Steel battery housing
Advanced surface finishing for maximum protection
The surface finishing of steel battery housings is a critical factor in ensuring long-term durability, corrosion resistance, and optimal adhesion for subsequent coatings like e-coat and fire-retardant layers. Our multi-layered electrolytic plating system enhances protection by integrating zinc nickel plating, a passivate layer, and an optional sealer, providing superior resistance to harsh environmental conditions.
Our solutions
Zinc nickel plating: The superior protective layer
Zinc nickel plating is the most effective surface treatment for steel battery housings, outperforming traditional zinc phosphate coatings. This cathodic protection system prevents red rust formation by acting as a sacrificial layer, ensuring that even if the surface coating is compromised, the steel substrate remains shielded from corrosion.
- Zinni? 220: Acid zinc nickel process that combines high plating efficiency with superior thickness and alloy distribution across a wide current density range
- Zinni? AL 450: Alkaline zinc nickel plating process with stable nickel incorporation of 12? ?? 15%
Passivate layer: Essential for adhesion and additional protection
A thin passivate layer is applied over the zinc-nickel plating to improve the performance and durability of the coated surface. This layer plays a critical role in enhancing adhesion between the zinc-nickel deposit and any subsequent coatings, such as electrocoat (e-coat). By stabilizing the surface, it also contributes significantly to corrosion resistance, acting as a protective barrier that delays the onset of degradation. Moreover, the passivate ensures a uniform, defect-free finish that optimizes the overall surface quality for demanding automotive and industrial applications.
- EcoTri? NC:?Cr(III)-based, cobalt-free, environmentally sound passivate offering high corrosion protection
- Tridur? DB: High-performance blue trivalent chromium passivation process for zinc and zinc alloys. In combination with Tricotect? auxiliary equipment, best plating quality can be achieved with reduced consumption of resources.
Optional sealer: Additional corrosion resistance
For applications requiring even higher corrosion protection, a sealer can be applied over the passivate layer. This additional barrier increases resistance against environmental factors such as moisture and salt exposure. However, careful selection is necessary, as some sealers may slightly reduce adhesion to subsequent coatings.
- Sealer 300 W: Clear reactive inorganic sealer providing superior appearance and corrosion performance
Superior fire protection for steel battery housings
Battery housing fire resistance is a critical factor in electric vehicle (EV) safety. Our zinc flake coating systems ? free from cadmium, lead, nickel, and boron ? offer outstanding protection. Applied as single layers or multi-coat systems, they meet corrosion resistance standards of 500 to 1,000 hours against red rust and remain stable at temperatures exceeding 450?¡ãC for at least 10 minutes. This thermal durability provides crucial time for EV occupants to evacuate safely in the event of a fire.
- Zintek? Top XT: The inorganic, clear topcoat combined with the premium basecoat.
- Zintek? 200 XT: The silver zinc flake basecoat provides outstanding corrosion protection with delayed white rust formation.
- Zintek 300 HP + Techseal? Black SL F: The combination of the organic black topcoat and the black
Full surface coverage for maximum protection
Traditional plating methods can leave edges and stamped areas vulnerable to corrosion. Our cyclical plating process ensures full coverage across the entire steel surface, including edges, by applying a uniform layer of zinc nickel, passivate, and protective coatings. This prevents localized corrosion and ensures the highest level of structural integrity over the battery housing¡¯s lifespan.
With our advanced surface finishing solutions, steel battery housings offer unmatched protection, superior adhesion, and long-term performance, ensuring the safety and reliability of electric vehicles.