The Plating and Coating Industries’ Technology Magazine www.metalfinishing.com C C a a d d - - F F r r e e e e F F l l y y Z Z o o n n e e O Or rg ga an ni ic c c co oa at ti in ng g a al lt t e er rn na at ti iv ve e t t o o c ca ad dm mi iu um m, , c ch hr ro om mi iu um m t t o ou ut ts s e en nh ha an nc ce ed d c co or rr ro os si io on n p pr ro ot t e ec ct ti io on n. . April/May 2011 Vol. 109 No. 3 Technically Speaking High-performance acid zinc nickel electrolyte Setting up a RoHS-compliant EN line Environmental Spotlight EPA partnership program emphasizes chemicals reduction over waste management Finishers Directory: Aerospace Specialists
Transcript
The Plating and Coating Industries’ Technology Magazinewww.metalfinishing.com
y Equipment Co., Ltd.oshimoto Mechanical Manufacture Co., Ltd.
List updated as at April 26, 2011 Nordson (China) Co., Ltd.Suzhou Magni Coating TITW Finishing Equipment (Shanghai) Co., Ltd.Graco Inc. Shanghai Rep.Office
Environmental Spotlight12 EPA’s Partnership for Environmental Priorities
Program Encourages ‘Proactive’ Reduction of Hazardous Chemicals, Waste
WHAT’Sinside
Columns
3 Tucker’s Take
Missed Opportunities
34 Cleaning Times
Aerosol-Dispensed Cleaners and Cleaning Part I
37 Sherwood on Management
Do-it-Yourself Management Training
Departments
4 News & Briefs
39 New Products
44 Finishers’ Directory
45 Classifieds
47 Calendar of Events
48 Advertisers’ Index
tuckerstakeThe 2011 Washington Forum
offered everything attendeeshave come to expect from a well-run,highly organized legislative/environ-mental conference: appointmentson Capitol Hill; a stable of dynamic,knowledgeable, entertaining speak-ers; a diverse array of topical presen-tations; and a networking atmos-phere conducive to lively andinsightful exchanges. If it were a“Broadway” show, it could not havebeen scripted any better.
There’s just one nagging littleproblem: the vast majority of surfacefinishing industry members—finish-ers and suppliers alike—don’t botherto attend. Not that I don’t look for-ward to catching up with familiarfaces and colleagues in D.C. everyyear, but it’s typically the same 100or so stalwarts who turn out at theForum year after year in support ofthe conference. Where are the thou-sands of other owners, managers,and supervisors, etc., estimated to becurrently operating in our industry?
Now, before you start lobbingdarts in my direction, I do realizethat in these lean times it’s notalways feasible for shop owners andprincipals to dedicate two to threedays out of what is likely an alreadytight schedule to attend an industryconference. But to remain conspicu-ously and perennially absent fromwhat is arguably the single-mostimportant industry event suggests alack of interest or concern. I’m sureyou don’t need me to remind youthat critical decisions are beingmade virtually every day down inD.C. Sadly, too many folks are nottaking part in those discussionsregarding policy decisions and delib-erations that not only impact criticaloperations employed in our busi-ness, but also issues related to work-
er and workplace rules, health careand tax reforms, and so on.
To be fair, I completely under-stand the frustrations inherent intrying to encourage lawmakers toadopt more industry-friendly poli-cies. Those infinitely more experi-enced in governmental relations willtell you that breaking throughrequires an ample supply of bothpatience and persistence. While youmight feel your efforts in meetingwith your representatives are fruit-less, please consider this: the alterna-tive—inaction and disengagement—would be disastrous. No, it’s not aperfect system, but when the politi-cal process functions properly, it’spretty darn good.
At the risk of sounding like astumper for the NASF (you don’thave to be a member to attend theWashington Forum, by the way),there are merits in participating inthe ongoing political discourse as itpertains to shaping regulationsimpacting manufacturing. Fairly orunfairly, a lot depends on the “sizeand scale” a particular industry orsector brings to bear on lawmakers.The joint lobbying efforts of thePrecision Metalformers Associationand the National Tooling &Machining Association is a primeexample of the assertion of collectivepower.
In illustrating the importance ofsustained involvement in the politi-cal process, I think Kevin Bradley,president of the Nickel Institute,probably framed it most appropri-ately, telling Forum attendees: “Ifyou’re not at the table, then you’reon the menu.”
Metal Finishing (ISSN 0026-0576) is published 10 times peryear in January/February, March, April/May, June,July/August, September, October, November,November/December, and December by Elsevier Inc., 360Park Avenue South, New York, NY 10010. POSTMASTER:Send all address changes to Metal Finishing P.O. Box 141,Congress, NY 10920-0141. Metal Finishing is free to qualifiedmetal finishers in North America. For others related to thefield the subscription rate per year, including a copy of the“Metal Finishing Guidebook and Directory Issue” and the“Organic Finish ing Guidebook and Directory Issue” is:
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Change of Address: Postmaster—send address changes to Metal Finishing, P.O. Box 141, Congers, N.Y. 10920-0141.Toll-free (for U.S. customers) (800) 765-7514. Outside of theU.S. call (845) 267-3490, fax: (845) 267- 3478. E-mail:[email protected], 45 days advance notice required.Please include both new and old address.
Copyright by Elsevier, Inc. Permission for reprinting selectedportions will usually be granted on written application to thepublisher.
metal finishing
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APPOINTMENTSEnthone Inc., a business of CooksonElectronics, recently appointedMark Hutchinson technical serviceengineer, U.S. Central Region.Hutchinson is responsible for on-sitecustomer training and the installa-tion of Enthone processes, furtherstrengthening Enthone’s applica-tions expertise and customer sup-port network in the region.
Hutchinson has extensive expert-ise in plating on plastics and relatedspecial finishes, having served inroles of increasing importance andtechnical responsibility over thepast decade. He is a graduate ofWestern Kentucky University,where he received a bachelor’sdegree in chemistry.
Metal Finishing magazine has addedJim Wetherald of Ronatec C2C, Inc.,to its list of resources in the “Ask theExperts” program featured on met-alfinishing.com. Wetherald’s partic-ular specialty is electroless nickeltroubleshooting.
Wetherald serves as a technicalsales representative for theElectroless Nickel Division ofRonatec, C2C, Inc., based inFallbrook, Calif. He works closelywith direct customers and distribu-tors, addressing issues with a “hands-on” approach.
Wetherald graduated from SanDiego State University with degreesin Integrated Financial Systems andApplied Mathematics. He has alsostudied chemical engineering andJIT systems management. His sixyears in the metal finishing industry,combined with training from ShawnWetherald, Mike Aleksinas, JoeZabielski—as well as other well-known industry experts—has madehim a valuable asset in electrolessnickel problem solving and its relat-ed applications.
Ronatec has been a leader in the
electroless nickel industry since the1980s. The company works withfacilities across the United States,Mexico, Canada, China, Brazil,Thailand, and Ireland. Ronatec oper-ates warehousing facilities in eightconvenient locations, providing ship-ping on a same-day basis.
Feel free to submit your electrolessnickel questions to Jim Wetheraldonline by visitingmetalfinishing.com and clicking onthe “Ask the Experts” tab.
Columbia Chemical, one of theworld’s largest manufacturers of zincand zinc-alloy plating additives, con-tinues its commitment to providingits customers and partners with themost knowledgeable and experi-enced technical support team byadding Matt Schario to the positionof technical support representative.Schario’s responsibilities will bedivided between routine day-to-dayanalysis, troubleshooting, visitingshops, collecting samples andinstalling new baths and processes.
Schario attended LakelandCommunity College and Kent StateUniversity, and he holds a degree inchemistry. Schario began his earlystart in the metal finishing industrywhile still in high school. He nowbrings 10-plus years of industryexperience with specialization in lab-oratory analysis.
PROMOTIONSCoventya has promoted BradDurkin to the position of director ofInternational product management.In this role, Brad will work closelywith the group’s international prod-uct managers, R&D teams and localmanagers to continually improve theIPM program’s effectiveness.Through regular interaction andexchange with local teams in allcountries, and via the coordinationand implementation of global tech-
nology training programs, Brad’snew role will prove to be an effectivestep in continuing the momentumthat is building in the IPM programand ensure its long-term contribu-tion to the success of Coventya.
EXPANSIONSAtotech officially inaugurated theexpansion of its North AmericanTechCenter located in Rock Hill,S.C. on April 5. The 200,000-sq-ftfacility is equipped with Atotech’smost innovative and environmen-tally responsible plating technolo-gies and features state-of-the-artanalytical and material sciences lab-oratories.
The Rock Hill TechCenter isspecifically dedicated for use bymajor local industries such as auto-motive, appliance and sanitaryproducts manufacturers. With thisexpansion, Atotech intends to pro-vide additional and targeted supportto the well-established decorativeplating business in the Southeastregion via the following:
• Customer samplings • Production scale qualification runs
for OEM specifications• External and internal training
sessions• Environmentally sustainable
solutions and processes
Atotech president ReinhardSchneider—along with Kuldip Johal,managing director of Atotech USA—personally welcomed nearly 100 cus-tomers and business partners to theevent. “We invite you to bring yourparts and engineers to theTechCenter and use the facility forpilot production and prototyping foryour customers,” Schneider said.
Several noteworthy attributes ofthe Rock Hill TechCenter: 120 X 60X 25 plating tanks—the largest of anyutilized in Atotech’s 15 global tech-
NEWS&briefs BRAD
DURKINMATT SCHARIO
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eral metal finishing) facilities. “It isour intention to maintain this busi-ness—in a green way—for the sur-vival of the industry.”
Schneider reiterated those greenobjectives during his openingremarks to attendees, when hestressed Atotech’s emphasis on lead-ing the change to more environmen-tally friendly plating technologies.For Atotech, he said, this means tak-ing a methodical approach to ulti-mately replacing all CMR, toxic, andallergenic substances. Another highpriority on the company’s list is moreefficient utilization of raw materials,water, energy, and the avoidance ofwaste in its processes.
