COATINGS
CORROSION
BONDING
INTERNET OF THINGS
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THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING
SURFACE TREATMENT & FINISHING
CONTENTS
Digital Edition No.9 Editorial Editor: Nadine Bloxsome Tel: +44 (0) 1737 855115 nadinebloxsome@quartzltd.com
COVER COATINGS
CORROSION
BONDING
INTERNET OF THINGS
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Production Editor: Annie Baker
coating
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THE JOURNAL OF ALUMINIUM PRODUCTION AND PROCESSING
Sales Sales Manager: Nathan Jupp nathanjupp@quartzltd.com Tel: +44 (0)1737 855139
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WHY POLYMER COATINGS ARE A NECESSARY EVIL
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LATEST HENKEL THIN FILM CONVERSION COATINGS SAVE PROCESS TIME AND COSTS
Sales Director: Ken Clark kenclark@quartzltd.com Tel: +44 (0)1737 855117
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SURFACE TREATMENT & FINISHING
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COPING WITH CORROSION
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THE EDITOR’S COMMENT
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APPLYING INDUSTRY 4.0 TO ALUMINIUM PRODUCTION
anodisied aluminium
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STURDY AND STYLISH
deoxidizing 10
AEROTECH PROCESSING SOLUTION: PREPARATION IS KEY
company update 13
GENERAL MAGNAPLATE CORPORATION BRINGS APTIMAG-XTM TO THE NORTH AMERICAN MARKET
surface treatment
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ALUMINIUM ALLOY FOR AUTOMOBILES
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The Finishing Touch Welcome to this special digital issue of Aluminium International Today, which focuses on surface treatment and finishing technology. As many of you reading this will know, aluminium has a naturally occurring oxide film that protects it from corrosion. This oxide film is sufficient for many applications, but in extreme environments, extra protection may be needed. Aluminium can be buffed, blasted, polished, grinded or sanded. These finishes can improve surface quality or prepare the aluminum for other cosmetic finishes such as dipping, anodising or powder coating. Because of its versatile and relatively low-cost nature, as well as high strength-to-weight ratio and non-corrosive properties, aluminium is becoming the material of choice for a range of applications, from designing a new building to fitting out a train interior. I’m interested to make finishing and treatment technologies a regular feature in the printed version of the magazine, so please get in touch if you’d like to submit an article or any press releases in this sector. I hope you enjoy this very colourful issue! Nadine Bloxsome Editor, Aluminium International Today E: nadinebloxsome@quartzltd.com W: www.aluminiumtoday.com
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Digital Edition - August 2018
2 COATING
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Why polymer coatings are a necessary By Colin Butler*
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Fig1. Excessive plastic packaging on food (Andy Wells,Yahoo News U
We’ve all read recently about the scandal of plastics floating about in the rivers and oceans of the world. Of course the retail/ packaging industries do themselves no favours with stories such as the cauliflower “steak” in a plastic tray covered in film. We all hate having to tear off that nasty, unnecessary packaging to get to our deliciously nutritious ready meal. In the aluminium industry we feel righteous about the recycling record and environmental credibility of cans, don’t we? Reported recycling rates of beverage cans were 99% in Germany and Finland, and 73% in Europe in general in 2014. In this blog I want to sound a few cautionary notes about babies and bathwater, and why we need to think hard about becoming entangled in the clamour for the elimination of plastics. Here I’m lumping coatings and lacquers in with plastics since they’re all polymers. They come from the same starting stock (oil), have the same stubborn resistance to degradation and ultimately will end up as carbon dioxide.
Polymer coatings on beverage cans Let’s start with the beverage can. It’s a great success story when it comes to low carbon footprints. Boy scouts, girl guides and charity collectors the world over love them! In 2011, in the EU, 16% of aluminium rolled products went into beverage can manufacture(1). Polymer coatings cover all internal surfaces and most of the outside of aluminium cans. If we assume a coating thickness of 1 µm (about one hundredth of the thickness of a human hair), this translates to 2500t of coating on 59 billion cans. We apply these polymer coatings to the cans largely for protection and decorative purposes. Protection works both ways: we have to stop the aluminium from interfering with the drink, and also stop the drink from eating away at the aluminium can. The fact that this amount of coating might seem relatively small given the size of the beverage can industry is testament to the effort put in to minimise material use. This goes for the metal as well as the coating. In general packaging companies
want to use as little of the Earth’s resources as possible. Put like this, they sound like a very altruistic bunch. However, it all comes down to money. Polymer coatings and aluminium cost something. Therefore, reducing the amount used, in general, reduces costs. It’s not all bad news! So what happens to this 2500t of polymer coatings when the cans are recycled? In a nutshell, it gets burnt off. However, do not despair. This isn’t the big, black environmental mark against can recycling that you might believe. This is because we use the energy released during can decoating to help heat up the furnaces that melt the aluminium. We need to heat and melt the aluminium to transform it from cans back into ingots, which we then use to make other useful products. Bioplastics I like this description of the coating being a staging post in the life cycle of oil. Unfortunately, it still ends up as carbon dioxide emissions and contributing to
*Innoval Ltd UK Digital Edition - August 2018
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y evil
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UK•January 9, 2018)
Fig 2. Polymer coatings are an essential part of beverage cans Fig 3. Can conventional plastics be substituted with biodegradables?
