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Zinc
Plating: Three
automatic rack plants with a maximum process window of
3.6m x 1.5m x 0.7m. Two large automatic
barrel process plants with 1.2m cylinders.
The process solutions are alkaline non-cyanide based. Clear,
Colour and Hexavalent Chrome
Free passivation and topcoats are available. All plants
have fully automated transporters with a high degree of
process control, which includes automatic dosing of process
chemicals and additives as well as process solution temperature
and direct current control.
Benefits: Zinc
is the process of choice for a cost effect method of
achieving enhanced corrosion protection. It is also an
ideal sub-surface for final finishing.
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Corrosion
Protection: Corrosion
protection is directly proportional to the electroplate
thickness (3-30µm according to our client's
specification). The principal protection is due
to the zincs encasement of the item, which prevents
contact with the environment. An important feature
of zinc is it’s sacrificial property,
which means that where the ferrous base of the
item is exposed to humidity for example, the
associated chemical reactions of corrosion will
affect the zinc in preference to the steel. Zinc
also provides outstanding metal distribution
and uniform covering power. The coating is capable
of accepting the environmentally friendly clear
blue trivalent chromium passivate as well as
yellow and olive drab finishes.
Wear
Protection:
Zinc
plating bestows an increased surface hardness on
the item with the finished hardness (100g HV) ranging
between 80-150HV. Zinc is beneficial where items
must retain their original appearance for many years. [top]
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Corrosion
Protection
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White-h |
Red-h |
| Clear
Passivate |
20 |
100 |
| Yellow
Passivate |
70 |
150-200 |
| Hexavalent chrome Free Thick
Film |
130 |
300 |
| Olive
Drab Passivate |
150-200 |
250-360 |
| Black
Passivate |
30-50 |
120-50 |
Above
data relates to corrosion testing in accordance
with ASTM B117 procedures, 5% neutral salt spray,
and deposit thickness 8µm. Silicate post
dips and lacquers can add 100-250h to the above
values. Protection of steel substrates (red rust
corrosion) is proportional to the deposit thickness.
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Value
Added Services:
Zinc
plating can be used as a final finish or as a base for
post-treatments. Additional treatments can be applied to
complement the primary finish such as clear or coloured
lacquering, oil seals, wax silicate finishes, leach and
seal systems or wax emulsions dosed with corrosion inhibitors.
Post treatment applications can be applied for functional
or aesthetic purposes. [top]
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Zinc-Nickel
Plating: One
automatic rack plant with a maximum process window
of 3.6m x 0.9m x 1.1m. One large automatic barrel
process plant with 1.2m cylinder. Both plants are
operating an alkaline zinc-nickel process depositing
12-15% nickel.
Benefits: High
zinc-nickel alloy provides an excellent level of corrosion
protection, especially under arduous thermal conditions
and also lessens the process of voluminous white corrosion
deposits typical of conventional and low alloy zinc finishes. [top]
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Post-Treatment: High
nickel-zinc alloy can be post treated with Hexavalent
Chrome Free Thick Film iridescent yellow, bright, blue,
olive drab or clear passivate as well as a high quality
colour fast black finish. Other post-treatments are available
including sealants, lacquers and oils for specific requirements
such as enhanced corrosion protection and high torque
lubricity.
[top]
Corrosion
Protection: In
general, corrosion protection is a function of the
thickness of the deposit. The neutral salt spay test
is used to assess the performance of a finish on a
component. The test assesses the time before the onset
of corrosion to the coating itself, the formation of
white rust as well as the time before the onset of
corrosion to the component substrate material, red
rust. The tables below demonstrate some results from
an ASTM B117 5% neutral salt spray test applied to
a 5µm deposit. [top]
Neutral
Salt Spray - hours to red (white) rust |
Passivate type |
Conventional zinc |
High Nickel Alloy zinc |
| Clear |
100 (6-24) |
900 (240) |
| Iridescent Yellow |
150-200 (72-96) |
1500+ (1000) |
| Black |
120-150 (72-96) |
1500+ (500) |
| Hexavalent Chrome Free Thick Film |
300 |
1500+ |
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Properties |
Conventional Zinc |
Standard Zinc Alloy |
High Nickel Zinc Alloy |
| Nickel % |
Nil |
5-8 |
12-15 |
| Vickers hardness (100g) |
90-130 |
200-250 |
400-500 |
| Weldability |
Poor |
Good |
Good |
| Thermal stability |
Poor |
Good |
Excellent |
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Electrophoretic
Paint: An
automatic electrophoretic paint (E-coat) plant with a process
window of 1.5m x 0.9m x 0.3m and a maximum
load capacity of 250Kg. E-coat offers
high corrosion resistance coupled with an excellent aesthetic
appearance which is fast becoming
the coating of choice for the automotive industry.
Benefits: The
principal benefit of electrophoretic paint is the uniform
density of the finish across the whole part, even on
complex shapes. The benefit of a uniform coating density
is an important feature where colour consistency
is required. E-coat
is often
applied where corrosion protection is required to satisfy
warranty agreements. Electrophoretic paint is a low cost
treatment that offers the opportunity for a quick turn
around on large volumes. [top]
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Technology: Electrophoretic
paint (E-Coat) technology is particularly advantageous
for the application of a uniform organic coating
formed on fabricated metal components. Unlike
sprayed or dipped coatings, an electrophoretic
coating is of uniform thickness on even the most
complex shapes, including the edges. The size
of components and parts is not in itself limiting;
motor vehicle manufacturers routinely coat car
chassis and other parts for corrosion protection
with electrophoretic paint. [top]
Quality: Electrophoretic
paint coatings are free of sags, beads and runs.
