TiZr enhanced bonding in Nichols N1A Supercar
Powdertech Surface Science (PSS) has considerable expertise in applying titanium zirconium (TiZr) passivation treatment to aluminium to prepare it for bonding prior to the application of structural adhesive. When the work you perform is hidden from view and never to see the light of day, one’s pride in its efficacy resides in the finished article.
Such it is for the PSS team; we are extremely proud that our TiZr passivation service has played an essential part, albeit hidden, in the construction of the Nichols N1A super car.
“An unadulterated connection to the road”
The Nichols N1A is undoubtedly one of the most exciting new sports cars to land in the niche vehicle arena, not least due to its incredible pedigree – designed by none other than Steve Nichols, design engineer for reputedly the most successful Formula 1 car ever – the McLaren Mp4/4.
This is a petrol-based vehicle which will appeal to those not relishing the demise of the sound and smell of a fuel driven vehicle.
The N1A looks beautiful and provides the ultimate driving experience. It weighs around 900kg and has 650 brake horse power, which gives some idea of its performance capability.
Advanced aluminium chassis technology
Hiding its light under the impressive bushel of the magnificently curved and honed exterior of the car is a revolutionary chassis design, made almost exclusively from extruded aluminium parts which are adhesively bonded in preference to being welded. Carbon fibre is used in certain parts of the chassis for ultimate stiffness.
The chassis construction is the brainchild of Bob Mustard, a veteran of automotive engineering, formerly Director of Stalcom Automotive Technologies, now CTO at Watt Electric Vehicles. Bob and his team have developed Flex-tech, a patented aluminium extrusion system with a unique interlocking feature which can create a bonded and riveted space frame structure with joining nodes.
After many years of involvement with chassis construction, Bob considers adhesive bonding to be far superior to welding for strength and has many test pieces to prove the point
TiZr pre-treatment for bonding – the most critical component
Bob described, in an interview for Petrol PED, how the most important step for successful bonding is careful pre-treatment of the aluminium Flextech components.
“People think that it’s a case of putting a good industrial adhesive on the aluminium surface and bonding will be as strong and reliable as it could be, but this is not the case. It is imperative that the aluminium surface is pre-treated properly before it sees any adhesive.”
The pre-treatment required is called passivation and Bob turned to PSS and our TiZr titanium zirconium passivation service.
Passivation, sometimes called conversion coating, involves immersing the metal component in a series of chemicals to clean the surface, remove the natural oxide and replace it with a stable, chemically modified, oxide ‘shield’ layer – the passivation layer. We measure the cleanliness with XRF equipment, Dyne inks and UV-Fluorescence and can demonstrate compliance to specifications detailing RFU limits. The chemical functionality of the passivation layer allows adhesives or paints/powder coatings to anchor, providing both strength and long-term corrosion protection. At Powdertech Surface Science we use titanium-zirconium pre-treatment processes, free from any chromates. Our Gardobond systems meet the specifications of leading car manufacturers such as JLR, Tesla, VW/Audi and BMW.
Entire Flextech chassis components cured in an oven
Powdertech treated over one hundred tub and subframe components in a titanium zirconium system and sent them back to Stalcom for assembly.
The pre-treated (passivated), glued and riveted assembly was fully powder coated for enhanced durability and for aesthetic purposes – though it would remain hidden.
Curing of both the adhesive and the powder coat could take place concurrently once the entire assembly was placed in the oven in a method unique to Stalcom.
Our expert TiZr pre-treatment is now hidden, yet it is critical to the successful bonding of the Flextech components making up the chassis.
Images of the spectacular N1A will soon be adorning our plant. It is always rewarding to have a tangible reminder of the end result of hours of careful work