Final Report Summary - AVCOP (Added-value for metallic coated products by new sol-gel process)
Executive Summary:
The AVCOP project is the result of synergistic working relationship between seven industrial SME’s from the metal finishing industry and three leading RTD providers in Europe. The project has enabled the research orientated companies in the hot dip galvanising, electrolytic zinc and Al anodising industries to innovate and lead in a radically new approach to surface finishing using ecofriendly ionogels and other novel sol-gel coating materials with low VOC amounts. AVCOP project has developed improved materials with prolonged lifetimes and aesthetic appeal.
Firstly a series of IL/Sol-gel (ionogel) formulations were examined by the RTD’s. Based on the characterization data, the most adequate formulations for each application were proposed.
However, in most cases the ILs were not found to be a cost-effective solution for application in the metal industry. To remediate to this essential issue, the RTD partners have also decided to develop other VOC reduction strategies.
The work followed with the optimization of the processing and curing conditions adapted for each application with consideration given to the processing logistics, capital equipment investment and required performance levels. The results indicated that the processing conditions such as the deposition process and cure temperature play an important role in the final coating properties. Other curing strategies such as latent heat curing for the HDG application or UV-curing were also developed to provide further choices to the SMEs.
In order to proceed to the final product validation for each application final test-pieces were selected. Then pilot-scale deposition trials onto these final agreed industry-pieces were conducted at the SME sites or at the pilot-plant facilities of the RTDs under the direction of the SMEs employing the best performing formulations.
These sol-gel coated industry pieces were subjected to the final characterization and performance tests according to the different industry standards for final product validation as agreed between the SMEs and the RTDs. Currently used solutions by each SME was also tested as benchmark in order to compare results to the newly developed AVCOP coatings.
In parallel, the most promising formulations developed along the project have been deeply studied from the point of view of storage stability, ecotoxicity, environmental impact (LCA analysis) and cost.
The results were compared to those of other products on the market that are currently used in the metal finishing industry for the studied applications.
As outcome of the project, new improved low-VOC ecological coating materials with prolonged lifetimes and aesthetic appeal are available for the choice of the SMEs. Successful technical results have been obtained and the technology would be ready to be implemented into a further scaled-up industry-scale after carrying out the necessary capital investment from the side of the SMEs.
Project Context and Objectives:
Project objectives and context:
The main objective of this project was to minimize the concentration of VOCs in sol-gel systems capable of providing corrosion protection and aesthetic appearance to a range of application surfaces including hot dip galvanising (HDG), electroplated zinc and anodised aluminium.
The project has been led by SME’s to:
1. Develop new ionogels and other environmentally-friendly sol-gel based coatings with low VOC contents to address the specific needs of the HDG, electrolytic Zn and Al anodising industries:
a. HDG: Achieving enhanced performance and novel coloured finishes for a range of surface applications and finishes
b. Electrolytic Zn: Replacing non environmentally friendly Cr(VI) and Co-containing passivation processes with a combination of Cr(III) passivation and newly developed sol-gel layers
c. Al Anodising: Improving the sealing process with less energy along with novel finishes with improved long-term performances
2. Examine the production of sol-gel technologies at pilot scale levels
3. Investigate the use of conventional and emerging application techniques to optimise transfer efficiency (minimising waste)
4. Validate the new technologies at prototype and small industry scales
5. Conduct full environmental impact assessments of the new coating systems
The project has been delivered by RTD’s who have:
1. Benchmarked current known sol-gel technologies for the three industrial applications
2. Investigated the impact of a range of IL’s on forming protective coatings while minimising VOC output
3. Optimised the sol-gel/IL formulations using standard performance enhancing additives (inhibitors, densifiers etc.)
4. Proposed other VOC reduction strategies in sol-gel formulations
5. Optimised the coating deposition techniques and curing methodologies using energy efficient processes
Project Results:
Impact:
· Industry driven
The SME’s have been intimately involved in the development of the work packages. The companies´ interest in the potential outcomes of the project has been recognised through the SME’s attendance at the progress and review meetings where their views are made to the consortium as a whole. Therefore the project has been centred on their research needs.
