The European End-of-Life Scrap Vehicle Directive approved in September of 2000 effectively bans the use of hexavalent chromium in automotive applications after July 1, 2003. In response to the directive, The United States Council for Automotive Research (USCAR) will disallow the use of hexavalent chromium in corrosion-resistant coatings effective July 1, 2002. A new, chromium-free coating became commercially available in 1998 which provides a solution to this new directive.
The coating is zinc- and aluminum rich, silver in color, thin, water-based, volatile organic compound (VOC) compliant, and contains no toxic metals. It is heat resistant and offers excellent corrosion protection without adversely affecting brake performance.
This report summarizes validation testing for the automotive industry of brake rotors coated with the new, chromium-free coating. Corrosion testing was conducted by an independent laboratory and included neutral salt spray, water fog and adhesion, and 350°C (662°F) heat to part metal temperature followed by SAE J2334 cyclic testing. Dynamometer testing was conducted by a separate independent laboratory.