the Earth’s greenhouse gas problem. However, we’ve diverted its path more than if we burnt the oil, say, in a car engine. But wouldn’t it be better if we didn’t use petroleum based coatings at all? What about bioplastics? Could we make polymers, including coatings, from sustainable sources? Well yes, it’s already done. In 2009 Coca Cola launched their Plantbottle, “the first-ever fully recyclable PET plastic bottle made partially from plants”. A couple of points I should mention here: Coke’s development is a recyclable plastic which can integrate into current PET recycling systems. Although it is a bioplastic, it is not biodegradable. Consequently, since Coke has distributed 40 billion Plantbottle packages worldwide, it is possible that some of the debris found floating in the Pacific is bioplastic. Eliminating plastics Conversely much has been made of efforts to “eliminate plastics” by
substituting biodegradables, notably in one supermarket in Amsterdam(2). You might care to look at the blog of Tetracycle founder Tom Szaky(3) for a description of why you’d need an industrial composter (and not your garden heap) to break down the biodegradable polymers in use. Another thing to consider is that bioplastics don’t grow on trees. They actually start life as crops growing in fields. At the moment the availability of fields is, as far as I understand it, limited given that we generally want to grow food without resorting to a vast increase in the use of fertilizers, pesticides etc. However, that’s a whole new blog for someone else to write. A note of caution To finish, I think we need to be cautious about “eliminating plastics”. They cover a wider range of useful products than the litter they are commonly portrayed as. In the aluminium industry we coat a lot of our products. It’s a simple fact that these products could not exist
if we didn’t. Bioplastics may become useful when we’ve learnt how to farm them efficiently without disrupting food production. In the meantime, let’s think about how we make best use of oil based products before sending them up the chimney. Furthermore, let’s recognize that ultimately energy recovery through thermal recovery is critical. If you need support choosing, optimising or minimising your aluminium coatings, please feel free to contact Innoval Technology via enquiries@innovaltec.com � References:
1. Joerg Sander, “Coil Coating”, p. 147 (Vincentz Network), 2014 2. h t t p s : / / w w w. t h e g u a r d i a n . c o m / environment/2018/feb/28/worlds-firstplastic-free-aisle-opens-in-netherlandssupermarket 3. https://www.huffingtonpost.com/tomszaky/bioplastics-and-the-truth_b_8954844. html
* Colin Butler has a PhD in polymer science and 30 years’ experience in the aluminium industry working with products ranging from packaging to automotive to lithographic. Aluminium International Today
Digital Edition - August 2018
4 COATING
Latest Henkel thin film conversion coatings save process time and costs
Henkel can now offer a number of new generation solutions to metal pretreatment processes. BONDERITE® M-NT thin film conversion coatings are designed to enhance multi-metal parts (steel, iron, aluminium, zinc) and overcome the issues associated with traditional phosphating, such as high energy costs, excessive sludge and scale generation, environmental and health and safety concerns. In contrast, BONDERITE® M-NT coatings, which are much thinner than traditional zinc or iron phosphates, offer a 10-30% process cost saving, while further advantages include the absence of phosphate or nickel salts, and no polymers in the conversion bath. Henkel can provide products such as BONDERITE® M-NT 1200, BONDERITE®MNT 20120, BONDERITE® M-NT 2011 and BONDERITE® M-NT 40042 to suit different Digital Edition - August 2018
pre-treatment processes requiring various numbers of steps. To illustrate the potential benefits available, a traditional zinc phosphating process comprises seven steps: cleaning, rinse, conditioner/activator, phosphating at 55°C, rinse, post-rinse and DI (deionised water) rinse. Using BONDERITE® M-NT 1200, however, this can be reduced to just five steps*: cleaning, water rinse, DI rinse, BONDERITE® M-NT 1200 thin film conversion coating, and a final DI rinse (*note, this is dependent on a high level of cleaning; sometimes two cleaning stages will be required, meaning a minimum of six stages). In addition, conversion coating takes place at ambient temperature, so there is no need to use energy heating the bath.
In a customer case study, a UK painting subcontractor switched from zinc phosphating to thin film BONDERITE® M-NT 1200, achieving a safe and reliable process as a result of easy bath controls and fewer steps to monitor. Not only did the company reduce its energy costs, but maintenance was also reduced considerably as very little sludge or scale is produced. Furthermore, the highperformance product passed the 1000hour neutral salt spray test. Similar success has been witnessed at a French manufacturer of agricultural plant that is now using zirconium-based BONDERITE® M-NT 20120 in place of a five-step phosphating process. Along with reduced energy consumption, the plant is experiencing excellent paint adhesion and no flash-rusting. The latter creates a Aluminium International Today
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powdery layer that lowers paint adhesion and was previously causing a problem for the plant. Also in France, outdoor furniture manufacturer, Fermob, is exploiting the benefits of BONDERITE® M-NT 20120 to protect its products against corrosion while at the same time minimising environmental impact. Fermob processes some 3200 tonnes of steel and aluminium every year at its Thoissey plant. With a thickness of only 20 to 30nm, the nano-ceramic BONDERITE® M-NT 20120 coating is much thinner than the layer achievable with conventional iron phosphating, which is typically 500 to 1000nm. What’s more, paint adhesion and corrosion protection are substantially better – salt spray tests show that switching to BONDERITE® M-NT 20120 improves anti-corrosion performance by about 30%. A further product of interest is BONDERITE® M-NT 2011, an advanced pre-treatment system that provides a nano-ceramic coating to metal substrates, and is especially formulated for use on steel surfaces, aluminum and zinc. Totally free of phosphorus, COD, BOD and heavy metals, the product operates at room temperature and offers a high level of pre-treatment performance. It needs fewer chemical steps and reduces power consumption, water and space requirements in plants. As a simple solution for short lines of three or four pre-treatment steps, BONDERITE® M-NT 40042 cleans and deposits a conversion coating simultaneously (in the same bath). A Finnish manufacturer operating in the white goods sector is among those already benefiting from this innovation. Producing refrigerated food shelves, the facility has reduced process costs by 30%, solved phosphate pollution issues in its wastewater and improved mechanical and corrosion-protection performance. Finally, a further Henkel innovation is BONDERITE® no-rinse passivation, which offers another way for plants to improve performance on short lines. This turnkey solution comprises a combination of chemistry and equipment, where instead of a conventional tank there is a ring of nozzles between stages that blows a mist on the parts. The process is not only highly flexible, but produces very few drips and ensures there is always fresh chemistry misted on the components. For any plant looking to improve its metal pre-treatment processes, BONDERITE® M-NT technology from Henkel can deliver clear competitive advantages. � Aluminium International Today