For more images on Atotech’s Rock HillTechCenter, please visit www.metalfinish-ing.com and search “Atotech.”
TITAN Metal Fabricators hasannounced the opening of a wholly-owned production subsidiary inIndia. Known as TITAN MetalFabricators India, the new operationis TITAN’s first expansion outsidethe United States. TITAN MetalFabricators India includes manufac-turing facilities located in Mathura,approximately 90 miles south ofNew Delhi, with corporate adminis-tration offices in Noida, eight milesfrom New Delhi. At launch, TITAN’sIndia manufacturing facility is com-
nical centers; a new fully automaticproduction scale plating line for pre-treatment, decorative coatings andplating on plastics; auxiliary equip-ment, including a trivalent chromi-um ion exchange unit; organic fin-ishing “paint support” technologiesfocused on coating stripping andsubstrate preparation; on-site wastewater treatment equipment; andcutting-edge analytical devicesdesigned to provide customers withroutine analyses and sophisticated,customized investigations. The lat-ter includes high-tech material sci-ence labs offering inspection of coat-ings on a nano-level for both ele-mental and compositional analysis,as well as standard XRF and FTIRtechnologies.
“The Rock Hill TechCenter pro-vides services for local customersalong with leading green technolo-gies,” said Gertjan van der Wal,Atotech’s vice president, Europeand North America. “More impor-tantly, this facility provides testingwithout interruption of our cus-tomers’ production.”
In the grand scheme of things, theexpanded TechCenter reflectsAtotech’s support of the surfacefinishing sector at large. “We areinvesting in the electroplating busi-ness for the future,” said PabloNieto, vice president of GMF (gen-
NEWS&briefs
Ribbon-cutting ceremony at Atotech’s Rock Hill, S.C. location (from left): Pablo Nieto; Kuldip Johal;Rock Hill Mayor Doug Echols; Chuck Bundy, South Carolina Department of Commerce; ReinhardSchneider; and Gertjan van der Wal.
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heat exchangers, columns, con-densers, piping, reactors, vessels,and tanks for the local market andexport throughout Asia and theMiddle East.
“We pre-qualified our India pro-duction welding staff as per ourASME system,” Muscarella noted.“The QC department in Indiareports directly to TITAN’s VP ofQA/QC, and procedures in Indiawill be essentially the same as inCalifornia. And, finally, to assurecomplete assimilation of TITAN’sstringent systems, we have madecommitments with select membersof our California operation to mul-tiple-year arrangements to work inthe TITAN Metal Fabricators Indiaoperation.”
ACQUISITIONSGraco Inc., which supplies technol-ogy and expertise for the manage-ment of fluids in both industrialand commercial applications, hasentered into a definitive agreement
prised of 25,000 sq. ft. with 10,000sq. ft. dedicated to “clean room”operations.
“Our move into fabrication inIndia marks a substantial increase inTITAN’s ability to serve customersrequiring corrosion-resistant equip-ment for chemical, pharmaceutical,oil, gas and petrochemical, steel andplating and anodizing applications,”said Steven Muscarella, TITAN’spresident. “Our management andproduction teams in both Californiaand India operate in concert—alldepartments, systems, and proce-dures. The intent is to build the samequality equipment from either facili-ty. The engineering, drafting, QC,operations and IT departments arecompletely integrated.”
TITAN Metal Fabricators Indiaproduces custom designed corro-sion-resistant equipment such as
to purchase the operations of thefinishing businesses of Illinois ToolWorks, Inc. in a $650 million cashtransaction.
The ITW businesses manufactureand distribute equipment forindustrial liquid finishing, powdercoating and automotive refinish-ing, worldwide. Key attributes ofthe businesses include:
• 2010 revenues of $305 million, of which 40% were in the Americas
• Significant operations are located in the United States, Switzerland, United Kingdom, Japan, Brazil and Mexico, with sales offices andistribution capabilities in several additional countries
• Leading equipment technologies and brands, such as Gema® powder finishing equipment, Binks® industrial pumping solutions, DeVilbiss® auto refinishguns and accessories, Ransburg® electrostatic guns and accessories,and BGK curing technology
• Professional management and 900 employees worldwide
• Global manufacturing capabilities/capacity
“This acquisition is an excellentstrategic fit with Graco’s Industrialsegment,” said Pat McHale, Graco’sCEO. “It will advance all of our stat-ed core growth strategies: new prod-ucts and technology, geographicexpansion, and new markets.”
Via the acquisition, Hale notedthat Graco gains a leading positionin industrial powder paint equip-ment—a growing global marketwhere Graco previously had no offer-ing. With regard to liquid finishing,the acquired product technologiesare complementary to Graco’s indus-trial offering and also give the com-pany a leading position in automo-tive refinish—another sector whereGraco has had little presence.
“The acquired businesses generatetwo-thirds of revenue outside NorthAmerica, increasing our critical massin important international andemerging markets,” Hale explained.“This transaction will bring severalwidely recognized premium brands
NEWS&briefs
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interest in the variety of PalmettoPlating’s processes and its customerbase. He then greeted each employ-ee and briefly spoke with the group.“When introduced to StacieBradley, our new director of techni-cal services, I mentioned that herhusband, Jason, is a FirstLieutenant in the U.S. Army anddeployed to Afghanistan,” Cutchinrecalled. “When he finished hisremarks, he turned to her and said,‘May God bless and be with yourhusbands and his comrades.’ ”
Also on hand for the tour wereMike Aleksinas, president of MetalChem, Inc. (Greer, S.C.), and AndyCarr of the South CarolinaManufacturing Extension Program,
or SCMEP. Cutchin explained howthe SCMEP greatly helped PalmettoPlating achieve ISO:9001-2008accreditation at a reduced cost andexplained how this has aided in thecompany’s marketing.
“It is very difficult to get someoneof Senator Graham’s stature to visit aplating shop, but I feel that helearned more on this visit than wecould have ever told him in hisoffice,” Cutchin said.
(For more information, please visitwww.metalfinishing.com and search“Palmetto Plating.”)
to Graco, a strong distribution chan-nel, an installed base and approxi-mately 40% of revenue from partsand accessories. We believe thisacquisition will create long-termvalue for our shareholders.”
U.S. SENATOR VISITS PALMETTOPLATING U.S. Senator Lindsey Graham (R-S.C.) and three members of his staffvisited the facilities of PalmettoPlating on Tuesday, February 22.The one-hour visit to the Easley, S.C.,plant gave the prominent senator a
rare opportunity to gain insightfulknowledge and information aboutthe surface finishing industry.
“Senator Graham asked a lot ofquestions as to the direction ourindustry is going, what effect off-shore manufacturing had on ourmarkets, what impact the new healthcare laws will have on us, the effec-tiveness of the technical educationprograms, and many other ques-tions,” said John Cutchin, PalmettoPlating president.
During a tour of the facilities,Senator Graham showed genuine
NEWS&briefs
U.S. Senator Lindsey Graham (R-SC) gets a tutorial about the surface finishing industry from a plater'sperspective by John Cutchin (left) president of Palmetto Plating of Easley, S.C.
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“Accreditation of these importanttesting procedures at Enthone’sAutomotive Science Corrosion Labvalidates the excellence the labexhibits on a daily basis,” saidTerrence Copeland, Enthone vicepresident, Americas. “With thisaccreditation, Enthone can provideour customers and their customerswith even greater confidence in theperformance of Enthone productsand processes.”
The accreditation reinforcesEnthone’s analytical capabilities insupport of the company’s customer-driven research and product develop-ment activities.
For more information, visitwww.enthone.com.
ASSOCIATION ACTIVITIES The Metal Finishers Association ofIndia (MFAI), headquartered inMumbai, has accepted ColumbiaChemical as a life member company.The MFAI is the premier trade organ-ization for the metal finishing indus-try in India. It publishes a quarterlytechnical journal and hosts the ISFConference and Exhibition. BillRosenberg, Columbia Chemicalchairman, recently presented a paperat ISF 2011 this past February andserves as the first official companyrepresentative.
Columbia Chemical also supportsthe National Association of Surface
ACCREDITATIONS The Enthone Automotive ScienceCorrosion Lab (ASCL) was recentlyapproved for accreditation by theAmerican Association forLaboratory Accreditation (A2LA) inthe field of mechanical testing. TheASCL is now accredited to ISO/IEC17025:2005. The A2LA accredita-tion makes Enthone’s ASCL one of
an elite group of laboratories inNorth America to have earned sucha designation.
Specifically, the Enthone ASCL isaccredited to perform the followingtests on metals, plastics and othermetallized substrates, including suchapplications as fasteners, bolts,chains, connectors and wheels:
Finishing (NASF) via its recentlyacquired corporate supplier mem-bership. The NASF provides valuablenetworking events and opportunitiesand training programs, along withrepresentation and advocacy con-cerning government relations withinthe surface finishing industry. BrettLarick, Columbia Chemical presi-dent, will function as the primarycompany representative regardingNASF involvement.
The NAMF New England Chapterheld its annual Supplier’s Nightmeeting on April 7 in Marlboro,Mass., where. 18 tabletop exhibitorsand 109 attendees participated inthe mini trade show, networkingand educational event. Attendeesreviewed the exhibits and met withsuppliers specializing in chemicals,insurance, quality systems, andpaint and powder equipment.Chapter president Chris Capalboupdated attendees on various chap-ter and association activities.
The evening also included doorprizes and a raffle. The evening wascapped off with the presentation ofnine scholarships awarded to chil-dren of employees of member com-panies who are senior high schoolstudents pursuing higher education.There have been over 100 of thesescholarships presented to studentssince the program began.
NEWS&briefs
CALL FOR SUR/FIN 2011 BOOTH DESCRIPTIONS!
