Manufacturing Process Specification

This document is to be referenced on engineering drawings. It defines functional/performance requirements, manufacturing process methods and levels of quality of the components being produced. Seating Products Group 1455 Fairchild Road Winston-Salem, NC 27105 USA 607 Bantam Road Litchfield, CT 06795 USA 2 Moor Road, Kilkeel County Down, Northern Ireland BT34 4NG

Manufacturing Process Specification Nbr.: Title: Revision: Issue Date: Authored by:

SPG - MPS - 007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005 Date:

Signatures on file Steven R. Bell - Manager Value Engineering: Winston-Salem

Approved by:

Victor Clark - Manager Quality: Winston-Salem

Date:

Approved by:

Tommy Plant - Director Engineering: Winston-Salem

Date:

Approved by:

Scott Postle - Manager Engineering: Winston-Salem

Date:

Approved by:

Dave Cekuta - Director Operations: Winston-Salem

Date:

Approved by:

Jerry Gourd Director Quality: Litchfield

Date:

Approved by:

Mark Leone - Manager Engineering: Litchfield

Date:

Approved by:

Wynn Parrish - Director Engineering: Litchfield

Date:

Approved by:

Sami Kazi - Manager Engineering: Litchfield

Date:

Approved by:

Tom McQuaid - VP Quality: Kilkeel

Date:

Approved by:

Ian Rae - Director Manufacturing: Kilkeel

Date:

The information and designs disclosed in this specification were originated by and are the property of the "B/E Aerospace" who reserves all patents, proprietary, design, processing, reproduction, use and sale rights thereto, and to any article disclosed therein except to the extent rights are granted in writing to others by an authorized official of B/E Aerospace. This cover page with the original/wet signatures is on file in the Engineering /Processes. This Manufacturing Process Specification is controlled per SPG-EN-P2030-04. Hardcopies are to be considered Uncontrolled unless marked otherwise. All Procedures are current as of this date can be accessed on the B/E Network @ [Burns\Winstonfs2\Data\Engineering\Manufacturing Process Specifications\BE Specs] RELEASED Page 1 of 14 Last printed: September 25, 2008

B/E Aerospace, Inc. Specification Nbr: Title: Revision: Issue Date:

Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

1. Revision History
Approval: PCS Cert. Eng. Scott Postle Approval: MCS Cert. Eng. Sami Kazi

Rev. Level A Initial Release

Description

Author Steve Bell

Date
01-08-03

Added paragraph 4.9

David Carter

09-05-08

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B/E Aerospace, Inc. Specification Nbr: Title: Revision: Issue Date:

Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

1. Revision History..............................................................................................................2 2. General Information........................................................................................................6 2.1 Introduction .............................................................................................................6 2.2 Scope of Specification ............................................................................................6 2.3 Reference Documents............................................................................................6 2.3.1 Industry Documents .....................................................................................6 2.3.2 ASM Documents ..........................................................................................6 2.3.3 Superseded B/E Aerospace Documents .....................................................6 2.4 Definitions ...............................................................................................................6 2.4.1 Aluminum .....................................................................................................6 2.4.2 Anodized Aluminum .....................................................................................7 2.4.3 Average Coating Thickness .........................................................................7 2.4.4 Type and Class ............................................................................................7 2.4.5 Type I: Chromic Anodize..............................................................................7 2.4.5.1 General.........................................................................................7 2.4.5.2 Advantages...................................................................................7 2.4.5.3 Suitable Alloys ..............................................................................7 2.4.5.4 Relative Cost ................................................................................7 2.4.6 Type II: Sulfuric Anodize ..............................................................................8 2.4.6.1 General.........................................................................................8 2.4.6.2 Advantages...................................................................................8 2.4.6.3 Suitable Alloys ..............................................................................8 2.4.6.4 Relative Costs ..............................................................................8 2.4.7 Type III: Hard Anodize .................................................................................8 2.4.7.1 General.........................................................................................8 2.4.7.2 Advantages...................................................................................8 2.4.7.3 Suitable Alloys ..............................................................................9 2.4.7.4 Relative Costs ..............................................................................9 2.4.8 Coating Class...............................................................................................9 2.4.8.1 Class 1..........................................................................................9 2.4.8.2 Class 2..........................................................................................9 2.4.9 Significant Surfaces .....................................................................................9