ABOUT HENKEL Henkel operates globally with a well-balanced and diversified portfolio. The company holds leading positions with its three business units in both industrial and consumer businesses thanks to strong brands, innovations and technologies. Henkel Adhesive Technologies is the global leader in the adhesives market – across all industry segments worldwide. In its Laundry & Home Care and Beauty Care businesses, Henkel holds leading positions in many markets and categories around the world. Founded in 1876, Henkel looks back on more than 140 years of success. In 2016, Henkel reported sales of 18.7 billion euros and adjusted operating profit of 3.2 billion euros. Combined sales of the respective top brands of the three business units – Loctite, Schwarzkopf and Persil – amounted to more than 6 billion euros. Henkel employs more than 50,000 people globally – a passionate and highly diverse team, united by a strong company culture, a common purpose to create sustainable value, and shared values. As a recognized leader in sustainability, Henkel holds top positions in many international indices and rankings. Henkel’s preferred shares are listed in the German stock index DAX. For more information, please visit www.henkel.com
Digital Edition - August 2018
6 CORROSION
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Coping with corrosion By Jan-Olov Nilsson, Hydro With its lightness, high conductivity and low cost, aluminium has proven to be an excellent metal for use in heat exchangers and other HVAC&R applications. It also has very good corrosion resistance if coupled with the right design and coatings. Corrosion is the deterioration of properties in a material due to reactions with its surroundings. Metals react (oxidise) when they are exposed to water and oxygen. Aluminium generally corrodes at a low rate when it is exposed to most environmental conditions as a very stable oxide protects it. It copes very well when exposed to many aggressive chemicals and it performs much better than copper when exposed to formic acid or ammonia (as a refrigerant). It is nonetheless important to understand when aluminium corrosion can occur in HVAC&R applications in order to make the right material and design choices. When it comes to HVAC&R applications, the most common aluminium corrosion processes are pitting corrosion, uniform corrosion and galvanic corrosion. Digital Edition - August 2018
Pitting corrosion Micro-galvanic coupling fuels pitting corrosion. Most alloys have several intermetallic phases. In the pitting form, corrosion of aluminium alloys is essentially a micro-galvanic process between the phases and the matrix alloys.
other in the presence of an electrolyte (liquid). Under such conditions the more active of the two metals corrodes faster, and the more noble metal is protected. In most combinations with other metals, aluminium is the less noble and is therefore of greater risk of galvanic corrosion.
Uniform corrosion Aluminium very readily forms an oxide layer that is stable under most environmental conditions. Corrosion of aluminium may take place when the oxide breaks down due to particular environmental conditions influenced by the presence of the following: � High pH, e.g. alkaline washing detergents or concrete � Low pH � HCl � Formic acid � Battery acid � Chlorides � Road salt, sea air
Design for great results Selecting the right alloy for the different components and using proper design techniques will help protect against corrosion. It is important to use coating solutions like zinc or Hydro’s HYBRAZTM/® or HYCOT M/® tube coating solutions. It is also important to consider the tube wall thickness, the brazed joints design and the connection fittings selection, to extend the lifetime of the finished aluminium product by preventing corrosion. Corrosion is the deterioration of properties in a material due to reactions with its surroundings. Metals react (oxidise) when they are exposed to water and oxygen. �
Galvanic corrosion Galvanic corrosion is an electrochemical process that takes place when two different metals have contact with each
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Applying Industry 4.0 to aluminium production Following on from the success of the inaugural Future Aluminium Forum, the Organiser’s, Quartz Business Media, are pleased to announce that the event will be moving to the Sheraton Warsaw Hotel in Poland on 22-23rd May 2019.
FUTURE ALUMINIUM Aluminium manufacturers are constantly looking to improve the efficiency of their production processes and are relying upon increasingly sophisticated digital technologies to streamline their operations. In such a fast-moving world, characterised by complex Internet-based manufacturing systems, the Future Aluminium Forum 2019 is a must-attend event for aluminium professionals who want to unravel the mysteries and get to grips with the complexities of Industry 4.0. The Forum is a live discussion of the issues surrounding innovation and will endeavour to cover all bases, including the all-important subject of machine learning, digitalisation, disruptive technologies, information sharing, process safety and control. This international technology conference will draw upon the unrivalled expertise of aluminium industry professionals, production technologists and academics, to create an event designed specifically for those seeking a greater understanding of ‘smart manufacturing’.
WHO SHOULD ATTEND? The Future Aluminium Forum is primarily concerned with Industry 4.0 and other advanced technologies that are impacting global aluminium manufacturing. The conference focuses on ‘the factory of the future’ and linked technologies, such as artificial intelligence. It is the ideal event for senior level aluminium executives, chief technology officers and specialists with an interest in the application of new technologies to the aluminium manufacturing process. The Forum’s key audience consists of those with a leading role in process technology excellence, industrial innovation, research and development, digital transformation and value acceleration, process simulation and engineering education and development.
22-23 MAY 2019 • SHERATON WARSAW • POLAND
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EXHIBITION If you are interested in promoting your products and services to an international audience from across the aluminium manufacturing supply chain, then this is a unique opportunity to position your brand alongside leading experts in this field. There are very limited opportunities available and these will be allocated on a first-come-first-served basis. TABLE TOP EXHIBITION SPACE £1,950
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8 ANODISED ALUMINIUM
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Sturdy and Stylish: Anodised aluminium provides excellent durability and ease of installation for architectural exteriors, all while making fashionable, modern designs a reality Unlike any other metal available for the construction market, coil-anodised aluminum is uniquely suited to exterior architectural applications. Its unmatched durability, extreme light weight, high strength to weight ratio, and easy installation make it a highly functional material, while its three-dimensional look and ability to be colored to match project needs ensure superior aesthetics. Anodised aluminium can provide the likeness of a number of different metals for architectural applications, but with lower costs and better weathering resistance. This article will help explain the benefits of anodised aluminium, and provide inspiration for how to best leverage its unique characteristics when creating great building projects.