In its June edition, Metal Finishing magazine will feature a special sectionon SUR/FIN 2011 exhibitors. To be included in this FFREE product infor-mation section, please provide the following:
• 50-75 word description of what you plan to unveil or showcase at the show
• High-resolution color photo depicting your product(s). Note: 300 dpi graphics preferred
• Booth number and contact information
Please send your materials via e-mail to: [email protected]. Note: The deadline for materials is Friday, MMay 13.
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where the coatings contain compounds of chromium (Cr), lead (Pb), manganese (Mn), nickel(Ni), or cadmium (Cd).
Additionally, from May 18–20,DeVilbiss, Binks and OwensCommunity College will hold athree-day training Spray FinishingTechnology Workshop in Toledo,Ohio. Classes meet from 8:30 a.m. to4:00 p.m. daily at the college andinclude both classroom and hands-on sessions. Two continuing educa-tion units are awarded. Attendeesshould be involved with industrial,contractor or maintenance spray fin-ishing applications, or spray equip-ment sales and distribution. Topicsfor the Spray Finishing TechnologyWorkshop include:
• Equipment types and selection• Equipment set-up, operation and
maintenance• Surface preparation and defect
analysis
TRAINING PROGRAMSDeVilbiss, Binks and OwensCommunity College have teamedup to present a NESHAP SubpartHHHHHH “6H” training program.This half-day intensive training pro-gram is scheduled for May 17, 2011in Toledo, Ohio. Training is con-ducted from 1 p.m.–5 p.m. andincludes both classroom and“hands-on” sessions. Certification isawarded upon successful comple-tion. Attendees should be involvedin any of the following:
• Paint stripping operations that use methylene chloride (MeCl)-containing paint stripping formulations
• Spray application of coatings to motor vehicles and mobile equipment
• Spray application of coatings to a plastic and/or metal substrate
• Material selection• Safety and regulatory concerns
To register, contact JaimeWineland at (800) 466-9367, ext.7320, or send an e-mail to: [email protected].
Global Finishing Solutions (GFS)has launched of a new section of edu-cational material on the FinishingAcademy training website (visitwww.finishingacademy.com) dedi-cated to aerospace finishing. Thisnew training module providesdetailed information on the differenttypes of aircraft painting facilities,including the advantages inherent ineach design, as well as the keys toproducing a top-quality finish onaircraft of all sizes.
The Aerospace Training Modulecurrently contains three sections:“Crossdraft vs. Downdraft,” “TheUse of Inserts for Painting Aircraft,”and “Paint Booth Pressure Levels.”
Visit www.globalfinishing.com for
NEWS&briefs
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bead blasting, recently announcedthe launch of its new website,www.rockfordmetalpolishing.com.
The new website was created withthe customer in mind. Easy naviga-tion throughout the website andeasy-to-read content helps currentand potential customers find theinformation they are looking forquickly. In addition, there are pic-tures of samples that allow cus-tomers to see RMP’s capabilities.Customers can also e-mail orrequest a free quote directly fromthe new website.
“We feel that RMP’s new websitewill really get us up to date in the21st century and help get our nameout there on a more national level,”said John Gagliano, sales director forRMP. “We have been in business formore than 30 years and are alwayslooking for new ways to better our-selves, and we feel that our new web-site does just that.”
RMP, located in Loves Park, Ill.,was established in 1977 and is fami-ly-owned and operated.
The new Pangborn Group websitewww.pangborngroup.com.,unitesfour distinct, industry-leading sur-face preparation brands—Pangborn,Pangborn Europe, BergerStrahltechnik and Vogel &Schemmann.
According to Henrik Jensen, pres-ident and CEO of Pangborn Group,establishing a unified online pres-ence is a critical step in solidifyingPangborn Group’s presence as aglobal brand and leader in the sur-face preparation industry. “All fourbrands—three of which are well overa century old—were acquired byAtlas Holdings LLC over the lastseveral years, but until now eachmaintained its own identity andwebsite, and operated somewhatindependently,” Jensen said.“However, as we build and growPangborn Group as a global brand,the opportunity and ability tocross-sell our collective product lineis critical. And our new website is atremendous representation of thatcapability.”
According to Jensen, one of the
more information on the program.
OPEN HOUSEITW Gema hosted SystemIntegrators at the ITW GemaTechnology Open House & Seminaron March 10 at their Indianapolis,Ind., facility. The open house andeducational seminar featureddemonstrations and presentationsto introduce industry partners to thelatest Color Change Technologyavailable for powder coating. ITWGema highlighted the
MagicCylinder® andMagicCompact® Quick ColorChange Booths, the MagicCenter®and OptiCenterTM PowderManagement Systems, and theOptiColorTM designed for quickcolor changes with manual powdercoating units. The ITW GemaOptiFlex® Series Automatic andManual powder coating guns wereutilized for all demonstrations.
ITW Gema continues to be a pio-neer in the powder coating industryand a global manufacturer of superi-or quality powder coating equip-ment. As a business unit of theIllinois Tool Works Corporation,ITW Gema operates its NorthAmerican Headquarters fromIndianapolis, Ind.
For more information, contactKaren Walters by telephone at (317)298-5072, by e-mail [email protected].
NEW WEBSITES Rockford Metal PolishingCompany (RMP), which specializesin polishing, buffing, vibratory fin-ishing, O.D. tube polishing, and
website’s key features is the abilityfor visitors to navigate based on thetype of products they are searchingfor, such as wheel blast machines orshot peening machines, and viewavailable products from allPangborn Group brands. Therevamped site also highlightsPangborn Group’s capabilities andexperience in key industries such asaerospace and automotive trans-portation, defense, energy, generalmanufacturing and more.
In addition, Pangborngroup.comboasts a robust customer care sec-tion, highlighting services such asPangborn Group’s CustomerTechnology Center and Researchand Development facilities, as wellas a resources section that includesdownloadable literature, a varietyof videos that showcase its solu-tions, and a comprehensive list ofindustry links.
DONATIONS The New England SurfaceFinishing Regional made a $1,000donation to the NASF GovernmentRelations Fund at the 2011Washington Forum in D.C., heldApril 12–14 at the Ritz Carlton,Pentagon City.
According to Marc Pelissier, chair-man of the New England SurfaceFinishing Regional and environmen-tal manager for Valley Plating, Inc.,in Springfield, Mass., “the continuedsuccess of the New England RegionalConference has equated to financialstability, whereby it has given theorganization the ability to make anannual donation to what we feel is aworthy cause that benefits the overallinterests of the metal finishingindustry.”
Pelissier stressed that the NewEngland Surface FinishingRegional’s donation is made possibleby the attendees and suppliers thatcontinue to support the group’sannual conference. This year’s eventis scheduled to take place on Friday,Nov. 4, at the Hyannis Resort &Conference Center.
NEWS&briefs
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Reserve Your Space Today for the 2011/12 Metal Finishing Guidebook!
The Metal Finishing Guidebook, often referred to as the industry "bible," contains awealth of technical articles covering virtually every aspect of surface finishing. Fromcleaning and pretreatment procedures to specialty processes to wastewater handlingand treatment, the Metal Finishing Guidebook is an indispensable resource for job andcaptive finishing shops alike.
This year's Metal Finishing Guidebook follows on the heels of the previous edition's significant upgrade with both new and updated articles, expanded chapters, and current MIL-SPECS.
Another plus: Beyond the print edition, a digital version of the Metal Finishing Guidebook will be developed and posted on metalfinishing.com for additional exposure.
So don't miss out on a valuable opportunity to be included in one of the most frequently referenced technical resources. Contact your territory representative today to learn more!
EPA is Looking for a Few Good ‘Volunteers’National Partnership for Environmental Priorities programencourages ‘proactive’ reduction of hazardous chemicals, waste.
environmentalspotlight
achievement awards. Many of theprogram’s past and current partici-pants, he said, have parlayed theirsuccesses into “goodwill” initiativesfor shareholders via highly publi-cized articles and pressreleases/events.
SUCCESS STORIES At present, 281 partners are enrollednationwide in the NPEP program,according to Hansen. Among themare large and small companies,including: DuPont, NorthropGrumman, 3M, Exide, LAX, the U.SPostal Service, Coatek, and ValleyChrome Plating. Although theirrespective areas of specialty may varywidely, their environmental goalsand objectives run parallel.Following are a few highlights andbrief case histories:
Exide Technologies. Operating inmore than 80 countries and generat-ing fiscal 2010 net sales of approxi-mately $2.7 billion, Exide
Technologies is one of the world’slargest producers, distributors andrecyclers of lead-acid batteries. Thecompany’s four global business divi-sions—Industrial Energy Americas,Industrial Energy Europe,Transportation Americas, andTransportation Europe—provide acomprehensive range of stored elec-trical energy products and servicesfor industrial and transportationapplications. In addition, Exide’sAsia Pacific/Rest of World opera-tions contribute sizeable revenues tothe company, divided evenlybetween the Industrial Energy andTransportation products and servic-es sectors.
At its battery recycling facility inVernon, Calif., Exide Technologiesreduced more than 200,000 lbs oflead from its blast furnace slag whilesimultaneously boosting produc-tion 34%. What’s more, the companyimproved its recycling rate by 27%,resulting in annual savings of$350,000.
Northrop Grumman SpaceTechnology. Designs and manufac-tures spacecraft systems and sub-
systems, electronic systems, spacescience instruments, environmen-tal monitoring space systems,advanced avionics systems, andhigh energy laser systems. Thecompany also develops defensemissiles, satellites, and antennas.
Northrop Grumman SpaceTechnology successfully eliminat-ed trichlorobenzene at itsRedondo Beach, Calif., micro-elec-
tronics plant by more than 11,000lbs—all without sacrificing productquality.
