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Finishing Spotlight:
From the
Forum: Anodizing
Aluminum;
First Annual Gebhardt Award
where went presented at SMF 2008 Economic Instability can
(page 6) wrong? Promote Innovation (p.15)
(page 9)
Page 2
FINISHING TALK
Newport News, VA Andrew ers. The firm, a division of Charter prevention plans to protect water
George Bachmann, inventor, entre- Manufacturing Co., Mequon, WI, quality. Facilities are required to
preneur, and business leader, died manufactures engine dipsticks, install control measures that meet
on Sept. 15, at the Riverside Re- transaxle retaining rings, valve keys established technology- and water
gional Hospital in Newport News, and valve-spring retainers. To fur- quality-based effluent limits and
Va. He was 68. Founder and Chair- ther its global reach, in February must develop a stormwater pollution
man of the Dymax Corporation, 2007 Charter Mfg. acquired Valve prevention plan. The new permit
Bachmann's adhesive inventions and Train Components Limited, Lichfield, offers several improvements from
successful marketing led to the England; and recently opened a the previous MSGP, including easier
creation and development of prod- manufacturing, warehouse and dis- to understand discharge require-
ucts used in the manufacture of tribution facility in Wuhu, China. ments; fast and easy electronic filing
medical, electronic, automotive, Learn more at charterautomo- of Notices of Intent (NOIs) and
aerospace, and consumer products. tive.com. monitoring reports; web-based tools
Bachmann's adhesives changed the for locating waterbodies and deter-
Netherlands DSM Powder Coat-
way many of the items used daily mining impairment status; and up-
ing Resins recently launched Ura-
are manufactured, helping compa- dated monitoring, inspection and
lac® Corres – a new technology
nies to become "green" manufactur- corrective action schedules. More
platform, based on breakthrough
ers while becoming more competi- information on the MSGP: epa.gov/
innovative polyester resins for corro-
tive in the global marketplace. npdes/stormwater/msgp
sion protective coatings. The first
Independence, OH The newly product from this line, Uralac® P Cuba, MO Paul Fredericks and his
released September 2008 Precision 7604 is specifically developed for company Usona Metal Finishing Co.
Metalforming Association (PMA) top coat and primer applications and were indicted on federal charges
Business Conditions Report indicates provides exceptional corrosion pro- involving the illegal transportation,
metalforming companies expect tection in metal coating. For top storage and discharge of hazardous
business conditions to weaken coat applications, the unique Ura- waste at the company’s Cuba, Mo.,
somewhat during the next three lac® Corres technology offers the plant, U.S. Attorney Catherine
months. When asked what the trend possibility to significantly reduce and
Hanaway said Thursday. The indict-
in general economic activity will be sometimes completely eliminate ment alleges that in April 2007, the
during this period, metalformers chemical pre-treatment Usona powder coating plant on Clin-
anticipated a slight decline. 53% steps.Through the reduction of pre- ton Street ceased operations and
predict activity will remain un- treatment chemicals, less process that Fredericks, 44, of St. Louis,
changed (compared to 52% last waste is created, resulting in a sig- directed the illegal transportation of
month), while 31% forecast a de- nificant reduction in environmental drums of hazardous waste to his
cline in business conditions (up from impact. DSM Powder Coating Res- plant in Cuba. Between April 2007
28% in August). "Increased eco- ins, the global leader in powder and April 2008, approximately 100
nomic uncertainty in the credit and coating resins and part of the Busi- drums of hazardous waste were
financial markets are having an im- ness Group DSM Resins, specializes illegally stored at the Cuba plant,
pact on PMA members, giving them in innovation, development and and in April 2008, Fredericks alleg-
less confidence that there will be manufacture of polyester resins for edly directed the illegal discharge of
any rebound in orders and ship- powder coatings. More information those pollutants into the sanitary
ments in the fourth quarter," said on DSM can be found at sewer drain at the Usona plant in
William Gaskin, PMA president. For www.dsm.com. Cuba. If convicted, violations of the
a complete copy of the report,
Washington, D.C. The U.S. Envi- Resource Conservation & Recovery
please visit www.pma.org/about/
ronmental Protection Agency (EPA) Act carry a penalty range of two to
stats/BCreport.
