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The automobile markets are subjected to greater cost pressures than ever before. At the same time, all of the vehicle parts utilised need to satisfy very high safety requirements and be available worldwide at the highest quality, at any time. Against this background, corrosion protection for the parts fitted to vehicles plays a key role. From bolts to chassis components and on to engine mounts: each individual component requires a special coating precisely tailored to the requirements in order to satisfy the strict automobile specifications of the national and international OEMs.

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Application segments

Car
Engine compartmentChassisInteriorUndercarriage

COMPREHENSIVE SPECTRUM OF CORROSION PROTECTION

Chassis, engine compartment or interior: parts made from different materials are fitted in and on cars, with these parts also required to satisfy numerous corrosion protection requirements, depending on application. Whilst the coating systems for components in the interior are required to ensure functional criteria beyond corrosion protection, such as sliding performance, parts in the engine compartment – in addition to very high corrosion protection performance – also need to take account of factors such as process-secure fastening and the increasingly common use of high-tensile steel.

Engine compartment

VERSATILE SOLUTIONS REQUIRED

A wide range of components are used in the engine compartments of cars, frequently resulting in the pairing of different, in some cases high-tensile materials. The requirements of corrosion protection are similarly varied as a consequence. For example, in the case of bolts, these need to be equipped with as thin a coat as possible – only in this way can ease of fastening be ensured. Depending on components, the choice of coating must also take account of criteria such as temperature resistance, sliding properties and resistance to chemicals.

Requirements

  • Corrosion resistance 720h (e.g. ISO 9227)
  • Resistance to stone chip
  • Resistance to temperature
  • Colouring silver or black
  • Ductility
  • Resistance to abrasion
  • Coefficients of friction
  • Resistance to chemicals

Solutions

Depending on component, Dörken MKS offers various solutions for optimal corrosion protection in the engine compartment: from the use of pure zinc flake systems to the combination of different base coats with an organic or inorganic top coat. Our specially-developed systems enable a high degree of corrosion protection to be achieved with comparatively very thin coats. In the case of fasteners, secure fastening is therefore achieved against different backings, whilst also effectively avoiding contact corrosion. One particular advantage of zinc flake coating is that it does not cause application-related hydrogen brittling – which is why zinc flake is in standard use for high-tensile components.

Example components

Spring band clips

Spring band clips are used to secure hose connections. In addition to high corrosion protection with limited coat thickness, depending on use these must also display functional characteristics such as chemical resistance or adhesiveness.

Fasteners

Fasteners are used in various geometries and dimensions in the engine compartment to establish screwed connections. Coatings for bolts and nuts need to be as thin as possible and display excellent corrosion and fastening characteristics (co-efficients of friction) – in particular where different materials are paired.

Steel and stainless steels

The engine compartment contains numerous stamped parts, clips and springs made from steel and stainless steel. Stainless steels are often required to offer good sliding properties and protection against contact corrosion in addition to corrosion protection. Specific sliding properties are also frequently required for steel components.

Chassis

Exposure to extreme stresses

Chassis components are subjected to extreme static and dynamic stresses. These are joined by mechanical effects such as stone impact. Especially resistant coating systems are required here to satisfy the high requirements of corrosion protection and long lifetime. In addition, special requirements such as the secure coating of pipe constructions can only be satisfied with individual corrosion protection solutions. Lastly, factors such as the reduction in material thickness for weight savings also play a role in the choice of coating systems.

Requirements

  • Corrosion resistance 720h (e.g. ISO 9227)
  • Colouring black or silver
  • Coefficients of friction
  • Resistance to chemicals
  • Resistance to stone chip
  • Resistance to temperature

Solutions

Zinc flake-based coating systems represent a practical solution for chassis components. These can be applied in comparatively thin coats at low annealing temperatures. A further advantage:no hydrogen is produced during the coating process, with the result that there is no risk of hydrogen-induced stress corrosion cracking. This means that the zinc flake coating is also suitable for high-tensile steels of the categories 10.9 and 12.9. In combination with a matching top coat a high degree of cathodic corrosion protection is ensured – including after stone impact. Zinc flake systems also satisfy the strict requirements of manufacturers' own driving tests, thus meeting the increasingly high quality requirements of the OEMs.
 

Example components

Rear subframe

The rear subframe connects the vehicle chassis to the bodywork. The continuous static and dynamic stress here means that highly resistant and longlasting corrosion protection is required.

Track-rod ends

Secured to the steering knuckle, the track-rod ends stabilise the vehicle when it is driving straight ahead. This means that they are subjected to enormous dynamic stress as well as high temperatures. This makes protection against rusting very important.

Cross struts

Cross struts are key components of the axle. In addition to general requirements, corrosion protection here must also ensure ongoing resistance to stone impact.

