Transcript Workshop on Hazardous Substances Affecting Metallic-Coated Steel and Other Metals

Workshop on Hazardous
Substances Affecting
Metallic-Coated Steel and
Other Metals
May 23, 2007
Henkel – RoHS Compliant
Passivate Discussion
 Agenda:
• Position on RoHS
• Products Discussion
•
•
•
Offerings
Corrosion performance
Field experience
• References
page 2
Henkel Position on RoHS





Electrical and electronic equipment (not all end users)
• Appliances
• Computers
• Televisions, video recorders
Hexavalent Chromium (CrVI) is critical element for metal passivation
treatments listed in RoHS regulation
• Must contain less than (0.1%) 1000 ppm. Hexavalent chromium or contain no
intentionally added hexavalent chromium in any homogeneous layer
• Henkel position is that passivate coatings do not become a homogeneous
layer with substrate, but, the discontinuous layer of the passivate. (IBM agrees
with this position).
Chromium free products are compliant simply because there is no chrome
present
Chromium III (trivalent) products are compliant in both the product and asdried surface since Cr(VI) is below 1000 ppm and no Cr(VI) is intentionally
added.
Conversion of Cr(III) → Cr(VI) will not happen under “normal” circumstances
• PH≥14 or extreme oxidation are required
• Practical basis, Cr(VI) not present during life-cycle of the coated materials.
page 3
Hexavalent Chrome-Free Passivation
Offerings
 Three
approaches:
• Non-chrome containing inorganic passivate
• Trivalent chrome inorganic passivate
• Thin organic coating non-chrome containing
(acrylic coatings)
page 4
Hexavalent Chromium Containing Inorganic
Passivates: “Chemtreats”
 Typical
coating weight: 1.0 – 2.0 mg/sq.ft. Cr
 Applied
by flood squeegee and dried by hot air dryer
 Corrosion
performance by neutral salt spray (NSS):
96+ Hrs.
 “Wet”
 Low
corrosion tests: 800+ Hrs.
cost, good corrosion prevention
 “Non-Paintable”
page 5
Henkel Passerite 5004 W
Chromium-Free Inorganic Passivate
Major Coating Constituents
 Molybdenum
 Titanium
 Phosphate
 Fluoride
 Organic
Polymer
page 6
P-5004 W
Chrome-Free Inorganic Passivate
Application
Bath Concentration
20%-100% (Dependent On Coater)
30% is Typical
Run as Flood or Dip/Squeegee or Chemcoater
Bath pH:
Coating Wts.:
2.5-3.5
30-80 mg./sq.ft. (50 mg. is recommended)
Bath Temperature:
<40C (104°F)
Strip PMT:
50-60C min., 120C max.
(Above 120°F)
Drying Time:
< 10 seconds recommended
page 7
Passerite 6001 / Passerite 6003 / Bonderite 6020
Trivalent Chromium Passivate Application Parameters
Application:
Spray / squeegee (low bath volume)
Chemcoater
Contact time:
< 10 seconds
Bath Temp:
< 110°F
Coating Weight:
30 – 40 mg./sq.ft. (20 – 30 mg./sq.ft. for
B6020)
Cr Coating Weight:
3.0 – 4.0 mg./sq.ft. (2.0 – 3.0 for B6020)
Bath pH:
< 2.5
Zn Dissolution:
< 1.8% by weight
Bath Concentration:
10 – 60% dependent on flow to line,
20 – 30% is typical
Strip PMT:
110°F → 200°F
page 8
Recommendations for Designing a System
for Hex-Chrome Free Passivates
contact time (time between application / drying ) –
as short as possible. Less than 5 seconds excellent.
 Solution
 Chemcoater
 Drying
best method (spray / squeegee is acceptable)
peak metal temp (PMT) - 120°F minimum (220°F max)
materials (contacts solution) – 316 or 304
stainless steel, or polymer (PVC, PEHD or PP) – no carbon
steel
 Equipment
rolls – Hypalon, Viton or polyurethane covering –
45 – 55 shore hardness
 Wringer
volume – as small as possible – less than 30
gallons – (Henkel “Coiltech” system)
 Solution
•
Maintain pH below 2.5 – minimize zinc contamination
 X-Ray
fluorescence (Portaspec) recommended for coating
page 9
weights
Henkel Standard Accelerated Corrosion
Tests for Passivation Treatments
 Neutral
 Wet
Salt Spray (NSS)
Stack
 Cleveland
 Butler
Condensing (CCH)
Water Immersion (BWI)
page 10
Corrosion Overview – Field Performance
NSS Results
Customer
Prouduct Used
24
48
72
96
Wet Stack
BWI
Cleveland
Condensing
A
P6001
5
10
20
35+
800 hrs.
800 hrs.+
1000 hrs. +
B
P6003
5
10
15
35+
800 hrs.
800 hrs.+
1000 hrs. +
C
P6003
5
10
20
40+
800 hrs.
800 hrs.+
1000 hrs. +
D
B6020
1
5
15
30+
800 hrs.
700 hrs.+
1000 hrs. +
E
B6020
0
1
5
10+
800 hrs.
700 hrs.+
1000 hrs. +
F
B6020
1
5
10
20+
800 hrs.
700 hrs.+
1000 hrs. +
G
P5004W
5
10
20
25+
800 hrs.
700 hrs.+
1000 hrs.+
H
P225W
0
0
1
5+
800 hrs.
700 hrs.
1000 hrs.
→ Wet Stack, BWI and Cleveland Condensing results are to 5% white rust
Coating Wts. (Chrome mg/sq.ft)
A - 4.0 - 6.0
B - 4.0 - 6.0
C - 5.0 - 7.0
D - 3.0 - 4.0
E - 3.0 - 4.0
F - 1.0 - 2.5
G – 40 – 60 mg./sq.ft. (total)
H – 1.0 – 2.0 mg./ft2 chrome VI
page 11
Trivalent Based Passivation – Product
Evolution Commentary
“Passerite 6001 → Passerite 6003 → Bonderite 6020”

