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Ford Developing New Anti-Corrosion Technology That Cuts Water Use and Sludge Production
3 September 2007
Ford Motor Company is developing a new anti-corrosion technology that cuts water use in automotive paint shops by 40% and decreases the production of sludge by 90%.
The new process uses a zirconium oxide vehicle bath, rather than the currently used zinc phosphate. Zirconium oxide doesn’t contain the heavy metals—zinc, nickel, manganese—found in the phosphate bath.
As a result, there’s a 40% savings in water usage and significantly less waste to be processed into non-hazardous sludge and taken to landfills. Additionally, it doesn’t require heated water to work, saving energy costs.
Zirconium oxide also covers the sheet metal with a uniform film versus the crystal-like structures of the phosphate system. This offers the potential for more robust corrosion resistance.
The new technology, currently being field-tested on a small fleet of Lincoln Town Cars, takes the entire pre-treatment process down to eight steps from the current 13 parts of the conventional pre-treatment process. Pre-treatment is critical to the paint process because it helps prevent rust and corrosion on the vehicle body.
Field tests will continue through 2008 when Ford will determine its rollout plans to paint shops in North America.
September 3, 2007 in Sustainability | Permalink | Comments (6) | TrackBack (0)
Comments
Posted by: JN2 | September 03, 2007 at 02:16 PM
Actually the technology is being developed by Henkel Corporation. It also cuts energy usage by operating at ambient temperatures rather than 135 deg F in the traditional zinc phosphate baths
Posted by: David Whitaker | September 03, 2007 at 06:49 PM
Hmm. Another article about Ford making (relatively minor) "green" improvements in manufacturing processes. Yet they continue to churn out "Light Trucks" for Soccer Moms to take the kids to Chuck E Cheese.
Posted by: George | September 03, 2007 at 08:01 PM
Fine by me. These processes also save the company money. This is yet another example of green being better business. That's where we need to get because that's what's going to change the world (for the better). It sucks that it has to be that way, but it would appear that that's the way things are. This is a baby step, but if other companies follow suit and start trimming their bottom line with more environmentally sound, less expensive business practices then everybody benefits.
Posted by: Tripp | September 03, 2007 at 08:05 PM
Greener can be cheaper and even better?
That just cannot be true!
There must be a mistake here.
Posted by: | September 04, 2007 at 08:19 AM
What a cool story. Looking forward to more. I love how green can equal clean and profitable.
Posted by: chillpill | September 04, 2007 at 08:42 AM
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Hopefully Ford's CEO from Boeing will convert them to carbon fibres - less weight, less pre-treatment required.