any given application. This not only helps with costs for the anodised aluminium products, but it also contributes to the cost savings for structural aspects of the project, as the structure does not need to support significant added weight as in the case of copper or steel. Functional benefits for architectural exteriors The molecular structure of the aluminium oxide layer formed by the coil anodising
process is hard like sapphire, second in hardness only to diamonds. This oxide layer thus provides long-term durability, as well as corrosion and abrasion resistance. It is also self-healing if damaged as the aluminum will naturally create its own protective oxide layer where it is exposed to the elements. Anodised aluminium also offers additional benefits for long-term maintenance beyond its unmatched durability. “Unlike paint warranties
Perforated anodised aluminium is a central façade design element in the recently constructed central library in Austin, Texas. Photo credit: Nic Lehoux
Stylish aesthetics complement versatile function The coil anodising process, pioneered by Lorin Industries, Inc. provides the aluminum with a protective layer that improves its aesthetic properties and durability. Continuous coil anodising forms a clear, translucent oxide layer that protects the metal, shows the metal’s natural beauty, and is consistent over every inch of aluminium. The three-dimensional crystalline structure of the aluminium oxide layer also reflects and refracts light in ways that help the surface come alive. Unlike paints or coatings, this oxide layer is grown from the raw aluminium and bonded at the molecular level so it cannot chip, flake or peel like paints and coatings often do. When metal fines are added to the coil anodising process, anodised aluminum can be made to mimic almost any other metal, such as brass, copper, zinc, bronze, gold, silver, stainless steel, titanium, or carbon steel. Anodised aluminium, however, does not tarnish like brass, patina like copper, or fade like bronze, so these metal looks are UV stable. Anodised aluminium is as much as 2/3 lighter than other metals. It thus offers a significant cost advantage, as the aluminum itself is often less expensive per square foot than other metals, and far fewer pounds of material are needed for Digital Edition - August 2018
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that require cleaning every year, Lorin’s anodised aluminium only needs to be cleaned every other year if it is on the exterior of a building, thus providing some really significant maintenance cost savings,” said Phil Pearce, Vice President Sales and Marketing at Lorin Industries, Inc. Although natural metals are a commodity and therefore prices can have a degree of volatility, generally due to its high strength to weight ratio, anodised aluminium can cost 60-70% less per square foot than many other natural metals. Coil anodising delivers consistent quality, and the handling and installation is simple as the material is light and workable. This solves many challenges faced in construction due to rigid or heavy materials. Many anodised aluminium panels can be installed on buildings with standard hand tools, not requiring the expense of a crane as is the case with other materials. Coil-anodised aluminium can also be perforated in a variety of patterns to a range of percentage openness before anodizing. Perforated aluminium serves both functional and decorative purposes.
of sunlight and/or environmental particulates, and management of a structure’s wind or heat loads. At the same time, it enhances the aesthetics of the building façade. Engineered correctly, perforated aluminium will last throughout a building’s lifetime.
A student housing building at the University of Texas at Austin (2400 Nueces). Lorin anodised aluminium is used to make shingles that are incorporated into the façade design, and perforated anodised aluminium sheets on the building’s garage help the building to meet ventilation requirements while coordinating with the overall building design. Photo Credit: Lorin Industries, Inc.
When used on building or garage exteriors, it can provide noise control, improved HVAC efficiency, screening
Applications for anodised aluminium Anodised aluminium can be used for a wide range of architectural and construction applications, including building facades, curtain walls, roofs, column wraps, and lighting. Building facades can be installed as honeycomb panels, ACPs (Aluminium Composite Panels), solid metal panels, and roll formed panels. Other common uses include trim, signage, and sunscreens. “Lorin’s anodised aluminium products are available with Architectural Class I and II films, and are offered in colors that are UV stable and can be used in coastal areas,” Pearce added. With functional benefits of a high strength-to-weight ratio and superior durability, and the aesthetic benefits of a beautiful natural metal look in a variety of colors, anodised aluminium is uniquely suited to bring innovative architecture designs to life for building exteriors. �
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10 DEOXIDIZING
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Preparation is key By Peter Totaro*
Surface preparation may consist of some sort of alkaline cleaning or de-greasing followed by an etchant and then desmut or deoxidizing. Deoxidizing removes aluminium oxide off the substrate layer of aluminium via redox reactions, which normal mineral acids cannot achieve. You can always desmut aluminium, but you may not always deoxidize aluminium prior to processing. Why deoxidizing works Aluminium is an interesting element because of its inherent nature to oxidize readily in contact with oxygen. This process called passivation happens when bare aluminium is in contact with oxygen. Aluminium oxide around 0.00005” thick will form naturally and will create a non-active surface. This surface will not allow the formation of anodize since the
surface is passive and may or may not be conductive. This thin layer of oxide is what we seek in anodizing, but it is not of a sufficient thickness to serve our applications. Thus, we need to remove it with a solution called a deoxidizer. Deoxidizers are able to work because of the transferring of electrons called Redox reactions. Redox is short for reductionoxidation reaction. Any such reaction involves both a reduction process and a complementary oxidation process, two key components involved with electron transfer process. The chemical component, called a species, may have an electron stripped from it or added on. In the case for when it is stripped, the species is said to have been oxidized and when the species gains an electron, it has been reduced. Deoxidizing of aluminium can only be successful
if there is aluminium oxide present on the part or is there is a chemical species willing to donate or accept electrons in the solution. For example, the key constituents in a common deoxidizer are ferric sulphate and nitric acid. Since Ferric is in the +3 states, it can be the oxidizing agent and reduce the Aluminium oxide on the surface of the aluminium. Nitric acid is very important because of its inherent oxidizing abilities. This helps speed up the reaction to lower time spent in the deoxidizer. Once the thin layer of aluminium oxide is gone, bare aluminium is the substrate left and has been “activated.” Activation means that the bare aluminium is looking to donate electrons to maintain equilibrium. This is why deoxidizing is right before anodization or plating.