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Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

2.4.10 Production Lot ..............................................................................................9 2.4.11 Sealing Anodic Coatings ..............................................................................9 2.4.12 Contact Mark................................................................................................9 2.4.13 Natural (Clear) Anodize................................................................................9 2.4.14 Dull Anodize ...............................................................................................10 2.4.15 Bright Anodize............................................................................................10 3. How to reference this document...................................................................................10 3.1 General Data ........................................................................................................10 4. Process Requirements .................................................................................................10 4.1 Alternate Process Specification............................................................................10 4.2 Toxicity Provision..................................................................................................10 4.3 Materials ...............................................................................................................10 4.4 Equipment and Processes....................................................................................11 4.5 Handling and Cleaning .........................................................................................11 4.6 Pre-Anodize Process............................................................................................11 4.6.1 General Requirements ...............................................................................11 4.6.2 Anodizing of Parts ......................................................................................11 4.6.3 Anodizing Assemblies / Complex Shapes .................................................11 4.7 Sealing Anodic Coatings ......................................................................................12 4.8 Coating Thickness ................................................................................................12 4.9 Bright Anodized Samples..................................................................................12 5. Quality Assurance Provisions.......................................................................................12 5.1 Alternate Quality Assurance Provisions ...............................................................12 5.2 Responsibility for Inspection.................................................................................13 5.3 Responsibility for Compliance ..............................................................................13 5.4 Process Control Records......................................................................................13 5.5 Process Control Inspection...................................................................................13 5.6 Lot Identification ...................................................................................................13 5.7 Visual and Dimensional Examinations .................................................................13 5.7.1 Samples .....................................................................................................13 5.7.2 Visual Examination.....................................................................................13 5.7.3 Dimensional Examination...........................................................................14 5.7.4 Sealing Inspection......................................................................................14 5.7.5 Hard (Type III) Anodic Coating Inspection .................................................14

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B/E Aerospace, Inc. Specification Nbr: Title: Revision: Issue Date:

Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

5.7.6 Class II (Dyed Coatings) ............................................................................14 5.8 Failure to Conform................................................................................................14 5.9 Reprocessing and Repair of Failed Parts.............................................................14

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B/E Aerospace, Inc. Specification Nbr: Title: Revision: Issue Date:

Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

2. General Information 2.1 Introduction

This specification provides procedures for electrolyticaly forming anodic surface coatings on aluminum and aluminum base alloys to provide corrosion resistance and increased paint adhesion. Anodic oxidation of aluminum alloys can be achieved through charging aluminum surfaces in a number of acidic solutions; sulfuric acid being the most widely used electrolyte. The coating formed because of electrolysis is mainly anhydrous aluminum oxide and in case of sulfuric acid electrolyte, the coating is clear to opaque. Such a coating improves corrosion and abrasion resistance and provides a good foundation for an organic finish. Any reference to B/E Aerospace, B/E Aerospace Inc, Seating Product Group, B/E SPG, or variations of these descriptions contained within this document, shall refer to the specific B/E Aerospace facility issuing the purchase order for the products or service required to comply with this specification.

2.2

Scope of Specification
This specification covers the requirements for production of anodic oxidation on aluminum alloys, achieved by utilizing sulfuric and chromic acid electrolytes, for components of passenger aircraft seating products.

