Advanced Aluminum Anodizing Technology

Overview
Conventional Anodizing
Factors Influencing Coating
Characteristics
Using Process Control Technology
Benefits & Payback
Cr+6 Free Post Anodize Sealing
Future Goals/Objectives
Advanced Anodizing using Process

Control Technology
By
Ruben A. Prado, CEF

Naval Air Systems Command (FRC-SE)
Materials Engineering Laboratory
Testing and Corrosion/Wear, Code 4.9.7.5
Jacksonville, FL 32212-0016
NAVAL AVIATION TECHNOLOGIES
DoD Metal Finishing Workshop 16, 17 May 2007
Factors Influencing Properties

Of the Oxide
Conventional Anodizing
Electrolyte Concentration
Manual Control of rectifier

Voltage Anodizing
Lead Cathodes
Copper Buss Bars
Sulfuric Acid Electrolyte (no Additives)
Current Density
Anodizing Time
Bath Temperature
Alloy Composition
Agitation
Human Error
Pore
Cell
Wall
(+) Anode
Cathode
(-)
(-)
Porous layer
H2
-
Oxide Dissolution
Anode/Cathode Ratios
SO4
H+
OH
O2-
O2
H+
-
O2SO4
H+
H2
-
Barrier layer
SO4
Unsealed Anodic Coating
OH-
Aluminum
Volts
Volts
15
15
20
20
30
30
2
9
Pores/in
Pores/in2xx10
109
498
498(smaller)
(smaller)
334
334
179
179(larger)
(larger)
Film Thickness
Effects of Burning
Burning
Process Control Technology
burning
Bath Additive
Interface
Controller
soft films
Current Density
Process
Controller
Photos courtesy of Metalast International, Inc.
Anodize Tank Modification

Anode/Cathode/Air Sparger
Regenerative Blower
4 line sparger
6063-T6 Al Cathodes
Al 6063-T6 extruded Anode Bar
Low Pressure High Volume Air Supply for Sparger
Anodize Tank at FRCFRC-SE JAX
Electrolyte Additive
Improves consistency & uniformity

Decreases oxide dissolution burning
burning
Increases Coating Ratios
Improves efficiency reduces decants
Increases apparent density
Reduces cracking & crazing
Allows for higher current densities
Reduces operating costs
Metalast AA-200
10
Benefits both Type II & Type III baths
Coating Ratio & Efficiency
Chemical Dissolution Rates
Chemical dissolution rates of Anodic Coatings (Type II)

Conventional vs. Metalast Technology
Before Anodizing
w1
Anodic Coating
After Anodizing
w3
About 15% - 20% Reduction in

Chemical Dissolution Rates
can be observed on Type II
anodizing with the AA-200
additive.
w1
w2
Coating Ratio: (w3-w2)/(w1-w2)
Metalast AA-200
w1: Weight of original panel

w2: Weight of Al after coating is stripped
w3: Weight of Al with anodic coating
w3-w2: coating weight
w1-w2: Weight loss of aluminum
Information obtained from Metalast Report, Comparative Studies of Anodic Coatings Formed in the Metalast and Traditional Electrolytes (Part 1 & 2) by
Shi Hua Zhang and Lin Zhang 2001
11
Information obtained from Metalast Report, Comparative Studies of Anodic Coatings Formed in the Metalast and Traditional Electrolytes (Part 1 & 2) by
Shi Hua Zhang and Lin Zhang 2001
12
General System Parameters
Operating Parameters
Cathode material of 6063-T5 or T6 is vital
Bath Chemistry, Tank 209 @ FRC JAX

Chemical Component
Concentration Range (g/L)
Concentration (g/L))
METALAST AA-200
35
Sulfuric Acid
165 220
192
Aluminum ion (Al+3)
4 15
Maintaining a 3:1 Anode-to-Cathode ratio is best

Sufficient volume and uniformity of agitation must be
maintained (recommended scfm = surface area x 2).
Proper Temperature range needs to be maintained:
Type II: 70 2F
Type III: 32 2F
Anodizing Conditions
Anodizing Type
Current Density
Bath Temperature
Type II
12 ASF
70F
Type III
24 ASF
34F
Type IIB
*8 ASF
80F
Use a 10 to 100 micron spun polypropylene filter

Keep electrolyte below 100F
Normal tank solution may be clear to slightly cloudy
Slight foaming is normal
*Based on corrosion pre-screening evaluation of Metalast provided coupons/strategies and alloy being anodized.
13
14
Metalast
Metalast System
Block Diagram
Installed Metalast Process

