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Zero-Interference Dacromet & Geomet Coating Solutions
Overcoming the critical risk of hydrogen embrittlement in high-tensile fasteners and structural components, we engineer uniform, thin-film zinc flake protections across complex geometries without inducing structural micro-cracking. By deploying automated dip-spin and precision spray lines coupled with strictly modulated thermal curing cycles, our processing transforms vulnerable high-load hardware into highly resilient, chemically resistant assets. Backed by our rigorous IATF 16949-certified quality framework, we guarantee superior coating adhesion that achieves an industry-leading 1000-hour salt spray resistance, thereby safeguarding structural integrity and maintaining exact engineering tolerances under the most punishing environmental conditions.
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SURFACE ENGINEERING
What is Dacromet & Geomet: The Science of Zinc Flake Protection
Dacromet and Geomet are high-performance, non-electrolytic zinc flake coatings engineered for extreme corrosion resistance. Unlike traditional plating, this process utilizes a proprietary water-based or solvent-based dispersion of zinc and aluminum flakes that bond to the metal through thermal curing. By eliminating the acid pickling stage, it provides a crucial advantage: the total absence of hydrogen embrittlement, making it the industry standard for high-strength fasteners, automotive chassis components, and heavy-duty industrial hardware.
Surface Preparation & Shot Blasting
To ensure flawless adhesion without compromising structural integrity, raw components undergo alkaline degreasing followed by mechanical shot blasting. By replacing traditional acid pickling with mechanical cleaning, we eliminate the risk of hydrogen absorption. This creates an ideal, activated surface profile necessary for the zinc flakes to form a robust metallurgical bond with the substrate.
Precision Coating (Dip-Spin or Spray)
Components are processed using automated dip-spin or spray systems to apply a uniform layer of zinc and aluminum dispersion. We meticulously monitor viscosity, temperature, and centrifugal parameters to ensure a controlled thin-film application. This precision prevents “clogging” in recessed areas and maintains tight thread tolerances for complex stamped and machined parts.
Controlled Thermal Curing
The coated parts are passed through multi-zone conveyorized ovens for sintering. During this high-temperature curing phase, the zinc and aluminum flakes cross-link to form a multi-layered barrier. This creates a unique “lamellar” structure that provides both a physical barrier against moisture and active galvanic protection, resulting in significantly higher durability than standard galvanization.
Advanced Quality Validation
Every production batch is subjected to rigorous outbound inspection protocols. We verify coating thickness using non-destructive X-ray fluorescence (XRF) and perform standardized salt spray testing (ASTM B117) to confirm 1,000+ hours of corrosion resistance. Our QA process ensures total compliance with IATF 16949 standards and global environmental regulations, including RoHS and REACH.
Surface engineering isn’t just a finishing touch—it’s a critical performance factor. You don't just need a vendor; you need a partner who masters the technical nuances of both metal and plastic. Discover our tailored solutions designed to meet your industry's most rigorous standards.
CAPABILITY DATA
Engineered Zinc Flake Coating Specifications & Capabilities
Kravzik provides rigorous process control to ensure consistent, repeatable results for high-performance anti-corrosion requirements. Our Dacromet and Geomet capabilities are calibrated to meet the extreme durability and zero-embrittlement criteria required for high-tensile fasteners, critical automotive stampings, and renewable energy infrastructure.
Request DFM EvaluationCoating Classifications
Dacromet 320/500 (Standard) & Geomet 321/500/720 (Chrome-Free/Eco-Friendly).
Coating Thickness
5µm – 12µm (±2µm) — maintaining precision tolerances for fine-pitch threads and assemblies.
Corrosion Resistance
Exceeds 1,000 to 1,500 hours in neutral salt spray testing (ISO 9227 / ASTM B117 compliant).
Hydrogen Embrittlement Risk
0% Risk — Non-electrolytic process ensures structural integrity for Grade 10.9 and 12.9 high-strength steel.
Friction Coefficient Control
Integrated lubricants providing stable COF (0.06 – 0.18) to ensure consistent torque-tension performance.
Thermal Stability
Maintains superior anti-corrosive properties at continuous temperatures up to 300°C (572°F).
ALLOY VERSATILITY
Compatible Material Substrates for Zinc Flake Coating
The performance of Dacromet and Geomet coatings is fundamentally rooted in the metallurgical synergy between the zinc-flake matrix and the substrate surface. Kravzik engineers utilize mechanical pre-treatment—specifically controlled shot blasting—to replace traditional acid pickling. This critical technical shift ensures 100% structural integrity for high-strength materials and optimizes adhesion across diverse alloys, providing a robust anti-corrosion barrier without the risk of chemical degradation.