Valley Chrome Plating. Clovis,Calif.–based captive finishing facili-ty specializing in trivalent-chromi-um-plated truck bumpers and acces-
Focusing on “cradle-to-cradlesolutions” rather than “cradle-
to-grave waste management.” That’s the underlying theme of an
EPA initiative developed with surfacefinishers and chemical suppliers inmind. Via the National Partnershipfor Environmental Priorities (NPEP),the EPA is promoting a voluntaryrecognition program that fosters col-laboration with industry for the pur-pose of reducing the use and/orrelease of highly toxic chemicals.Specifically, NPEP encourages con-servation of resources and better waysto substitute, reduce, reuse, or recyclechemicals.
Olof Hansen, of the U.S. EPA,Pacific Southwest Region, providesan overview of how NPEP isdesigned to work: Partners (i.e., fin-ishers, in this case) enrolled in thisprogram select one in a set of “prior-ity” chemicals1 targeted for reduc-tion as well as establish a strategy foraccomplishing that reduction. Thenext step entails estimating an over-all reduction goal (in pounds) andsetting a specific target date for com-pletion. According to Hansen, EPA’snational objective is to work withindustry to reduce the presence ofthese priority chemicals by 4 mil-lion pounds by the end of 2011.
The purported benefits of theNPEP program extend beyondthe obvious environmental con-siderations. According to Hansen,there’s also an economical upside.Namely, the cost savings associatedwith pollution prevention efforts:reduction of waste hauling fees;lower raw materials/feedstock pur-chases; decreases in utility bills; andfewer administrative/regulatory fees.
Additionally, Hansen noted,being recognized as a sustainablebusiness allows partners to receiveboth the official NPEP enrollmentplaque as well as the resultant
BY REGINALD TUCKER
www.metalfinishing.com April/May 2011 I metalfinishing I 13
changeover to graphite anodes rep-resented $6,000 in savings.
The switch from hexavalentchromium to trivalent chromiumentailed a much bigger initial outlay:$150,000, to be exact. The then-impending environmental rules cre-ated the prospect of an expenditureof $100,000 to install a chrome fumescrubber. After careful considera-tion, Valley Chrome Plating decidedto do what was best for the environ-ment and its business over the longhaul. During this transition, ValleyChrome Plating saw an opportunityto upgrade its plating tanks andequipment. The combined actionseliminated the chrome waste stream,reduced waste treatment costs aswell as post-plating and energy out-lays. More importantly, the elimina-tion of all the hexavalent chromiumenabled the company to avoid anyassociated environmental andhealth concerns, placing it in a morecompetitive position within theindustry.
sories.2 Valley Chrome Platingreplaced its lead anodes withgraphite anodes, eliminating theassociated waste stream in theprocess. The company also imple-mented ion-exchange waste reduc-tion systems through its manufac-turing and finishing operations. Theend result was the elimination 6,000lbs of hexavalent chromium and amuch safer work environment for itsemployees.
Valley Chrome Plating’s environ-mental initiatives required initialupfront investments (some very sig-nificant) but panned out over thelong haul in the form of annual sav-ings. For instance, an initial finan-cial commitment of $2,000 wasrequired to replace 40 lead anodes.However, this expense was recoupedin less than a year. Similarly, thereplacement cost for a complete
“Changing the way a companymanufactures its products doesn’tcome quick or easy, yet ValleyChrome Plating set out to voluntari-ly make these changes to protect itsemployees and the environment,”said Jeff Scott, waste managementdirector for the EPA’s PacificSouthwest Region. “Valley ChromePlating is providing a great exampleof how a company can protect boththe environment and still make apositive impact on the bottom line.”
For more on EPA’s NPEP program,please visit www.epa.gov.
REFERENCES1. Priority chemicals include: per-
sistent, bio-accumulating materi-als such as lead, mercury, sol-vents, PCBs, and dioxin.
2. “Valley Chrome Plating’s Journeyto Zero Discharge,” MetalFinishing, Nov./Dec. 2011, p 17
environmentalspotlight
14 I metalfinishing I April/May 2011 www.metalfinishing.com
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Cadmium- and Chromate-FreeCoating Schemes for Corrosion
Protection of 15CDV6 Steel
ABSTRACTElectrodeposits of cadmium- andchromate-based inorganic inhibitorpigments in paint formulations areextensively used in the aerospaceindustry to provide long-term cor-rosion protection for high-strengthsteel hardware. Due to environmen-tal concerns and worker safetyissues, there is a pressing need toidentify and adopt alternative eco-friendly coatings with equivalentperformance. In this work, an eco-friendly cadmium- and chromate-free coating scheme comprised ofzinc nickel alloy plating, trivalentchromium- based passivation, fol-lowed by a primer based on polyani-line phosphate, is studied for itsanticorrosive properties. Long-termperformance evaluation studies ofthis eco-friendly coating schemewere carried out on 15CDV6 steel,an ultra-high- strength steel used inthe aerospace industry.
For comparative purposes, twoextensively used cadmium- and chro-mate-based schemes complying toaerospace and military specificationscomprised of cadmium plating,hexavalent chromium-based passiva-tion followed by two different chro-mate-based primers were studied on15CDV6 steel substrate.Electrochemical impedance spectro-scopic studies and salt fog exposuretests were carried out to evaluate theanticorrosive properties of the coat-
ing schemes. Cadmium- and chro-mate-free scheme exhibited excellentperformance in the long-term corro-sion evaluation studies. The resultsobtained in accelerated tests showthe possibility of replacement of cad-mium- and chromate-based schemesfor corrosion protection of steelswith an eco-friendly option.
INTRODUCTIONCadmium coatings and chromate-based corrosion inhibitors in pro-tective coatings are extensively usedin the aerospace industry at presentto protect high-strength structuralsteel. 15CDV6 steel is a low carbon,low alloy, ultra-high-strength steelpossessing yield strength of 950 to1000 MPa. This steel also possessesgood weldability and toughness,and is extensively used for the fabri-cation of pressure vessels, rocketmotor casings and other structuralhardware in the aerospace anddefense industries. A proven andpreferred scheme for long-term cor-rosion protection of this structuralsteel is cadmium plating carried outeither by electrodeposition or physi-cal vapor deposition followed by anefficient painting scheme. The cad-mium coating on steel acts both as abarrier coating, separating the steelsubstrate from the environment,and as a sacrificial coating, provid-ing protection when the coatingbecomes damaged. A chromate pas-
sivation treatment is applied to thecadmium plating to promote adhe-sion of the subsequent paint layerand to improve the corrosion resist-ance of the cadmium coating.
Cadmium plating is provided asan undercoat to chromate-basedprimers on steel hardware demand-ing longer service life.Electroplating of cadmium is car-ried out from hazardous, cyanide-based chemicals. The usage of cad-mium and chromates is regulatedworldwide due to environmentalconcerns and the adverse healtheffects surrounding the usage ofsuch hazardous chemicals. Studiesare being carried out extensively toidentify potential alternatives [1].
Electrodeposited zinc nickel alloycoatings being tested worldwide,particularly zinc nickel alloy coat-ings with 10 to 15% nickel in thedeposit, were found to possess supe-rior corrosion resistance and lessersusceptibility to hydrogen embrittle-ment when compared to the exten-sively used electrodeposits of cadmi-um [2-5]. Zinc cobalt alloy platingwith 1% cobalt in the deposit and athin nickel interlayer on high-strength steel was found to possess alower hydrogen embrittlement indexwhen compared to electrodepositsof cadmium [6].
Chromate compounds are exten-sively used in the protective coatingsto protect industrial ferrous andnonferrous alloys. Here, chromatesrefer to compounds containing hexa-valent chromium (Cr6+). They areemployed in the coating systemsthrough various means, such as pig-ments in paints like strontium chro-mate and zinc chromate, chromateconversion coatings and chromicacid anodization of the aluminumalloy substrate [7]. Chromates are thecommonly used pigments in theprimer coating [8]. Apart from theirimpact on the environment, usage ofchromate-containing compounds
ORGANIC finishing
BY INDUMATHI S.N.A, T. VASUDEVANB, S. SUNDARRAJANA, B.V.SUBBA RAOA,C.V.S. MURTHYA AND D.R. YADAVA
ADEFENCE RESEARCH AND DEVELOPMENT LABORATORY, KANCHANBAGHP.O, HYDERABAD – 500 058, ANDHRA PRADESH, INDIABKALASALINGAM UNIVERSITY, KRISHNANKOIL - 626 190 VIRUDHUNAGARDISTRICT, TAMIL NADU, INDIA
[13]. Polyaniline is an important can-didate material for anticorrosivecoatings in the family of electroactiveconducting polymers. Polyaniline-containing paints are studied fortheir anticorrosive properties onsteel [14-16].
Barbucci et. al. reported the studyon chromate-free pretreatments andprimers for the corrosion protectionof galvanized steel sheets and recom-mended a chromate-free coating sys-tem consisting of nitro-cobalt chem-ical conversion with fluoro zincatepassivation coated by an epoxypolyurethane primer having ionicexchange active pigments [17].
Studies finding alternatives to haz-ardous chromate pretreatments,primers and cadmium coatings areavailable individually, but little infor-mation is available on cadmium- andchromate-free coating schemes forstructural steel demanding longerservice life. This paper deals with theperformance evaluation studies car-ried out to assess the efficacy of cad-mium- and chromate-free coating
pose serious worker safety issues. In finding a replacement for chro-
mate inhibitors, Kendig et al studiedthe characteristics of Cr6+ that makeit an effective inhibitor [9]. Some ofthe most promising chromatereplacement inhibitors are derivedfrom cerium salts [10]. Zinc phos-phates were the initial replacementpigments for zinc chromate; they dis-play no toxic effects and providesome corrosion protection by form-ing a Zn3(PO4)2. 4 H2O film [11]. Y.I.Kuznetsov et al studied organic cor-rosion inhibitors as possible chro-mate replacements. This resulted in athin (up to 20 nm) but tenaciouspassive layer [12].
