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health endangering heavy metals, following consequently be excluded [1]. The toxicological equipment utilised in the application of the
the transition with Cr(VI) materials previously dubiousness of nickel – and nickel dust in systems. This must ensure that the valuable
viewed as alternative are finding increasing particular – means that the medium-term materials are employed economically and the
number of coatings kept to a minimum. This is
often only possible via close co-operation
between plant manufacturers, coating
materials producers and coaters.
An excellent example
One example of increasingly efficient
systems is that of zinc flake basecoats with
integrated lubricant. Here the additional
topcoat for the creation of the friction factor
required for screw connections is dispensated
with. This saves the time and cost-consuming
change of material, as well as additional
handling and process costs.
Depending on which system design is
compared, this corrosion protection system
provides users with a significant cost reduction.
For this reason, the DELTA-PROTEKT® KL105
system was awarded the Material Efficiency
Prize 2006 by the Federal Ministry of
Education and Research.
The success o the high performance zinc
use, including Cr(III), Mo(VI), Co(II) and nickel.
future of high nickel content coatings
flake micro-layer corrosion protection system
In the long term, only those systems will
(Zinc-nickel contains 12-16% nickel) remains
is set to continue at global level. More and
persevere that contain little or no hazardous
questionable. In addition, the problem of
more new developments in the increasing
Cr(VI) replacement. Dörken MKS-Systeme
contact allergy (zinc-nickel allergy) is being
efficiency of the systems in conjunction with
GmbH & Co. KG, Herdecke, addressed this
increasingly debated.
more efficient application technology are the
situation at an early stage, working
keys to success.
continuously towards “anticipatory” problem
Cost pressures make efficiency essential
solutions. For example, a new corrosion
However, the market does not consist
protection system for brake discs also meets
solely of quality and environmental
the requirements of other environmental
regulations, there is also the general
directives such as surfactant guidelines or the
pressure of cost and subsequent decline
conditions of REACH, with air drying also
in margins for the companies in the
generating savings in the application process.
market. This creates pressure for common
efforts to be made in the development of
Systems in benchmark testing
systems that are increasingly more
Complex industries with high quality
efficient. This means corrosion protection
requirements such as the automobile industry
systems are required to provide higher
are increasingly turning to zinc flake or
and higher quality at lower coat
galvanic zinc-nickel systems for corrosion
thicknesses or with a reduction in the
protection. In particular, connecting elements –
number of coats required. This often leads
i.e. also safety-relevant components of vehi-
to a significant reduction in process costs.
cles – are increasingly utilising zinc flake
As these constitute by far the largest cost
systems. There are a number of reasons
factor in the coating process as a whole,
behind this:
at around 75%, the savings potential is
The strict selection of appliers of zinc flake
highest here.
systems in the scope of the previously-
An efficient coating system, for
mentioned licensing system and the frequent
example one that meets the required
practice of naming zinc flake system
specifications without sealing, can bring
manufacturers in automobiles specifications with it a whole range of “savings factors”.
enables a globally standardised quality The lack of an additional coat alone can
standard to be provided – in contrast to other lead to material savings of up to 50%.
systems. A further argument in favour of the This is joined by the time saving from
zinc flake system is the avoidance of removal of a coating process with often
hydrogen-induced stress cracking corrosion in complex change of material. At the same
application. In contrast, the application process time, the removal of one coating and
with galvanic coats leans to the inclusion of annealing stage leads to significant
hydrogen. The latest investigations of the savings in energy. If further efficiency
Zentralverband Oberflächentechnik (ZVO) show
increases are to be achieved, then it is
that the formation of brittle fracturers cannot
necessary to examine the plant
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