchmarked
New Developments – 2016
Beyond the Surface www.coventya.com Page 13
The “House of Quality”
New Developments – 2016
Beyond the Surface www.coventya.com Page 14
Example: A new Black Top-Coat
How does it correllate? e.g. more black less corrosion resistance
What does the customer want? e.g. „black“
How does the competition perform?
How to measure? e.g. L-value
What‘s the target? e.g. L < 20 using
BYK Colorimeter XY
New Developments – 2016
Beyond the Surface www.coventya.com Page 15
Example: A new Black Top-Coat
The targets, probabilities and competitive environment is well defined at the very beginning of the development per the best available knowledge
The progress can be constantly benchmarked during the development
Whenever new approaches are taken (e.g. basic formulation changes) the potential consequences on the outcome can be forseen
New Developments – 2016
Beyond the Surface www.coventya.com Page 16
Content
Drivers for Innovation in Surface Finishing REACH Increased Quality and Performance Requirements New Applications
Innovation Management from a Process Supplier’s View Technology Monitoring and Benchmarking Strategic R&D Project Selection and Management
Innovation Pipeline Current R&D Focus at COVENTYA (PROTECTIVE) Radical Innovations in Other Fields
New Developments – 2016
Beyond the Surface www.coventya.com Page 17
Corrosion Protection
Barrier Cathodic
Concept Challenge
Development Potential
• Lower Potential than base material (Zn, ZnX, Al)
• Isolate the base material from corrosive media (Nickel, Lacquer)
• Layer thickness • Protect the sacrifical
layer against corrosion
• Pore free • Crevice corrosion
• Lower corrosion rate by increased potential of the deposit
• Primer and Top-Coats for good adhesion and durable coatings
New Developments – 2016
Beyond the Surface www.coventya.com Page 18
Cathodic Corrosion Protection Known Components and their Properties
Diffusion layer with base material (hot dip galvanizing, sheradizing)
- Alloy components for a lower corrosion rate (Sn, Ni, Fe) or better self passivation (Mg, Al, Mn) - Dispersion Coating
- Thick, compact conversion coating - Incorporation of inhibitors (SiO2, Co, V, Zr
etc.) - „Sealing“/Increase of layer weight by Post-Dip
- Temporary isolation, Protect the passivate against dehydratation, Control surface properites like the coefficient of friction
Passiviate Post-Dip
Sealer/ Top-Coat
Zinc (+X)
Base Material
New Developments – 2016
Beyond the Surface www.coventya.com Page 19
“Morphological Box” *
*F. Zwicky
Application for problems of non-reducible complexity - Definition of main- and secondary goals - List all essential parameters and properties - Combination of properties to generate a new product
Sacrificial Coating Barrier Coating Distribution of corrosion current
Conversion Coating Dip-Spin Coating Monolayer
Self Passivation Inhibitor Intrinsically noble layer
Batch Coating Continuous Coating Coating of single Pieces
Permanent Protection of Base Material
Permanent Protection of entire Part
Permanent Protection of Entire Part with changed
Aspect
CMR-Metal containing CMR-Metal free Metal free
…
Example of a morphological box for an innovative corrosion protection system
New Developments – 2016
Beyond the Surface www.coventya.com Page 20
Concepts of Innovation
*Clayton M. Christensen, Harvard Business School „disruptive“ Innovation „sustaining“ Innovation
The S-Curve Concept
Limit of old Technology
Limit of new Technology
Status Today
Status Today Technological Potential
Performance of the Technology
Cumulated R&D Investment
New Developments – 2016
Beyond the Surface www.coventya.com Page 21
COVENTYA’S PLAN FOR INNOVATIVE CORROSION PROTECTION
Improved Performance of Established Processes (e.g. ZnNi, Co-free Passivates) through sustaining Innovation with parallel Development of Novel Processes using Harmless and Sustainable Materials (disruptive Innovation)
New Developments – 2016
Beyond the Surface www.coventya.com Page 22
COVENTYA’S PLAN FOR INNOVATIVE CORROSION PROTECTION
2015 2016 2017 2018
Duktile Alkaline ZnNi
„Drop“-free Cr(III) Post-Dip
Improved Flow Silicate Sealer
Complete Replacement of Cobalt in Passivates
High Performance (Boric-Free) Acid ZnNi
Alloy to Replace ZnNi
Development Introduction Fully Implemented
PROTECTIVE (Zn & Zn Alloys)
2015 2016 2017 2018
Curable Top Coat Range for electroplated Fasteners
Rheology modified Zinc Flake Process
ORGANIC COATINGS
2015 2016 2017 2018
Cr(III) Conversion Processes for 7xxx Aluminium-Alloys
REACH adapted Cleaning and Sealing processes
ALUMINIUM
New Developments – 2016
Beyond the Surface www.coventya.com Page 23
Alkaline ZnNi for Bendable Parts PERFORMA 288 produces ZnNi deposits with high corrosion protection after bending or crimping due to a specific crystal structure.
PERFORMA 288 more (330) slip planes
Standard alk. ZnNi more (600) planes
600 330
X-Ray Diffraction shows the preferred crystalline orientation of the ZnNi γ-Phase
Standard alk. ZnNi
PERFORMA 288
The Bending Test shows less damage of the coating and better corrosion protection
New Developments – 2016
Beyond the Surface www.coventya.com Page 24
024681012
0
5
10
15
20
%Ni µm
High Performance Acid ZnNi
γ-Phasen ZnNi
PERFORMA 560 BF gives superior aspect and corrosion protection through a burn free deposit with a very homogeneous alloy distribution.