Electroactive conducting polymerscontinue to be of considerable inter-est as components of corrosion-resistant coating systems.Electroactive conducting polymers,in addition to being conductive, areredox active materials with poten-tials that are positive of most metalsand alloys such as aluminum, mag-nesium, steel, and zinc. As with chro-mate, interesting and potentiallybeneficial interactions of electroac-tive conducting polymers with activemetals and alloys are anticipated
scheme comprised of zinc nickelalloy plating + trivalent chromiumbased passivation + polyanilinephosphate-based primer on ultra-high-strength 15CDV6 steel againstthe conventionally used scheme ofcadmium plating + hexavalentchromium-based passivation + chro-mate based primer.
EXPERIMENTALThree coating schemes on 15CDV6steel substrate, two based on cadmi-um plating, hexavalent chromium-based passivation and chromate-based primers conforming to mili-tary specifications and aerospacestandards and a cadmium- and chro-mate-free coating scheme were evalu-ated for their anticorrosive proper-ties by means of electrochemicalimpedance spectroscopy and salt fogexposure tests. The chemical compo-sition of 15CDV6 steel substratetaken up for experimental work isprovided in Table 1.
The details of cadmium- and chro-mate-based coating schemes taken
ORGANIC finishing Alloying
ElementC Mo Cr V P S FE
% composition
0.15% 0.90% 1.25% 0.25% 0.035max
0.040max
Remainder
Table 1. Chemical composition of 15CDV6 steel
Order of treatment Process step details Cadmium and chromate based
scheme 1
Cadmium and chromate based
scheme 2
Cadmium and chromate based
scheme
1. Electroplating Cadmium plating of 8–10 μ thickness fromcyanide bath as perthe specification SAEAMS -QQ-P-416
Cadmium plating of 8–10 μ thickness fromcyanide bath as per thespecification SAE AMS -QQ-P-416
Zinc nickel alloy platingof 8–10 μ thicknessfrom non-cyanide bathas per the specificationSAE AMS 2417G
3. Primer Coating Commercially availablezinc chromate-basedepoxy primer of 30μthickness in compliance with specifications of MIL–P-23377G , Type I,Class C
Commercially availablestrontium chromate-based epoxy primer of30 μ thickness in com-pliance with specifica-tions ofMIL–P-23377G ,Type I, Class C
Polyaniline phosphate-based epoxy primer of30μ thickness preparedin the laboratory whosedetails are provided insection 2.1
Table 2. Details of coating schemes taken up for experimental study on 15CDV6 steel substrate
16 I metalfinishing I April/May 2011 www.organicfinishing.com
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tective value of the various coatingsschemes. 1cm2 area of the coatedsample was continuously exposed toa corrosive solution of 3.5% sodiumchloride contained in a three elec-trode polarization cell. Silver/silverchloride was used as reference elec-trode and platinum as auxiliary elec-trode. An AC signal of 10mV ampli-tude was applied to the metal solu-tion interface at the open circuitpotential in the frequency range of100KHz to 10mHz. The impedance
up for study and its cadmium andchromate free counterparts are pro-vided in Table 2.
2.1 Formulation details of Polyanilinephosphate-based epoxy primer.Polyaniline phosphate pigment wasprepared by the oxidative polymer-ization of aniline monomer in phos-phoric acid medium using ammoni-um per sulphate as an oxidant. Thereaction was conducted at 5±10°C.All the chemicals used were ARgrade. A dark green colored conduct-ing polyaniline phosphate salt thusformed was filtered and repeatedlywashed with distilled water toremove excess acid content. Thepolymer was dried in an oven at 750°C for two hours. The driedpolyaniline phosphate salt was finegrinded using mortar. A primer with50% volume solids and 30% PVC wasprepared by using polyaniline phos-phate, talc and titanium dioxide aspigments. An epoxy resin with epoxyequivalent of 500 (M/S Atul poly-mers, Gujarat) was used in the for-mulation and the primer was curedusing amine hardener. The concen-tration of polyaniline phosphate inthe primer was 1% by weight. Theprepared paint was pneumaticallysprayed to a dry film thickness of 30microns on 15CDV6 steel panels of100mm x 50mm x 3mm size coatedwith the scheme provided in Table 2.The primer coated panels were curedfor seven days at room temperaturebefore proceeding for further evalua-tion studies. For comparative stud-ies, 15CDV6 steel panels were alsocoated with cadmium plating andchromate-based passivation, andwith two chromate-based primers asper the scheme provided in Table 2.
2.2 Evaluation of anticorrosive prop-erties. The evaluation of anticorrosiveproperties of the coating schemes on15CDV6 steel substrate (Table 2) wascarried out using AC impedance spec-troscopy and salt fog exposure tests.Alternating current impedance tech-nique was used to evaluate the pro-
measurements were carried out peri-odically and the resultant data wasanalyzed for protective ability of thevarious coating schemes. Impedance measurements were car-ried out using computer-controlledPotentiostat/Galvanostat of AUTO-LAB PGSTAT30 equipment. Theelectrochemical impedance monitor-ing of the various coating schemeswas carried out for 120 days in orderto assess the capability of theschemes to provide long-term corro-
ORGANIC finishing
Figure 1. Bode plots as a function of time for cadmium- and chromate-free coating scheme on15CDV6 steel substrate.
Figure 2. Bode plots as a function of time for cadmium- and chromate-based coating scheme 1 on15CDV6 steel substrate.
Figure 3. Bode plots as a function of time for cadmium- and chromate-based coating scheme 2 on15CDV6 steel substrate.
studied at a low frequency of 10mHzas a function of exposure time isgiven in Table 3. The decrease in lowfrequency impedance values as afunction of exposure time is repre-sented graphically in Figure 4.
An organic coating on the metalsurface can be considered as multi-phase heterogeneous system andthe corrosive species such as water,oxygen, ions of corrosive electrolytepenetrate through the defects (i.e.,pores in the coating) and reach themetal/coating interface, leading tothe corrosion processes. Theresponse of the coating system tothis corrosion process can be moni-
sion protection of the hardware.In salt fog exposure tests, the sam-
ples were continuously exposed toalternate wet and dry cycles of saltfog generated from 5% sodium chlo-ride solution as per MIL STD 810Fand the chamber temperature wasmaintained at 350°C throughoutthe test duration. The test was con-tinued until the failure of a particu-lar sample by visual appearance.Since the coating schemes studiedwere intended to provide long timeservice life for the structural hard-ware, Taber abrasion tests were con-ducted on the different coatingschemes as per the ASTM D 4060test method. The adhesion of thecoating schemes to the 15CDV6 sub-strate material was evaluated bysandwich pull-off method as perASTM D4541.
RESULTS AND DISCUSSION3.1 Electrochemical impedancespectroscopic measurementsThe evaluation of protective proper-ties of different schemes studiedwas carried out using electrochemi-cal impedance measurements over arange of frequencies. Since theschemes taken up for study werecomplex, monitoring the totalimpedance of the coating schemeanalyzed at the low frequency of10mHz as a function of time waschosen as an effective way to deter-mine the condition of the deterio-rating system. The relatively smalldecrease in the impedance of thesystem at the low frequency regionfrom its initial value even after pro-longed exposure to the corrosiveelectrolyte is a good sign for theeffectiveness of the system. This cri-teria was considered to grade thesystems under study for their per-formance in impedance studies.
The superimposed Bode plots ofthe impedance data of the differentcoating schemes studied as a func-tion of exposure time is provided inFigures 1, 2 and 3.
The logarithmic impedance valuesfor the different coatings schemes
tored in terms of impedance in elec-trochemical impedance spec-troscopy [18-25]. The data fromimpedance spectra can be dividedinto two major parts: the high fre-quency region and low frequencyregion. The low frequency part ofthe spectra represents the reactionsoccurring at the bottom of the poresof the coating and is characteristicof the metal-coating interface interms of anticorrosive or corrosiveproperty [26-27].
From the impedance studies car-ried out on the coating systemstaken up for study, it is observedthat the cadmium- and chromate-
ORGANIC finishing Logarithmic impedance values at 10mHz frequency(ohm/cm2)
Exposure duration(in days)
Cadmium andchromate based
scheme 1
Cadmium andchromate based
scheme 2
Cadmium andchromate free
scheme
5 5.40 x 109 6.05 x 109 8.80 x 1011
30 4.10 x 109 1.10 x 109 2.10 x 1011
60 2.00 x 109 7.80 x 108 1.20 x 1010
100 9.90 x 108 5.10 x 108 9.80 x 109
120 7.80 x 108 6.50 x 107 8.30 x 109
Table 3. Logarithmic impedance values measured at 10mHz for the coating schemes studied atvarious exposure durations.
Details of coating schemes on 15CDV6 steelsubstrate
Salt fog resistance in hours
Chromate and cadmium free coating scheme 1290
Chromate and cadmium based coating scheme 1 1230
Chromate and cadmium based coating scheme 2 1225
Table 4. Results of salt fog exposure tests.
Details of coating scheme Adhesive strength inN/mm2
Weight loss inmg/1000cycles
Chromate and cadmiumfree coating scheme
5 0.0096
Chromate and cadmiumbased coating scheme1
4.7 0.0085
Chromate and cadmiumbased coating scheme 2
4.9 0.0077
Table 5. Results of adhesion and abrasion resistance measurements.
