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QPS

  • Meeting directives, such as ELV REACh and RoHS continues to be essential requirements. QPS delivers on all of these needs. QPS complies with the conditions set forth in the ISO 9001: 2015.

     

    QPS helps automotive engineers to specify the right products in a sustainable world. The steady evolution of the program has enabled many global OEM’s to specify ever-higher performance standards and represents:

    • Approved applicators: Applying these products to a common audited standard ensures the same coating performance throughout the applicator base.
    • High performance: Exceeding the high demands for corrosion resistance and exceptionally consistent torque and tension characteristics.
    • Global consistency: Wherever ZinKlad, DecoKlad or XMAPP standards are applied, applicators know they are using the same high-performance products.

    What do we do?

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    QPS flow chart

    We supply and develop QPS standards that meet and exceed OEM specifications. We validate applicators processes by conducting audits, carrying out inspections and testing the production output to make sure they meet pre-defined QPS standards and agreed technical requirements.

    We monitor and report results on a global scale to be able to service and continuously improve performance. 

    Why do we do what we do?

    We believe that we are able to assure a global consistent performance at a local level meeting the global OEM requirements with a select number of world class applicators.

    How do we do what we do?

    ESI Automotive has developed a unique Quality Performance System called QPS that tackles the challenges for high-performance automotive coatings. OEM’s can be confident that the same coatings and consistent performance are available worldwide.

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Car gearbox with blue cogs

Zinc and zinc alloy systems

Automotive approved, hexavalent chromium-free zinc ans zinc alloy coatings for EV, hybrid and ICE powered vehicles

Steel components including fasteners, battery trays, brakes parts and fluid handling tubes need protecting. But how do you choose the optimum coating, achieve consistency in your global supply base and avoid using proscribed materials? Here is how ESI Automotive have helped automotive design and corrosion engineers overcome their issues.

High tensile steels

High strength steel fasteners are replacing mild steel fasteners. As the strength of steels increases, the susceptibility to hydrogen embrittlement (HE)1 increases. High strength steel fasteners (>1000 N/mm²) 10.9 and higher are more susceptible to embrittlement. For hydrogen embrittlement to occur, a combination of three conditions are required;

  1. The presence and diffusion of hydrogen
  2. A susceptible material
  3. Stress

High strength steel fasteners require Enviralloy®zinc-nickel and TriPass heat resistant passivation to avoid the risk of hydrogen embrittlement.

How does zinc-nickel and passivation help reduce hydrogen embrittlement?

MacDermid Enthone Enviralloy zinc-nickel provides a micro-cracked surface, preventing a local high concentration of hydrogen (it can readily escape). Zinc plated fasteners require a heat treatment (typically 8 hours at 210 °C) to avoid the risk of hydrogen embrittlement. Heat resistant passivation can be applied before this treatment is carried out and the coating still retains its color and corrosion protection.

To find our more about Enviralloy zinc-nickel and TriPass passivation, visit out technology pages.

HE also known as hydrogen assisted cracking (HAC) and hydrogen-induced cracking (HIC), describes the embrittling of metal after being exposed to hydrogen.

 

Joining aluminum surfaces

Contact corrosion

The use of aluminum components is increasing in lightweight vehicle construction. Using zinc plated fasteners for joining aluminum components will result in galvanic corrosion 2 (contact corrosion). For that reason Enviralloy zinc-nickel is recommended. The low potential difference between zinc-nickel and aluminum alloys reduces the corrosion current when these are joined in component assemblies. In contrast, zinc plated fasteners corrode 5 times faster when in contact with aluminum surfaces.

Coefficient of friction

Additionally, within the component assembly, friction properties are a safety critical safety feature.  Specific coefficient of friction targets (as set by automotive manufacturers) have to be met against various material surfaces such as; aluminum, painted steel, steels, and diecast. 

For aluminum surfaces; Enviralloy zinc-nickel and the use of Torque and Tension dry film® lubricated sealers are proven to give the desired coefficient of friction properties. This avoids galling and therefore aids optimum tightening of the joint.

Regenerative braking

To compliment the light weighting efforts optimized regenerative braking 3 increases driving range in electrical vehicles.

In addition to improving the overall efficiency of the vehicle, regeneration can significantly extend the life of the braking system as the mechanical parts will not wear out very quickly.  As a direct result of this cast iron brakes as well as brake pads need to be protected from corrosion much longer.  Enviralloy zinc-nickel is recommended over zinc as it provides superior long-lasting corrosion protection.

 

Galvanic corrosion (also called bimetallic corrosion or dissimilar metal corrosion) is an electrochemical process in which one metal corrodes preferentially when it is in electrical contact with another.

Regenerative braking is an energy recovery mechanism that slows down a moving vehicle by converting its kinetic energy into a form that can be either used immediately or stored until needed. In this mechanism, the electric traction motor uses the vehicle's momentum to recover energy that would otherwise be lost to the brake discs as heat.