Challenge
In the field of decorative add-on components such as covers, trims and frames, automotive suppliers now predominantly use aluminium – lightweight, robust and easy to process. The surfaces are often anodised for corrosion protection and visual enhancement. The result is hard and scratch-resistant. However, black-anodised components tend to develop an unwanted bluish tint over time. If this change is to be prevented and lasting colour fidelity with a piano lacquer-like surface achieved instead, a high-quality coating system is required. This is precisely where the problem begins: the chemically resistant anodised surface does not inherently ensure coating adhesion. The market had no suitable solution.
- For mechanical reasons, the anodised surface prevents coating adhesion
- Black-anodised components develop a bluish tint over time
- No process is available on the market for fully sealed surfaces
- High OEM requirements for appearance and long-term quality
Solution
As no existing system could meet the requirements, KSK developed its own process. Targeted factorial trials with chemical pretreatments were carried out in a pilot facility. Test No. 240 delivered the breakthrough: the KSK EloCoat® process was born. KSK then designed its own pretreatment plant, selected an innovative plant manufacturer and placed the production order. After just ten weeks of construction, the plant was commissioned. Today, production components for premium OEMs are treated there using the EloCoat® process and subsequently coated to a high standard.
- In-house pretreatment process developed through 240 factorial trials
- EloCoat®-modified anodised layer as an adhesion-promoting base for high-quality coating
- In-house pretreatment plant built in ten weeks
- Low drying temperatures allow pre-assembly of plastic add-on components
- Established in high-volume production for leading premium OEMs
Results
- High-quality piano-gloss finish on anodised components
- Excellent corrosion resistance – filiform corrosion is effectively prevented
- Anodised and high-gloss black variants from the same basic process
- Visually defective anodised parts can be enhanced by coating – less scrap
- Cut edges remain protected from weathering after anodising
- Plastic add-on components can be assembled before coating
