Beruflich Dokumente
Kultur Dokumente
SURFACE FINISHING
USERS GUIDE
ALUMINIUM
Aluminium Federation of
Southern Africa
Introduction
INDEX
Introduction
ASFA
Finishing Processes
Atmospheric Corrosion
11
Powder Coating
15
Wet Coating
18
19
Contact Details
20
References
20
Introduction
ASFA
The Aluminium Surface Finishers Association (ASFA) replaced
the original Anoda that was formed in 1992 as an Association
under the aegis of the Aluminium Federation of Southern Africa
(AFSA) - to address the needs of companies involved in the
surface finishing of aluminium.
The Purpose of the Association is to represent its members
in matters of common interest or concern in the fields of
aluminium surface finishing, relevant quality and environmental
management and related research, technical advice and
technology transfer.
In achieving its purpose, ASFA will, amongst other things:
z
Provide a forum where members can discuss technical
matters of common interest.
z
Promote quality aluminium surface finishing that ASFAs
members offer their customers, adhering to relevant
SANS and other International Quality Standards.
z
Promote the awareness of aluminium finishing and its
applications through technical interchange and education.
z
Promote the mutual benefit of membership to the surface
finishing industry, including use of the ASFA hallmark / logo.
z
Provide a customer focussed education / advice /
information service including maintenance of relevant
technical data.
z
Facilitate training support and education for members and
aluminium Stockists' staff.
z
Make mandated representations on behalf of members
and the Industry on relevant matters opposite regulatory
bodies.
ASFA thrives on the participation of its members. The
Association, through its members and the Federation,
incorporates the best knowledge pool in aluminium surface
finishing in Southern Africa. Over the years, this knowledge has
been accessed to produce a definitive guide on aluminium
surface finishing in South Africa, namely the "Aluminium Surface
Finishing Users Guide". This publication contains technical and
practical guidelines and has proven successful with architects,
specifiers and other users of surface finished aluminium.
Industry stakeholders include companies engaged in aluminium
finishing, suppliers of products and services to the finishing
companies, purchasers of coated products and specifiers of
surface finishes.
Technique
Characteristics
Extruded
Mechanical
Grinding / brushing
The grinding lines partly disappear with polishing. Reduces stress risers.
Removes die lines and tool marks and surface blemishes.
Vibration polishing
Yields a matt to shiny surface suited to small batches and mass produced parts.
For cast aluminium components to remove cast skin and improve appearance.
Milling
Etching
Chemical
Brightening (prior to anodising) Removes surface texture and gives a mirror finish. Film usually < 15 microns
Chromating / phosphating
Hard anodising
Electrolytic polishing
Gives various degrees of protective and decorative finishes that can withstand
heavy chemical attack (provided surface coating is unbroken).
Screen printing
Wet coating
Mainly used in capital intensive operations for coil coating, effective and
efficient. Mainly for building industry.
Finishing Processes
z
Mechanical finish, if any is required
If specified, mechanical finishing is done before chemical
finishing or andodising. Mechanical finishes give surface texture
or remove surface defects and irregularities. Appearance can
be varied but usually gives a uniform, matt finish, directional or
non directional-sanded finish, or a specular (mirror-like) finish.
The mechanical finish shows through the anodic oxides because
uncoloured anodic oxides are transparent or translucent and
anodic oxides conform to the surface texture. Examples of
mechanical finishes are buffing, polishing, sanding, sand blasting
and shot peening.
Atmospheric Corrosion
Category
Description
C1
very low
C2
low
C3
medium
C4
high
C5
very high
Description
Type of corrosion
Intertidal to 5km
inland
Severe marine
100 - 300
Up to 3
15
80 - 100
0.5 - 2
15
Temperate marine
Marine
30 - 50
3-7
20
Sub-tropical marine
50 - 80
3-5
>20
Desert
<5
> 30
>30
Inland
Rural
10 - 20
> 20
>30
Inland urban
Inland industrial ++
15 - 40
5 - 15
20
Urban coastal
Marine industrial ++
50 - 150
1-3
20
Inland arid
Semi desert
5 - 10
> 30
>30
KEY:
* Higher corrosion rate usually indicates proximity of sea.
