Background: Hexavalent chromium (Cr(VI)) has long been used in various industrial processes, including surface treatments for corrosion protection and decorative finishes. However, due to its toxicity and environmental impact, there is a growing need to find safer and more sustainable alternatives. Avocet Research Centre (ARC) was approached by a Li-ion battery component manufacturer seeking to develop a chromium-free surface treatment that could provide comparable performance while meeting stringent environmental regulations.
Challenge: The challenge was to develop a surface treatment that could effectively replace Cr(VI) without compromising on performance, durability, or cost-effectiveness. The treatment needed to meet industry standards for corrosion resistance against Li-ion battery electrolyte, adhesion, and fatigue life while also being environmentally friendly and compliant with regulations such as REACH and RoHS. Additionally, the treatment must be available for implementation in a reel-to-reel production method.
Solution: ARC’s team of materials scientists embarked on an extensive R&D program to identify and optimise alternative surface treatment technologies. After thorough analysis and testing, the partnership developed a novel conversion coating system that surpassed the performance for Cr(VI)-based treatments. The new surface treatment offered several advantages over traditional Cr(VI)-based wet chemical treatments:
1. Environmental sustainability: the new treatment eliminated the use of toxic Cr(VI), eliminating the waste stream and the associated environmental impact whilst complying with regulatory standards.
2. Corrosion Protection: extensive testing demonstrated that the new coating system provided superior corrosion resistance to Li-ion battery electrolyte when compare to traditional Cr(VI)-based treatments.
3. Adhesion and Durability: the coating exhibited excellent adhesion and wettability to key substrates and demonstrated long-term durability under harsh chemical conditions.
4. Cost-Effectiveness: the new treatment provides a low-cost alternative to the traditional Cr(VI) processes, reducing footprint of the treatment equipment, processing steps and therefore the overall production costs for the component manufacturer.
Results: The successful development of the Cr(VI)-free surface treatment represented a significant milestone in ARC’s commitment to sustainability and innovation. The component manufacturer has filed IP for the new coating system for use in critical components. Implementation is on-going and will lead to:
- Improved environmental performance and compliance with regulatory standards.
- Enhanced corrosion protection and longevity of Li-ion battery components.
- Cost savings and operational efficiencies in the manufacturing process.
- Positive reputation and recognition for adopting sustainable practices in the battery industry.
Conclusion: ARC’s collaboration with the component manufacturer exemplifies its ability to develop innovative solutions that address industry challenges while prioritising sustainability and performance. The successful replacement of Cr(VI) with a Cr-free surface treatment underscores ARC’s dedication to advancing materials science and promoting environmentally responsible practices in manufacturing. This case study demonstrates ARC’s expertise in developing sustainable solutions for industrial applications and highlights the positive impact of adopting environmentally friendly alternatives.