These coatings exhibit excellent salt spray and
humidity resistance, high throwing power, good
hardness and flexibility. [top]
Automotive: E-coat
is commonly used through out the automotive industry
where high corrosion resistance is required on
sub frame components such as steering racks,
suspension mounts, chassis fixtures and auxiliary
attachments such as tow bars. [top]
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| Paint
Process |
PPG
POWERCRON Cationic epoxy coating-high build |
| Thickness |
15-30
micron, according to specification |
| Hardness |
2H
minimum |
| Throwing
Power |
18-20cm
(Ford Test) |
| Ductility |
Very
Good |
| Cross
Hatch Adhesion |
95-100% |
| Colour |
Black |
| Gloss-60
degree |
20-60% |
| Corrosion
Protection |
Neutral
salt spray resistance 1000 h plus |
Film
properties based on zinc phosphate pretreatment
with chromate seal.
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Powder
Coating: An
automatic powder coating line offering a complimentary
finish to our other surface treatment services.
Benefits: Powder
coating is an ideal method of adding a colour or aesthetic
coating to a zinc or zinc-nickel item. Thermosetting
powders, having a wide field of use, are well established.
Automated process plant and a powder utilisation in
excess of 95% ensure that powder coatings offer a viable
commercial option to conventional industrial liquid
paints. A high gloss, decorative and, depending on
polymer, corrosion resistant finish with excellent
cover on sharp edges is obtained with powders. Semi-gloss,
matt, metallic and textured finishes are also available.
Areas of use include automotive components, point of
sale equipment, garden tools, satellite dishes and
audio speaker housings. [top]
Colour
Charts: Click
these links to see our colour charts: BS4800 -
Pantone - RAL
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Polyester
Powder: Recommended for use on exterior
fittings where high resistance to weathering
is required, and suitable for products used
at elevated temperatures due to its high resistance
to yellowing.
Epoxy
Polyester Powder: A high performance
product, classified during manufacturing and
recommended for use where good chemical and
detergent resistance is needed. Combined also
with excellent decorative appearance and ease
of application, is the advantage of good colour
stability. [top]
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Polyester
Powder |
Epoxy
Polyester Powder |
| Film
thickness |
50-70
microns |
30-70
microns |
| Full
gloss |
85%
+ @ 60° |
95%
+ @ 60° |
| Semi
gloss |
50-70%
+ @ 60° |
| Matt |
25-35%
+ @ 60° |
20-40%
+ @ 60° |
| Scratch |
BS
3900 E2 Pass 4kg |
| Impact |
BS
3900 E3 Pass 80 in/lbs |
BS
3900 E3 Pass 100 in/lbs |
| Humidity |
BS
3900 F9 No blistering after 1000 hours (zinc phosphated
steel) |
| Salt
Spray/ASTM B117 |
2-4mm
creep after 1000 hours (zinc phosphated steel) |
| Heat
Stability |
No
yellowing on continuous exposure up to 130°C
or intermittent exposure up to 140°C |
No
yellowing on continuous exposure up to 110°C
or intermittent exposure up to 130°C |
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Technical
Services: Metal
Colours Ltd operate a technical centre whose task it is
to ensure high quality standards across all finishing operations.
The technical centre is equipped with a range of analytical
tools and reference material with which to monitor operating
processes, optimise chemical process routines and liaise
with customers regarding the most suitable finish for their
components. [top]
Expertise: The
Technical Centre is directed by an experienced professional
chemist whose principal responsibility in conjunction
with the Quality Manager, is the maintenance of the highest
standard of quality for all clients' work. [top]
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Technology: The
Centre operates state of the art analytical technology,
including x-ray fluorescence equipment for the determination
of plated metal thickness and zinc alloy analysis, an atomic
absorption spectrophotometer, and a potentiostat. The Centre
is also responsible for the optimum process control of
the plating, electrophoretic paint and powder coating plants
and carries out non-destructive testing on behalf of clients. [top]
Salt
Spray Testing: The Centre operates a full
salt spray testing cabinet and carries out testing
on behalf of clients in accordance with ASTM B117 for
runs of up to 2000 hours. [top]
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Environmental: Metal
finishing processes are subject to strict environmental
control. Our purpose built plant uses the latest technology
to limit particulate and chemical emissions to air and
water. We have eliminated the use of trichloroethylene
and cyanide in all our treatment processes. Plating operations
are Part-B processes controlled by the local authority
to which Metal Colours must demonstrate the use of best
available technology to control pollution. We also satisfy
all waste minimisation and IPPC requirements and are
compliant with the End Of Life Vehicle Directive and
the Waste Electrical and Electronic Equipment Directive. [top]
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WEEE
& RoHS Compliance: Metal
Colours Ltd is WEEE & RoHS compliant and offer suitable
alternatives for both Lead and Hexavalent Chromium compounds
and do not operate any treatments that contain Polybrominated
Biphenyls (PBB), Polybrominated Diphenyl Ether (PBDE),
Mercury or Cadmium. If you have a requirement for a
WEEE & RoHS compliant service or are unsure of your
responsibilities, feel free to call and we will be happy
to help.
We
offer statements of compliance where required.
[top]
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Quality:
Metal
Colours Ltd hold current accreditations for ISO 9001
-general management practice and ISO 14001 - environmental
management systems. Certification was awarded through
Independent European Certification Ltd.
Certificates:
You can view our certificates here: ISO9001,
ISO14001
Customer
Focus: Metal
Colours Ltd is a technically competent, service
focused and client-oriented company. We aim to
continuously improve client satisfaction. Our
marketing strategy is to develop partnership
relationships with our clients and our technology
suppliers. [top]
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Logistics: Metal
Colours Ltd operate a fleet of three articulated lorries
and one 12 tonne lorry which are available for regular
delivery and pick up of clients components subject
to commercial agreement. All our services offer a maximum
five-day turn around. [top]
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