** Commercial grade Z 275g/m (unpainted).
^ Life in years - until 5% of surface area showing red rust.
Atmospheric Corrosion
NOTE:
z Metal corrosion depends
on time of exposure to
moisture and relative
humidity and temperature.
z Rate of corrosion reduces
rapidly the greater the
distance from the sea.
z For aluminium, aggravating
conditions can be a strong
sulphurous atmosphere, the
occurrance of chloride salts
and stagnant water - but the
right aluminium alloy still
outperforms copper, zinc
and carbon steel! Regular
cleaning and surface coatings
reduce the affect on
aluminium.
z Pitting
corrosion
in
aluminium may be unsightly,
but it is not structurally
significant.
Geographic Area
Description
ISO
Category
Comments
To 5 km
Above C5
N. of Olifants River
W. Cape Atlantic
shore-line
To 3 km
Above C5
W. Cape coastal
To 5-15 km
Coastal area
C4
W. Cape urban
To 25 km
Coastal urban/industrial
C5
To range of fall-out of
salt aerosols
Cape Town and
surrounds
S. and E. Cape
shore-line
To 1 km
Temperate shore-line
C5
To 5-10 km
Temperate coastal
C4
KZN shore-line
To 4 km
Subtropical shore-line
Above C5
KZN coastal
To 15-25 km
Sub-tropical coastal
C4
Durban urban
To 10 km
Upper C5
Richards Bay
To 15 km
Lower C5
Coastal cities
To 10-15 km
Lower C5
C3
C4
Amanzimtoti to Durban
North
Atmospheric Corrosion
Table 5: Recommended Specification
of Anodised Coating Thickness
(Please refer to the map on page 7)
Location
Distance
from sea or
source
of corrosion
agents (km)
Western
Cape
(West of
Hermanus)
C
<2
2 - 25
>25
25
25
15
25
15
15
Southern
and
Eastern
Cape
E, K
<2
2 - 20
>20
25
25
15
25
15
15
Natal
<2
South
2 - 15
Coast
>15
(south of
Amanzimtoti)
F
25
25
15
25
15
15
Durban
area and
Natal
North
Coast
G, H, I, J
<2
2 - 25
>25
25
25
15
Near a
chemical
or related
process
plant
M
<5
>5
25
15
25
15
In areas
where
windborne
sand may
be abrasive
(Western
Cape Coast
and the
Karoo
around
Beaufort
West)
Not
relevant
25
15
Other
areas
Inland
Corrosion Resistance
Many decades of experience with applications in a variety of
markets including construction, land-based installations and
shipbuilding have shown that aluminium and its alloys in the
1000, 3000, 5000, 6000 and 8000 series have excellent
resistance to atmosheric corrosion and to marine, urban and
industrial environments.
Combined with its light weight, aluminiums excellent
corrosion resistance accounts for the growth of aluminium
applications and offers users a number of advantages:
z
25
15
15
15
15
Location
Exterior use
Recommended
micrometers (m)
Interior use
Recommended
micrometres (m)
All areas
Polyester powder
to SANS 1578.
60-80m metal coating in
accordance with SANS 1796
or other international
standard.
Epoxy or Epoxy
polyester powder
to SANS 1274.
50-80m
Anodising
Powder Coating
Wet Coatings
Specifications
(ensure relevant use of most
current revision)
Colour range
Dependent on type of
coating used, a large range
is available. PDVF colours are
limited
Appearance
Colour fastness
Coating thicknesses
5 - 25 microns depending on
application.
60 to 80 microns
20 to 28 microns
Life expectancy
Warranted 10 years.
Experience over 20 years.
15 - 20 years if applied in
accordance with powder
manufacturers conditions.
Warranted 10 years.
Experience over 25 years.
Installation
Abrasion resistance
Maintenance
Common applications
On aluminium sheet,
extrusions, plate, etc.
On aluminium sheet,
extrusions, plate, etc.
Corrosion Resistance
Pre-treatment Finishes
Etched, polished,
brightened, brushed,
sanded, shot blasted, etc.
NOTE: All anodised and powder coated surfaces need regular care depending on the location and installed life. After installation, the
surfaces should only be cleaned with suitably approved cleaning materials. Site repair or changes to colour or finishes requires
expert opinion.