2.3

Reference Documents 2.3.1 Industry Documents

MIL-A-8625F Anodic Coating for Aluminum and Aluminum Alloys ASTM B-244 Standard Test Method for Measurement of Thickness of Anodic Coatings on Aluminum and of other Nonconductive Coatings on Nonmagnetic Basis Materials with Eddie-Current Instruments ASTM B-136 Standard Method for Measurement of Stain Resistance of Anodic Coatings on Aluminum ASTM B-137 Standard Test Method for Measurement of Coating Mass per Unit Area on Anodically Coated Aluminum

2.3.2 ASM Documents

ASM Handbook Volume 13 - Corrosion

2.3.3 Superseded B/E Aerospace Documents

APS 1 Anodizing APS 100 Decorative Bright Dip Anodizing BAC 5028 Sulfuric Acid Anodize Coating for Aluminum and Aluminum Alloys

2.4

Definitions 2.4.1 Aluminum

Aluminum and aluminum based alloys.

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Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

2.4.2 Anodized Aluminum

Aluminum with a natural anodic oxidation coating produced by an electrolytic oxidation process in a electrolyte, which mainly contains sulphuric acid.

2.4.3 Average Coating Thickness

The mean value of a specified number of local thickness measurements that are evenly distributed over the significant surface of a single anodized part.

2.4.4 Type and Class

MIL-A-8625 uses Type and Class to describe different anodic processes. In general, Type deals with coating characteristics like thickness and resistance to corrosion and wear, while Class specifies whether or not the coating is dyed. There are three types and two classes. The following provides a brief description of the main types of anodic coatings. For detailed information, see MIL-A-8625.

2.4.5 Type I: Chromic Anodize

2.4.5.1 General The Chromic Anodize (Type I) coating is nominally 2m (0.08mils) thick, relatively soft, susceptible to damage through handling, has very good corrosion resistance, and is clear to gray depending on alloy, heat treat conditions, and whether the coating is sealed. Although the coating can be dyed, this is generally not done because the coating is thin and does not retain dye well. 2.4.5.2 Advantages CrO3 is less aggressive toward the Al than H2SO4 so it is a better choice for difficult to rinse parts such as riveted and welded assemblies. The coating is only 2m (0.08mils) thick with good repeatability so it is better where precise dimensions are critical. CrO3 produces the least reduction in fatigue strength. 2.4.5.3 Suitable Alloys Any aluminum alloy containing more that 5% Cu, 7% Si, or a total alloying element of 7.5% should not be coated by this process. 2.4.5.4 Relative Cost Chromic anodize costs more than sulfuric (Type II) but less than hardcoat (Type III).

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Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

2.4.6 Type II: Sulfuric Anodize

2.4.6.1 General The Sulfuric Anodize (Type II) coating is nominally 8m (0.31mils) thick, harder than Type I but still susceptible to damage through handling, has very good corrosion resistance, and is yellow-green due to the preferred sealing method of immersion in sodium dichromate. Clear coatings can be produced by sealing in hot water and are specified as Class I, clear. This coating can be dyed to produce the most pleasing colors of the three anodizing processes. 2.4.6.2 Advantages Fairly hard and suitable for applications that require light-tomoderate wear resistance such as lubricated sliding assemblies. It is the most aesthetically pleasing type of anodize. It can be dyed to almost any color and produces deep, rich shades that make the item appear to be made of a material bearing the color throughout. Corrosion resistance is good, therefore this type of anodize should be used where corrosion resistance is needed but the specialized benefits of the other types are not required. 2.4.6.3 Suitable Alloys With the exception of high-silicon die-cast alloys, all aluminum alloys can be successfully sulfuric anodized. It should be noted that clarity and depth of color increase with the purity of the alloy. 2.4.6.4 Relative Costs Sulfuric anodize is the least costly and most widely available type of anodize.