Deox before...
and after
*Quality Manager Chemical Engineer CAF Aerotech Processing Solutions Digital Edition - August 2018
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12 DEOXIDIZING
Solution types and applications Deoxidizers can be aggressive in nature due to the chemicals used to create the solution. For the sake of simplification, I will describe the solutions in two categories. The first is a “non-etching” deoxidizer and the second will be deoxidizers that are capable of etching material. Nitric Based deoxidizers are deoxidizers that cause minimal or no etching of aluminium and aluminium oxide. These solutions are some of the most common deoxidizers used today. Nitric acid is commonly a choice because of its ability to slowly attack aluminium and because of its autocatalytic abilities as an oxidizer. Nitric acid based deoxidizers will produce satin type finishes while not removing the finished metal shine. Nitric acid base deoxidizers are useful for salvaging parts. Nitric acid Is known to “open” the pore structure of anodic films which allow for easier stripping of anodize. Nitric acid based deoxidizers can be used before any subsequent processing such as paint, chemical conversion, anodizing, etc. This solution is an effective deoxidizer/desmut, which can be used at room temperature. The immersion time for this solution is 1-5 minutes. The proper rinsing should be deionized water that is low in anions such as chloride and fluoride. Triple rinsing is the most effective way of removing the ferric solution. These deoxidizers are typically the most environmentally friendly since there is no chromium involved. These deoxidizers can have tanks made of stainless steel 316, polypropylene, or have some sort of Kynar liner. Fluoride based deoxidizers will give a light etch and a matte finish. These deoxidizers are very effective against casting alloys because of the fluoride’s ability to dissolve silica. Silica is, for the most part, a chemically inert element which is used to make glass and in aluminium castings. Fluoride – acid based deoxidizers should be used very carefully and operators should be fully trained in self-first-aid if they are using these types of solutions. It only takes about 25 in2 of a splash on the skin to kill a grown male with hydrofluoric acid. This acid does not burn initially when it contacts your skin, which makes it even more deadly because of your unawareness of contact. Please use caution and train your personnel thoroughly before using this solution. Deoxidizer solutions will build up chlorides and copper contaminants, which directly results in pitting. For this reason, the copper concentration should Digital Edition - August 2018
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be checked monthly and deionized water should only be used for solution make-ups and rinsing. Deoxidizers should be employed for the following conditions: � As a desmut bath or neutralizing rinse after alkaline etching � Removal of oxide, mill scale, corrosion products, heat treatment scale, or welding fluxes. � Matt etching or bright etching for decorative effects. � Deep selective etching for patterns in relief. � Very deep etching for chemical milling or contouring. � Etching to increase the surface area of electrolytic capacitor anodes. � Undercut etching to give a mechanical key for PTFE application. � Electrolytic etching for lithographic printing purposes. � Heavy duty deoxidizing for casting � Light duty deoxidizing Aluminium oxide
Maintaining your deoxidizer Quality control and good general practices are imperative in order to maintain the optimal performance of the deoxidizer. Quality control will discuss the frequency and what you should be testing to maximize the effect your deoxidizer has on hardware and good general practices are things to keep in mind when processing parts Quality control is the monitoring of the solution and its constituents and the machinery needed to keep the manufacturing process going. Solution control is a must if you are a NADCAP shop or if you are looking for higher end commercial work. One of the main tasks would be to monitor the process and examine the parts frequently to make sure everything in your process control document is being met. The chemical solutions should be analysed weekly to ensure proper maintenance
of composition, stability, and etch rates. Other testing may be required by the OEM the parts are for or from the technical data sheet of the product itself. There are 6 tests which should be assigned to the deoxidizer tank to make sure the tank is running properly, they are: � Monthly temperature readings � Rinse water: you should always use deionized water. Chlorides and other heavy metals can pit a surface that has been freshly activated from deoxidizing. I would recommend the TDs be between 50-300 ppm. If the rinse water is too clean, below 50 TDS, then the water will passivate the part and prevent surface conversion as well. � Etch Rate � Solutions Analysis � Examination of parts: This examination should be done by the operator after any deoxidizing step. What the operator should do is look for any smut that is still present on the part after deoxidizing. If the maximum immersion time has been reached and the smut is still present, then a decant or addition should be made to the tank. � Intergranular Attack/End grain Pitting General good practices (GGP’s) should always be employed at the processing facility. Some of these GGPs are self-explanatory. Here are some GGP’s: � Parts should always be completely immersed in the tank. This means before having parts enter the line, make sure each solution is properly filled. � Parts shouldn’t be allowed to dry between tanks, this can cause water stains which will show up after anodizing/ plating. � When racking, the position and shape of the part should be taken in account to make sure that the circulation of solution is touching the whole surface area of the part. You should also keep conscious of air pockets and blind holes which can entrap solution. � Keep the solution free of excessive oils, scum, floating debris, and other foreign material. � Deoxidizers may accumulate sludge requiring occasional removal and this sludge should never encounter any part. Desludging requires decanting the settled bath into a clean tank and then removing the sludge from the bottom of the tank. When this is done, you can return the solution to the tank, agitate and re-test.�
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General Magnaplate Corporation brings AptiMag-X™ to the North American Market General Magnaplate Corporation has signed an exclusive license agreement with the UK’s Poeton Industries Ltd for the Apticote A20X™ surface enhancement process, used for treating the innovative A20X™ aluminium alloy. A20X™ has a unique solidification mechanism and highly refined microstructure giving it exceptional strength, fatigue and thermal performance characteristics in both cast and additively manufactured form. Developed and patented by Aeromet International Ltd, a leading UK-based aerospace casting supplier, A20X™ is now licensed to foundries around the world, including across North America, and is also available in powder form for additive Aluminium International Today
manufacturing. The agreement means that General Magnaplate will become the exclusive supplier of Apticote A20X™, which they will brand AptiMag-X™ in North America. Licensed A20X™ foundries, additive manufacturing companies and aerospace customers will be able to have parts treated with AptiMag-X™ at the company’s facilities in Linden, New Jersey and Arlington, Texas. A20X™ is MMPDS certified (as AA205) and is the strongest cast aluminium alloy available today, with strength properties comparable to 7000 series wrought material. A20X™ cast and additively manufactured parts are in production today for major aerospace customers.
