Supported by the European Commission’s Seventh Framework Programme AVCOP Added value for metallic coated products by new sol-gel process GA nº 315041 FP7-SME-2012-1 Project start: 01/12/2012 Project end: 30/11/2014 Mika Kolari (Millidyne), Juha Mannila (VTT), Usoa Izagirre and Cecilia Agustín (Tecnalia) Mohamed Oubaha, Brendan Duffy (CREST) Terry Hinds (Galco), Vasile Rus (Betak) Ramón Sagrista (Galdesa) Xurxo López de Caamaño (Cialsuga)
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Supported by the European Commission’s Seventh Framework Programme
AVCOPAdded value for metallic coated products
by new sol-gel process
GA nº 315041FP7-SME-2012-1
Project start: 01/12/2012Project end: 30/11/2014
Mika Kolari (Millidyne), Juha Mannila (VTT), Usoa Izagirre and Cecilia Agustín (Tecnalia)Mohamed Oubaha, Brendan Duffy (CREST)
Terry Hinds (Galco), Vasile Rus (Betak) Ramón Sagrista (Galdesa)Xurxo López de Caamaño (Cialsuga)
Supported by the European Commission’s Seventh Framework Programme
• Overview• Partners and requirements• Sol-Gel Technology• Coating Performances• Scaled Up Prototypes
Supported by the European Commission’s Seventh Framework Programme
Hot dip Galvanizing (HDG), zinc electroplating and aluminium anodising are traditional engineering solutions in which Europe has the leading knowledge. However, because the techniques used are very mature, SMEs operating in this sector are facing decline due to strong competition. There is an urgent need for the introduction of advanced added-value materials and processes to increase competitiveness.
The aims of AVCOP were to:• Strengthen the competitiveness of SMEs in these sectors through the
introduction of new, added-value surface-finishing solutions• Solve specific market needs that can be met by the SMEs. • Develop novel nano-structured thin-films to deliver surface attributes
beyond state-of-the-art in the market.
Project Concept
Overview
Supported by the European Commission’s Seventh Framework Programme
PROJECT OVERVIEW
Consortium: The AVCOP consortium consists of 11 European organisations: 8 SME partners and 3 RTD centres.
Supported by the European Commission’s Seventh Framework Programme
PROJECT TARGETS
1. The investigate use of Sol-Gels (somewith Ionic Liquids) as protectivecoatings.
2. To investigate up-scaling of chemistries from the laboratory to the factoryA. Use of residual heat energy to cure
sol-gels without any separate heat treatment
B. Using UV cross linking methods to lower the cure temperature of the sol-gel process
Supported by the European Commission’s Seventh Framework Programme
PROJECT OVERVIEW
• To develop new sol-gel coatings to address the specific needs of the HDG and electrolytic Zn industries.
• To Implement the new sol gel processes at pilot scale for the HDG, electrolytic Zn and Al anodising fields
• To develop application techniques to optimise implementation in OEMs
• To test and validate the new coating processes
• To assess the health, safety and environmental impact of the developed processes
Technical Objectives:
Supported by the European Commission’s Seventh Framework Programme
Expected output:To develop coated galvanized finishes for guard rails (especially rail ends) in highly visible colours (orange if possible)This would ensure a new market position in an increasingly competitive product sector.
Bistrita, Romania
Supported by the European Commission’s Seventh Framework Programme
Galicia - SPAIN
Expected output:To develop coated galvanized fittings with longer working lifetimesCentrifuge-HDG process
Supported by the European Commission’s Seventh Framework Programme
Bergara, Spain
Expected output:To develop new finishes for Zn plated parts Compare to control samples with Cr(III) passivation
Supported by the European Commission’s Seventh Framework Programme
Dublin, Ireland
Expected output:Maintain bright fresh Galvanised appearance for as long as possible.Minimise the contrast on the same productHigher quality appearance.Elimination of white rust or wet storage staining.Improved corrosion resistanceIncreased life of the product.Elimination of the use of Cr+(VI) Cr+(III)
Supported by the European Commission’s Seventh Framework Programme
SOL-GEL CHEMISTRYExpertise To Date
Sol-Gel Process• A liquid phase method of producing glass and
ceramics at moderate temperatures through hydrolysis and condensation reactions of metal alkoxide precursors.
• Sol gel can be easily tailored by utilising organically modified silanes OrmoSils to impart desired functionality to the coatings.