2.4.7 Type III: Hard Anodize

2.4.7.1 General Hard Anodize (Type III) coating is nominally 50m (2 mils) thick, although other thickness can be specified. The coating is extremely hard (60 to 70 HRC). The color ranges from gray to bronze to almost black, depending on the alloy coated, the coating thickness, and the electrolyte temperature. The coating can be dyed to produce a Class 2 coating. Because thick coatings are naturally very dark, only colors darker than natural are possible. Sealing hard anodize (Type III) is prohibited, as sealing reduces hardness and wear properties. 2.4.7.2 Advantages Extreme hardness. Is suitable for applications in which wear resistance is required such as valve/piston assemblies. Excellent corrosion resistance. Is suitable for marine components.

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Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

Excellent electrical resistor, it can be used to insulate heat sinks for direct mounting of electrical or electronic equipment. Because of natural porosity, it is used in areas in which adhesion or impregnation of other materials to aluminum is needed. 2.4.7.3 Suitable Alloys Although almost all alloys can be coated, the 6000-series produce the best hardcoat properties. High-silicon die-castings produce the lowest-quality coatings. Because of sensitivity to copper, the 2000 series should be avoided. 2.4.7.4 Relative Costs Hardcoat anodize is the most expensive type of anodize.

2.4.8 Coating Class

2.4.8.1 Class 1 Class 1 is not dyed. 2.4.8.2 Class 2 Class 2 is dyed.

2.4.9 Significant Surfaces

For significant surfaces, the anodic coating is essential for serviceability or appearance.

2.4.10 Production Lot

A lot shall be defined to consist of all parts or assemblies with anodic coatings of the same type and class, approximately the same size, shape, and thickness, that were anodized in the same bath at the same time.

2.4.11 Sealing Anodic Coatings

Sealing is a hydrothermal treatment carried out after anodizing or color dying to reduce porosity and absorptivity of the oxidation film. Sealing hard anodize (Type III) is prohibited, as sealing reduces hardness and wear properties.

2.4.12 Contact Mark

The anodic process requires passing an electrical current through the parts while the coating is being formed. No coating will form where the parts contact the rack. This results in contact marks. Larger parts may have larger contact marks because the amount of current required is a function of the surface area being coated. Contact marks are not acceptable on significant surfaces (See Section 2.5).

2.4.13 Natural (Clear) Anodize

This directs the finisher not to modify the reflectivity of the part before applying the anodic coating.

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B/E Aerospace, Inc. Specification Nbr: Title: Revision: Issue Date:

Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

2.4.14 Dull Anodize

This directs the finisher to reduce the reflectivity of the part before applying the anodic coating.

2.4.15 Bright Anodize

This directs the finisher to increase the reflectivity of the part before applying the coating.

3. How to reference this document 3.1 General Data

The following information shall be given on the drawing, contract, or purchase order: The name of the process - Anodic Oxidation Coating of Aluminum Alloys, number of this specification, Type, and Class of the required treatment, (when no Type or Class is specified the process shall be carried out for Type II and Class I. The required pre-processing, including any chemical or mechanical decorative surface treatment. The required post-processing, including any special rinsing, sealing, and/or any dye coloring. Significant surfaces. The specification and metallurgical condition of the basis metal(s).

4. Process Requirements 4.1 Alternate Process Specification

The process conditions defined herein may, with the written concurrence of B/E Aerospace Quality Assurance, be replaced by the process conditions and/or procedures defined in military specification MIL-A-8625, Anodic Coatings for Aluminum and Aluminum Alloys.

4.2

Toxicity Provision
The coating and the chemical processes used to develop anodic coatings shall have no adverse effect on the health of personnel when used for their intended purposes.

4.3

Materials
The chemicals used shall be such as to produce coatings that meet the requirements of MIL-A-8625. The quality or composition of the basis alloy is not specified but it is deemed suitable for anodizing. The base metal shall be free from surface defects caused by machining, cutting, scratching, polishing, buffing, roughening, bending, stretching, deforming, rolling, sandblasting, vaporblasting, etching, heat treatment condition, alloy chemistry imbalance and inclusions, that will cause coated test panels or parts to fail any of the requirements of this specification. Die-cast or investment molded parts may contain too much silicon and magnesium to be properly anodized. The clarity and quality of the anodic coating increases with the purity of the alloy.

