ZerCor is a brand of coatings which is targeted to provide long term corrosion protection to metallic components due to their tendency

to corrode when exposed in various environments. Our innovative ZerCor brand zinc based systems are environmentally friendly, harmless from a health point of view and at the same time resilient and durable. ZerCor sets new standards in the market and fulfils the ever-more complex demands of the automotive, electrical, building and aviation industries to the highest extension. The coatings have been developed to satisfy the stringent upcoming requirements of the metal industry. They include:1. Higher corrosion protection with reduced coating thickness. 2. Improved aesthetics 3. Chrome free coatings 4. Narrow and controllable coefficient of friction. 5. Removal of contact corrosion We have engineered a series of coatings which can provide salt spray life ranging from 600 hours to 2000 hours without base metal corrosion, temperature resistance at 180 C for 100 hours and bursts of 230-250 C, coefficient of friction from 0.09 to 0.18. These properties can be achieved individually or as a complete package on a single product.

Properties of the Coatings:

1. Appearance: Standard colours are silver and black. Others are available on request. 2. Chemistry: Free from hexavalent or other chromium and heavy metal salts. 3. Coating Thickness: Easily variable for differing requirements. With 6-8 microns to

be minimum.
4. Corrosion Resistance: More than 200 hours salt spray without white rust, more than

600 hours up to 2000 hours salt spray without base metal corrosion.
5. Torque Tension: Controlled coefficient of friction can be provided. 6. Temperature Resistance: Treatment at 180 C for 100 hours has no effect on the

corrosion resistance or appearance.

Four Way Corrosion Protection

1. Barrier Protection: Overlapping zinc and aluminium provide an excellent barrier

between the steel substrate and the corrosive media.

2. Galvanic Action: Zinc corrodes to protect steel. 3. Passivation: Metal oxides slow down the corrosion reaction of the zinc and the steel to

provide 3 times greater corrosion protection than pure zinc.

4. Self-Repairing: Zinc oxides and carbonates migrate to the damaged area of the coating

to actively repair the coating and restore barrier protection.

Wondering how can we achieve so much?

ZerCor systems consist of a base-coat and topcoat. This makes them just as robust as they are varied. Here it is the basecoat that defines the corrosion protection quality properties of the system, while providing the cathodic protection. Topcoats compliment the properties of the basecoat. Influence the chemical or mechanical resilience of the whole system and thus permit a broad range of application. It is by the means of topcoat, that the properties are set which are required for the specific application. The basecoat after curing provides a pure inorganic matrix which holds the zinc and aluminium particles in a way to provide the best possible corrosion protection. Depending upon the required application, both organic and inorganic topcoats are available.

ZerCor systems includes: ZerCor Base

ZerCor Base is not just another zinc rich basecoat, but a high reactivity system containing zinc or zinc/aluminium particles. The metal particles, together with a binding technology, react on the steel substrate to produce a non-toxic zinc aluminium coating after curing. The coating does not contain any chromium, or any heavy metals. It may contain lubricants for controlling the coefficient of friction.

The minimum thickness of ZerCor coatings in bulk treatments is governed by the properties required on the finished parts. In general a single coat thickness ranges between 4 and 6 microns, so that a typical two coat application measures between 8 and 12 microns. ZerCor Base is environment friendly product which meets the requirements of a low solvent content material. ZerCor produces a silver coloured sacrificial coating with a corrosion resistance of more than 600 hours which can be further enhanced by application of the inorganic topcoat ZerCor Top (L) or by the application of the organic topcoat ProSeal.
ZerCor Top (L)

ZerCor Top is a chromium free, mineral topcoat. It improves the corrosion resistance and the mechanical performance of ZerCor coatings. ZerCor Top(L) contains an internal lubricant allowing to achieve different coefficient of frictions. The dry film is inorganic, improving the sacrificial protection of ZerCor and the bimettalic corrosion as well.
ZerCorSeal

ZerCorSeal is an organic topcoat which can be applied on top of zinc and zinc alloy deposits or ZerCor coatings. ProSeal is also available with lubricant for coefficient of friction adjustment.

Benefits by comparison with electroplating:Unlike in the case of electroplating, ZerCor systems by their nature do not lead to the hydrogeninduced cracking corrosion (Hydrogen embrittlement) that is a cause of the fracturing of the high-tensile steels. Zinc Yellow Chromatisation:1. High ecological pollution and health hazard because of chrome (VI). 2. Relatively low corrosion protection. 3. Low temperature resistance. 4. Hydrogen embrittlement. Zinc Nickel Coating:1. Cost intensive because of high proportion of nickel. 2. Complex process technology conceals the risk of quality fluctuation. 3. May cause allergies.

Benefits by comparison with hot dip galvanising:A prerequisite for the coating of high tensile steel is the low curing temperature of our ZerCor systems (200 250 deg C), since steel loses strength from the high temperatures required in hot dip galvanising. Hot dip galvanising is therefore unsuitable for high tensile steel and also has the following disadvantages:1. High Energy Costs from high bath temperatures. 2. No micro layering is possible.