The AptiMag-X™ treatment enhances the surface of A20X™ parts improving wear resistance, hardening and finish. Adam Smith, Group Commercial Manager for Aeromet and A20X™ commented: “Aeromet is pleased to welcome General Magnaplate to the global A20X™ supply chain. By bringing AptiMag-X™ to North America, General Magnaplate will be well placed to support the growing number of aerospace and defense customers taking advantage of A20X™ advanced aluminum castings and additively manufactured parts”. � For more information visit www.magnaplate.com
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14 SURFACE TREATMENT
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Surface treatment technologies of aluminium alloy for automobiles Yosuke Ota*1, Tetsuya Kojima*1
*1 Aluminium Sheets & Coils Research Dept,. Moka Plant, Aluminium & Copper Business Digital Edition - August 2018
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Light materials, such as aluminium alloy sheets, are increasingly being used for the purpose of reducing weight in automotive bodies. Regarding the surface characteristics required for such aluminium alloy sheets, emphasis is being placed, especially in Europe, on bonding durability to suppress the deterioration of joints bonded using adhesive in environments such as saltwater spray conditions. Titanium/zirconium (Ti/Zr) treatment is a surface treatment adopted by automotive manufacturers outside Japan to improve the bonding durability of automotive aluminium materials. In Europe, electric discharge texturing (EDT) surfaces, as well as dry lubricant, are being used in addition to Ti/Zr treatment. In order to use materials that are surface treated in accordance with European specifications, the process conditions, including conversion coating, must be optimized. Kobe Steel can provide Ti/ Zr treatment, EDT surfaces and dry lubrication. Introduction With a social need to improve the fuel consumption of automobiles as a climate change mitigation measure, light materials, such as aluminium alloy sheets, are increasingly being used for reducing the weight of automotive bodies, which would be a promising measures for that purpose. Surface characteristics required for aluminium alloy sheets for automotive panels include weldability and the ability to be lubricated for forming. It is necessary to uniformly apply conversion coating, such as zinc phosphate treatment, to provide
acceptable painting quality and corrosion resistance, and thereby requiring the ability to be degreased and chemical treatability. On the other hand, emphasis is now being placed, especially in Europe, on bonding durability to suppress the deterioration of joints bonded using adhesive in environments such as saltwater spray conditions. Bonding with adhesive is positioned as a secondary measures for mechanical joining or welding; however, it contributes also to improvement in rigidity, safety in collisions, and NVH properties (Noise, Vibration, and Harshness). In order to improve the bonding durability of joints bonded using adhesive, a surface treatment to suppress the deterioration of the interface between adhesive and base material has been developed. This paper evaluated the characteristics of Ti/ Zr treatment as applied to Kobe Steel's products, a treatment which is extensively used especially in Europe to improve bonding durability. It examined also the application of the Electron Discharge Texturing (hereinafter referred to as EDT) method to our products, a method, which controls dry lubrication and surface roughness to improve the ability to be lubricated. The results are reported below. Ti/Zr treatment Generally in Japan, aluminium alloy sheets for automotive panels are subject to acid pickling, etc. to remove the oxide film generated in the annealing process,2) and then shipped as raw material. By contrast in Europe, Ti/Zr treatment is applied at the raw material stage as a surface treatment, in addition to such acid pickling treatment, etc.1), 3) Ti/Zr treatment is a technology that has been extensively used by overseas automotive manufacturers, including German-affiliated companies, and it features oxide films of Ti/Zr formed on the surface of aluminium alloy with oxide film removed, using oxide hexafluoride of Ti and Zr.4) The film formed on the surface is known not to interfere with formability, weldability, and zinc phosphate treatability, in addition to its contribution to improving bonding durability. Ti/Zr treatment process Fig. 1 shows the manufacturing and processing process of aluminium
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COLD ALUMINUM STRIP Cold rolled coil
MF/EDT
Annealing
Surface treatment
Cleaning Conversion coating Ti/Zr, PT2, etc. Liquid/dry-lube
Lubricator
BODY IN WHITE
Press shop
Welding/adhesive
Assembly
Pre-treatment
Cleaning Zinc phosphate/Zr oxide/ Oxsilane etc.
Paint shop
Fig. 1 Manufacturing process of automotive aluminium sheets (surface related technology)
Alkaline degreasing Rinse Acid pickling Rinse Ti/Zr spray Rinse Dry
Fig. 2 Process flow of surface treatment for coiled aluminium strips
Ti distribution near surface
Zr distribution near surface
STEM
Fig. 3 Cross-sectional image and distribution of Ti, Zr in Ti/Zr conversion coating
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16 SURFACE TREATMENT
sheets for automotive panels from the viewpoint of the technologies related to surface treatment. Fig. 2 shows the Ti/Zr treatment process that is performed in the surface treatment process shown in Fig. 1. Heat-treated cold-rolled coils require the removal of oxide film, in advance, through acid pickling to be performed after alkaline degreasing. Ti/Zr coating is then formed by spraying a chemical agent for Ti/Zr treatment and thereafter rinsing and drying. We formed the Ti/Zr coating using Gardobond® X4591 provided by Chemetall as a chemical agent for Ti/ Zr treatment. Fig. 3 shows the crosssectional observation photo of this Ti/ Zr coating. This photo shows that an oxide film of several tens of nanometers in thickness containing Ti and Zr has been formed. Bonding durability and hydration of Ti/Zr coating material Fig. 4 shows the evaluation results of bonding durability after salt spray tests for 3,000 hours using our 6022 alloy both with Ti/Zr coating and with acid pickling and rinsing only (hereafter referred to as material with cleaning only). Specimens for shear tests were manufactured using epoxy resin based adhesive, zinc phosphate electrodeposition coating was applied, and then shear tests were performed before and after durability tests. The results revealed that the material with Ti/Zr coating scarcely decreases in its cohesive failure rate and adhesive bonding strength, but is superior in bonding durability, when compared with the material with cleaning only. Factors in the deterioration of bonding durability in the interface between adhesive and aluminium base material include the hydrated oxide produced on aluminium surfaces when moisture penetrates and is diffused near the interface.1) Fig. 5 shows the influences of Ti/Zr coating on hydration. Ti/Zr coating proves that, once formed, it suppresses hydration on the base material surface that is equivalent to a bonding interface. It would appear that this difference in hydration behaviour corresponds to bonding durability5). Influence of Ti/Zr coating on zinc phosphate treatment, filiform corrosion resistance, and weldability The influence of Ti/Zr treatment on zinc phosphate treatment and filiform corrosion resistance was evaluated using 6022 alloys and general test conditions. Fig. 6 shows the observation results of the change in the film weight of zinc phosphate coating and its morphology
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Cohesive failure (%)
80 60 40