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Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

4.4

Equipment and Processes

The equipment and processes employed shall be such as to produce coatings that meet the requirements of MIL-A-8625 and this specification. Process operating conditions shall be at the option of the anodizing vendor, subject to approval by B/E Aerospace.

4.5

Handling and Cleaning

Parts shall be so handled during all pretreatment, anodizing, and post treatments to prevent mechanical damage or contamination. Parts shall be free of all foreign substances, oxides, and soils, such as grease, oil, paint, and welding flux. Parts shall have oxide and interfering films removed by the use of proper cleaning procedures that produce water break free surfaces. Abrasives containing iron, such as steel wool, iron oxide rouge and steel wire, which may become embedded in the metal and accelerate corrosion of aluminum and aluminum alloys, are prohibited as a mean of mechanical cleaning prior to anodizing. If special cleaning requirements are necessary, B/E Aerospace must specify them in either the purchase order, the appropriate B/E Aerospace Engineering Drawing, or in writing.

4.6

Pre-Anodize Process 4.6.1 General Requirements

All parts shall be thoroughly cleaned before immersion in the sulfuric acid bath. Decorative parts that require specific texture may need to have their surfaces modified chemically, mechanically or electrochemically.

4.6.2 Anodizing of Parts

In order to obtain maximum protection from anodic coating, all heat-treating, welding, machining, forming, drilling, and cutting shall be completed before anodizing. Individual parts shall be anodized before their incorporation into assemblies whenever possible.

4.6.3 Anodizing Assemblies / Complex Shapes

Assemblies that, because of their geometric shape (i.e., joints, recesses, etc.), can entrap electrolyte shall be anodized using only the chromic acid based process. B/E Aerospace shall specially identify on the purchase order, the appropriate B/E Aerospace Engineering Drawing, or in writing all parts that are subject to this limitation. Assemblies that contain nonaluminum parts shall not be anodized without the written consent of B/E Aerospace. This consent must attest to the adequacy of the methodology used to mask or electrically insulate the non-aluminum parts from the electrolyte, without degrading the non-aluminum parts or compromising the ability of anodic coating to meet the requirements of this specification.

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Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

4.7

Sealing Anodic Coatings

All anodic coatings, except hard anodize (Type III), shall be completely sealed, unless otherwise specified in the purchase order, applicable B/E Aerospace Engineering Drawing, or in writing by B/E Aerospace. Sealing hard (Type III) anodize is prohibited, as sealing reduces hardness and wear properties. Adequacy of the sealing process shall be verified by successfully demonstrating resistance to the staining test specified in ASTM B-136. If not specified in the purchase order, the applicable B/E Aerospace Engineering Drawing or in writing from B/E Aerospace the corrosion resistance requirements specified in MIL-A-8625 are an acceptable alternative.

4.8

Coating Thickness
Minimum Coating Thickness m mils 2 0.08 8 0.31 50 1.97

Coating Type Type 1 Chromic Type II Sulfuric Type III Hard Anodize

Thickness may be measured using an eddy current technique, such as that described in ASTM B-244, or metatallographically using a microscope with calibrated eyepiece. An alternate acceptance criterion is a coating weight of 2450 mg/ft2 as determined by the technique described in ASTM B-137. If not specified in the purchase order, the applicable B/E Aerospace Engineering Drawing, or in writing from B/E Aerospace, the coating weight requirements specified in MIL-A-8625 are an acceptable alternative.

4.9

Bright Anodized Samples

Bright anodized samples may be provided to a supplier and/or customer to establish cosmetic surface finish acceptance requirements. Mechanical Modification of Surfaces, SPG-MPS-005, may be required to achieve the cosmetic surface finish represented by the samples. Samples will typically represent a minimum and maximum acceptable brightness. In all cases where the customer has a duplicate sample of acceptable cosmetic conditions, such sample shall be of a quality standard equal to or lower than that of the suppliers or B/Es sample. B/E reserves the right to replace samples issued to suppliers to assure their condition is equivalent to or marginally better than, the latest customer requirements.