Continuous improvement in all of the following:
• Corrosion performance (NSS)
• Lower coating weight (lower applied costs)
• Improved “paintability”
• Improved conductivity (IBM and HP)
• Less corrosive to equipment (304 and 316SS)
• Bonderite 6020 – removal of organics – no foaming

Products have become more operator and end-user friendly

Next generation product – Bonderite 6010 – “fluoride free” –
being tested in Europe
page 12
Thin Organic Non-Chrome Coating:
(Replacement For Hexavalent Cr Containing Acrylics)
Granocoat 342
•
Primarily Used For Galvalume and HDG Coated Steel
•
Expected Performance:
Roll forms without oil
Good fingerprint resistance
Excellent corrosion
performance
180° – 220° F PMT
page 13
Non-Chrome Thin Organic Coating: Granocoat 342
Specifications:
Galvalume
HDG
Corrosion Data In Hours To Failure
Stack
BWI
NSS
Cleveland
Stack BWI
NSS
Cleveland
Cr+6
(Present Day)
2016
1008
760
672
1008
1008
760
672
Granocoat 342
1008
1008
760
672
1008
1008 336
672
page 14
Non-Cr Thin Organic Passivate:
Application Parameters:
 Coating
Weight:
 PMT:
 Application
Method:
 Concentration:
 Application Temperature:
 Recoil Temperature:
75-200 mg./sq.ft.
170° - 250° F
Chemcoater
Used Neat
Ambient
<160°F
page 15
Granocoat 342 (Non-Chrome Acrylic)
Summary:
 Corrosion
performance slightly inferior in NSS (HDG)
and wet stack (Galvalume)
 Roll-forming
excellent and verified at 9-stage roll
former (correlates well with Butler Building roll
former)
 “Paintable”
surface
use at Precoat – Portage and CFM for small
applications
 In
trials at Mittal – Sparrows Point
(Galvalume) and Nucor – Berkeley (HDG)
 Successful
page 16
INORGANIC PASSIVATION HEX-CHROME FREE
REFERENCES LIST
CUSTOMERS
page
CUSTOMER
PRODUCT
APPLICATION
SUBSTRATE
CONTACT
TKS EBA1
GERMANY
PASSERITE
6003(20% vol)
Spray +
Squeegee
EG
Dieter Schrocer
+492035223865
VOEST
(4 lines)
Austria
PASSERITE
5004
Spray +
Squeegee
Rollcoater
HDG
Franz Androsch
+4373265856852
TKS FBA7
Germany
PASSERITE
6003(40% Vol)
Spray +
Squeegee
HDG
Kurt Motte
+492349193492
TKS FBA4
Germany
PASSERITE
6003(30% vol)
Spray +
Squeegee
HDG
Udo Schulokt
+492035227700
page 18
CUSTOMER
PRODUCT
APPLICATION
SUBSTRATE
CONTACT
ACCIAIERIA
CREMONA (IT)
PASSERITE
6001 (40 to