is issuing a new Stormwater Multi- five years prison and/or fines up to
Milwaukee, WI Milwaukee Wire Sector General Permit (MSGP) for an $250,000; and violation of the
Products has been renamed Charter estimated 4,100 industrial facilities Clean Water Act carries a maximum
Automotive to reflect its commit- in 29 different sectors to implement penalty of three years prison and/or
ment to global automotive custom- site-specific stormwater pollution fines up to $250,000.
Page 4
FINISHING TALK
Belton, SC — On September Firefighters, said damage to the dled the cleanup of sulphuric
25th an early morning fire broke interior of the metal building is acid. McGee said the acid, used
out in the Belton, SC based B & “considerable.” in the electroplating process,
B Plating plant, part of the Bel- spilled and Hepaco workers were
Though at least one of the two
ton Standpipe Industrial Park. attempting to neutralize it before
production lines is likely up and
The fire is expected to sideline it became mixed with storm wa-
running again by this point, em-
about 30 workers in a plant that ter runoff. An official with the
ployees on the other line could
uses high-voltage electricity to South Carolina Department of
be out of work for about two
coat metal with nickel. Health and Environmental Con-
weeks.
trol was monitoring the cleanup.
Jim McGee, owner of the facility,
“Nickel has to be heated to 140
said he was notified of the fire
degrees,” McGee said. “It ap-
around 4 a.m. - two hours after
pears to have gotten too hot and
the plant's second, nine-hour
shorted out a 208-volt power
shift had closed the plant.
line.”
Belton Fire Chief Alan Sims said
Many of the workers in the facil-
Thursday afternoon that the fire
ity have been affected, and as
was accidental, caused by over-
many as 10 are involved in
heated chemicals in a vat.
cleanup operations.
McGee, noting that roof panels
Later that afternoon, crews from
and wiring were destroyed, but Cleaning Crew member, being sprayed
the Charlotte-based Hepaco,
the building was saved from down with decontamination solution.
wearing protective clothing, han-
other damage by Belton City
Page 6
FINISHING TALK
Posted on February 16, 2007 8. my bushing in the part dissolved quickly (ok b/c
October is all about cruising through the country- old bent lever used for test)
side, watching the leaves change. What better way 9. left on for 20 min until neg stopped bubbling
to do that than from a motorcycle? Unfortunately, and
Hard Color is having a hard time anodizing the 10. the charger showed zero current was being
clutch on his Yamaha, but has received some ex-
drawn
pert advice forum members Zurv, Labrat, Ryan
11. took part out and rinsed in cold water
Cook, DustinGebhardt, Smittys800, and John
Hu. Feel free to add your thoughts to their ongo- 12. dipped in Rit black dye for 15 min
ing discussion by visiting the forums at 13. rinsed off in water, and it looked just like I
www.finishingtalk.com/community and choosing started!
the “Anodizing” forum. For more ‘From the Forum’
Do you guys have any ideas of where I went
discussions, check out our internet television show,
wrong, or of where I could look for a better proc-
Finishing Talk Live, where hosts Paul Fisher and ess? I would really like to figure this out, it is driv-
Paul Skelton bring the boards to life! ing me nuts. Some teenagers are doing this and I
www.finishingtalklive.com can’t even get it...:confused:
Hard Color
Hard Color
(update) Okay, I just found a different "how to"
Where am I going wrong, guys? I am trying to online that says that I need 3 parts water to 1 part
anodize the clutch lever on my Yamaha motorcy- battery acid to get 20%. A different source said
cle, but it will not take color and I don’t know if it 50/50, and even another said 2 parts battery acid
even took any anodizing. I am using the battery to 1 part water! Ahh, my head!
charger method, if you are familiar with it. These
edit: Wikipedia says battery acid is 33.5%, battery
were my steps:
acid (used in lead-acid batteries) (pH 0.5). That
1. rinsed part in muratic acid to ensure perfectly means a 1/1 ratio of water/battery acid should
have been right on. Hmm...at least I am learning.
clean.