5. Quality Assurance Provisions 5.1 Alternate Quality Assurance Provisions

The quality assurance provisions defined herein may, with the written concurrence of B/E Aerospace Quality Assurance, be replaced by the process conditions and/or procedures defined in military specification MIL-A-8625, Anodic Coatings for Aluminum and Aluminum Alloys.

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Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

5.2

Responsibility for Inspection

Unless otherwise specified in the purchase order or in writing from B/E Aerospace, the anodizing vendor is responsible for the performance of all inspection requirements as specified herein.

5.3

Responsibility for Compliance

All parts must meet all requirements of Section 4 of this specification. The inspection set forth in this specification shall become a part of anodizing vendors overall inspection system or quality program. The absence of any inspection requirements in the specification shall not relieve the vendor of the responsibility of assuring that all parts submitted to B/E Aerospace comply with all requirements of this contract or purchase order. Sampling in quality conformance does not authorize submission of known defective material, either indicated or actual, nor does it commit B/E Aerospace to acceptance of defective material.

5.4

Process Control Records

The finishing vendor shall maintain a record of the history of each processing bath, showing all chemicals or treatment solutions added to the baths, and the results of all chemical analysis performed. The processed parts and Certification of Conformance shall be sent to B/E Aerospace. These records shall be in a form suitable for incorporation into the permanent Quality Assurance record file maintained at B/E Aerospace and will be maintained for not less than seven (7) years from date of delivery.

5.5

Process Control Inspection

Process control inspections of Section 4.3 of MIL-A-8625 must be performed and logged per section 5.4 of this specification unless otherwise specified in writing by B/E Aerospace.

5.6

Lot Identification
Identification of each part as to its lot number must be preserved during shipment to B/E Aerospace.

5.7

Visual and Dimensional Examinations 5.7.1 Samples

Unless otherwise specified in the purchase order, applicable B/E Aerospace Engineering Drawing, or in writing from B/E Aerospace, samples for visual and dimensional examinations of anodized articles shall be selected from each lot of anodized parts in accordance with a statistically valid sampling plan.

5.7.2 Visual Examination

The applied anodic coating shall be uniform in appearance, free from breaks, scratches, and other defects that will reduce the quality of the coating. All parts shall be visually examined for any defect in the anodic oxidation coating after the final drying stage. Part surfaces shall not be powdery. When such defects are more than 3 per square foot of a part's significant surfaces, the

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Seating Products Group SPG-MPS-007 Anodic Oxidation Coating of Aluminum Alloys Rev. B April 25, 2005

part shall be rejected. Parts retaining residual chemical from the anodic coating process shall be rejected.

5.7.3 Dimensional Examination

Samples selected in accordance with Section 5.7.1 shall be dimensionally inspected; using the methods specified in Section 4.8, to verify the anodized layer thickness conforms to the requirements of Section 4.8. After anodizing, the overall dimensions of the part must fall within the tolerances of the applicable Engineering Drawing or specification.

5.7.4 Sealing Inspection

Samples selected in accordance with Section 5.7.1 shall be tested according to ASTM B-136, as required by Section 4.7, to verify that the parts were properly sealed.

5.7.5 Hard (Type III) Anodic Coating Inspection

Hard (Type III) anodic coatings are required to meet ASTM A8625 wear requirements.

5.7.6 5.8

Class II (Dyed Coatings)

Class II (Dyed Coatings) must match the appropriate color chip.

Failure to Conform
Failure to conform to any of the quality conformable requirements specified in this document may result in rejection of the represented lot.

5.9

Reprocessing and Repair of Failed Parts

The vendor shall report the details of the reprocessing, or touch up, including the lot and part numbers, to B/E Aerospace. Unless otherwise specified by the procuring activity, mechanically damaged areas from which the coating has been removed may be reworked.

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