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How to Shield New, Lighter Metals from Corrosion

    June 29, 2016

Just as a knight protects itself with the use of a shield, vehicles are shielded from corrosion through the use of coatings. In an effort to meet CAFE standards, new metals are being used in engine and powertrain designs.

According to the Center for Advanced Automotive Technology (CAAT), using lightweight components and high-efficiency engines enabled by advanced materials in one quarter of the U.S. fleet could save more than five billion gallons of fuel annually by 2030.

Therefore, lighter metals like titanium, aluminum and magnesium can have a big impact on fuel savings. Incorporating them into designs, however, requires different pretreatment methods. Electro ceramic coatings are a solution that enables a broader use of aluminum and magnesium by virtually eliminating corrosion and withstanding extreme temperature conditions.

Here’s how it works:

electro ceramic coating process

Henkel offers two innovative BONDERITE solutions to protect lighter metals against corrosion:

  • BONDERITE EC2 provides corrosion protection for aluminum and titanium. This low-friction coating is optimal for powertrain and transmission application. The ECC coating can allow for material substitution providing a wear resistant low CoF layer. The thermal efficiency of the ECC coating can protect against detonation, improve combustion stability in lean run conditions and improve heat transfer in engines at temperatures well above the melting point of aluminum.
  • BONDERITE MGC allows for magnesium substrates, which are 75 percent lighter than steel, to be introduced into a vehicle. MGC provides corrosion protection to magnesium which is typically applied in the car body and chassis. The lighter the vehicle, the better fuel efficiency achieved. This has excellent paint adhesion which is an important added benefit to the manufacturing process.

Both of these technologies improve efficiency across the coating process, and are environmentally safe and compliant.

Over to You

To learn more, download the Smart Chemistry Hub presentation: BONDERITE Coatings for Powertrain Applications, or ask a question in the comments section below.

About the Author, David Caro

David Caro is Head of Global Engineering Transport and Metal SBU at Henkel and has more than 20 years of international experience in automotive. After joining Henkel in 2001, he held roles in the company’s operations in North America, Germany and Spain. David has degrees in Mechanical Engineering from Polytechnic University of Barcelona and in Business Administration from IESE Business School, University of Navarra.

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