Excellent adhesion
Wet Coating
Colour retention
TABLE 7: Main Types of Anodising Treatment - for different aluminium alloy series
Alloy
Series
1000
Treatment
3000
Typical applications
Cans, buildings,
domestic utensils.
Engineering
5000
2000
Aeronautics.
Mechanical applications.
7000
Aeronautics, mechanical
applications, sports
goods.
6000
10
Architecture, building.
Anodising
What is Anodising?
Anodising successfully combines science with nature to
create one of the world's best metal finishes that is also
environmentally safe.
Anodising Definitions
There are five main types of anodising, each with a range of
possible processes:
z
Barrier anodising, used for refined aluminium only, for
electrical applications
z
Sulphuric acid anodising, used mainly as protection against
weathering
z
Chromic acid anodising for aerospace applications
z
Hard anodising which increases the surface hardness of
the metal, mainly for engineering applications
z
Phosphoric acid anodising, used to prepare surfaces for
adhesive bonding
ELECTROLYTIC
COLOURING (AC)
TIN or
COBALT SOLUTIONS
INORGANIC or
ORGANIC
DYEING ABSORPTIVE
NATURAL
COLD WATER RINSE
While the chemical anodising process remains the same for all
applications, the mechanical methods vary according to the
physical types and shapes of metal used.
Sheet Anodising
Uses
Advantages
z
z
z
Small runs.
Thicker films.
Anodised edges.
z
z
z
Small runs.
Thicker films.
Anodised edges.
z
z
z
z
Disadvantages
z
z
z
z
z
z
z
Colour variance.
High costs.
Film thickness variance.
Crazing when severely formed.
z
z
z
11
Anodising
Suggested Specifications
Substrates
Important information
Before agreeing to have material anodised, it is important for
the purchaser to discuss process parameters with the Anodiser.
Such parameters include:
z
Minimum and maximum rack lengths.
z
Jigging effects, especially on precut and long items.
z
Possible colour variations.
z
Any critical surfaces.
z
Effect of moisture and packaging (especially adhesives) on
the uncoated surface.
z
Minimum order size / value.
SPECIFY...
Finish appearance (bright, matt. coloured, etc) alloy and
end use of product and any special packaging required.
Anodic Film
Thickness
Colour
12
or
or
Inland
Coastal
15
25
Inorganic
Natural
Light Bronze
Bronze
Dark Bronze
Very Dark Bronze
Black
541
543
545
547
549
Organic
SANS Standards
External Finishes
Anodised finishes to be in accordance with SANS 999,
current date - Anodised coatings on aluminium (for
architectural applications)
or
Internal Finishes
SANS 1407, current date - Anodised coatings on
aluminium (for general applications)
Protective
Coating for
Installation
Anodiser
To be a certified markholder of SANS 999 and/or
SANS 1407 and/or ISO 9000/14000 or at least conforming
to SANS 999/1407 standards in terms of reference,
Qualanod certification may also be relevant.
Anodising
Defects originating during work piece preparation yielding stains, striping and cloudiness and also spotty
discolouration.
Defects originating from anodising itself - yielding
rainbow colouration, corroded appearance, spotty film,
uneven film, discolouration and hairline cracks. Also burnt
spots.
Defects originating during colouration - colour variation,
mottled colours (light and dark), not abrasion resistant,
colour not lightfast and colour cloudy.
Bright Anodising
z
z
z
z
Alloy
Type
E
E
V
F
G
G
V
E
V
V
G
E
F
Al 99,8
Al 99,5
Al 99,0
Al Cu Si Mg
Al Mn
Al Mn Mg
Al Mg2
Al Mg1
Al Mg Mn
Al Mg3 Mn
Al Si Mg Mn
Al Mg Si
Al Zn Mg
E
E
V
F(D)
G
G
V
E
V
V
G
E
F
V-E
V
G
U
F
F
G-V
E
G
G
F
V
U
Note: The various forms of semi-fabricated aluminium have their own characteristics affecting the anodising finish. Different alloys
anodise to slightly different shades.
