SurTec 650 Tri-Chrome Passivation of Aluminum

SurTec International GmbH - July 2011

SurTec
International GmbH

SurTec 650 Tri-Chrome Passivation of Aluminum

Content

TCP of Alu_0711_TK

Best Available Technologies

ONE Process Market Specific Parameter

Process Control/ Maintenance

Resource Load

Total Process Costs

SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

Best Available Technologies for Aluminum Pre-treatment

Yellow Chrome

Green Chrome

TCP Cr(III)

Chrome-free

Bath contains Cr(VI)

Bath contains Cr(VI)

Bath free from Cr(VI)

Bath free from any Cr

Coating contains Cr(VI)

Coating free from Cr(VI)

Coating free from Cr(VI)

Coating free from any Cr

Gold/ yellow color of coat

Green/ Clear color of coat

No color of coat

No color of coat

SurTec 655

SurTec 657

SurTec 650

SurTec 641

Labelling as toxic

Labelling as toxic

No labelling

Labelling as irritating

Effluent: Cr-reduction

Effluent: Cr-reduction

Effluent: Neutralisation

Effluent: Neutralisation

Disposal as special waste

Disposal as special waste

Disposal as normal waste

Disposal as normal waste

TCP of Alu_0711_TK

SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

Best Available Technology for Aluminum Pre-treatment

Completely free of Cr(VI), other heavy metals and COD

Effluent treatment via simple neutralisation

One product for numerous markets, management via process parameter

Product is a REACH compliant, registered substance

Coating is WEEE, RoHS and ELV compliant
Only labeling free chromating alternative
Storage and transport w/o limitations
Shelf life of min. 12 months
Product categorized in WGK 1

Waste disposal as standard waste

TCP of Alu_0711_TK

SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

ONE Process Market Demand Driven Operation Parameter
1
Alcaline Degrease/ Etch
2
Rinse (Cascade)
3

Switch from Chromating is possible

without major line modifications

By improving the rinse quality prior to

the active baths the drag-in of
contaminations (= driver for life time
and quality) can be minimized

Acid Deox/ Etch/ Desmut

4
Rinse (Cascade)

< 400 S/ cm prior to passivation

5
Passivation SurTec 650

6
Rinse
7

Process sequence can be used for

different final applications; parameter
of the active baths might have to be
adapted to final application

DI-Rinse
8
Dry
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SurTec International

SurTec 650 Tri-chrome passivation of Aluminum

Example 1: Architectural Industry - Market Specific Process

Using only acid etch prior to passivation is also possible

Optimum coating weight 50 -120 mg/ dm

Min. etch rate 2 g/m for all steps prior to passivation recommended
Optimum process parameter:
pH = 3,0; conc. = 4,0 %, T = ambient, t = 1-2 min.

Major contaminants: Fe < 50 ppm; Al < 500 ppm

Specifications/ Demands

Performance

Substrates: Mainly 6000 series, e.g. 6060, 6063

Paint adhesion (wet cross hatch): Gt 0

Mainly paint Adhesion to Epoxy/ PE powder paints

SS Resistance (3000 h):< 1 mm creepage

Painted Corrosion Resistance in SS, AASS and FFC

AASS Resistance (3000 h): < 3 mm creepage

Spray, dip, basket, vertical and shower application

FFC/ Filiform (1000 h): F < 0,4 (l < 2 mm; H < 1/ 10 mm)

Compatibility to small amounts of Fe, & Zn substrates

Approval by GSB, Qualicoat & Schueco

TCP of Alu_0711_TK

SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

Example 1: Architectural Industry - Broad Operation Window
Temperature

pH
CW

CW

max.

max.

min.

min.
pH

Operation at room temperature possible

Operation at pH 2,5 to 3,5 is possible

Concentration

Time
CW

CW

max.

max.

min.

min.
conc

Operation at conc. 3-5% are possible

Treatment times from 1 5 are possible

Coating weight as determining criteria, as destinct correlation between coating weight

and corrosion resistance (e.g. filiform corrosion) could be proven

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SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

Example 2: Aerospace Industry - Market Specific Process

Best results achieved with sequence degreasing/

alcaline etch/ acid etch/ passivation

Correct etch parameter are crucial

Optimum coating weight > 400 mg/ dm

Optimum passivation process parameter:

pH = 3,75 4,0; conc. = 20 %, T = 30C, t = 5 min.

