APPLICATION TECHNOLOGY
Rigorously implemented
By Rudolf Knott, Central Engineering Division, MAN Truck & Bus A, & Dr. Jochen Schneider, Customer Service, Dörken MKS-Systeme GmbH & Co. KG
Commercial vehicle manufacturer MAN will from now on be using a chrome (VI)-free coating from Dörken for the surface protection of high-strength steel fasteners. Its layered structure made up of a zinc flake coating with coordinated post-lubrication achieves the specified high level of corrosion resistance and fulfils at the same time the coefficient of friction requirements.
technology, the company is constantly looking for new solutions to reduce fuel consumption, exhaust emissions and noise level. The MAN TGX 18400, for example, received the ‘Green Truck 2011’ award, having impressed judges with the lowest level of fuel consumption and CO2
M emissions on the European market. However, ecological accomplishments have taken a high
priority at the company for many years. Regular internal and external audits are, for example, run at every production site in order to review the environmental protection measures in place and to continually improve the company’s sparing use of water and material resources and the reduction in air pollutants. Some of these measures are concerned, for instance, with reducing use
AN Truck & Bus AG of Munich is the largest company in the MAN Group and one of the world’s leading suppliers of commercial vehicles and transportation solutions. As a pioneer in all areas of relevant
of coolants and lubricants and the associated consumption of water, while others relate to optimising fasteners’ anti-corrosion coating from a ‘green’ perspective.
Responsible decision making Although EU Directive 2000/ 53/EC, which has been in force
since July 2007, does not apply to vehicles over 3.5 tonnes, MAN decided to switch surface coatings for all bolts and other fasteners to chrome (VI)-free alternatives. This decision was, of course, taken partly to reduce the risks to humanbeings and the environment. However, commercial and logistical considerations also played a part. That’s due to the fact that at every stage of the production process right through to assembly chrome (VI)-free parts have to be strictly separated from parts with a chrome (VI) content. A duplicated production line would also mean higher logistical and manufacturing costs. Furthermore, since the EU End-of-Life Vehicle Directive came into force coatings with chrome (VI) content are becoming less and less available and therefore also more expensive. In search of alternatives for the
previously used systems consisting of coatings with chrome (VI) content and post- lubrication, the company quickly became aware of Dörken MKS-Systeme GmbH & Co. KG from Herdecke. Dörken’s zinc flake systems have not only been chrome (VI)-free from the outset, but through the company’s close contacts with many representatives of the value-added chain, it was also possible to link up quickly with an international fastener manufacturing company, which was then incorporated into the early discussions. The aim here was to specify the parts provided for extensive test cycles and to define all key additional factors, such as fastening parameters and bearing surfaces. The parts tested were high-strength steel bolts and nuts ranging in size from
124 Fastener + Fixing Magazine • Issue 73 January 2012
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