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Henkel & Fiat Chrysler to Discuss New Coating Processes at Surcar 2017

Published on 2017-06-06. Author : SpecialChem

Henkel and Fiat Chrysler Automobiles (FCA) are set to discuss their close cooperation in the development of ground-breaking new treatment processes applied to the latest version of the Alfa Romeo Giulia. Both companies will share the podium at Surcar 2017, the international meeting on automotive body finishing taking place in Cannes, France, on June 29-30. FCA and Henkel worked together for almost three years to develop and tailor Henkel materials and systems for FCA’s specific needs.

New Materials for FCA’s Specific Needs

fca alfa romeo giulia
FCA’s Alfa Romeo Giulia

At Surcar, Roberto Selvestrel from FCA Materials Engineering Paint and Manfred Holzmueller, Sales Director Transplant OEM Business at Henkel, will discuss results achieved by using new metal treatment systems applied to the new Giulia, created through close cooperation between body engineering, process & materials engineering, and the process material supplier. They will shed light on a holistic approach involving state-of-the-art multi-metal pretreatment technology as well as acoustic, structural, sealing & coating technologies in the body and paint shop.

Pretreatment Processes

  • The Bonderite two-step metal pretreatment process was developed by Henkel for multi-metal bodies with very high aluminum contents (up to 80%)
  • It provides superior corrosion performance while reducing investment- and processing costs
  • The dip-coating process uses zinc phosphate in the first step to treat the steel, followed by aluminum treatment in the post rinse

“Aluminum can be eaten up by the acids normally used to phosphate steel, so there is a need to find a balance in the treatment process,” says Holzmueller. “Corrosion performance is equal to tricationic Zn-Phosphate, but the Bonderite process generates 30 – 50% less sludge, consumes fewer chemicals, and creates less surface roughness that demands rework. Lower operating temperature also saves energy.”

Keeping Noise Out

The Alfa Romeo Giulia also benefits from Henkel Teroson high expansion pillar fillers. These are moldings made from a special foamable elastomer that are inserted into cavities in the car body – in the A-pillars for example – during assembly in the body shop. When the body passes through the e-coat oven, the high temperatures cause the moldings to expand to up to ten times their original volume, completely filling and sealing the cavity. This prevents any air entering into the cavity while the vehicle is in motion, and eliminates any wind noise that would otherwise result.

According to Holzmueller: “The new Cassino paint shop is providing FCA with a step-change in quality for its vehicles. The company now uses the most modern paint shop technology for the production of high class vehicles. We believe that the innovative spirit at Henkel is clearly on show in the new Giulia. We are facilitating weight reduction through the use of lighter metals, and we are helping our customer cut costs and improve sustainability by using fully automated application systems and reducing waste by avoiding sludge and overspray in its the processes.

Furthermore, we are reducing the need for cleaning and maintenance. FCA has taken a major step forward with the simultaneous implementation of numerous new technologies and processes for the new Alfa Romeo Giulia. Very close and intensive cooperation between our two companies was essential, and I am happy that it has resulted in such a beautiful new car!”

Henkel and FCA’s presentation, “Reducing Applied Weight While Improving Performance”, will take place June 29th at 10:30 in the Hôtel Majestic Barrière Cannes. Presenters are: Manfred Holzmueller, Sales Director Transplant OEM Business at Henkel and Roberto Selvestrel, EMEA Region, Materials Engineering Paint at FCA.

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Source: Henkel
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