High-Strength Alloy Steel (Grade 10.9, 12.9, 4340, 4140)
Critical for heavy-duty automotive fasteners, chassis components, and structural engine mounts. Our non-electrolytic application process completely bypasses the acid-induced hydrogen absorption risk inherent in traditional plating. This eliminates the danger of delayed brittle fracture, maintaining maximum tensile strength and fracture toughness for high-load engineering applications.
Aluminum Alloys (6061-T6, 5052, ADC12)
Crucial for weight-sensitive robotics, aviation, and medical housings. To overcome the natural oxide layer, our process includes specialized acid etching followed by non-chrome passivation, creating a robust chemical barrier that guarantees superior salt spray resistance while maintaining critical dimensional tolerances.
Spring Steel & High-Carbon Steel (65Mn, SK5, 51CrV4)
Essential for precision clips, wave washers, and suspension springs where elastic memory is vital. We utilize specialized dip-spin technology to apply a flexible, multi-layered lamellar structure. This ensures uniform coverage across complex geometries without compromising the material’s fatigue life or inducing the hydrogen-induced cracking common in standard galvanization.
Cast Iron & Ductile Iron (HT250, QT450, GJS-400)
Commonly specified for brake discs, heavy industrial housings, and planetary gear carriers. Our mechanical surface activation techniques effectively address the high porosity of cast surfaces. By ensuring deep-pore cleaning and a dense, blister-free deposition, we create a stable barrier that prevents sub-surface oxidation and delivers exceptional durability in harsh environments.
Aluminum Alloys (6061, 7075, ADC12)
Primarily utilized in EV battery enclosures and aerospace components to prevent bimetallic (galvanic) corrosion when in contact with steel hardware. Our specialized Geomet pre-treatment protocols ensure superior adhesion on aluminum substrates, creating a thermally stable barrier that prevents “white rust” while maintaining the tight tolerances required for lightweight assembly.
Sintered Metal & Powder Metallurgy (Fe-C-Cu Alloys)
Ideal for high-volume automotive transmission gears and complex appliance hardware. The low-viscosity dispersion of our coating allows for deep penetration into micro-pores, effectively sealing the sintered structure against internal corrosion. This results in a smooth, high-precision finish that facilitates seamless mechanical mating and assembly.
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PROCESS GUIDELINES
Essential Design Guidelines & Process Limitations for Zinc Flake Coating
Early-stage design optimization is critical to maximizing the performance of Dacromet and Geomet coatings. To ensure your components meet exact engineering specifications and functional requirements, please consider these geometric, thermal, and dimensional factors before finalizing your CAD models for the zinc flake application process.
Zinc flake coatings typically range from 5µm to 12µm in thickness. Since the coating builds up on both sides of a thread, the pitch diameter can increase by up to four times the coating thickness. Kravzik engineers recommend specifying pre-plate thread allowances or utilizing slightly oversized taps for fine-threaded fasteners to ensure smooth mechanical assembly without compromising the protective barrier.
As a dip-spin or spray-applied process, high-viscosity dispersion can accumulate in deep blind holes, narrow channels, or internal diameters. This may lead to “clogging” or uneven coating thickness. We advise designing components with adequate drainage pathways or generous radii to facilitate centrifugal evacuation and ensure a uniform, functional layer across complex geometric features.
The curing phase for Dacromet and Geomet involves thermal sintering at temperatures between 200°C and 300°C (392°F – 572°F). For precision-machined or stamped parts that have undergone specific heat treatments, it is essential to verify that these curing temperatures will not affect the material’s hardness or mechanical properties. Our team can adjust bake cycles to balance anti-corrosion performance with metallurgical integrity.
Due to the nature of dip-spin application and the high-temperature curing process, selective masking is significantly more complex and costly than in electrolytic plating. We generally recommend full-part coating for maximum protection. If specific surfaces must remain uncoated for electrical grounding or tight press-fits, please consult our engineering team during the design phase to evaluate the feasibility of high-temperature masking solutions.
VISUAL EXCELLENCE
Visual & Functional Excellence: Data-Driven Coating Profiles
Beyond visual appearance, the performance of zinc flake coatings is defined by its chemical composition and friction characteristics. Explore our specialized Dacromet and Geomet profiles to identify the precise technical specifications and corrosion resistance required for your critical engineering assemblies.
INORGANIC ZINC FLAKE
Dacromet® 320 Series
The original zinc-flake technology utilizing a water-based dispersion of zinc and aluminum flakes. It provides a grey, metallic finish with exceptional sacrificial protection and heat resistance, ideal for heavy-duty industrial fasteners where extreme durability is the primary requirement.