This is a fun new challenge for me.
2. used 14ga alum wire to hang part in a solution
Zurv
of
Haha, yeah... you will find that. Hopefully one of
3. 50% premixed battery acid, 50% water the many experts that visit our forums will be able
4. which should have given me about a 20% sulfu- to help your with you problem.
Check to make sure these 2 components are within minimum of 30 minutes (this is the poor boy’s style
the recommended ranges per the technical data of sealing the anodized coating; crude, but effec-
sheets that should have been included with the tive.) Voila - you should have a good, black, ano-
dyes. Also, you said you clean with muriatic acid. dized part. Post your findings here and feel free to
This will remove metallic contamination from the contact me at Ryan.cook@teammetalfinishing.com
surface (oxides, etc.), but not organics like soils,
fingerprints, etc. You’ll need to pre-clean in a de- Smittys800
tergent based cleaner to remove these contami- Sounds like you did not have a good connection to
nants. Make sure the cleaner is not caustic based, the part.
or it will etch or dissolve the aluminum. You may
John Hu
also want to include a deoxidizer prep to remove
Your problem seems to me to lie in not having con-
any smut that could be present on the surface.
trol of anodizing temperature. Anodizing is a com-
50% nitric acid works well. There are also proprie-
petitive process. Electric current makes the anodiz-
tary deoxidizers on the market.
ing thickness grow, while electrolyte consumes the
Welcome to the forum! layer of anodizing. As during anodizing, lots of heat
is released, and it will make the solution tempera-
Hard Color ture go up quickly if no chilling system is there -
Muratic acid attacks aluminum the same as it does and higher temperature in the solution consumes
other metals, correct? So, shouldn’t muratic acid the anodizing layer more quickly. If the speed of
work as an etcher also? consuming is faster than that of growing, there will
be no anodizing layer.
Ryan Cook
DustinGebhardt
Let’s do this…
If you have a conductivity tester, you can test for
Go to the kitchen. Get out the big old bottle of dish the presence of a non-conductive layer (i.e. the
detergent - Dawn, Joy, etc…all have a great deal of anodized aluminum oxide layer). I've seen them at
surfactants and emulsifiers in them that will rid Harbor Freight for about $10. It looks like an ice
your not so pristine clutch handle of any dirt, oil, or pick with a light in the handle and a wire lead with
grease. If you can heat the solution, great! Heat an alligator clip attached.
at 130 degrees, and soak it for 10-15 minutes, agi-
tating the part occasionally. Next, rinse the part To make sure that the part is clean before anodiz-
really well, and prepare to anodize it. The concen- ing, do a water break test. Remove the part from
tration of the bath should be about a 15% sulfuric your rinse after the acid and see if the water beads
acid solution, at around 70 degrees. Lead cathode up or breaks. On a clean part, the water should
will work, but make sure your cathode is at least 2 sheet perfectly. If there is any debris or oils, the
times the size of your part. Anodize the part at 16 water will break or bead up (just like a freshly
volts for about 45 minutes and you should achieve waxed car).