18 I metalfinishing I April/May 2011 www.organicfinishing.com
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free coating scheme shows a rela-tively small decrease in the logarith-mic impedance value at a low fre-quency of 10mHz after an exposureduration of 120 days compared tothe other two cadmium- and chro-mate-based systems taken up forstudy. The cadmium- and chro-mate-free coating based on zincnickel alloy plating, trivalentchromium-based passivation andpolyaniline phosphate- basedprimer exhibited a low frequencyimpedance value of 8.30 x 109 at ameasurement frequency of 10mHzeven after continuous exposure for120 days to the corrosive 3.5% sodi-um chloride solution. The imped-ance value of the order of 109 afterprolonged exposure to corrosivesolution indicates the highly protec-tive nature of the coating. The rela-tively high order of impedance ofcadmium- and chromate-free
ORGANIC finishing
Figure 4. Graphical representation of variation of logarithmic impedance values for the different coat-ing schemes studied as a function of exposure duration
Figure 5. Photographs of test specimen after failure in salt fog tests
lent chromate based passivationcarried out on cadmium plating.
From the electrochemical imped-ance spectroscopic and salt fog expo-sure studies, it is evident that zincnickel alloy plating, trivalent chromi-um-based passivation and an anti-corrosive primer based on polyani-line phosphate provide superior cor-rosion resistance when compared tothe cadmium- and chromate-basedschemes selected for study in compli-ance with military and aerospacespecifications.
Due to the basic nature of theamine hardener used to cure thepolyaniline phosphate-based primer,deprotonation of polyaniline phos-phate salt is possible, thus convert-ing the salt form to emeraldine baseform of polyaniline, liberating thephosphate species. This emeraldinebase form of polyaniline plays anactive role in corrosion protectiondue to the ability of emeraldine basespecies to intercept electrons fromthe corrosive ions at the metal sur-face and to transport these electronsoutside the primer surface [28].
This conductive property ofpolyaniline species was demonstrat-ed in as little concentration of0.6–0.9% polyaniline in the organicmatrix[29]. To enable this protectiverole by polyaniline species, someelectrochemical activity at the metalpolymer interface needs to start. Assoon as water and ions of corrosivespecies diffuse through the poresand defects present in the coatingand reach the metal surface, theemeraldine base form of polyanilineprotects the substrate by the mecha-nism explained previously. Thismechanism is also supported by aninitial decrease in low frequencyimpedance values due to the trans-port of corrosive ions into paintfilm and relatively higher imped-ance values after 120 days of expo-sure to corrosive electrolyte whencompared to the cadmium- andchromate-based scheme.
From the results of accelerated cor-rosion tests and evaluation ofmechanical properties—such asadhesion and abrasion resistance ofthe coating schemes—it is evident
scheme after 120 days when com-pared to the other two chromateand cadmium-based coatingschemes studied indicates it has bet-ter anticorrosive properties on15CDV6 steel substrate.
3.2 Salt fog exposure tests. Salt fogresistance of the coating schemesstudied in terms of time taken forthe appearance of first failure onprolonged exposure to salt fog is pre-sented in Table 4. From the results, itis evident that the cadmium- andchromate-free coating scheme stud-ied exhibits better anticorrosiveproperties on 15CDV6 steel sub-strate when compared to the othertwo cadmium- and chromate-basedschemes studied. (The photographsof the test panels after exposure tosalt fog tests are shown in Figure 5.)From the photographs, it is evidentthat the cadmium and chromatescheme is less affected at the time ofoccurrence of first failure when com-pared to the other two cadmium-and chromate-based schemes takenup for experimental study.
3.3 Adhesion and abrasion resistancemeasurements. The results of adhe-sion and abrasion resistance meas-urements carried out on differentcoating schemes are provided inTable 5. From the results of adhe-sion measurements, it is evidentthat cadmium- and chromate-freecoating scheme possesses compara-ble adhesive strength to that of thechromate- and cadmium-basedschemes studied. The abrasionresistance of the coating schemes isalso comparable and, hence, thecadmium- and chromate-freescheme studied shows comparablemechanical properties to that ofcadmium- and chromate- basedschemes. It is also seen that trivalentchromate based passivation processused in the present study forimproving the adhesion of the sub-sequent paint layer serves the pur-pose when compared to the hexava-
that cadmium- and chromate-freecoating scheme exhibits superiorperformance when compared to thewidely used cadmium- and chro-mate-based schemes.
CONCLUSIONSEfficient and eco-friendly alterna-tives to cadmium- and chromate-based coatings is a major require-ment in the area of protective coat-ings for aerospace and defenseapplications. In this paper, experi-mental work to evaluate and findan efficient alternative to cadmi-um- and chromate-based coatingschemes used to comply with aero-space and military specificationswas carried out.
The proposed cadmium- and chro-mate-free scheme comprised of zincnickel alloy plating, trivalent chromi-um-based passivation and polyani-line phosphate-based primer offerssuperior corrosion protection to the15CDV6 steel substrate when com-pared to the cadmium- and chro-mate-based schemes taken up forstudy. The mechanical properties ofthe cadmium- and chromate-freeschemes are also comparable to thecadmium- and chromate-basedcounterparts. These promisingresults show the possibility ofreplacement of the widely used cad-mium and chromate based schemesfor corrosion protection of 15CDV6steel with an eco-friendly schemecomprised of zinc nickel alloy plat-ing, trivalent chromium based passi-vation and polyaniline phosphatebased primer.
ACKNOWLEDGMENTSThe authors would like to expresstheir sincere gratitude to Shri. P.Venugopalan, director, DRDL,Hyderabad for his constant supportto carry out this work. The authorsalso thank Shri. N. Viswanathan,Scientist G (retd), Shri. B.Madhusudana rao, Scientist F (retd)of DRDL, Hyderabad for theirencouragement to initiate work inthe area of eco-friendly coatings.
REFERENCES1. R. Fratesi and G. Roventi, Surface
ORGANIC finishing
20 I metalfinishing I April/May 2011 www.organicfinishing.com
www.organicfinishing.com April/May 2011 I metalfinishing I 21
N. Parvini-Ahmadi, J. Manzoori,Surface and Coatings Technology 140(2001) 278 -283.
Serving the industry since 1983, SFCHINAhas been Asia’s largest “finishing” eventthat helps hundreds of overseas suppliersto develop and grow their China business.Last year, the must-attend industry galaattracted 255 exhibitors from 19 countriesand 10,151 visitors from 40 countries.
This year, SFCHINA, the 24th event inits series, is to be held on 23-25 November,2011 in Shanghai. We are honoured to talkto Mr. Raymond Ho, Director of SinostarInt’l Ltd., the organizer of SFCHINA. Mr.Ho has been involved in trade show busi-ness for nearly 30 years with insight onsurface finishing industry and a profoundknowledge of industry exhibition in thispart of the world. He launched SFCHINAin 1983.
Would you please introduce SFCHINA briefly?Ho: Serving the market since 1983,SFCHINA is one of the most prestigious
one-stop events covering the entire finish-ing industries, from substrate prepara-tion to recycling, in two major themes -1. Coating application & Coatings
Products;2. Electroplating & Finishing
Technology.
On top of a highly professional tradeevent, we add a lot of educational ele-ments in terms of Technical Seminars,New-Tech Corner and Workshops. Lastyear, 7 sessions of Technical Seminars, 5sessions of New-Tech Corner and 2 ses-sions of Presentation on NewEnvironmental Technologies were heldand the response from attendees wasencouraging. SFCHINA is not just ameeting place for the trade professionals,but a learning platform for the latesttechnology and application for ourindustry sector.
As of today, over 80% space of the 2011event is reserved by exhibitors fromAustria, Brazil, France, Germany, HongKong, India, Japan, Russia, Singapore,Switzerland, Taiwan, the USA and China.It is indeed an annual internationalindustry gala for both exhibitors and visi-tors. We believe the show will furthergrow in the years to come.
Why is finishing technology soimportant to China?Ho: China is now the world’s largest manu-facturer in automobiles, consumer electron-ics, household appliances and many otherindustries that require superior finishingtechnology. In the realm of the global sur-face finishing community, the unrelentingsearch for new value-added products is syn-onymous with the idea of quality.
Extreme weather resistance, colour-fastness, brilliance, product excellence,emerging-green- sustainable technologiesare by now familiar terms for anyoneinvolved in the world of surface finishing.But what does it really mean? First and
Proudly Presenting SFCHINA, 23-25 November 2011,
Shanghai
Mr. Raymond Ho, Director of Sinostar Int’l Ltd.
foremost, quality is inextricably linkedwith R&D and only those companies whoreally understand their clients’ diverse andspecific requirements and produce novelproducts will be the survivors.
New finishing technologies with supe-rior efficiency and unique capabilities,are becoming an integral component of aproduct. The importance of finishing isuniversal. It is no longer just a metallic ororganic topcoat for a substrate. It hasbecome an integral part of the entireengineered product. It is the market ofunlimited potential.
Could you share with us why SFCHINA exhibition series are moresuccessful and how they delivermore value than other similarevents?Ho: SFCHINA is the first professionaltrade event serving this industry sector forthe last 28 years in the China and Asianmarket. We position our show as anunique platform for exhibitors and visi-tors to meet once a year, alternately inGuangzhou and Shanghai, with an areafocus on the Pearl River Delta and YangtzeRiver Delta Regions, both of which are keyindustrial base of China. It helps us differ-entiate from other local events.
In terms of number of exhibitors andvisitors, we are No. 1 and a real interna-tional finishing event for China that iswell-received by our customers and estab-lished an excellent reputation in the indus-try. Result of the 2010 show has proved it:• A total of 290 companies from 19
countries and regions had exhibited;• 1,035 international visitors from
40 countries and regions of the five continents and 9,051 domestic visitors, i.e. a total of 10,151 visitors visited the show;
• 900+ visitors joined our technical programs which were held along-side the 3 days exhibition;
• 85.7% of exhibitors viewed the participation in the show was very important for their sales and marketing;
• 88.2% of visitors commented the show was successful.
All in all, it is simply an annual indus-try gala for all industry professionals andplayers in our market.