· Economic and social benefits
The total annual economic loss caused by corrosion is about 6 % of the gross national income in industrial countries2. This amounts up to € 725 billion for Europe every year3! Therefore, corrosion 2 J. A. Vogelsang: Anticorrosive pigments and pre-treatment – Introduction and basics about self-healing properties, EUROCORR 2007 Proceedings, Eds. DECHEMA e. V., Freiburg im Breisgau (2007).
3 GDP EU27 2010 = 12 028.7 billons of EURO – EU economic data pocketbook 2-2010, Eurostat European Commission, © European Union, Brussels 2010 [ISSN: 1026-0846, Cat.: KS-CZ-10-002-EN-C].
Protection is amongst the most critical cross-sectorial technologies with high economic and ecological importance. The interaction with the companies in early trials is an indication of the urgency they feel from global economic pressures to innovate and develop new protective coatings.
· Competitiveness
The interaction with the relevant representative bodies has informed the consortium of the growing need for next generation technology in this engineering sector. The interaction with EGGA and IZA has ensured that the competitive advantage that the AVCOP project will generate will benefit European industry as a whole.
Potential Impact:
Project public website:
www.avcop.eu
Participant list and contact details:
· MILLIDYNE: Mika Kolari (Project coordinator) mika.kolari@millidyne.fi
· TECNALIA: Usoa Izagirre Etxeberria (Project office) usoa.izagirre@tecnalia.com
· EUROSINKITYS: Jarno Kiviluoma jarno.kiviluoma@eurosinkitys.fi
· GALCO: Terry Hinds Terry.Hinds@galco.ie
· BETAK: Vasile Rus vasile.rus@betak.ro
· GALDESA: Ramón Sagristá ramon@galdesa.com
· GRAPH: Nova Sharkey nova.sharkey@graphengineering.ie
· FINITEC: Santos Samos ssamos@finitec-electrolisis.com
· DIT: Brendan Duffy bduffy@dit.ie
· VTT: Juha Mannila Juha.Mannila@vtt.fi
· CIALSUGA: Xurxo López Caamaño xurxolc@megalta.com
List of Websites:
AVCOP project video:
http://youtu.be/ifxjC6MJfZs
The AVCOP project is the result of synergistic working relationship between seven industrial SME’s from the metal finishing industry and three leading RTD providers in Europe. The project has enabled the research orientated companies in the hot dip galvanising, electrolytic zinc and Al anodising industries to innovate and lead in a radically new approach to surface finishing using ecofriendly ionogels and other novel sol-gel coating materials with low VOC amounts. AVCOP project has developed improved materials with prolonged lifetimes and aesthetic appeal.
Firstly a series of IL/Sol-gel (ionogel) formulations were examined by the RTD’s. Based on the characterization data, the most adequate formulations for each application were proposed.
However, in most cases the ILs were not found to be a cost-effective solution for application in the metal industry. To remediate to this essential issue, the RTD partners have also decided to develop other VOC reduction strategies.
The work followed with the optimization of the processing and curing conditions adapted for each application with consideration given to the processing logistics, capital equipment investment and required performance levels. The results indicated that the processing conditions such as the deposition process and cure temperature play an important role in the final coating properties. Other curing strategies such as latent heat curing for the HDG application or UV-curing were also developed to provide further choices to the SMEs.
In order to proceed to the final product validation for each application final test-pieces were selected. Then pilot-scale deposition trials onto these final agreed industry-pieces were conducted at the SME sites or at the pilot-plant facilities of the RTDs under the direction of the SMEs employing the best performing formulations.
These sol-gel coated industry pieces were subjected to the final characterization and performance tests according to the different industry standards for final product validation as agreed between the SMEs and the RTDs. Currently used solutions by each SME was also tested as benchmark in order to compare results to the newly developed AVCOP coatings.
In parallel, the most promising formulations developed along the project have been deeply studied from the point of view of storage stability, ecotoxicity, environmental impact (LCA analysis) and cost.
The results were compared to those of other products on the market that are currently used in the metal finishing industry for the studied applications.
As outcome of the project, new improved low-VOC ecological coating materials with prolonged lifetimes and aesthetic appeal are available for the choice of the SMEs. Successful technical results have been obtained and the technology would be ready to be implemented into a further scaled-up industry-scale after carrying out the necessary capital investment from the side of the SMEs.