Controller at FRCFRC-SE JAX
120V, 60 Hz Facility
Service Panel
Audio/Visual
alarm
Type T
thermocouple
Data
Logger
Printer
METALAST JobPro
Operators Control
Console (OCC)
Metalast Process Controller
Audio/Visual Cycle Alarm
15
16
(-)
Process Controller Features
Main Menu
Interfaces with existing system

rectifier
Rerun last Strategy
Strategies can be created and

stored via touch screen console
Create & Run Strategy
Auto regulates & controls

rectifier voltage & current output
Select & Run from

active cue
Optional Material Handling

System & Temperature monitor
System Setup &

Service
Pre-run/End of Cycle Alarm

Operator ID
17
Anodize Tank
(+)
System
Rectifier
Metalast Interface Controller
Interface
Controller (IC)
Generates Progress
Verification Reports (PVR)
Metalast IPC JobPro

18
Create a Strategy
PrePre-Run Alarm
Enter ramp time

Enter target amps
Enter plateau time
10
Pre-Run Alarm (PRA) count down

19
20
Run in Progress
End of Cycle
Strategy steps are executed
End of Cycle Alarms

goes off
Rectifier current output
goes to zero
Process Verification
Report is generated
32
Interface Controller Monitors Voltage/

Current outputs from System Rectifier
during Anodizing
21
22
Accuracy of Desired
Oxide Thickness
Type II Coating Thickness

(mils)
Conventional
Alloy
Type II Anodizing (Unsealed)

B-117 Corrosion Test Coupons
20242024-T3 Al Alloys
Type III Coating

Thickness (mils)
Target
Actual
Target
Actual
2024-T3
0.5
0.48 0.03
2.0
1.92 0.05
6061-T6
0.5
0.53 0.03
2.0
1.91 0.06
6061-T6
0.7
0.73 0.04
7075-T6
0.5
0.52 0.03
2.0
1.95 0.06
1900 Hrs
2900 Hrs
3900 Hrs
8500 Hrs
Metalast
4 to 6 % deviation from run to run using Metalast System

MIL-A-8625 states: Coating shall not vary by more than 20% for coatings up to 2 mil thick
23
24
Taber Abrasion Testing of

Anodic Coatings
Type II Anodizing (DiCr Sealed)

Wear Test Coupon (2024-T3)

Type III Coating, (1.93 mil)
CS-17 Wheel @ 10,000 cycles
Model 5155 Taber Abraser
25
Conventional
Metalast
8500 Hrs
8500 Hrs
Test panels produced under the OSD Corrosion IPT funded project
26
Alloy
Measured Wear Index

(Average)
Max. Allowable Wear Index

(MIL-A-8625F)
2024-T3
1.53
3.5
7075-T6
0.31
1.5
Wear Resistance Test Results of Type III Coatings produced by Metalast Technology - May 06
Benefits of Process Control

using the Metalast
Metalast Technology
Investment/Payback
INITIAL INVESTMENT
BENEFITS
Reduces Operator error and
Supervision of Process
Reduces cycle & throughput times
Improves accuracy and repeatability
Improves quality of the oxide formed
Reduces defects and rejects
Provides Accountability of Work
Performed
Generates a Process Report
Verification
Reduces Waste due to consolidation of
bath chemistry & extended life
Energy savings are realized due to use
of aluminum cathodes
Allows for consolidation of anodizing
processes
Modified Tank with Proper Air/Sparger - $14K

Heating Elements/Temperature Controller - $7K
JobPro Process Controller - $35K
Chemistry - $2K
Replace Cathodes/Buss Bars with Aluminum - $6K
COST AVOIDANCES
Labor Avoidance Associated with Controlled Rectification
$20.8K savings /yr (assume 10 min/batch @ 1250 batch loads/yr)
Labor Savings with Reduced Rework
$11.9K savings /yr (assume 0.5% vs. 10% rework)
Reduced Surveyed components
$5K savings /yr
Cost Avoidance with Increased Efficiency
$18.8K (assume 15% efficiency increase)
27
28
TCPTCP-HF Operating Conditions
Metalast TCP-HF currently in Dem/Val at FRC JAX as a post

treatment for anodic coatings produced by the Metalast Technology.
Trivalent Chromium Post-Treatment Process

Concentration: 10 50% by vol
TCPTCP-HF
Temperature: 65 120F
Time: 1 10 minutes
29
Type II & IIB oxides sealed in TCP-HF being evaluated at JAX
Total Annual Cost