a thickness of at least .7 mils. Rinse the part thor-
oughly, as any acid left in the anodic pores will ruin Make sure that your anodizing acid is cold. When
the dying process you are about to perform. you mix up the acid and water, you will generate
heat and the bath will be too hot to use for anodiz-
DO NOT TOUCH THE PART WITH YOUR HANDS ing. 70F is generally considered the optimum temp
AFTER ANODIZING!! (not yet, anyways.) for anodizing. As the temperature increases, the
Your dye tank should be at a generic PH of 5.5 at anodizing layer starts to be consumed during the
130 degrees (each dye is different, tech data process. At a high enough temp, the oxide is dis-
sheets are great to find parameters). Dye the part solved at fast as it is formed. An aquarium chiller
for at least 10 minutes, longer for lower tempera- can help keep the temps down for those of us on a
tures. Finally, you will need a boiling pot of Dis- budget. Just be aware that the acid can and will
tilled/Deionized water; submerge your freshly eat up the internals of the aquarium chiller unless
dyed/rinsed-off handle in the boiling DI water for a
Continued on page 13...
Page 8
FINISHING TALK
F I N I S H I N G S P O T L I G H T , CONTINUED...
neer) for Danaher Tool Group online forum and I signed up “But all of those take a back
in Gastonia, NC. when it went live. The rest, as seat to hanging out with the
“We left Arizona wearing shorts they say, is history.” kids, where I am a coach for
and sandals with a temperature the boys’ flag-football team
in the 70’s, and arrived in Char- In addition to a successful ca-
and unofficial cheerleader for
lotte to a light snow storm. Talk reer in metal finishing, Dustin
my daughter’s gymnastics
about a change in scenery.” enjoys spending time with his
class. First and foremost, I am
family - 5 year old twin boys,
Gebhardt says that he first a family man.”
3 years old and 1 year old
learned about Finishing Talk
daughters, and his beautiful Dustin hopes to stay in the
through Paul Fisher, whom he
wife. As far as pets go, they metal finishing industry for a
met for the first time at the Los
are down to two dogs and a long time. He aspires to ac-
Angeles Powder Coating School
large freshwater fish tank. quire the skills and knowledge
(sponsored by the Surface Fin-
possessed by the “gurus” that
ishing Academy) while he was Dustin spends his free time on
he’s met along the way, includ-
still working for A Brite. “When “tinkering in the garage”,
ing Bruce Anderson, Scott
I moved to NC, I realized he working on his car, woodwork-
Dunigan, Bob Kosier, Larry
was just down the road, and ing, computers, fish-keeping,
Farnsworth, and Dianne Patter-
we met up several times. He camping, and on role-playing
son.
mentioned his ideas for an games.
Page 11
VOLUME 1, ISSUE 9
they can withstand the acid. BUT WHY CAN I NOT REPEAT same; battery acid cut 50/50 wit
THE PROCESS? DI water. I store acid in a clear
Heating the dye can speed the
plastic container, outdoors, be-
penetration of the dye into the I tried the above process with
hind my shed from direct
pores of the oxide layer. There the same bit of metal, this time
sunlight. I have also noticed
is a limit, of course, but around only filed the anodizing away to
that the acid color is now clear
130-140 is pretty common. reveal virgin material, and in-
instead of that very light yellow
creased the size of the lead…but
Your power supply may be un- when first mixed. Do I need to
nothing happens. The metal
dersized for the part. I'd imag- change the acid, dye after every
only turns grey after boiling. I
ine that the shift lever is no job...this is extremely frustrat-
tried the same process with
more than 0.25 square feet of ing. Please help.
other bits of metal, used a dif-
surface area, which needs about
ferent power supply, checked
3-4 amps of constant current. Do you have something
temperature, distance of anode
and cathode, and polarity. I
to add? Log on to the
Hard Color
even "over cleaned” the work Finishing Talk forums to-
Why can I not repeat the proc-
ess? I had great success anodiz- with ultrasonic - most bubbles day to join in on this dis-
ing a single piece of ali 1 inch at the lead, and still no joy. I cussion – or start a dis-
sq. at 175 ma for 1 hour, rinsed notice there is a bit of crystalli- cussion of your own!
