Patented Two-Step Process for Auto Body Surface Treatment


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Challenge
In cooperation with Audi, Henkel has developed an auto body pre-treatment process. The patented two-step process enables surface treatment of multi-metal auto bodies with an aluminum content of up to 100 percent. In zinc phosphating, which was the conventional process, the volume of waste products increases as the aluminum content of mixed material bodies rises. These are very costly to remove from the pre-treatment bath and the surfaces that are treated in them.

Solution
Due to the different surface properties of steel and aluminum body components, the Bonderite two-step process pre-treats them in two stages. This allows more aluminum to be used, while reducing the disadvantages of the current process, i.e. energy and chemical use decrease during the production process. Servicing expenses, the associated downtime, and waste volumes are also reduced.

Audi was the first company to integrate this method into its processes. The two-step process has now become the global standard for pre-treatment of auto bodies with a high aluminum content and is applied by leading automobile manufacturers around the world.

Benefits
The two-step process is a sustainable surface treatment method that offers the following advantages:

  • Resource-efficient thanks to reduced waste, energy and chemicals
  • Enables pretreatment of body shells with an aluminum content of up to 100%