MV Eksler, a spokesman «Victocor Technology», Belgium
Technology «Levikor» successfully won the European car market, which is the legislator of fashion technology for the global automotive market, as well as for many other industries. Conducted tests to introduce zinc coating aircraft, which previously ruled cadmium coating. In addition, preparing the introduction of new kinds of anti-corrosion and-wear coatings based on other powder metals, but in application, well-established process of thermal diffusion saturation. This year, our company is committed to the development of all the features of the zinc coating. What does this mean in practice?
We are accustomed to the fact that the traditional processes galvanizing work quite narrow specializations or a specific range of parts. Tech.
«Levikor» is almost universal, allowing a very different look at the approach to production.
Conventionally, we divide the market into only two categories — large parts market and the market of metal products.
The practice is so well established that the application engineers of our company that covering «Levikor» universally for all types of steels and cast irons, initially was made by experts of the Russian market in arms.
To dispel any doubts, it is necessary to clearly separate questions directly to the process of forming the coating layer, and questions regarding the equipment for processing of different types of parts.
Formation of the coating layer.
Formation of coating layer takes place in a temperature from 310 to 390 ° C. To properly select a coating metals are divided into 3 groups. Each group selected its own technology temperature conditions:
— structural steel from 360-380 ° C;
— high-alloy steel from 310 to 360 ° C;
— cast iron from 370 to 390 ° C.
For the above groups are also used various formulations of saturating mixtures and passivation solutions.
We would like to note that the formation of corrosion-resistant layer does not affect the types of steels and cast iron or special alloys, in which the presence of certain chemical elements is a no-go zone for many other technologies of corrosion protection.
Changing the characteristics of the metal during the coating process.
Depending on the type of steel manufacturers may require both preserve the basic characteristics of the metal, but also of certain improvements.
These objectives are the right choice in terms of the technological mode of selection of relevant processing temperatures and process times. For example, car clip (steel 65G) prior to treatment is 32 units. Hardness HRC. Manufacturer parts has set the task to increase HRC 8-10 units. Technologists picked up the processing mode, where a single process was coated as well as increased hardness of the metal into a predetermined number of units.
Additional processing details after coating.
To give further details of the corrosion resistance after coating are applied one or two layers of passivation solutions. These solutions do not contain a composition of Cr + 6 and Cr + 3, and are environmentally friendly.
However, the challenges of today, market opportunities are not limited to a passivation treatment.
When the automatic assembly of the finished product with threaded connections must meet certain surface coefficient of friction. Accordingly, when applying a protective anti-corrosion coating, the challenge is not only to not go beyond the permissible thickness, but in the correct selection of passivation materials that will give the desired coating coefficient of friction.
Such passivation material must not impair the corrosion properties of the coating and must be applied in a single technological chain, without any additional operations.
For certain types of parts is important, not only the corrosion resistance of the product, but also the appearance, to which the market is used, or which is included in the technical documentation of the consumer.
The most demanded color exterior parts — a black or silver. Such an appearance is seeking by coating the resulting coating additional layer — «top kotinga.»
The technology application «top kotinga» on the threaded part fully worked and produced with the help of special equipment, which is the same as all the other equipment may be part of the production line «Levikor.»
The thickness of the «top kotinga» together with the thickness of the zinc coating does not go beyond the tolerances allowed.
In addition to these requirements, the market still makes a lot of additional conditions to the corrosion resistant coating, namely good adhesion of various types of rubber, which must be welded to the coating.
Details after the thermal diffusion treatment must be well welded, and, if necessary, and well bonded.
For all of these technology requirements «Levikor» on the basis of numerous tests that were carried out various automotive concerns, occupies a leading position among all known anti-corrosion protection technology is far superior to them all of the above parameters.
Configurations and dimensions of the details.
Crucial for the formation of the coating or the configuration or size of the parts does not matter. It is important to choose the right equipment, which will be provided the opportunity to coating and finishing, such as large parts.
To avoid deformation of thin pieces became standard equipment equipped with special equipment, which is loaded products for galvanizing. Attachments can be delivered as a finished product, and in the engineering documentation and drawings.
Just as the technology of anticorrosive coating, developed and constantly improved equipment, which is part of the process line.
One of the last steps in improving the surface conditioning components to the coating was developed and installed equipment to remove parts from the surface of residual traces of rust and scale, using ultrasound.
This new development allowed to abandon the shot blast technology, by which previously clean the metal surface prior to coating. Refusal to allow shot blasting equipment to remove all fears for changing the geometric dimensions of parts, damage to threaded parts, etc. It reduces the cost by reducing the cost of purchasing expensive consumables, namely metal fractions.
Unique solutions for ultrasonic baths, designed by Victocor Technologies, have been tested first in coating parts for the automotive industry and received the highest evaluation specialists. These solutions were purified by metal traces of ultrasound scale and rust for only 25 seconds. Furthermore, solutions are environmentally friendly and does not cause harmful vapors when heated.
We are concerned, as far as possible in the format of articles, almost all production cycles protective coating that accompany parts of steel and cast iron at all stages on the way to the finished product.
Under certain technological rules covering «Levikor» can be called universal for any kind of metal.