To achieve SS resistance of 336 h it is neccessary to

use a final seal

Specifications/ Demands

Performance

Substrates: mainly 2000, 5000, 6000 and 7000

series e. g. 2024, 6063, 7075

Wet adhesion test (wet cross hatch): Gt 1

Wet adhesion to Aerospace (Hex Cr) Primer system

Bare metal corrosion resistance in NSS: 168 h

Bare metal corrosion resistance in NSS

FFC/ Filiform (1000 h): F < 0,4 (l < 2 mm; H < 1/ 10 mm)

FFC filiform - ASTM D 2803

QPL listing

Repair or batch in spray, brush, basket, pen or

immersion application

TCP of Alu_0711_TK

SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

Example 3: Electronic/ 3C - Industry - Market Specific Process

Optimum passivation process parameter:

pH = 3,75 4,0; conc. = 20 %, T = 30C, t = 2 min.

Optimum coating weight : ca. 100 - 250 mg/ dm;

depending on application of final paint

Process sequence is a compromise between bare

metal corrsosion resistance driven & painted driven
sequence

Specifications/ Demands

Performance

Substrates: Mainly 6000 , series e.g. 6060

Painted SS resisatnce 3000 h 1 mm

Corrosion resistance with PE- powder paints

Bare metal corrosion resistance in NSS up to 168 h

Bare metal corrosion resistance in NSS

Surface resistance prior NSS < 500 / inch

Surface resistance after 168 h NSS < 1000 / inch

Surface resistance prior and after NSS

(MIL-DTL-81706 B)

Shielding Effectiveness: up to 100 dB at 100 Mhz

EMI Shielding (ASTM D-4935)

OEM approvals, eg Ericsson

Spray or immersion application

ELV, WEEE and RoHS compliant

TCP of Alu_0711_TK

SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

Example 4: Automotive Industry - Market Specific Process

Optimum passivation process parameter:

pH = 3,75 4,0; conc. = 20 %, T = 35C, t = 3 min.

Optimum coating weight cannot be measured due to

high roughness of the casted surface

Specifications/ Demands

Substrates: Mainly cast Aluminum, e.g. 226, 230, 231

Paint adhesion to E-coat & Epoxy/ PE paint

Painted corrosion resistance in OEM specific test, eg.

Cyclic corrosion test

Bare metal corrosion resistance in NSS

Spray or immersion application

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Performance

10

Cross hatch Gt 1 for all paint systems

Bare metal corrosion resistance up to 240 h depending

on substrate; e. g. Cu-content 1%: NSS = 240 h

E-coat painted corrosion resistance: NSS 400 h < 1mm

creepage

SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

Model for Chemical Reaction

Aluminum
TCP Coating

SEM

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SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

Simple Operation Process Maintenance
1st Indication:

Too thick layer leads to irrisicdence

on Al-substrates

Quantitatively:

XRF handgun to measure

Zr and Cr on-line

Correlation between
XRF and RFA proven
for SurTec 650

Correlation betwen XRF

measurement and coating
weight could also be proven

Layer Control

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Bath Analysis

Replenishment

Photometric method to
check Zr concentration

Direct calculation of
product concentration
out of Zr-concentration

High accuracy in conc.

range from 0.5 10%

Time demand for one

analysis max. 5 min.

Pre-masking of Fe
necessary

No cross sensitivity
towards Al, Mg, Zn or Cr

SurTec 650 = 1K product

Replenishment based on the measurement of
the Zr and/ or Cr concentration
12

SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

Minimum Resource Load

Water

Energy

Effluent

Waste

50% Reduction of ionic

load compared to
traditional chromates;
more cascades possible

Due to the broad

operation window
SurTec 650 operates
w/o heating or cooling

No Chrome(VI)
reduction required,
simple neutralisation
sufficient

Lower amount and

less hazardous
sludge compared to
traditional chromates

Reduction
in rinse water
consumption

Reduction
in energy
consumption

Reduction in chemicals
and technology
for effluent treatment

Significant reduction
in waste and related
disposal costs

Ecological Footprint

SurTec 650 Process

Traditional Cr(VI) Process

Resource Load
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SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

Minimized Total Process Cost
Standardized
Costs

TCP of Alu_0711_TK

Cost savings vs. Cr-free pre-treatments

Cost neutral vs. Cr(VI) pre-treatment

14

SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

Most wanted by the Industry

Approved by major OEMs in Aerospace, Architectural and Electronics/ 3C-industry

Used by top global automotive supplier

Approved by leading associations

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SurTec International

SurTec 650 Tri-Chrome Passivation of Aluminum

Summary

No labelling of the product

Easy and exact process control

Very broad operation window

Optimized total process costs

ONE Product for various industries

TCP of Alu_0711_TK

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SurTec International

SurTec 650 Tri-Chome Passivation of Aluminum

SurTec International GmbH - July 2011

SurTec
International GmbH