Interior

Securing functional characteristics

In the coating of components in the vehicle interior the requirements of corrosion protection are typically lower. In return, the components fitted need to fulfil numerous functional characteristics. For example, parts such as safety belt buckles that are subject to high stresses on a daily basis need to display defined sliding properties. Criteria such as avoidance of squeaking noises for spiral or torsion springs and the long-term securing of the black component appearance are also achieved via a suitable corrosion protection system.
 

Requirements

  • Corrosion resistance 96h (z.B. ISO 9227)
  • Colouring black or silver
  • Antifrictional properties
  • Coefficients of friction
  • Compability to micro-encapsulation

Solutions

Depending on the components to be coated, Dörken offers a wide range of micro layer corrosion protection systems. Where there are low requirements of corrosion protection a top coat coating with specific functional characteristics such as glide or friction properties is often suitable. In other cases special systems consisting of a zinc flake coating and a top coat can be applied, depending on the parts concerned. The very thin coats are annealed at comparatively low temperatures. No hydrogen is involved in the coating process, with the result that there is no risk of stress corrosion cracking. A further advantage of zinc flake coating is dry lubrication. The dry lubricating film generated by the application displays excellent friction and wear characteristics and ensures good grip properties of interior surfaces.

Example components

Belt buckle

The belt buckle serves to receive and secure the safety belt system. The requirements of corrosion protection are comparatively low. However, the protective effect must still be ensured after multiple use. Regular use means that the components also need to have good sliding properties.

Spiral/torsion springs

These retaining springs are fitted to foldable rear seats and ensure that the seat can be easily returned to the original position after being folded down. A suitable coating system ensures the avoidance of squeaking here - including after long-term use.

Latch pins

Latch pins are fitted to seats as safety-relevant components. They ensure that the seat remains in its anchoring in the event of an accident. At the same time, seat adjustment should also be smooth. This compromise can be achieved with a suitable slide coating featuring a defined coefficient of friction.

Undercarriage

Contributing to operational safety

Wheel hubs, retaining springs, cover plates:the various high-tensile parts installed in the undercarriage of a car are exposed to sometimes high temperatures and strong mechanical stresses during operation. High-performance corrosion protection makes a decisive contribution here to maintaining the functionality and operational safety of the vehicle. In addition, modern coating systems avoid contact corrosion where different materials are paired, as well as ensuring reproducible fastening properties, securing optimal sliding characteristics - for example for pressure springs - and guaranteeing chemical resistance throughout the lifetime of the vehicle.

Requirements

  • Corrosion resistance 720h (e.g. ISO 9227)
  • Colouring silver or black
  • Coefficients of friction
  • Resistance to chemicals
  • Resistance to stone chip
  • Resistance to temperature

Solutions

Various coating systems can be used to create capable corrosion protection for components in the undercarriage. In addition to purely zinc flake systems, individual combinations of special Dörken base coats and organic or inorganic top coats can also be used, depending on operating conditions. With zinc flake coating protective effects of up to 1,000 hours against base metal corrosion(red rust)according to DIN EN ISO 9227 can be achieved using only extremely thin coats. Zinc flake technology is also applied at comparatively low temperatures. No hydrogen is generated in the coating process and there is therefore no risk of hydrogen-induced stress-cracking corrosion.

Example components

Fasteners

Fastening elements such as undercarriage connections, nuts and bolts are used in many different forms and geometries in undercarriages. Coating systems help to achieve the required fastening characteristics and avoid contact corrosion.

ABS counters

ABS counters are fitted to the brakes and are required to withstand very high temperatures during the braking process. The component is very delicate and can therefore only be coated with a very thin coating.

Springs in the brake system

The numerous springs in the brake system of a vehicle have various different dimensions, designs and functions. In addition to effective corrosion protection, coatings must also possess functional properties such as wear resistance.

Truck
ChassisEngine compartmentInteriorUndercarriageTrailer

Corrosion protection in accordance with specifications

Whether it is the chassis, engine compartment or trailer:a range of components made from different materials are installed in and on trucks that require effective protection against corrosive influences. For example, with parts situated in the engine compartment, in addition to the need for very high corrosion resistance performance it is also necessary to take account of factors such as temperature resistance, simple screw fastenings and the increasingly frequent use of high-tensile steel. For components in the interior the corrosion protection must also account for long-term, user-friendly application and additional functions such as good sliding properties.

Depending on application, Dörken offers a comprehensive range of micro layer corrosion protection systems for truck components.
 

Chassis

Protective effect under extreme influences.

Components fitted to the truck chassis need to withstand enormous static and dynamic stresses. These are joined by sudden mechanical effects such as stone impact. Especially resistant coating systems are required here to satisfy the high requirements of corrosion protection and long lifetime. Special requirements such as secure and fastening-friendly interior coating of pipe constructions can also be fulfilled with the matching corrosion protection solution. Lastly, the reduction in material thickness also results in weight savings for truck chassis.
 