Initial SST 300h
20 0
Cleaning only
Shear strength (MPa)
Ti/Zr
Initial SST 300h
Ti/Zr
Cleaning only
Fig. 4 Adhesive durability (cohesive failure ratio and shear strength) of 6022 alloy with and without Ti/ Zr coating
1.2 1.0 0.8 0.6 0.4 0.2 0.0 Cleaning only
Ti/Zr (2mg/m2)
TiZr (10mg/m2)
Fig. 5 Influences of Ti/Zr coating on hydration (50ËšC , 95%RH, 24 hrs)
Improvement in formability through applying dry lubrication In order to improve formability, paraffin wax, surfactant, etc. with a melting point of about 40 to 50°C are used as dry lubricant. In various methods, dry lubricant is applied mostly by heating, melting, and then electrostatic spraying. Fig.10 shows the formability when dry lubricant E1 from Zeller + Gmelin is used with 6022 alloy and Kobe Steel's 5182 alloy. The results reveals that excellent punch stretch forming height and drawing height are achieved when compared with using liquid oil. On the other hand, dry lubricant is inferior in its capacity for being degreased; therefore, dry lubricant could not be removed sufficiently using the same degreasing conditions as are used for liquid oil. It appears that when dry lubricant is applied it is necessary to adjust the concentration and temperature of a degreasing bath. Conclusions Ti/Zr treatment is a surface treatment adopted by automotive manufacturers outside Japan, and it improves bonding durability of aluminium material for automobiles. In Europe, EDT surfaces, as well as dry lubricant, are being used in addition to Ti/Zr treatment. Not only in Europe but also in North America, there is a need to improve bonding durability, and chromium-free PT2 consisting of colloidal silica (developed by Novelis), ALCOA951 consisting of organic components, and new surface treatment, such as thin film anodic oxidation, also beginning to be applied, and they are currently supplied to overseas automotive manufacturers.1) However, when such "surface treatment agent for overseas use" is used in Japan, optimised conversion treatment conditions are required. Kobe Steel therefore promotes the development of the surface treatment technology that
1.60 1.40 Ti/Zr
1.3g/m2
Zinc phosphate (g/m2)
EDT and dry lubrication Control of surface roughness by EDT Mill Finish (hereinafter referred to as MF) material is used in Japan, whereas EDT material is extensively used in Europe. EDT features surface morphology formed by rolling with rolls that were dull electric discharge machined. Fig. 9 shows the comparison of the surface morphology in 6022 alloy between EDT and MF. The surface morphology with EDT has no rolling line, indicating that it is a morphology having irregularity without anisotropy. When dry lubrication is used, which will be described at a later stage, two sheets may adhere to each other in a destacking process, in which stacked aluminium sheets are lifted. However, it is known that the material surface morphology with EDT suppresses adhesion, thereby improving the workability in the destacking process.3) The advantage of dry lubrication includes behaviour that eliminates the influence of forming direction in the forming process, allows lubricant to be retained more easily, thereby contributing to improvement in formability, eliminating anisotropy in the appearance after coating, etc.8)
100
Increment of peak area at OH stretching (FT-IR: ca 3400cm-1)
when varying the amount of fluoride in a zinc phosphate treatment bath, for both materials with Ti/Zr coating and with cleaning only. The results reveal that the material with Ti/Zr coating has achieved a zinc phosphate treatability equivalent to that of the material with cleaning only. However, the film weight of the zinc phosphate coating may decrease in the case of material with a large film weight of Ti/Zr coating, or depending on the conditions of zinc phosphate treatment. While chemical agents for other than zinc phosphate treatment have been used as environmental measures6), 7), it seems that the chemical agent for Ti/Zr treatment can be applied in place of these various chemical agents by adjusting the treatment conditions. Fig. 7 shows the filiform corrosion test results of material with zinc phosphate treatment and electrodeposition coating. The results revealed that the material with Ti/Zr coating achieves basically the same filiform corrosion resistance as the material with cleaning only. Fig. 8 shows the MIG and laser welding tests results for the weldability evaluation using Kobe Steel's 6016 alloy. During tensile tests, every specimen was fractured in the base material but not in the weld, showing that the level of strength was the same. It thereby proved that the material with Ti/ Zr coating achieves the weldability equivalent to that of the material with cleaning only.
1.20 1.00 0.80 0.60
Ti/Zr
0.40
Cleaning only
0.20
Cleaning only
0.00 0 1.3g/m2
100
200
300
Fluoride in bath (ppm)
Fig. 6 Surface morphology and film weight of zinc phosphate coating
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corresponds to the surface treatment conditions used in automotive manufacturers in Japan. Kobe Steel can provide Ti/ Zr treatment material, and EDT and dry lubrication treatment materials. �
12 Maximum length
Length of filament (mm)
10
Total length 8
References 1) EAA Aluminium Automotive Manual - Joining 9. Adhesive bonding. http://c.ymcdn.com/sites/www.aec. org/resource/ resmgr/PDFs/9-AdhesiveBonding_2015.pdf, (Accessed 201604-26) 2) H. Ishii. Surface Technology. 1997, Vol.48, No.10, p.691. 3) G. M. Scamans et al. Surface and Interface Analysis. 2013, Vol.45, No.10, pp.1430-1434. 4) O. Lunder et al. Surface and Coatings Technology. 2004, Vol.184, No.2, pp.278-290. 5) T. Kojima et al. Japan Institute of Light Metals, 127th Annual Autumn Meeting Proceedings. 2014, pp.143144. 6) Werner Rentsch. Automotive Finishing JOT-International Surface Technology. 2012, Vol.5, Issue 1, pp.16-19. 7) T. Higashii. Coating Technology. 2013, Vol.52, No.7, pp.51-55. 8) The Aluminium Automotive Manual - Manufacturing - Surface finishing. http://european-aluminium. eu/media/1529/aam- manufacturing4-surface-finishing.pdf, (Accessed 2016-04- 26)
6 4 2 0 Ti/Zr
Cleaning only
Fig. 7 Filiform corrosion test results of materials with and without Ti/Zr coating after 8 cycles Cycle: SST 35°C×24 hrs - 40°C, 85%RH×120 hrs - r.t. 24h
200 100 0 Ti/Zr
Cleaning only
Tensile strength (MPa)
Tensile strength (MPa)
300
300 200 100 0
Ti/Zr
Cleaning only
Ti/Zr
Cleaning only MIG
Laser
MF
SEM
18.5 6022
18.0
5182
17.5 17.0 16.5 16.0
D optical proflometry
Dry-lube (E1)
Fig. 9 Comparison of surface morphology between EDT and MF
Maximum forming height with spherical head (mm)
EDT
Maximum forming height with spherical head (mm)
Fig. 8 Tensile strength test after welding
Liquid oil
12.0 10.0 8.0 6.0 4.0
6022
2.0
5182
0.0 Dry-lube (E1)
Liquid oil
Fig.10 Influence of dry lubrication on punch stretch forming (using spherical head (φ50mm) and square tube (50mm))
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Adhesive bonding in multi-material concepts By Martin Schön, Hydro An adhesive that can bind to several different materials is an interesting alternative for product developers working with aluminium. There are many types of joining methods. Adhesive bonding is one. It is a joining method that can result in highperformance joints when aluminium is joined to aluminium as well as with other materials. If you as a designer choose adhesive bonding as the joining method for your product, then you need to know that you are selecting more than only a specific adhesive. You are choosing a whole adhesive system. This includes mechanical properties, surface treatment, mechanism of cure, application technique, joint configuration, quality assurance, corrosion properties, and aspects related to health, safety and the environment. And more.