and rinsed again, soaked in dye zation at the acid waterline with
for 30 minutes, boiled for the metal. I am using 2 liters of
45...beautiful acid and fresh de-ionized water www.finishingtalk.com
every time to rinse. Acid is the
Page 14
FINISHING TALK
By: Anna Levitsky, Editor life, and they chose to build some- a discussion on Innovation, and so
thing from the ashes. far I have digressed. The most
T he past few weeks have been
marked by a steadily increasing
Today, as we face mass lay-offs,
falling property values, an increas-
effective way to break out of a
failing system, in my opinion, is to
create your own. This is the es-
economic turmoil - with financial ing gap where the middle class
sence of innovative thinking. If all
institutions lined up and falling like once reigned, and other harbin-
around you people are struggling,
dominos, echoing down the corri- gers of economic recession, we
and they are all trying to stay
dors of Wall St. But it isn't just too are challenged to either fall
afloat using the same old, worn
banks, credit card companies, and behind with the rest of the coun-
out, and ineffective methods, it is
other lending institutions that are try, or use innovation to regain a
up to you to come up with a new
feeling the crunch; every individ- semblance of stability; and who
and novel solution. To get you
ual, organization, or business that knows, maybe even prosperity?
started, here are a few areas
relies on these institutions (which What can we do, as employees
which you might want to collabo-
is basically everyone) is being ei- and business owners alike to com-
rate on with some coworkers to
ther directly or indirectly affected bat high energy costs, rising raw
come up with solutions to kick
by the crisis. material prices, a shrinking dollar
start your business during these
value, and financial insecurity?
While it's tempting to let the me- trying times:
dia's constant economic updates The answer lies in community and
* Reevaluate and consider adding
and premonitions of disaster en- collaboration. These two concepts
or removing steps in your business
shroud you with despair, it is not are pivotal to Finishing Talk's busi-
processes.
necessarily the only way of ap- ness ideology, and for good rea-
proaching the issue. Historically son. When times are tough, recen- * Combine steps for better effi-
(and philosophically), times of cri- tralization occurs en masse in ciency
sis or upheaval - anything that communities and industry alike.
* Find ways to conserve energy in
blatantly resembles an uncomfort- People will pool their resources,
the office, factory, or warehouse
able change - are not simply de- knowledge, and skills with every-
fined by their obvious jolt to the one else, because they end up * Determine which materials can
status quo, but by their ability to gaining stability through contribu- be reused to cut down on ex-
transform and create. Think about tion to the whole. People will also penses
it: when the American Colonists cut down on superfluous expenses
* Simplify your products
first decided to challenge the au- (which, unfortunately, often re-
thority and rule of the British Em- sults in downsizing in industrial These are just a few challenges to
pire, the ensuing revolution was situations), leaving them with only get your creative juices flowing.
by no means a pleasant response, the bare necessities. This phe- Here is another challenge: branch
but it was in fact a change; one nomenon is occurring all over the out to your comrades in the in-
that would later lead to the crea- country right now, and in all sec- dustry, and learn from each
tion of one of the most long- tors. Businesses are laying off em- other. Our online forums have
standing, thoroughly composed, ployees by the thousands, and become a great resource for con-
and well known governing docu- people are cutting excessive ex- structive and professional feed-
ments that the world has ever penditures from their family budg- back on finishing related ques-
seen - the United States Constitu- ets. But the upside of this seem- tions and more, posed by industry
tion. (The reason I use this as an ingly negative trend is the first 'C' members across the country
example of a transcending result I mentioned - the resurgence of and around the globe. Have
of tumultuous times, in addition to community. This is a subject we a problem that you can't quite
its analogous pertinence, is be- have covered in several past is- figure out on your own? Visit
cause this past September 17th sues, and it appears to have been www.finishingtalk.com and click
marked the 221st anniversary of well-timed in light of current on "Community". See how others
the U.S. Constitution.) Then as events. are handling current economic
now, the people of America faced But the title of this article suggests conditions, get inspired, and let
a changing economy and way of the innovation begin!
PRST/STD
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October 2008
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