OPTIMA - Optimisation of a chrome-free pre-treatment process for lightweight alloy components

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The increasing use of Al by vehicle OEMs is driven by its high strength to weight ratio, enabling substantiallyimproved fuel economy & reduced CO2 emissions when substituted for heavier materials. However, the changeof material presents new challenges with respect to design & methods of joining. The pre-treatment of the Alsurface prior to bonding is the key to long service life. Pre-treatments successfully employed by the aerospaceindustry cannot be used in automotive production, where cheaper & more environmentally friendly pre-treatments are required. Specifically, the use of chromates is unacceptable. Hence, there is a need to developchromate-free pre-treatments that will consistently provide the required level of performance, whilst beingacceptable both in terms of general engineering practice and economy.OPTIMA will therefore prove technical feasibility of implementing in-line NDT within our chrome-free pre-treatment process for lightweight alloys to provide process control and assurance that we can achieve the levelof performance required by our customers.