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Adhesives spread load over large areas An adhesive can form a tight bond over the entire overlap area, spread load over large areas, and keep the joining processes at moderate temperatures. The biggest difference between adhesive bonding and joining methods such as soldering and fusion welding, is that the additive that creates the joint is made of plastic/polymer, rather than molten metal. This permits the joining of different types of materials that could not otherwise be reliably joined. For example, welding and soldering do not work when joining metal to plastics. Heating a material, as in soldering, brazing and fusion welding, can reduce strength and cause deformation. This does not occur with adhesive bonding, due to the low or moderate temperatures involved in the process.
Joining thin materials As I mentioned, an adhesive joint can carry load over larger areas when compared with “spot” mechanical joints such as rivets, clinches and screws, which can have relatively high local stress. The strength, stiffness, energy absorption and durability of a correctly dimensioned adhesive joint will therefore be better. Uniform load distribution can also enable a reduction in material dimensions. In general, the advantages of adhesive bonding become more apparent when joining thin materials. I will talk more about the adhesive bonding of aluminium in the months to come, because joining is an important part of product development, and adhesive bonding can be a good alternative for multi-material concepts and solutions. �
Digital Edition - August 2018
20 INTERNET OF THINGS
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WAGNER presents new IoT platform: Greater transparency for higher produ
Digital Edition - August 2018
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uctivity
WAGNER Industrial Solutions presented its new Internet of Things solution at the PaintExpo trade fair in April 2018.
The web-based IoT platform allows intelligent monitoring of powder coating, bonding, sealing and liquid coating systems. The platform is accessible via PC, tablet or smartphone and allows secure access to your own production data from anywhere. “Anyone using the IoT platform increases transparency and process reliability in their industrial coating. Downtimes can be minimised and thus productivity can be increased. The operator is constantly in close contact with his systems and always wellinformed”, explains Mario Oesterle, Senior Product Manager Automation & Sensoric at WAGNER. Access from anywhere and at any time Industrial companies are faced with the challenge of constantly improving productivity, quality and costs. This requires accurate production data and ongoing monitoring, if possible from anywhere and at any time. This is now delivered by the new IoT solution from WAGNER. The Internet platform offers clearly visualised key figures, live productivity monitoring, information on the exchange of spare parts, operating instructions with spare parts list and an interface to WAGNER’s remote maintenance service. The controllers and sensors in the WAGNER products provide the raw data for this purpose. They are transmitted to the IoT platform via a secure VPN connection and prepared graphically for display there. Perfect process overview The start page of the WAGNER IoT platform already offers the user an overview of all his lines and the most important productivity indicators. It is the starting point for detailed, visually prepared reporting for each integrated plant. Data such as coating time, number of coated parts or conveyor section are updated every minute so that live monitoring is possible. The measured values of the last 365 days are used as reference values. The evaluation can be displayed as a graphic over freely selectable periods of time, for example also per shift. Everyone involved in the production process benefits from the high level of transparency and simple operation - from the operator to production managers, quality managers and top managers. Aluminium International Today
Productivity increase of up to five percent One principle of Lean Management is: Only what can be measured can be improved. With the IoT platform, optimisation potentials become quickly apparent and the success of the measures taken can be easily tracked. The platform also displays warnings and notes. If the WAGNER service is required, the information can be forwarded directly. The WAGNER experts access the line controls via a remote function and carry out remote maintenance if necessary. “For our pilot customers, we expect our solution to increase productivity by up to five percent,” reports Mario Oesterle. “These consist of less downtime, tight process control with notification function, short reaction times for less rejects and predictive service measures such as the timely replacement of wear parts.” Networked systems for production 4.0 An example shows how the IoT solution can increase efficiency and implement production 4.0 solutions: If the layer thickness measurement device WAGNER Layer Check LC 1000 is networked with the platform, the layer thickness can be monitored contactlessly in real time. If an undercoating or overcoating occurs, the operator is immediately notified and can readjust. This prevents rejects and rework. Pilot customers attest to high benefits In general, all WAGNER lines can be connected to the IoT platform, which have an up-to-date programmable logic controller (PLC) and corresponding sensors. “We recommend our solution for new plants or for systems that are not older than five years. All other systems can be upgraded and integrated as part of a retrofit,” says Mario Oesterle. Five pilot customers had already been able to test the platform before its market launch. The feedback was consistently positive. “What is particularly interesting is that we can access the platform from any device with an Internet connection, regardless of location. We have been waiting for such a product - and probably not only us, but also other industrial coaters,” explains Mattias Larssen, CEO of the Swedish company ALSAB. � Digital Edition - August 2018