Over the years, how could you
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ensure the result to exhibitors?Ho: Good question. We believe qualityand quantity of visitors are the key of suc-cess for a trade show. Rome was not builtin one day. We are the only organizers inAsia that publish surface finishing tradejournal (SFJ) since 1990 to serve the read-ers, which are the fundamental basis ofour visitors. They are served with marketinsight, latest technical articles andresearch materials from the magazinethat helps bonding our relationship withbuyers from this part of the world.
In addition, we invest millions of dol-lars over the years in visitor marketing byadvertising in all the leading websites andtrade journals of surface finishing circu-lated locally and worldwide. We also par-ticipate in leading exhibitions around theglobe to promote our show and recruitvisitors for our exhibitors.
To visitors, SFCHINA is a place formeeting, sharing and learning. The pur-poses of their visiting have supported this:• 64.8%: sourcing suppliers/new products;• 26.95%: seeking partner/sales agents;• 26.5%: evaluating market trends;• 16.93%: visiting current suppliers;• 13.8%: attending
And this is how we ensure the exhibit-ing result to exhibitors all these years.
Compared with the last event, whatwill be the highlights of SFCHI-
NA2011?Ho: This year, in addition to the TaiwanPavilion, we will have for the first time anOfficial German Pavilion presented bythe Federal Ministry of Economics andTechnology (BMWi), in cooperation withthe Association of the German Trade FairIndustry (AUMA) and supported by theVDMA (German EngineeringFederation), Surface TreatmentTechnology. The Pavilion will occupy aprominent area in SFCHINA2011. It issimply an endorsement of the Germangovernment and a major recognitionfrom the industry.
Last but not least, would you pleasediscuss the concurrent events withSFCHINA?Ho: At the same time of SFCHINA, we are
also holding the CHINACOAT2011, the16th event in its series with its origindated back to 1996. It is China’s largestinternational exhibition for Coatings,Printing Inks, Adhesives Products andtheir raw materials. Result of 2010 showin Guangzhou:• A total of 751 companies from 32
countries and regions had exhibited;• 3,377 international visitors from 71
countries and regions of the five continents and 20,367 domestic visitors, i.e. a total of 23,744 visitors visited the show;
• 2,500+ visitors joined our technical programs which were held alongside the 3 days exhibition.
A variety of technical events aiming topromote intellectual interflow amongvisitors and exhibitors was held, whichincluded: 47 sessions of TechnicalSeminars, a Conference on ArchitecturalCoatings, a Workshop, 10 sessions ofNew-Tech Corner, and a NationalPresentation from Bangladesh.
We believe all these could add value toexhibitors and visitors and make ourshows stand out from others. We areproud of bridging the exhibitors and visi-tors since 1983 and will keep doing ourbest to grow our shows for the benefit ofour customers.
Mr. Ho, thank you very much for yourtime. May we wish SFCHINA and CHINA-COAT a great success in the years to come!
Investigation of High-PerformanceAcid Zinc Nickel Electrolyte
ABSTRACTZinc nickel alloy coatings are increas-ingly demanded by the automotiveindustry due to their highlyimproved corrosion protection overpure zinc and other zinc alloy coat-ings. To produce zinc nickel coatingswith a nickel incorporation of 12 to16%, mainly alkaline zinc nickel elec-trolytes are used in the plating indus-try. Continuous improvements in thefield of acidic zinc nickel alloy elec-trolytes now meet the needs of theautomotive industry while beingadvantageous in specific fields ofapplication.
In this paper, zinc nickel coatingsdeposited from alkaline as well asfrom ammonium-free acid zinc nick-el electrolytes are investigated. Themorphology is evaluated by scanningelectron microscopy; the texture isinvestigated by focused ion beam,and X-ray diffraction patterns identi-fy the structure of the coating. Thecorrosion protection of the zinc nick-el coatings and the adhesion of thezinc nickel coatings have been bench-marked. For applications on fasten-ers, the coefficients of friction havebeen measured and compared.
1.INTRODUCTIONThe demand of zinc nickel alloy coat-ings has increased significantly overthe last decade, especially in theautomotive industry. (In the brakecaliper industry, acid zinc nickel elec-trolytes are established since cast ironmaterials can be directly plated by anacid zinc nickel electrolyte. Nowother applications follow as the useof acid zinc nickel electrolytes havemany advantages.) Coatings plated
out of an alkaline zinc nickel elec-trolyte are used for a wide variety ofapplications, such as fasteners, fluiddelivery tubes, door hinges and anti-vibration components.
In pure zinc plating, alkaline andacid zinc electrolytes are commonlyused. The advantages of an alkalinezinc electrolyte are its excellentthickness distribution and throw-ing power for complex shapedparts, which result in superior cor-rosion protection over zinc coatingsplated from an acid zinc electrolyte.On the other hand, for mass pro-duction of simple shaped parts,acid zinc plating is beneficial due tothe high current efficiency and,therefore, high productivity andreduced plating cost. For this rea-son, acid zinc plating is the estab-lished plating process for fastenerplating in barrel applications.
Based on these facts, zinc nickelcoatings plated from alkaline as wellas ammonium-free acid zinc nickelelectrolytes were investigated indepth to evaluate if acid zinc nickelcould also be beneficial for massproduction.
2. MATERIALS AND METHODSFor zinc nickel coating investiga-tions, 5 x 5 cm² panels were plated atcurrent densities of 0.7 A/dm² and2.5 A/dm². Zinc nickel coatings wereplated from three commercialAtotech zinc nickel electrolytes:
Reflectalloy ZNA (alkaline zincnickel rack plating process): 10 g/l zinc, 120 g/l NaOH, 88 ml/lReflectalloy ZNA 92 Make Up,88 ml/l Reflectalloy ZNA 94 Carrier,
1 ml/l Reflectalloy ZNA 95Brightener, 3 ml/l Reflectalloy ZNA97 3x Brightener and 1.5 ml/lReflectalloy ZNA 98)
Zinni AL 450 (alkaline zinc nickelbarrel plating process):8 g/l zinc, 120 g/l NaOH, 12.5 ml/lZinni AL 451, 100 ml/l Zinni AL 452,1.5 ml/l Zinni AL 453
Zinni AC AF 210 (ammonium-freeacid zinc nickel plating process):26 g/l zinc, 170 g/l chloride, 30 g/lnickel, 20 g/l boric acid, 10 ml/lZinni AC AF 211, 20 ml/l Zinni ACAF 212, 60 g/l Zinni AC AF 213, 20ml/l Zinni AC AF 214
The plating conditions were fol-lowed according to the technicaldata sheets. The morphology of thecoatings was examined by scanningelectron microscopy. Cross sectionsof these panels were made by afocused ion beam instrument toinvestigate the texture of thedeposits. The zinc nickel alloy phasecomposition of these panels wasmeasured by X-ray diffraction. M10 x40 fasteners were plated in barrelapplication at 0.6 A/dm² and 0.85A/dm². The thickness and the zincnickel composition of the coatingswas measured using X-ray fluores-cence. The corrosion protection wastested in neutral salt spray testaccording to ASTM B-117 and thecoefficient of friction was evaluatedusing a Schatz instrument accordingto SAE/USCAR-11.
3. RESULTS AND DISCUSSION The morphology of the coatings wasinvestigated in a scanning electronmicroscope. Figure 1 shows the scan-ning electron micrographs of zincnickel coatings deposited from thealkaline Reflectalloy ZNA electrolyteat 2.5 A/dm² and respectively 0.7A/dm² at optimum plating parame-ters according to technical datasheet.
All the micrographs demonstrate aglobular morphology of the deposit-ed zinc nickel coatings. No obviousdifference can be seen between thezinc nickel coatings produced either
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After 240 hours, no white rust for-mation can be observed for all zincnickel electrolytes used.
After 1,000 hours no red rust for-mation can be observed for all zincnickel electrolytes used.
The adhesion of the zinc nickelcoating on the fasteners was checkedby heating to 200°C for 30 minutesand then quenching the parts inroom temperature water. The partswere checked afterwards for any blis-tering, flaking or chipping and allparts passed the test (Figure 7).
The coefficient of friction wasmeasured on 90 zinc nickel platedfasteners (30 fasteners per ZnNiprocess) according to SAE/USCAR-
from the alkaline electrolytes or theacid zinc nickel electrolyte.
The texture of the coatings wasinvestigated by etching a cross sec-tion in the zinc nickel coating usingan ion beam. Figure 4 demonstratesthe cross sections of zinc nickel coat-ings deposited from ReflectalloyZNA (alkaline rack zinc nickel elec-trolyte), Zinni AL 450 (alkaline barrelzinc nickel electrolyte) and Zinni ACAF 210 (ammonium-free acid zincnickel electrolyte).
No obvious difference can beobserved in the pictures. All zincnickel coatings show a field orientedtexture with a preferred columnargrowth. The zinc nickel coatingdeposited from the acid zinc nickelelectrolyte shares the same texture asthe zinc nickel coatings depositedfrom the alkaline zinc nickel elec-trolytes.
To investigate the structure of thezinc nickel coatings X-ray diffractionwith Cu Ka radiation was used(Figure 5).
The X-ray diffraction patterns ofall zinc nickel coatings show thesame pure zinc nickel g-phase com-position. From previous investiga-tions [1, 2, 3], it is known that zincnickel g-phase with 12 to 16% nickelincorporation has the highest per-formance in corrosion protection.
The corrosion protection of all zincnickel coatings was tested in neutralsalt spray test. All zinc nickel coat-ings were tested on fasteners. Thethickness of the coating and thenickel incorporation was measuredby X-ray fluorescence (Table 1). Allcoatings have a nickel incorporationbetween 12.0% and 13.3% and a coat-ing thickness ranging between 8 μmto 10 μm.
For corrosion protection the samepost treatment was used for all zincnickel coatings. EcoTri thick filmpassivate and Corrosil Plus 501 (BG)sealer with Rogard Lube 200 waschosen. Fasteners were evaluatedafter 240 hours for white rust forma-tion and after 1,000 hours for redrust formation (Figures 6a and b).