Requirements

  • Corrosion resistance 480h (e.g. ISO 9227)
  • Colouring silver or black
  • Antifrictional properties
  • Resistance to abrasion
  • Coefficients of friction for blocking function
  • Resistance to chemicals
  • Compability to micro-encapsulation

Solutions

Zinc flake coating systems have been proven to provide effective and long-lasting protection against corrosion for chassis components. These systems comprise a base coat and a top coat and can be applied in comparatively thin coats at low annealing temperatures. As no hydrogen is released in the coating process no stress corrosion cracking can occur – making zinc flake especially well-suited to high-tensile steels of the categories 10.9 and 12.9 or from 1,000 MPa. The combination of base coat and matching top coat ensures a high degree of cathodic corrosion protection – including after stone impact. Zinc flake systems also satisfy the strict requirements of manufacturers' own driving tests, thus meeting the high quality requirements of the OEMs.

Example components

Rear subframe

As a safety-relevant chassis component, the rear subframe connects the truck chassis to the bodywork. The continuous static and dynamic stress here means that highly resistant and long-lasting corrosion protection is required.

Track-rod ends

Secured to the steering knuckle, the track-rod ends stabilise the vehicle when it is driving straight ahead. As these components are required to withstand very high dynamic conditions and are sometimes also subjected to high temperatures, it is important that they are offered effective protection against rust.

Wheel nuts/bolts

Wheel nuts and bolts are safety-relevant components. The selected coating system must therefore satisfy highest requirements. In addition to high-performance corrosion protection, functional characteristics such as multiple screw capability with highly stable coefficients of friction must also be ensured.

Engine compartment

Numerous requirements of coatings

A range of different parts are fitted in the engine compartments of trucks. This often results in the combination of different, sometimes high-tensile materials, such as aluminium and steel. The requirements of corrosion protection are similarly varied as a consequence. With bolts and screws, for example, the aim is to select coatings that are as thin as possible, thereby enabling good screwing properties and a good fit for threads. Depending on components and area of use, the choice of coating must also take account of temperature resistance, sliding properties and resistance to chemicals.

Requirements

  • Corrosion resistance 720h (e.g. ISO 9227)
  • Resistance to stone chip
  • Resistance to temperature
  • Coluring silver or black
  • Ductility
  • Resistance to abrasion
  • Coefficients of friction
  • Resistance to chemicals

Solutions

Depending on component, Dörken offers various solutions for effective corrosion protection in the engine compartments of trucks:the spectrum ranges from the use of pure zinc flake systems to the combination of different base coats with an organic or inorganic top coat. The advantage of this system is that a very high degree of corrosion compared to other solutions is already achieved at very thin coats(from 8 µm). In the case of fasteners, a good connection is achieved with different backings. At the same time, it is also possible to avoid the risk of contact corrosion when pairing different materials. A further advantage of zinc flake coating:it does not cause application-related hydrogen brittling and is therefore long in standard use for high-tensile components.

Example components

Spring band clips

Spring band clips are used to create hose connections in the engine compartment. In addition to high corrosion protection with limited coat thickness, these must also display functional characteristics such as chemical resistance or adhesiveness.

Fasteners

Fasteners are used in various geometries and dimensions to establish screwed connections. Coatings for bolts and nuts need to be as thin as possible and display excellent corrosion and fastening characteristics(co-efficients of friction)– in particular where different materials are paired.

Steel and stainless steels

The engine compartment of a truck contains numerous stamped parts, clips and springs made from steel and stainless steel. Whilst stainless steels typically display good sliding properties and protection against contact corrosion in addition to corrosion protection, in the case of steel components specific sliding characteristics are required.

Interior

Fulfilling functional characteristics

When it comes to the coating of components in the truck cab, the required degree of corrosion protection is relatively low. Instead, the components are required to fulfil many functional requirements. For example, parts such as safety belt buckles that are subjected to high stresses need to display defined sliding properties. Criteria such as avoidance of squeaking noises for spiral or torsion springs and the long-term securing of the black component appearance are also achieved via a suitable corrosion protection system.

Requirements

  • Corrosion resistance 96h (z.B. ISO 9227)
  • Colouring black or silver
  • Antifrictional properties
  • Coefficients of friction
  • Compability to micro-encapsulation

Solutions

Dörken offers a series of proven and capable micro-layer corrosion protection systems for the coating of components in the interiors of truck cabs. Where there are low requirements of corrosion protection a top coat coating with specific functional characteristics such as glide or friction properties is often suitable. In other cases special systems consisting of a zinc flake base coat and a top coat can be applied, depending on the parts concerned. The very thin coats are annealed at comparatively low temperatures – without hydrogen embrittlement. One key advantage of zinc flake coating is dry lubrication. The dry lubricating film generated by the application displays excellent friction and wear characteristics and ensures good grip properties of interior surfaces.

