First-class results in corrosion protection thanks to deburring process

CDP plus powder coating versus galvanising. Previously, when the two most common methods of corrosion protection came up against each other, they were in for a tough fight. Cathodic dip painting, CDP for short, can often excel as a common method for coating surfaces. But if the metal needing protection from corrosion has already been processed, defects can occur on punch burrs, for example. Using a deburring machine, Solvaro is able to achieve excellent results in the salt spray test with deburred and subsequently CDP and powder-coated steel components. The paint’s adhesion properties are better on certain components than on pre-galvanised sheets.

The best rust protection for tough requirements

The best rust protection for tough requirements
In the field of agricultural and construction machinery in particular, components need to meet the harshest demands. They are not only constantly exposed to wind and weather, but stone chips and other problems are also commonplace in the use of heavy equipment. Reliable rust protection for components is an important fundamental prerequisite. So it is with the Multicar M27 all-rounder, which is fitted with a cooler grille from metal component specialist, Solvaro. The cooler grille, supplied by Solvaro and including frame and hinges, is equipped with HV 2–2.25 perforation and achieves an air passage of around 70% thanks to its undulating shape. Great for air intake, but a challenge for corrosion protection. With stamped and lasered plates, CDP coating can get very thin on the punch burr, thus compromising the rust protection.

The salt spray test says, ‘Wow!’

Effective rust protection with CDP coating can be achieved with special deburring technology. ‘The grilles are treated with this technology. This rounds off the edges in the ideal way for the subsequent coating process,’ explains Gerhard Bullinger, managing director of Solvaro. In order to find the optimum coating for the Multicar cooler grille, five coating variants were sent through the salt spray test in accordance with DIN ISO 9227. During the test, the cooler grilles were in a chamber at a temperature of 35°C which was continuously nebulised with a 5% saline solution at a controlled pH value. The spray condensed on the cooler grilles and coated them with a corrosive salt water film. The test took 528 hours. As, in this case, the focus was on testing the coating, this latter was scored down to the base metal. During the test, the base metal corroded along the score lines. The coating was eroded to a greater or lesser degree during the test due to the corrosion process. The resistance of the coating on the test cooler grille was determined by the degree of erosion. The erosion around the scoring was very good (0.16 mm–0.23 mm). However, the differing results with regard to rust formation on the surface and adhesion of the paint coating on the sheet were surprising. The cooler grille treated by Solvaro, which had a subsequent cathodic dip painting and powder coating, showed the best results. This combination even beat the galvanised cooler grille by a mile, as the paint didn’t adhere very well to the grille bars.

SOLVARO – custom solutions in metal.

SOLVARO provides engineering and development services as well as the production of perforated or non-perforated metal components for industry. SOLVARO serves a wide range of industries, such as agricultural and construction equipment manufacturers, with individual solutions. More information at

Printing of text and images is free of charge, copies requested.

Image 1: The Solvaro cooler grille for the Multicar M27 after 528 hours of salt spray testing – erosion along the score line is very good, the cooler grille has only sporadic rust formation on the surface.

Image 2: The Solvaro cooler grille achieves an air passage of around 70%. Great for air intake, but a challenge for corrosion protection.

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