Avoidance
$56.5K or 1.1 YRS Payback
Hexavalent Chrome free Sealing
Total Investment = $64K
pH: 3.6 4.0

Tank material: Polypropylene or Teflon-lined Tank.
30
Bare SO2 Corrosion Performance of Various

Anodize using Metalast Process
with Various Seals
Metalast Type IIB Anodize (TCP vs. DiCr Sealed)

2024
2024Bare
BareSO2
SO2Corrosion
Corrosion
10
10
9
9
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
0
0
Panels A2-BS1C (1 5)
1,068 Hrs NSF

Average Coating Weight:
450 mg/ft2 (~ 2.6 m)
TCP-HF
7075 Bare SO2 Corrosion

7075 Bare SO2 Corrosion
24hr AVG
24hr AVG
48hr AVG
48hr AVG
Time
Time
192hr AVG
192hr AVG
10
10
1654 Rating
1654 Rating
Current Density used:

8 ASF for 13 min
Panels A2-BS1T (1 5)
8
6
4
2
0
Batch Chemistry: 190 g/L H2SO4, 4 g/L AA-200
31
Type II coupons still in test
32
2024 Painted SO2 Corrosion
MIL-A-8625
Seal
1654 Rating
8
Type II Dichromate
Type IIB Dichromate

Type IIB TCP
TY IIB
8ASF-13min
0
192hr Avg
500hr Avg
1000hr Avg
1500hr Avg
2000hr Avg
3000hr Avg
Time
*Performance shown to be relatively

the same with painted coupons
7075 Painted SO2 Corrosion

10
1654 Rating
8
Type II Dichromate
6
Type II TCP
Type IIB Dichromate
TY II
12ASF-40min
Type IIB TCP

2
0
192hr Avg
500hr Avg
1000hr Avg
1500hr Avg
2000hr Avg
3000hr Avg
Time
*Painted Coupons: (Paint System used; Primer - MIL-PRF-85582, Type I, C1 ; Topcoat - MIL-PRF-85285
33
34
Seal
TY IIB
8ASF-10min
TY II
12ASF-35min
Dichromate
Dichromate
Dichromate
Dichromate
Dichromate
TCP
TCP
TCP
TCP
TCP
Dichromate
Dichromate
Dichromate
Dichromate
Dichromate
TCP
TCP
TCP
TCP
TCP
Thickness
(No Seal)
Witness
0.1 0.03
mils
(2.5 m)
0.5 0.03
mils
(12.7 m)
Coating
Weight
(No Seal)
Witness
478.2
479.6
483.9
(480.6 mg/ft)
2
0
24hr AVG
24hr AVG
48hr AVG
48hr AVG
Time
Time
192hr AVG
192hr AVG
*Dry
Adhesion
A
5
5
24 Hr
Wet
Adhesion
A
5
5
4 Day
Wet
Adhesion
I
5
5
7 Day
Wet
Adhesion
J
5
5
484.9
481
474.3
(480.1 mg/ft)
4
4
4
4
3
3
3
3
2,919.8
3,357.7
3,457.5
(3,245.0 mg/ft)
5
5
5
5
5
5
5
5
3,538.6
3,167.5
3,111.4
(3,272.5 mg/ft)
5
5
5
5
5
5
5
5
Painted Coupons: (Paint System used; Primer - MIL-PRF-85582, Type I, C1 ; Topcoat - MIL-PRF-85285
Dichromate
Dichromate
Dichromate
Dichromate
Dichromate
TCP
TCP
TCP
TCP
TCP
Dichromate
Dichromate
Dichromate
Dichromate
Dichromate
TCP
TCP
TCP
TCP
TCP
*Thickness
(No Seal)
Witness
0.1 0.03
mils
(2.5 m)
0.5 0.03
mils
(12.7 m)
Dry
Adhesion
A
5
5
24 Hr
Wet
Adhesion
A
5
5
4 Day
Wet
Adhesion
I
5
5
7 Day
Wet
Adhesion
J
5
5
447.9
454.6
447.9
(450.1 mg/ft)
4
5
4
5
4
4
5
5
2,756.7
2,979.5
2,903.9
(2,880.0 mg/ft)
5
5
5
5
5
5
5
5
3,007.7
2,941.9
2,798.8
(2,916.1 mg/ft)
5
5
5
5
5
5
5
5
Coating
Weight
(No Seal)
Witness
458.9
459.0
459.9
(459.3 mg/ft)
Painted Coupons: (Paint System used; Primer - MIL-PRF-85582, Type I, C1 ; Topcoat - MIL-PRF-85285
Paint Adhesion for Various Anodic Coatings on