45%vol)
Spray +
Squeegee
HDG
Carlo Lanzini
+3903724782
WUPPERMANN
(Holland)
PASSERITE
5004(40 to
45% vol)
Spray +
Squeegee
HDG
Hans G.
Klockner
+31168357150
CORUS
Holland
PASSERITE5
004(80 to
90% w/w)
Chem Coater
HDG
Thijs Post
+31622605651
page 19
CUSTOMER
PRODUCT
APPLICATION
SUBSTRATE
CONTACT
ARCELOR
AVILES
(Spain)
PASSERITE
6001
(40% vol)
Coil tech
HDG
Jose Manuel
Puente
+34985126137
WHEELING
NISSHIN (US)
PASSERITE
6001 (100%)
Spray +
Squeegee +
Roll coater
HDG
GALVANNEAL
USS POSCO
(US)
BONDERITE
6020 (20%)
Spray +
Squeegee
HDG
WUPPERMANN
(2 lines)
(Austria)
PASSERITE
5004
Spray +
Squeegee
Vacuumat
HDG
Hans Georg
Klockner
+31168357150
MITTAL
SPARROWS PT.
MD
PASSERITE
6001
Spray +
Squeegee
HDG
Rob Weber
page 20
CUSTOMER
PRODUCT
SSAB
BORLANGE
(SU)
Passerite 6003
(25 to 30% Vol)
MARCEGALIA
(Italy)
APPLICATION
COIL TECH
SUBSTRATE
CONTACT
HDG
Mat Eliason
+4624372902
PASSERITE
Spray +
6001(25to30% w) Squeegee
HDG
Mr IVALDI
+390544516611
GONVARRI
(Spain)
PASSERITE
6001(55 to
60%vol)
HDG
Jacek
Michalek
+34937734656
NLMK
(Russia)
PASSERITE
Spray +
5004(40 to 45%v) Squeegee
Roll coater +
Spray +
Squeegee
HDG
page 21
CUSTOMER
PRODUCT
APPLICATION
SUBSTRATE
Mittal Galati
ROMANIA
P. 5004
Roll Coater
HDG
Arcelor(VZA1)
Eisenhuttenstadt
P. 6003
(33 to 36%
v/v)
Spray +
Squeegee
HDG
RUUKI
Finland (1)
P. 6003
COIL TECH
HDG
RUUKI Finland
(3)
P. 6003
Chemcoater
HDG
CONTACT
Mr Munteanu
+40 722 56 42
48
Mr Paavilainen
+358205925554
page 22
CUSTOMER
PRODUCT
APPLICATION
SUBSTRATE
CONTACT
JSW - Tarapur
Passerite 6000
Spray +
Squeegee
HDG
Rajesh Singh
+919371750420
Ispat India
Passerite 6001
Spray +
Squeegee
HDG
R.S.Jain
+919823320396
Lloyds Steel
India
Passerite 6001
Spray +
Squeegee
HDG
P.K.Chatterjee
+919326036261
Tata Steel
Passerite 6001
Spray +
Squeegee
HDG
S. Beborta
+919234511144
page 23
CUSTOMER
PRODUCT
APPLICATION
SUBSTRATE
JINDAL (India)
Passerite 6000
Spray +
Squeegee
HDG
JINDAL (India)
Passerite 6001
Spray +
Squeegee
HDG
Bhusan Steel
(India)
Passerite 6001
Spray +
Squeegee
HDG
An Steel
(China)
Passerite 6000
Roll Coater
HDG
CONTACT
page 24
CUSTOMER
PRODUCT
APPLICATION
SUBSTRATE
Benxi (China)
P. 6003
Roll Coater
HDG
Borcelik
(Turkey)
P. 6003
Spray +
Squeegee
HDG
CONTACT
page 25
Thank you
page 26