Anodising Characteristics of Cast Aluminium
Alloy Designation
Alloy Type
E
F
E
G
G
F
U
Al Mg5
Al Si12
Al Mg10
Al Si5 Cu 1 Mg
Al Si12 Cu Fe
Al Si9 Cu3 Fe
Al Si18 Cu Mg Ni
E
U
F
F(D)
F(D)
F(D)
U
G
U
U
U
U
U
U
G = Good,
D = Dark Colours Only
13
Anodising
z
z
The thickness of the aluminium oxide coating can be varied by the anodising process time. The following figures
are usual:
5 Micron
10 Micron
Suitable for internal applications, and outdoor applications where cleaning is very
frequent, for example, caravan trim. Also for reflectors.
15 Micron
25 Micron
14
Powder Coating
Introduction
Range of Colours
Pre-treatment
Degreasing, rinsing,
caustic etch, rinse,
nitric acid desmutting,
rinse, chromate
conversion, rinse,
sealing rinse with
demin water.
Dry off / Cooling
Powder coating
Heat Curing
160 C to 210C
Cooling
Parts unloading
Versatile Finishes
Powder coated surfaces are more resistant to chipping,
scratching, fading and wearing than other finishes. Colour
selection is virtually unlimited with high and low gloss, metallic
and clear finishes available. And colours stay bright and vibrant.
Texture selections range from smooth surfaces to a wrinkled or
matt finish and rough textures designed for hiding surface
imperfections. Powder coating is a technology of the future!
Quality Standards
What factors should be addressed and clearly defined when
specifying architectural aluminium finishes? The importance
of clear technical specifications cannot be emphasized
enough because, at the end of the day, a professional
reputation may be at stake and costly disputes could arise.
Here is a handy check list of key elements that should be
addressed:
Material type:
Aluminium alloys produced to BS1470, 1471 or 1474.
Significant Surfaces:
Details which surfaces will have nominal 50-80 microns.
Colour:
As agreed upon from RAL or NCS standard colour chart.
Fabrication:
Detail any peculiar or difficult factors relating to the
fabrication requirements.
Type of Powder: Polyester, equivalent or better.
Gloss level: Gloss, matt or satin.
Applicator:
A certified SANS 1796 approved applicator.
Process Control:
Strictly in accordance with SANS 1796 or Qualicoat.
Certification:
Certificate of Conformance will be provided by an
approved applicator on completion of the coating.
15
Powder Coating
Environmentally Advanced
The powder coating process is also environmentally friendly as
it is virtually pollution free. Unlike liquid paint, no solvents are
used so only negligible amounts of volatile organic compounds
(VOC's) are released into the air. In addition, unused or oversprayed powder can be recovered so any waste is
minimal and can be disposed of easily and safely.
Advantages
There are many advantages that make the choice of applying
thermosetting powder coatings attractive to the coating
company. These include:
z
z
z
z
z
SPECIFY...
Colour
or
or
Finish
or
or
Powder Coating
Film Thickness
RAL / NCS
SANS
Mfrs
range
Gloss
Satin
Matt
60 - 80
16
SANS Standards
Powder coated finishes to be in accordance with SANS 1578.
Organic powder coatings for external architectural aluminium
Powder Coater
To be a certified markholder of SANS 1796 and / or an applicatior approved by the
powder manufacturer who must be a certified markholder of SANS 1578: Organic
powder coatings for external architectural aluminium.
Guarantee of coating given by the Powder Coating manufacturer is only valid
provided the applicator is approved by the coating manufacturer.
Powder Coating
aqueous solutions. It is therefore necessary that components
do not float or retain trapped solutions after treatment. Hollow
components may cause ingress of solutions that can boil out
during the powder curing cycle, spoiling the coating.
Most components can be suitably ventilated by a 6mm
diameter hole at a point permitting total drainage of the
components.
Large flat butting surfaces can also trap solutions by capillary
action and these should be avoided.
Sound deadening or porous filling materials that can absorb
pretreatment chemicals or materials likely to melt below
250C should not be built into an assembly before coating.
4. Powder (uneven surface) Penetration
Powder initially adheres during coating by electrostatic forces,
but a phenomenon known as "Faraday Cage" can counter the
action on components with narrow recesses, slots or sharp,
enclosed corners. Advice should be sought where these can be
avoided, but generally with slots, the width between the two
edges should be greater than the depth.