Example components

Belt buckle

The belt buckle serves to receive and secure the safety belt system. A low level of corrosion protection is generally required here, however, the protective effect must still be provided after multiple opening and closing actions. In addition, good slide properties are also required for ease of handling.

Clips

Clips are used, amongst other areas, to secure cable ducts in the console of the cab. As these are frequently produced from high-tensile spring steel, the coating aims to avoid the risk of hydrogen embrittlement – zinc flake technology is a good option for this. Further advantages are the thin coats which, tailored to the geometry of the clips, enable good adhesion as well as good ductility – this is important, as the clips open and close when fitted.

Latch pins

Latch pins are safety-relevant components and are installed inside the seat. They ensure that the seat does not release itself from the seat rail anchoring in the event of an accident. In order to also enable the "smooth" adjustment of the seat a suitable slide coating can be applied with a defined coefficient of friction.

Undercarriage

Ensuring long-term functionality

Wheel bolts, retaining springs, cover plates:the various high-tensile parts installed in the undercarriage of a truck are exposed to sometimes high temperatures and strong mechanical stresses during operation. To preserve and secure the functionality and operational safety of the truck in the long term long-lasting, effective corrosion protection is required. High-performance coatings also prevent contact corrosion when different materials are paired together, as well as ensuring reproducible fastening characteristics and optimal sliding properties – for example for pressure springs. Corrosion protection systems also make a key contribution to maintaining chemical resistance.

Requirements

  • Corrosion resistance 720h (e.g. ISO 9227)
  • Colouring silver or black
  • Coefficients of friction
  • Resistance to chemicals
  • Resistance to stone chip
  • Resistance to temperature

Solutions

To create a protective effect against corrosion in accordance with requirements components in the undercarriage can be coated with various different systems. In addition to purely zinc flake systems, individual combinations of special Dörken base coats and organic or inorganic top coats can also be used, depending on operating conditions. With zinc flake coating good protective effects of up to 1,000 hours against base metal corrosion(red rust)according to DIN EN ISO 9227 can be achieved using only extremely thin coats. Application occurs at a comparatively low temperature, without the generation of hydrogen. No stress corrosion cracking can occur as a result. The technology also enables a lower volume of resources to be utilised, from both ecological and economic view points

Example components

Fasteners

Undercarriage connections, nuts and bolts are used in many different forms in truck undercarriages. Coating systems help to ensure well-fitting threads, achieve good fastening properties and avoid contact corrosion.

ABS counters

The ABS counters fitted to the brakes are required to withstand very high temperatures during the breaking process. As the component is very delicate, it can only be coated with a very thin coating.

Springs in the brake system

Springs in the truck brake system have various different dimensions, designs and functions. In addition to long-lasting corrosion protection, coatings must also possess functional properties such as wear resistance.

Trailer

Achieving long-term durability

Whether it is flatbed vehicles, box trucks or tipper trucks:a wide range of components are used in and on truck trailers. Effective corrosion protection of the components helps to maintain the ongoing operational safety and function of the trailer. The coating systems employed must ensure corrosion resistance throughout the lifetime - including when subjected to stresses such as stone impact, dirt, frost and continuous cleaning cycles. Finally, achieving a stable and optically-appealing surface also plays a key role when choosing a coating.
 

Requirements

  • Corrosion resistance 720h (e.g. ISO 9227)
  • Colouring black or silver
  • Coefficients of friction
  • Resistance to chemicals
  • Resistance to stone chip

Solutions

In addition to the standard solutions of hot galvanisation and KTL+powder, special zinc flake systems comprising a base coat and organic or inorganic top coat are also suitable for the efficient coating of trailer components. Even with comparatively thin coats these offer long-term cathodic corrosion protection whilst at the same time ensuring a consistent appearance of the trailer. As the zinc flake coating is applied at low annealing temperatures, there is no risk of deformation or loss of rigidity of the components through excessively high temperatures. The recutting or reworking of bores and threads is also not necessary due to the extremely thin and efficient layer structure, which significantly facilitates fastening and assembly.

Example components

Fittings

Bolts and nuts are used to secure the wheel to the suspension as well as in the chassis construction. In addition to long-term corrosion protection, the coating system must deliver good fastening properties above all.

Axle support

The axle support module connects the vehicle to the undercarriage. The coating solution ensures long-lasting corrosion protection and resistance to a range of external influences and stresses.

Chassis

The supporting structural components of the trailer such as side beams or cross struts require long-term corrosion protection. In addition to the technical requirements the coating system must also contribute to preserving the optical appearance of the chassis.