New Technology to Lessen Impact of Cars Upon The Environment

CAMBRIDGE, England, April 5 -- New surface treatment technology developed by Keronite Ltd, the Cambridge-based technology company, is set to make a significant contribution to efforts to reduce the impact of cars on the environment. The Keronite process enables car manufacturers to use lighter metals in their vehicles and so cut fuel consumption and emissions.

The automotive industry is currently under increasing pressure from governments and public opinion to improve fuel economy and reduce CO2 emissions. According to US Government sources(1), every 10% reduction in vehicle weight represents a 7% reduction in fuel consumption and associated emissions. The obvious solution to produce lighter vehicles is counter-manded by customer demands for more on-board features and heavier vehicles such as SUVs.

For the automotive industry, Keronite Ltd believes that the only way to improve environmental performance without compromising on other consumer requirements, is an extensive programme of materials substitution. The Keronite process makes it possible to use magnesium and aluminium alloys in place of steel - with significant attendant environmental benefits. USCAR (US Council for Automotive Research) figures(2) indicate that each time 10kg of steel is replaced by 4kg of magnesium, there is a saving of at least 100kg of greenhouse gas emissions over the lifetime of the vehicle. This would mean a saving of 4 million tones p.a. if every passenger car produced worldwide made such a substitution.

Keronite surface treatment technology uses plasma electrolytic oxidation (PEO) to convert the surface of light metals such as aluminium, magnesium and titanium into an extremely hard, dense ceramic with outstanding properties in terms of resistance to corrosion and wear. An immersion process, Keronite is used to treat the inner as well as the outer surface of the most complex shapes and is being used successfully across a range of industries.

The Keronite process has other environmental benefits beyond allowing material substitution. Unlike conventional treatments, the Keronite electrolyte solutions contain no chrome or other heavy metals, no ammonia, no acids and the process generates no hazardous waste. Initial tests carried out for a leading automotive manufacturer also indicate that magnesium components coated with Keronite appear to present no problems when it comes to recycling.

Lars Olrik, CEO of Keronite is aware that it is unusual for a surface treatment company to be discussing the impact of their process on the environment, but believes that "Keronite has an important role to play in the battle against global warming. In addition to the benefits of the process itself in terms of protecting and strengthening components, Keronite presents a practical option for car manufacturers seeking for an answer to often extremely vocal demands for environmentally-friendly action."

   Editors Notes

   (1) Quoted on the US Government Fuel Economy website produced by the US
       Department of Energy and the US Environmental Protection Agency -
       http://www.fueleconomy.gov/feg/kightweight.shtml
   
   (2) Extrapolated from figures appearing on the USCAR website -
   http://www.uscar.org/media/releases/castmagnesium

An article discussing the benefits for the environment of the Keronite process in more detail is available on the website -- http://www.keronite.com/

  Examples of Keronite ceramic practical benefits:

  * Automotive door frames and other body parts can now be constructed from
    magnesium, with OEMs confident enough to offer a 12 year corrosion
    warranty

  * Engine performance is significantly improved by reducing the temperature
    of aluminium pistons by a critical 30 degrees C

  * Keronite-treated aluminium and magnesium are 100% recyclable

  * Magnesium can be successfully used for mobile phone cases, cameras, PDAs
    and laptops because of Keronite's superior corrosion resistance

  * Aluminium frying pans coated with Keronite and impregnated with PTFE,
    demonstrate unsurpassed scratch and corrosion resistance

  Examples of current Keronite users:

  * Automotive industry -- Keronite provides a durable surface for interior
    parts such as seat frames, instrument panel beams and supports, and
    airbag retainers; corrosion-resistance for exterior parts such as roof
    rails, door handles, door frames, body panels and wiper casings; and
    corrosion-resistance for powertrain components such as cylinder head
    covers and gearbox housings.

  * Aerospace industry -- about 80% of aircraft weight is now made up of
    aluminium.  Coating with Keronite improves durability and performance
    and allows the use of magnesium for seat frames, covers, gearbox
    housings and brake covers without the risk of atmospheric or galvanic
    corrosion

  * Transportation -- Keronite protects from corrosion the interior surfaces
    of complex shapes such as the frames for bicycles, wheelchairs and
    pushchairs

  * Fashion industry -- Keronite-coated magnesium is used in the production
    of sun-glasses giving a high-quality scratch-resistant finish, protected
    against the corrosive combination of cosmetics, sun creams and sweat

  * Food Industry -- Keronite-coated aluminium, impregnated with PTFE
    produces a non-toxic, durable scratch-resistant surface for high-quality
    non-stick cookware

  Independent Tests

Keronite coatings have been successful in independent tests conducted by a number of global companies and leading research institutions, eg:

   BMW
   Daimler Chrysler
   Fiat
   Ford
   General Motors
   VW

   European Space Agency
   Fraunhofer Institut, Germany
   Techniker, Spain
   The Welding Institute (TWI), UK
   University di Torino, Italy
   University of Cambridge, UK
   University of Sheffield, UK