Supported by the European Commission’s Seventh Framework Programme
SOL-GEL Applied
HDG SPRAYED SOL-GEL COATINGS
(a)(b)
Supported by the European Commission’s Seventh Framework Programme
TURBULA & BARREL-PROCESSING OF SOL-GEL COATINGS
Supported by the European Commission’s Seventh Framework Programme
Current treatment: Two passivating baths containing CrIII are applied and sealedwith commercial lacquers
Sol-gel coating has been developed in AVCOP FP7 PROJECT to replacecommercial lacquers
10 µm Zn thickness Passivated with Cr III 2 µm Sol-gel thickness
STEEL SCREWS ELECTROPLATED byGALDESA
Supported by the European Commission’s Seventh Framework Programme
Main application is automotive industry and demandingrequirements are requested in corrosion protection:- Neutral Salt Spray Fog- Thermal Shock
STEEL SCREWS ELECTROPLATED BY GALDESA
Supported by the European Commission’s Seventh Framework Programme
STEEL SCREWS ELECTROPLATED BY GALDESA
Hours to Zn corrosion Hours to base metal corrosion
DEVELOPED SOL-GEL COATING WOULD PERMIT TO PASS THE MOST DEMANDING
AUTOMOTIVE STANDARDS
Supported by the European Commission’s Seventh Framework Programme
Current process is Hot Dip Zinc and Centrifuge Sol-gel coating deposition is a further step that provides prolonged
lifetimes and aesthetic appeal to HDG-pieces
~ 140 hours to emergence of red corrosion
~ 1400 hours to emergence of red corrosion
STEEL SCREWS HOT DIP GALVANISED BY CIALSUGA
Supported by the European Commission’s Seventh Framework Programme
STEEL SCREWS HOT DIP GALVANISED BY CIALSUGA
CYCLIC CORROSION TEST ACC TO UNE EN ISO 11997-1RESULTS AFTER 10 CYCLES
Supported by the European Commission’s Seventh Framework Programme
Sol-gel coatings were cured at Betak on hot HDG (150°C)
using latent heat
Red corrosion after3 CYCLES
NO red corrosionafter 10 CYCLES
Red corrosion after336 h
Red corrosion after1800 h
Both samples losttheir initial gloss
STEEL FLAT PANELS HOT DIP GALVANISED by Betak
Supported by the European Commission’s Seventh Framework Programme
Salt Spray Testing• Salt spray can degrade the passive oxide/carbonate layer that
naturally develops therefore the NSS test artificially reduces the performance of zinc coatings.
• Cyclic corrosion testing is intended to be more as it includes both wet and dry conditions (more natural)• The same would be true for organic coatings and UV
degradation • As a consequence, testing design has consisted of salt spray test
(according to ASTM B117) in order to compare results to cyclic corrosion test (according to UNE EN ISO 11997-1) and cyclic UV-condensation test (according to UNE-EN ISO 11507).
Accelerated Testing
Supported by the European Commission’s Seventh Framework Programme
RESIDUAL HEATING OF SOL-GELS by Galco
HDG samples coated at Galco
250ºC 200ºC 180ºC 150ºC 120ºC
Supported by the European Commission’s Seventh Framework Programme
BRIGHT COLOURED FINISH by Galco
HDG + Sol-Gel (UV Cured)
Supported by the European Commission’s Seventh Framework Programme
NEUTRAL SALT SPRAY
T = 0hr T = 5 hrs T = 24 hrs
HDG
Supported by the European Commission’s Seventh Framework Programme
Neutral Salt Spray
T = 0hr T = 5 hrs T = 24 hrs
HDG + Organic Passivation
Supported by the European Commission’s Seventh Framework Programme
Neutral Salt Spray
T = 0hr T = 5 hrs T = 24 hrsHDG + Sol-Gel
T = 48hr T = 72 hrs T = 120 hrs
Supported by the European Commission’s Seventh Framework Programme
Coloured Finishes
Supported by the European Commission’s Seventh Framework Programme
HDG samples coated at Betak
Coloured Finish
Supported by the European Commission’s Seventh Framework Programme
Millidyne: End Manufacturer – Cost per Litre can vary from €10 up to €50 depending on complexity and end performance requirements
SCALE UP
Supported by the European Commission’s Seventh Framework Programme
Wide variety of sol-gels can be used Improved performance seen in all cases where Sol-Gels are used• Retains HDG brightness for longer • Improved NSS performance• Meets Automotive requirements• Colour can be introduced easily
Thanks to EGGA for the opportunity to speakThank you for listening!
