Abstract No.:
2444

 Scheduled at:
Wednesday, September 28, 2011, Saal C2.1 11:00 AM
Automotive Industry 1


 Title:
Local anti corrosion coating on automotive steel sheet by cold spray technology

 Authors:
Maurice Ducos* / CONSULTANT, FRANCE
Bruno Gay/ UMICORE, Belgium
Christophe Vershave/ RENAULT, France
Helmut Höll/ Cold Gas Technology - CGT, Germany

 Abstract:
Abstract

The zinc and the zinc alloys quantity used in Europe for coatings obtained by thermal spray is about 15.000 tons/year and represents 50 M euro. A large part of this zinc quantity is applied by Arc Spray or Flame Spray and intended for the protection against the corrosion of steel parts. The main applications are the corrosion protection of cast iron pipes, steel tubes, various long steel products, steel sections, gas cylinders, infrastructures elements (pylons, bridges, and viaducts), chemistry equipments, drilling platforms and electronic components. To realize these coatings by thermal spray it is crucial to prepare the surface of the substrate according to the standards EN 2063, ISO 2063 or ISO 8501-1. These substrate must be cleaned and have a roughness of «SA3 degree». In some application, the use of masks is essential.

In this presentation the deposits are realized on steel substrates used by cars manufacturers. These substrates have a surface perfectly smooth and oiled. Furthermore, in certain cases, these coatings were situated on a visible surface of the car body and on a precise position. The process used to reach the objectives of the customer is the dynamic cold gas projection more often named Cold Spray Technology.

The development of this application concerned mainly the study of a new zinc powder grade and the procedure of spraying which has of to adapt itself to the constraints of an automotive manufacturing line: non-stop operations, speed of translation of 1 m/s, no masks, low cost. Cold Spray addresses all these requirements. The positive results obtained on the mechanical examinations, the accelerated corrosion tests and chippings tests demonstrated that these new coatings meet the specifications of the customer for this kind of processes.


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