Project Context and Objectives:
Project objectives and context:
The main objective of this project was to minimize the concentration of VOCs in sol-gel systems capable of providing corrosion protection and aesthetic appearance to a range of application surfaces including hot dip galvanising (HDG), electroplated zinc and anodised aluminium.
The project has been led by SME’s to:
1. Develop new ionogels and other environmentally-friendly sol-gel based coatings with low VOC contents to address the specific needs of the HDG, electrolytic Zn and Al anodising industries:
a. HDG: Achieving enhanced performance and novel coloured finishes for a range of surface applications and finishes
b. Electrolytic Zn: Replacing non environmentally friendly Cr(VI) and Co-containing passivation processes with a combination of Cr(III) passivation and newly developed sol-gel layers
c. Al Anodising: Improving the sealing process with less energy along with novel finishes with improved long-term performances
2. Examine the production of sol-gel technologies at pilot scale levels
3. Investigate the use of conventional and emerging application techniques to optimise transfer efficiency (minimising waste)
4. Validate the new technologies at prototype and small industry scales
5. Conduct full environmental impact assessments of the new coating systems
The project has been delivered by RTD’s who have:
1. Benchmarked current known sol-gel technologies for the three industrial applications
2. Investigated the impact of a range of IL’s on forming protective coatings while minimising VOC output
3. Optimised the sol-gel/IL formulations using standard performance enhancing additives (inhibitors, densifiers etc.)
4. Proposed other VOC reduction strategies in sol-gel formulations
5. Optimised the coating deposition techniques and curing methodologies using energy efficient processes
Project Results:
Impact:
· Industry driven
The SME’s have been intimately involved in the development of the work packages. The companies´ interest in the potential outcomes of the project has been recognised through the SME’s attendance at the progress and review meetings where their views are made to the consortium as a whole. Therefore the project has been centred on their research needs.
· Economic and social benefits
The total annual economic loss caused by corrosion is about 6 % of the gross national income in industrial countries2. This amounts up to € 725 billion for Europe every year3! Therefore, corrosion 2 J. A. Vogelsang: Anticorrosive pigments and pre-treatment – Introduction and basics about self-healing properties, EUROCORR 2007 Proceedings, Eds. DECHEMA e. V., Freiburg im Breisgau (2007).
3 GDP EU27 2010 = 12 028.7 billons of EURO – EU economic data pocketbook 2-2010, Eurostat European Commission, © European Union, Brussels 2010 [ISSN: 1026-0846, Cat.: KS-CZ-10-002-EN-C].
Protection is amongst the most critical cross-sectorial technologies with high economic and ecological importance. The interaction with the companies in early trials is an indication of the urgency they feel from global economic pressures to innovate and develop new protective coatings.
· Competitiveness
The interaction with the relevant representative bodies has informed the consortium of the growing need for next generation technology in this engineering sector. The interaction with EGGA and IZA has ensured that the competitive advantage that the AVCOP project will generate will benefit European industry as a whole.
Potential Impact:
Project public website:
www.avcop.eu
Participant list and contact details:
· MILLIDYNE: Mika Kolari (Project coordinator) mika.kolari@millidyne.fi
· TECNALIA: Usoa Izagirre Etxeberria (Project office) usoa.izagirre@tecnalia.com
· EUROSINKITYS: Jarno Kiviluoma jarno.kiviluoma@eurosinkitys.fi
· GALCO: Terry Hinds Terry.Hinds@galco.ie
· BETAK: Vasile Rus vasile.rus@betak.ro
· GALDESA: Ramón Sagristá ramon@galdesa.com
· GRAPH: Nova Sharkey nova.sharkey@graphengineering.ie
· FINITEC: Santos Samos ssamos@finitec-electrolisis.com
· DIT: Brendan Duffy bduffy@dit.ie
· VTT: Juha Mannila Juha.Mannila@vtt.fi
· CIALSUGA: Xurxo López Caamaño xurxolc@megalta.com
List of Websites:
AVCOP project video:
http://youtu.be/ifxjC6MJfZs