Standard Acid ZnNi
2A, 5 min
PERFORMA 560 with new Additive System
Simple bath control with only 3 fully analyzable organic additives
Simple air agitation possible due to low foaming
PERFORMA 560 FINIDIP 129 FINIGARD 200A
After 25 cycles GMW14872-10
New Developments – 2016
Beyond the Surface www.coventya.com Page 25
Improved Flow Silicate Sealer FINIGARD 503 is an inorganic sealer
for high heat and chemical resistance.
Dedicated organic functionalization gives a crack-free amorphous film. Dynamic Surface Tension
FINIGARD 503 Std. Silicate Sealer
Small amounts of a harmless solvent lead to superior film formation properties compared to competitive products, little residue at edges and corners and completely covered iridescence.
SiOx
x SiOx
SiOx y
z
New Developments – 2016
Beyond the Surface www.coventya.com Page 26
Overview of known Zn alloys:
Alloy as ZnNi Replacement
ZnCo ZnNi ZnCr ZnSn ZnMn ZnFe
+
- Good corrosion resistance
- Easy passivation (esp. black)
- Excellent corrosion resistance
- Established processes
- Might be an interesting alternative
- Very good corrosion resistance
- Good ductility and solderability
- Good corrosion resistance
- Self-passivating property
- Good corrosion resistance
- Easy passivation (esp. black)
- Alloys with high Fe content are potentially interesting
-
CMR!! - Price - Waste water
treatment - Nickel is potentially
CMR
- Chrome is also a candidate to be potentially replaced
- Price (!!) - Availability of Sn - Passivation - Aspect
- Passivation (esp. black)
- Aspect of corrosion products
- Bath maintenance
- Bath maintenance - Alloys with high Fe
content are not well researched
New Developments – 2016
Beyond the Surface www.coventya.com Page 27
Experiments regarding the ideal alloy composition:
* Adaniya et al., Zinc-Iron alloy electroplating on strip steel , Nippon Kokan KK, 1975
The Phase Diagram* shows a ZnFe Γ-phase like in ZnNi alloys. In ZnNi this is the phase with the highest corrosion resistance.
COVENTYA found a bath composition and plating parameters that allow to plate ZnFe alloys in a wide range of Fe contents.
Alloy as ZnNi Replacement
New Developments – 2016
Beyond the Surface www.coventya.com Page 28
X-Ray Diffraction at different Fe-contents
Fe
without
without
∆T
∆T
Fe
With and without baking
New Developments – 2016
Beyond the Surface www.coventya.com Page 29
Fe
Fe
without
without
∆T
∆T
X-Ray Diffraction at different Fe-contents With and without baking
New Developments – 2016
Beyond the Surface www.coventya.com Page 30
It was shown, that a pure Γ-phase is only present at 30% Fe. The full phase equilibrium only takes place at baking temperatures
higher then in the typical hydrogen relief bake.
Which composition is really preferred for the layer properties and also without baking??
X-Ray Diffraction at different Fe-contents
New Developments – 2016
Beyond the Surface www.coventya.com Page 31
9,3 % 15 % 19,6 %
19,4 %
22,2 %
24,8 %
25 % 26,7 %
28,1 %
31
Crystallite morphology at different Fe contents
New Developments – 2016
Beyond the Surface www.coventya.com Page 32
Chronopotentiometry j= 10 mA/cm² in NaCl 50 g/L
earlier Layer Dissolution later
less
nob
le
P
oten
tial
no
ble
[V] [min]
Electrochemical Properties
The alloy with 13% Fe shows, like ZnNi, a delayed layer dissolution with steps.
New Developments – 2016
Beyond the Surface www.coventya.com Page 33
Finidip 128 CF + Finigard 150
Corrosion Test
NSST
The alloy with 13% Fe shows the best aspect and the best corrosion resistance.
New Developments – 2016
Beyond the Surface www.coventya.com Page 34 34
Zinc ZnFe 13% ZnNi 15%
1200h NSST
Comparison of zinc processes With cobalt-free passivation and top-coat
New Developments – 2016
Beyond the Surface www.coventya.com Page 35
ZnFe with 13% Fe is an interesting alternative for ZnNi The alloy and its protective properties are known for at least three
decades and it can be deposited from known ZnFe electrolytes with slight modifications.
Structure, aspect and passivate acceptance are comparable with current zinc processes.
It has to be confirmed in the industrial test for which application the process is suitable regarding layer properties like ductility as well as bath maintenance.
Alloy as ZnNi Replacement
New Developments – 2016
Beyond the Surface www.coventya.com Page 36
Curable Top Coat Range for electroplated Fasteners
In comparison to classical “Sealers” in electroplating, a new generation of top-coats will apply paint technology to get to the next level of performance
In return, the new processes will offer longer un-changed optical appearance and even higher resistance to red corrosion
New Developments – 2016
Beyond the Surface www.coventya.com Page 37
REACH adapted Cleaning and Sealing processes (Aluminium)
Example: Cleaner for Aluminium: Borate, EDTA, NTA and Silicate-free
after before
New Developments – 2016
Beyond the Surface www.coventya.com Page 38
Radical Innovations in Other Fields Cr(VI)-free etch for POP pre-treatment
New Developments – 2016
Beyond the Surface www.coventya.com Page 39
Radical Innovations in Other Fields
R&D Roadmap: Corrosion Protection
Cr(III) Hard Chrome
Results from „IRT M2P“ Project (France) Up to 200 µm can be plated
No adhesion failure ASM 2460
New Developments – 2016
Beyond the Surface www.coventya.com Page 40
„The future is already here, it is just not evenly distributed“
William Gibson
Thank You for your Attention!
New Developments – 2016