Coating TypeWater-based Inorganic Zinc
Chromium StatusContains Cr6+ (Standard Industrial)
Salt Spray Resistance1,000 – 1,500 Hours (ISO 9227)
Coefficient of Friction0.12 – 0.18 (Standard Range)
Ideal For:Heavy machinery, structural bolts, infrastructure hardware
ECO-FRIENDLY PROTECTION
Geomet® 321 / 500 Series
A high-performance, water-based, and completely chrome-free zinc flake coating. It offers a cleaner silver-grey aesthetic while meeting and exceeding the strictest global environmental and automotive OEM standards for anti-corrosion without compromising structural safety.
Coating TypeAqueous Chrome-Free Zinc Flake
Environmental Status100% Cr-Free (RoHS/REACH Compliant)
Salt Spray Resistance1,000+ Hours (at 8μm thickness)
Thermal StabilityMaintains performance up to 300°C
Ideal ForEV battery systems, automotive chassis, safety components
PRECISION TORQUE CONTROL
Geomet® 720 / Plus® Series
Specifically engineered for the global automotive and automation industries to solve the "stick-slip" phenomenon. This profile integrates specialized lubricants into the zinc-flake matrix to ensure a highly consistent coefficient of friction for precision-tightened fasteners.
Coating TypeLubricated Zinc Flake Matrix
Friction Coefficient (COF)0.08 – 0.14 (Meticulously Controlled)
Salt Spray Resistance1,200+ Hours (Premium Grade)
Surface FinishSemi-Matte Metallic Grey
Ideal ForAutomated assembly lines, high-tensile engine bolts, robotics
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SERVICES LIBRARY
Explore Other Industrial Surface Treatment & Finishing Services Available
Carburizing
Stop premature gear wear and catastrophic part failure today. Our precise carburizing achieves 64 HRC surface hardness with a ductile core.
Manganese Phosphating
Stop coating peeling and metal galling on high-stress joints. Our manganese phosphating ensures 100% oil retention for smoother robotic actuator performance.
Tin Plating
Stop tin whisker failures in dense electronics. Our 150°C annealing process ensures 100% solderability for critical terminals.
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TECHNICAL REFERENCE
Frequently Asked Questions
Answers to common questions regarding precision, tooling, materials, and our integrated molding capabilities.
Unlike electrolytic plating, Dacromet is a non-electrolytic process that bypasses acid pickling. By utilizing mechanical shot blasting and thermal curing, we ensure zero hydrogen absorption, providing a safe anti-corrosion solution for Grade 10.9 and 12.9 high-tensile steel components.
Our Geomet coating solutions consistently exceed 1,000 to 1,500 hours of neutral salt spray testing according to ASTM B117 standards. The multi-layered zinc and aluminum flake structure creates a superior physical and galvanic barrier that significantly outperforms traditional zinc plating or galvanization.
Our thin-film application typically ranges from 5µm to 12µm. Because the coating is highly uniform and controlled, it maintains the functional integrity of fine-pitch threads. We provide specific pre-plate allowance recommendations to ensure perfect mechanical assembly for precision-machined and stamped parts.
Yes, we specialize in the Geomet series which is 100% water-based and chrome-free. These coatings meet the strictest global environmental regulations for the automotive and electronics industries, delivering high-performance protection without the use of hexavalent chromium or other hazardous substances.
Dacromet is engineered for high thermal stability, maintaining its structural integrity and corrosion resistance at continuous temperatures up to 300°C. This makes it the ideal choice for automotive engine components, brake systems, and industrial hardware subjected to frequent thermal cycling.
We utilize Geomet Plus topcoats with integrated lubricants to precisely control the coefficient of friction. By maintaining a stable friction range between 0.08 and 0.14, we guarantee repeatable torque-tension performance and prevent galling during high-speed automated assembly processes.
Our processes are ideal for high-strength alloy steel, spring steel, cast iron, and aluminum. We utilize mechanical pre-treatment rather than chemical etching, ensuring maximum adhesion and surface activation on complex geometries without compromising the metallurgical properties or fatigue life of the base metal.
Absolutely. Our facility operates under a rigorous IATF 16949-certified quality management system. Every production batch undergoes automated process monitoring, X-ray thickness verification, and standardized salt spray testing to ensure 100% compliance with critical automotive and industrial engineering specifications.
Still have questions?
Our engineering team loves solving complex problems. Chat with us or send your drawing for a review.
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