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News Release from: Keronite | Subject: Plasma Electrolytic Oxidation process
Edited by the Manufacturingtalk Editorial
Team on 21 October 2005
Surface treatment toughens non-ferrous
metals
Patented surface treatment technology allows automotive companies to use lighter metals to reduce vehicle weight, thereby saving fuel and decreasing emissions.
Keronite, a United Kingdom-based pioneer in surface treatment technology, is expanding its presence in the North American automotive market with a breakthrough process that allows suppliers and automakers to use lighter metals to reduce vehicle weight, thereby saving fuel and decreasing emissions Keronite company officials today presented the company's business strategy and revolutionary patented surface treatment technology to current and potential customers and automotive media
This article was originally published on Manufacturingtalk on 2 Jul 2002 at 8.00am (UK)
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Plasma process decreases magnesium corrosion
Plasma electrolytic oxidation process gives magnesium alloys as much as 1,000 hours of corrosion resistance in the extreme environment of a salt spray test.
Electrolytic surface preparation is ISO approved
Keronite International has achieved ISO 9001:2000 certification for the application of advanced surface treatments using the Keronite Plasma Electrolytic Oxidation process.
The Plasma Electrolytic Oxidation (PEO) process transforms lighter metals such as aluminum and magnesium into a hard, dense ceramic that is extremely durable and resistant to corrosion and wear, making it an ideal choice to replace heavier metals in numerous applications.
Statistics show that a 10% reduction in vehicle weight can translate into a six to eight percent decrease in fuel consumption.
"Our scientifically developed coating process offers today's Tier Ones and OEMs a solution to a critical challenge: How to find ways to reduce overall vehicle weight without sacrificing performance and adding cost," says Lars Olrik, CEO of Keronite.
Further reading
Magnesium to grow in manufactured products
The market for cast magnesium components has been growing at around 15% p a in recent years and forecasts for the next decade - especially from the automotive industry - are even more bullish.
Process hardens and protects magnesium, aluminium
Surface treatment process is building quite a reputation as the preferred treatment for magnesium and aluminium alloys, providing the hardest and most corrosion resistant surfaces.
Aluminium tools reduce volume moulding costs
Plasma electrolytic oxidation enables aluminium to be used as a replacement for expensive steel tools by improving the durability and the release properties of the surface.
"This patented process will allow OEMs to replace heavier parts with lighter weight alloys without giving up any durability in the form of corrosion resistance or wear".
"We believe that as awareness of the Keronite process increases in the North American automotive industry, we will be ideally positioned to achieve very positive growth." With recent new contracts and discussions ongoing with major OEMs and suppliers, Keronite is poised to grow its automotive business and expects to increase sales by as much as 300 percent this year over 2004.
The company's existing automotive business is in Europe including a contract with Federal Mogul to treat cast-aluminum pistons and a contract to pre-treat magnesium body panels for BMW.
To facilitate growth with domestic automakers, Keronite has developed several key alliances this year, including: * Opening a North American office in Indianapolis through a partnership with Kecol Engineered Coatings, a company with 25 years experience in the coatings business.
* Developing a presence near domestic automakers with a sales office located in the Southfield, Michigan-based office of Morris and Associates.
* Forming a partnership with Ann Arbor, Michigan-based Thixomat to offer additional value to Tier One suppliers and automakers with Thixomat's expertise in the injection molding of magnesium alloys.
The Keronite process has already shown success in construction applications as a protectant for aluminum architectural panels, in a variety of consumer goods as a substitute for hard anodizing or chrome-based coatings and to improve durability in tooling and moulding applications.
The excellent wear characteristics have been proven in independent testing that shows the process makes aluminum seven times more wear resistant than hard anodizing, three times harder than untreated aluminum, and that Keronite on aluminium can withstand more than 2,000h in salt fog, a key test for corrosion resistance.
Keronite recently completed a cooperative agreement with German company Gramm Oberflaechentechnik, Germany, a recognised leader in coating systems in automotive applications.
This partnership allows Keronite to refine the process by targeting specific areas to be treated instead of an entire part.
The Gramm system is fully automated and can reduce steps in the manufacturing process by honing in on the specific area, no matter how small, that is vulnerable to corrosion or wear, meaning quicker coating time using less material.
These benefits make Keronite ideal for exterior automotive parts such as roof rails, door handles, door frames and body panels; interior parts such as seat frames, instrument panel beams and supports, airbag retainers and mirror brackets; and engine components including piston crown and ring grooves and clutch rings.
Currently the prestigious Indy Racing League (IRL) has made Keronite coating mandatory on all magnesium wheels used in IRL competition vehicles starting this year.
Also, Keronite is used by General Motors' Allison Transmissions as to treat a gearbox case on a new US military vehicle.
Another critical element of the Keronite process is its stringent adherence to environmental standards.
The Keronite process involves no chrome or other heavy metals and uses no ammonia or acid.
Also, there is no special treatment required for the disposal of the electrolyte solution after use, making the Keronite process one of the most 'green' surface treatment solutions in the world.
* About Keronite - Keronite, headquartered in Cambridge, United Kingdom, is a world leader in advanced surface treatment technology for light metals, significantly improving strength, durability and corrosion resistance of light alloys.
Established in 2000, Keronite works with more than 38 partners worldwide with 16 of those partners operating Keronite facilities.
Industries currently being served include automotive, textile, electronics, tools and molding, architecture and consumer goods.
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