8. Protective Tape
Though polyester powder is an extremely tough and resilient
coating, mechanical abuse can cause unsightly scratches and
blemishes. Obviously the best way to eliminate this is by
adopting good working practices both during fabrication and
installation. Not withstanding this, protective tape is used
extensively for the protection of architectural products.
9. Application
Protective tape is normally applied by the fabricator or window
manufacturer. The powder surface to which it is applied must
be free from dirt, oil, cement or other surface contaminates. If
necessary, the surfaces can be cleaned using a soft cloth
dampened in white spirit. The surface must be dry before tape
application.
10. Cleaning of residual adhesive
Where necessary, any residual adhesive left on the powder
coated surface following the removal of protection tapes should
be removed by wiping with a white spirit dampened cloth.
Solvents or cleaning solutions containing esters, keton,
chlorinated hydrocarbons or alcohols must not be used. It is
always recommended to try these procedures on a small area
first.
5. Dissimilar Metals
Assembles consisting of different metals or painted surfaces
should be avoided. The different materials may require noncompatible pre treatments and electrolytic corrosion may also
be encouraged.
6. Heavy Masses
Heavy components require a longer heating cycle due to the
metal temperature being the important criterion.
Consequently, these are more expensive to coat. The surface
appearance (but not colour) of the finished item may be
slightly different between substrates of differing mass due to
variations in "heat-up" and cool down times.
7. Exposed Surfaces
All drawings should indicate the area where the coating is
required.
17
Wet Coating
Introduction
Applications
For decorative and corrosion resistant surface finishes a large
variety of paint systems and colours are available including
alkyd, acrylic, vinyl and epoxy coatings as well as fluorocarbons
- with service lives exceeding 20 years.
Painted aluminium coil is a natural choice for the building
market with coating types designed to meet the varied
requirements and applications of the market. A wide range of
alloys, tempers, coating types and colours are available for all
the different cladding and roofing systems in use today and the
many different fabrication techniques employed. Painted coil is
also used in vehicles.
SPECIFY...
Alloy
Temper
Nominal Coil Thickness
Profile
Surface Finish
mill
stucco embossed
Colour
from coil coaters range
Gloss
18
PVDF
Polyester
Acrylic
As top side
or light grey
protective lacquer
Introduction
As with all materials exposed to the elements, regular
maintenance is required to ensure maximum life and
performance from the product.
A key to successful cleaning depends on the knowledge of what
type of surface finish you are dealing with. The life of an
anodised, powder coated or painted surfaces can be greatly
enhanced by applying a regular maintenance programme. This
will ensure the removal of any dirt, grime, grit, atmospheric
pollutants and iridescence.
Any chemical attack on a decorative surface that is not
regularly cleaned becomes increasingly severe and after
several years, the finish may prove impossible to restore.
Cleaning Procedure
A regular cleaning and maintenance system is essential for two
reasons:
z
To maintain decorative appearance; and
z
To reduce any chemical attack, if applicable.
The cleaning procedure may be broken down into three
distinct categories, namely:
1. Primary Cleaning:
Primary cleaning is the initial cleaning that should occur after
installation / completion to remove atmospheric dust, deposits
of dirt, possible cement deposits, glues, etc.
2. Secondary Cleaning:
This is normally a heavy duty clean that is carried out on a
surface that has not been cleaned for some time.
This is carried out by companies that specialise in the cleaning
of facades, windows, doors, curtain walling, etc.
The most important criteria of an aluminium cleaning agent is
that it should not be toxic, have a pH within 4,5 and 9 and it
must be free of fluorides, chlorides or sulphates.
3. Periodic Cleaning:
This is the cleaning cycle that should be done on a regular basis
AFTER the primary and secondary phase (in the case of a new
installation, it follows after the primary). The intervals of each
cleaning cycle are dependent on the atmospheric pollutants,
area, region, corrosion levels, etc. for a particular region approximately three months at the coast and six months inland.
19
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
AFSA has a number of reference sources on surface finishing of aluminium and its alloys. Members and non-members
are welcome to contact AFSA for more information (which is free to members).
Aluminium Federation of
Southern Africa