Application process for corrosion control technology streamlines processing.

After launching its MetalJacket metal treatment and coating system for corrosion control of metal parts, Lord Corporation has developed several key process improvements that are said to dramatically reduce the costs and space required to apply the technology.

Using robotics for part handling, tightly integrated automation of the process and an induction heating system for cleaning, drying and curing metal parts, the process takes advantage of the inherent speed and simplicity of the Metal Jacket corrosion control coating system. This is said to have resulted in a lower capital and operating cost application that most manufacturers can integrate into their current production process without the need for sending metal parts out for corrosion control coating to third parties, or disrupting their current process flow.

This process is said to represent cellular manufacturing at its best. In a space the size of a typical conference table, the MetalJacket application process is said to harness the best of robotics and automation to rapidly apply corrosion control coating to a single part or multiple parts, while eliminating several wet chemistry stages typical of other coating processes.

Air and waste water emissions are nearly eliminated, cycle times are on the order of a few seconds per part, and a completely coated part can be passed to the next stage of the manufacturing process without breaking the process flow. Working with Hahn Automation, Lord has developed a turnkey corrosion control system that can be utilized in lean manufacturing systems to reduce corrosion control coating application costs.

Key parts of the patented system include controlled induction heating for cleaning, drying and curing, robotics for rapid and precise part handling, automation for integrated process control and the MetalJacket corrosion control system for rapid precision coating of complex steel parts. The induction heating process works like a microwave oven to clean, dry and cure metal parts during various stages of the corrosion control treatment and coating process.

Induction heating can be performed as part of the MetalJacket treatment and coating process, eliminating all wet chemistry except for the coating itself. For many types of steel parts, typical alkaline cleaning, acid pickling and zinc phosphate processes are completely eliminated, along with the costs, processes and monitoring requirements.

MetalJacket coating systems apply by autodeposition, a process in which the coating interacts with an active ferrous steel surface to provide a uniform barrier coating over the entire part. This uniform coating is obtained regardless of part shape or size, and without the need for high voltage electric assistance or rinse steps. Suitable coating films can be deposited in a few seconds.

This combination of rapid process steps, including induction cleaning, deposition of MetalJacket coatings, induction drying and induction curing, coupled with the use of robotics for precise part handling and movement, enable corrosion control coating to be done in a manner not previously possible in small spaces, integrated with other production processes, with lower capital outlays than any other high performance coating process. Because of the small sizes of lines, short cycle times for coating and elimination of multiple processes, the overall cost for the turnkey MetalJacket application process is lower than for other corrosion control systems. Additional cost savings include reduced movement of parts within a plant, reduced inventory and elimination of transportation costs to third party coaters.

MetalJacket overview

The MetalJacket (MJ) corrosion control system has two layers for optimum uniformity, corrosion, protection and adhesion. The first, MJ1100 metal treatment, is a regulatory friendly, autodepositing, no-rinse metal treatment used in conjunction with a MetalJacket coating. This replaces the zinc phosphating step and prepares mild steel for the MetalJacket coating.

The second layer, MJ2110 coating, is an autodepositing corrosion resistant coating used in conjunction with a MetalJacket metal treatment. MJ2110 coating acts as a primer for rubber-to-metal bonding and provides a protective coating for the exposed areas of the part, and for non-bonded parts. MJ2110 coating forms self-limiting, uniform thin films, even on complex surfaces.

When used as a system with MJ1100 metal treatment, MJ2110 coating is said to provide excellent corrosion protection, passing GM, Ford, DaimlerChrysler, Freightliner and Nissan automotive corrosion specifications. It also provides comprehensive environmental protection for bonded parts, without the need for post-painting.

The aqueous MetalJacket system is environmentally friendly. It contains no hazardous volatile organic components, generates no hazardous wastes or sludge such as in zinc phosphatizing, and uses no toxic acids or heavy metals such as in zinc plating. Additionally, MetalJacket meets automotive substances use restrictions, and the European end of life recyclability directive.