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, cutting 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 U.S. Government sources, 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 program of materials substitution. The Keronite process makes it possible to use magnesium and aluminium alloys in place of steel-with significant attendant environmental benefits. 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.

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 aluminum pistons by a critical 30 degrees Celsius
• Keronite-treated aluminum and magnesium are 100% recyclable