70757075-T6 with Various Seals
MIL-A-8625
Paint Adhesion for Various Anodic Coatings on

20242024-T3 with Various Seals
10
Type II TCP
Painted SO2 Corrosion Performance of Various

Anodize using Metalast Process
with Various Seals
Type II Dichromate
Type II Dichromate
Type II TCP
Type II TCP
Type IIB Dichromate
Type IIB Dichromate
Type IIB TCP
Type IIB TCP
Type III No Seal
Type III No Seal
TCP consistently
Out Performs
Dichromate sealing
Type II Dichromate
Type II Dichromate
Type II TCP
Type II TCP
Type IIB Dichromate
Type IIB Dichromate
Type IIB TCP
Type IIB TCP
Type III No Seal
Type III No Seal
1654 Rating
1654 Rating
Dichromate
Seal (5% wt)
Racking of EAEA-6B MLG

Air
Air supply
supply Line
Line
Cathode
Cathode connection
connection
Center Cathode in ID of MLG

35
36
Anodizing of EAEA-6B MLG
Project Goals
Produce all three anodizing Types within a one-tank-system
using the Metalast process
Implement Technology Across Navy Depots
Make Metalast the new standard for anodizing
Cr6+ free Anodize Sealing using TCP as drop-in replacement
Anodized Part
Following Sealing Operation
37
38
Questions
39

Advanced Aluminum Anodizing Technology

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Overview

Advanced Anodizing using Process

Ruben A. Prado, CEF

NAVAL AVIATION TECHNOLOGIES

NAVAL AVIATION TECHNOLOGIES

DoD Metal Finishing Workshop 16, 17 May 2007

DoD Metal Finishing Workshop 16, 17 May 2007

Factors Influencing Properties

Manual Control of rectifier

Unsealed Anodic Coating

NAVAL AVIATION TECHNOLOGIES

NAVAL AVIATION TECHNOLOGIES

DoD Metal Finishing Workshop 16, 17 May 2007

DoD Metal Finishing Workshop 16, 17 May 2007

Process Control Technology

NAVAL AVIATION TECHNOLOGIES

Photos courtesy of Metalast International, Inc.

DoD Metal Finishing Workshop 16, 17 May 2007

DoD Metal Finishing Workshop 16, 17 May 2007

Anodize Tank Modification

Al 6063-T6 extruded Anode Bar

NAVAL AVIATION TECHNOLOGIES

NAVAL AVIATION TECHNOLOGIES

Low Pressure High Volume Air Supply for Sparger

DoD Metal Finishing Workshop 16, 17 May 2007

DoD Metal Finishing Workshop 16, 17 May 2007

Anodize Tank at FRCFRC-SE JAX

Improves consistency & uniformity

NAVAL AVIATION TECHNOLOGIES

DoD Metal Finishing Workshop 16, 17 May 2007

Benefits both Type II & Type III baths

DoD Metal Finishing Workshop 16, 17 May 2007

Coating Ratio & Efficiency

Chemical Dissolution Rates

Chemical dissolution rates of Anodic Coatings (Type II)

About 15% - 20% Reduction in

w1: Weight of original panel

NAVAL AVIATION TECHNOLOGIES

NAVAL AVIATION TECHNOLOGIES

DoD Metal Finishing Workshop 16, 17 May 2007

DoD Metal Finishing Workshop 16, 17 May 2007

General System Parameters

Cathode material of 6063-T5 or T6 is vital

Bath Chemistry, Tank 209 @ FRC JAX

Concentration Range (g/L)

Aluminum ion (Al+3)

Maintaining a 3:1 Anode-to-Cathode ratio is best

NAVAL AVIATION TECHNOLOGIES

Use a 10 to 100 micron spun polypropylene filter

Slight foaming is normal

DoD Metal Finishing Workshop 16, 17 May 2007

DoD Metal Finishing Workshop 16, 17 May 2007

Installed Metalast Process

Metalast Process Controller

Audio/Visual Cycle Alarm

NAVAL AVIATION TECHNOLOGIES

DoD Metal Finishing Workshop 16, 17 May 2007

Process Controller Features

Interfaces with existing system

Rerun last Strategy

Strategies can be created and

Create & Run Strategy

Auto regulates & controls

Select & Run from