First the zinc-nickel coating, then forming or bending

Development partnerships are a welcome challenge for the Holzapfel Group, as they lead to innovative coating processes and therefore to a new array of options for customers and their components. That is also how the Group developed the flexible FleXXKorr zinc-nickel coating, together with a process supplier and in close collaboration with a customer. At the end of 2006, after four years of development work, the Holzapfel Group was the first supplier to bring a bendable, ductile zinc-nickel corrosion protection coating to the market. The value stream-optimised process makes it possible to bend and/or form conduits, pipes and hydraulic lines after the coating process, significantly cutting handling costs. Using the conventional transparent passivated zinc-nickel process, coated parts can no longer be shaped without damaging the coating. Previously, the parts were first formed and then coated, which meant they took up a great deal of space on the racks of the coating systems and were very complicated to handle, making the coating process unnecessarily costly. FleXXKorr completely solves this problem, as it can be formed and bent together with the base material without any loss of quality.  Drop formation, e.g. on sealing surfaces or sticking on critical points such as threads or inlets and outlets, etc. is no longer a problem. FleXXKorr is therefore the ideal solution for all industrial fields requiring bent zinc-nickel-coated components, such as in the automotive industry or in plant engineering. Apart from conduits and pipes, the process is suitable for coating workpieces used in fastening technology, such as sleeves and bolts, as well as for sheet metal parts.

Zinc-nickel coating is also suitable for ductile, crimped and deep-drawn components
The ductile, formable, bendable zinc-nickel alloy surface also has great advantages when producing components that need to be formed or crimped. For example, they no longer need to be additionally sealed. Other fields of application can benefit from this process, too. For example, in the case of tower components used to attach shock absorber to car chassis, the conventional zinc-nickel coating began to flake off during assembly as the deep-drawn component became widened during the installation process to ensure that the shock absorber was firmly fixed to the chassis. Using FleXXKorr, the surface endured the widening process completely unscathed, without any cracking or flaking. The outstanding level of corrosion protection (salt spray-tested, minimum 720 hours without developing red rust) is also fully guaranteed after forming. In addition, FleXXKorr meets all established automotive industry standards, as do all zinc-nickel surfaces produced by the Holzapfel Group.

Possible standards as basis for zinc-nickel FleXXKorr coating are:

  • VW TL244 r642, r643 and r647
  • DBL 8427.10 1/12

FleXXKorr flyer as a PDF


On the process page you can find further information on the FleXXKorr formable zinc-nickel coating 

Conduits and hydraulic lines can be coated with zinc-nickel fleXXcor when stretched and subsequently bent, significantly reducing handling costs, both for transportation and coating.

A further example for the application of ZnNi fleXXcor are the deep-drawn towers used in shock absorbers, which are widened after coating in order to securely attach the shock absorber to the chassis.