Established, Cost-Efficient Corrosion Protection
Zinc Plating of Metal Surfaces
Galvanic Zinc Coating
The galvanic zinc plating process with subsequent passivation is the most widely used and most cost-efficient procedure for reliable corrosion protection in metal finishing.
Zinc layers with subsequent thin-film passivation (DÜSP) or thick-layer passivation (DISP) and, if required, sealing (TOPCOATS) are applied by HOLDER on state-of-the-art systems for rack-plated goods.
The fully automated systems ensure absolutely consistent and exactly repeatable plating quality – economically and with optimal conservation of natural resources.
Corrosion Protection, Materials, Test Values
> 120 h
without white rust
In the neutral salt spray test according to DIN EN ISO 9227.
> 360 h
without red rust
Depending on layer structure and post-treatment.
Steel & Cast Iron
suitable materials
Rack-plated coating, available as selective or internal coating with inner-anode technique.
Cr(VI)-free
passivations
Novatec 100 to 130 as well as TRICOAT black and silver.
Advantages of Galvanic Zinc Coating
- Economical procedure
- High level of corrosion protection
- Bending capacity and flangeability
- Enhanced temperature resistance
- High peel strength of the passivation layers
- Selective coating possible
- Internal coating with inner-anode technique
- Appealing cosmetics
More information about Zinc
Suitable materials:
- Steel
- Cast iron
Corrosion resistance:
According to DIN EN ISO 9227 – NSS
- > 120 h without white rust
- > 360 h without red rust
Post-treatment passivation:
- Rack: transparent, thick-layer passivation
Optional post-treatment:
- Sealing with or without slip additives
- TOPCOATS
- Lubricant treatment
- Heat treatment for hydrogen de-embrittlement (baking)
Chromium(VI)-free passivations:
- Novatec 100 to 130
Chromium(VI)-free combined coatings:
- TRICOAT black
- TRICOAT silver
Products:
- ZinKlad 96
- ZinKlad 250
- MG/MGL (against contact corrosion with magnesium)
- Gleitmo 605
- Torque’n Tension
Product Novatec 100 ff
Under the designation Novatec 100 ff, you receive a chromium(VI)-free galvanic zinc surface in a quality that meets and even exceeds all automotive specifications and surface standards.
This corrosion protection system, developed by HOLDER, is temperature-resistant. Under extreme thermal loads, for example in the engine compartment or brake area, the protective effect remains fully intact.
The corrosion protection system is environmentally friendly. Novatec 100 ff complies with the EU directives (chromium(VI)-free) and RoHS.
What is galvanic zinc plating and what is it used for?
In galvanic zinc plating, a zinc layer is electrochemically deposited onto steel or cast iron components and subsequently passivated. It is one of the most widely used and most cost-efficient metal finishing processes, offering high corrosion protection combined with an appealing appearance.
What advantages does galvanic zinc plating offer at Holder?
The fully automated rack systems ensure consistent, exactly repeatable plating quality with optimal conservation of resources. Advantages include high corrosion protection, bending capacity and flangeability, enhanced temperature resistance, high peel strength of the passivations, as well as optional selective coating and internal coating using inner-anode technique.
What post-treatments are possible (passivations, sealants, topcoats)?
The zinc layer is followed by thin-film or thick-layer passivation and, optionally, sealing (topcoats) with or without slip additives. This allows corrosion protection, friction values and appearance to be tailored precisely to the specific application.
What corrosion resistance do zinc layers achieve at Holder?
Corrosion resistance is tested according to DIN EN ISO 9227 (neutral salt spray test). Typical values are > 120 hours without white rust and > 360 hours without red rust, depending on layer structure and post-treatment.
Are the zinc surfaces chromium(VI)-free and standard-compliant?
Holder uses chromium(VI)-free passivations such as Novatec 100 to 130 as well as chromium(VI)-free combined coatings such as TRICOAT black and silver. The Novatec 100 ff system is free of CrVI, RoHS-compliant, and meets or exceeds common automotive specifications and surface standards.
Which standards and customer specifications govern galvanic zinc plating?
Zinc coatings are applied in accordance with, among others, VW/AUDI TL 217 (TL 13750), TL 194, BMW GS 90010 A5 ZNT, DBL 8451, DBL 8466, Ford WX100, Porsche PN 11011 and DIN 50979. Further customer-specific standards and individual specifications can be implemented by arrangement.
What typical products and systems are used in zinc plating?
In addition to Novatec systems for zinc and combined coatings, products such as ZinKlad 96, ZinKlad 250, MG/MGL for contact corrosion protection with magnesium, Gleitmo 605 and Torque’n Tension lubricants are used. These product lines are widely established in the automotive industry.
Which materials can be galvanically zinc-plated?
Suitable materials for galvanic zinc plating are primarily steel and cast iron components. For aluminium and other light metals, Holder offers separate processes such as passivation, anodizing and conversion coatings.
How is hydrogen embrittlement addressed (baking/tempering)?
To minimise the risk of hydrogen embrittlement, a heat treatment (baking/tempering) can be carried out after galvanic zinc plating. This post-treatment reduces the hydrogen bound in the component and increases operational safety, particularly for high-strength steels.
Which quality and environmental certifications safeguard the plating processes?
Quality and environmental management are certified according to IATF 16949:2016, ISO 14001, ISO 50001 as well as ZinKlad. This documents process reliability, energy efficiency and environmentally sound execution of the galvanic coating processes.