11 and compared to the requirementof a typical automotive OEM specifi-cation (Figure 8). All zinc nickel coat-ings are in the range of the automo-tive specification.
4. CONCLUSIONSZinc nickel coatings deposited fromtwo state-of-the-art alkaline, as wellas an ammonium-free acid zinc nick-el electrolyte, have been bench-marked to investigate the depositedzinc nickel coatings. The morpholo-gy has been evaluated by scanningelectron microscopy and indicatesthe same globular morphology ofthe deposited zinc nickel coating.The texture has been investigated by
TECHNICALLYspeaking
Figure 1: Scanning electron micrograph of zinc nickel coatings deposited from Reflectalloy ZNA alka-line zinc nickel electrolyte at 2.5 A/dm² (left) and 0.7 A/dm² (right).
Figure 2: Scanning electron micrograph of zinc nickel coatings deposited from Zinni AL 450 alkalinezinc nickel electrolyte at 2.5 A/dm² (left) and 0.7 A/dm² (right).
Figure 3: Scanning electron micrographs of zinc nickel coatings deposited from the ammonium-freeacid Zinni AC AF 210 electrolyte at 2.5 A/dm² and 0.7 A/dm², respectively, at optimum platingparameters according to technical data sheet.
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Figure 4: Cross sections of zinc nickel coatingsdeposited from Reflectalloy ZNA (alkaline rackzinc nickel electrolyte on top), Zinni AL 450(alkaline barrel zinc nickel electrolyte in themiddle) and Zinni AC AF 210 (ammonium-freeacid zinc nickel electrolyte on the bottom).
Figure 5: X-ray diffraction pattern of zinc nickelcoatings deposited from Reflectalloy ZNA (alka-line rack zinc nickel electrolyte on top), Zinni AL450 (alkaline barrel zinc nickel electrolyte in the
middle) and Zinni AC AF 210 (ammonium-freeacid zinc nickel electrolyte on the bottom).
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TECHNICALLYspeaking
Sample Number Thickness (μm) Alloy (% Nickel)
Reflectalloy ZNA
1 9.44 12.8
2 10.01 13.2
3 9.02 12.0
4 10.61 12.6
5 8.66 12.0
Zinni AL 450
1 9.23 13.2
2 9.25 13.1
3 9.40 13.2
4 9.08 13.3
5 9.09 12.6
Zinni AC AF 210
1 8.3 12.0
2 8.03 12.4
3 8.56 12.0
4 8.7 12.0
5 8.61 12.7
Table 1: Coating thickness and nickel incorporation tested on five fasteners for each zinc nickel process.
Figure 6a: Corrosion evaluation after 240 hours neutral salt spray test according to ASTM B-117. Zinc nickel coatings deposited from Reflectalloy ZNA(alkaline rack zinc nickel electrolyte on the left), Zinni AL 450 (alkaline barrel zinc nickel electrolyte in the middle) and Zinni AC AF 210 (ammonium-freeacid zinc nickel electrolyte on the right).
Figure 6b: Corrosion evaluation after 1,000 hours neutral salt spray test according to ASTM B-117. Zinc nickel coatings deposited from Reflectalloy ZNA(alkaline rack zinc nickel electrolyte on the left), Zinni AL 450 (alkaline barrel zinc nickel electrolyte in the middle) and Zinni AC AF 210 (ammonium-freeacid zinc nickel electrolyte on the right).
Figure 7: Photographs of fasteners after adhesion test: Zinc nickel coatings deposited from Reflectalloy ZNA (alkaline rack zinc nickel electrolyte on theleft), Zinni AL 450 (alkaline barrel zinc nickel electrolyte in the middle) and Zinni AC AF 210 (ammonium-free acid zinc nickel electrolyte on the right).
nickel g-phase. The corrosion pro-tection of the zinc nickel coatingshas been tested according to ASTMB-117. All zinc nickel coatingsachieve 240 hours without whiterust formation and 1,000 hourswithout red rust formation. Theadhesion of the zinc nickel coatingson the fasteners was checked byheating to 200°C for 30 minutesand then quenching the parts inroom temperature water. The partswere checked afterwards for any blis-tering, flaking or chipping, and allparts passed the test. The coefficientof friction of zinc nickel coated fas-teners was measured and achievedthe requirements of a typical auto-motive OEM specification with thesame post-treatment process for alltested fasteners. From all the investi-gations undertaken, the perform-ance of the zinc nickel coatingdeposited from a state-of-the-artammonium-free acid zinc nickelelectrolyte (Zinni AC AF 210) is com-parable to an alkaline zinc nickelelectrolyte (Reflectalloy ZNA orZinni AL 450).
ABOUT THE AUTHORS Dr. Birgit Sonntag is the worldwide busi-ness manager of Atotech’s CorrosionResistant Coatings department. Holding aPh.D. in electrochemistry from the FreieUniversitaet of Berlin, Germany, she hasworked in the plating industry for almost 20years. During the last 14 years she has beeninvolved with the electroplating of zinc, zincalloy and corresponding post-treatmentprocesses at Atotech GmbH, Berlin,
Germany, where shehas been working inresearch and devel-opment, as well asproduct manage-ment. Her team islocated all over theworld, with researchand development inGermany, Spain,and the CzechRepublic; productsupport personnel inall regions andTechCenters inGermany, Canada,and Korea.
focused ion beam. All zinc nickelcoatings show a field oriented tex-ture with a preferred columnargrowth. X-ray diffraction patternsidentify the formation of pure zinc
Dr. Björn Dingwerth is the technicalmanager of Atotech’s Corrosion ResistantCoatings department. Holding a Ph.D. inchemistry from the Heinrich-Heine-University of Düsseldorf, Germany, he hasmore than eight years of experience in thefield of cathodic corrosion protection withelectroplated layers. Dr. Dingwerth is pri-marily involved with R&D on new elec-troplating processes and the associatedpost-treatment applications.
Norm Irving has served as technicalproduct specialist of Atotech CRCTechnical Centre in Burlington, Ontario,since 2006. He has been active in themetal finishing industry since 1987.
3. Birgit Sonntag, Björn Dingwerth,Bryan Kelley, Konstantin Thom,Canadian Finishing and CoatingManufacturing, 11 (June 2009)
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Figure 8: Coefficient of friction values of ZnNicoated fasteners: 30 fasteners with zinc nickelcoatings deposited from Reflectalloy ZNA (alka-line rack zinc nickel electrolyte on the top), 30fasteners with zinc nickel coatings depositedfrom Zinni AL 450 (alkaline barrel zinc nickelelectrolyte in the middle) and 30 fasteners withzinc nickel coatings deposited from Zinni AC AF210 (ammonium-free acid zinc nickel elec-trolyte on the bottom).
Advanced Stainless Steel Finishing Tools from Metabo.
How to properly set up a mid-size, RoHS-compliant EN line without breaking the bank.
Over the last 35 years, Ronatechas supplied electroless nickel
(EN) to the automotive, aerospace,electronic, food, aquatic, plumbing,decorative, and naval industries.Our team has identified that manyof the technical “problems” we areasked to resolve actually relate touser error and equipment in use.While there is the occasional chem-istry issue, most can be easily avoid-ed by initiating some simple andinexpensive actions during the linedesign phase and chemical selec-tion process. This article is intend-ed to illustrate the most cost-effec-tive ways to “set up” a line, while atthe same time maintaining thehighest level of quality and keepingit simple.
For the purposes of this article, wewill be setting up a standard mid-phos, RoHS-compliant, bright elec-troless nickel line. The line isdesigned to plate aluminum.(Minor variations may apply if thegoal is to plate a different substratethan the above, i.e., copper, magne-sium, or steel).
Tank Construction. Various types oftanks are needed on an EN line.Please contact us for schematics oftanks designed that are prefered inthe industry.
Tank Material. The Ronatec teamprefers polypropylene tanks, for afew reasons (most cost effective, lastthe longest, easy to repair, lightweight, etc.). All polypropyleneshould be ½ '' thick material, with
the exception of the tank floor,which should be 1'' to avoid crack-ing if parts drop. Electroless nickeltanks should be made of naturalpolypropylene. If steel is preferred, orif steel is only available, please con-tact Ronatec for some helpful tips toavoid “plate-out.”
Insulation. All hot tanks should beinsulated, with at least a 3-inch sepa-ration between the inner and outerwalls. Insulation allows a tank toachieve desired temperature faster aswell as stay at the desired tempera-ture with the use of less energy.(Note: Use a high-density foam.)
Lids. Using tank lids on hot tanks isa great way to save energy. Lids alsokeep unwanted “alien” materials outof baths. They are inexpensive andalways help.
Girths. Larger tanks may requiregirths. Make sure all girths are incap-sulated to avoid corrosion underinsulation. Contact us for tank-size-to-girth ratio charts.
Welding. All meeting points/seamsshould be triple welded (for obviousstrength reasons) and shaved toavoid “plate-out” contention areas.
Tank Floor. All tank floors should beflat, with the exception of the elec-troless nickel tank, which should bea “cone bottom.” This helps elimi-nate plate-out and extends timebetween tank passivation. Contact usabout cone bottoms on flat surfaces.
Legs . Taller lines may require legs fortanks to reach the desired height.Legs should be built into the sidewalls of the tank and supported byfeet. Use a cross beam on larger tanksto avoid sagging.
Overflow. All rinse tanks shouldhave a cascade overflow, when possi-ble. It saves money and providessuperior tank cleanliness.
Heat Exchanger. If the facility hasboiler capabilities, then an externalheat exchanger is by far preferred(greater energy savings, limited bathexposure, longer exchanger life, etc.).There are also external electric heatexchanger options. The main idea isto heat the electroless nickel withoutplating the heater. Unless unavoid-able, do not use over-the-side heatersor internal heat exchangers. Tanksthat are normally heated are high-lighted in the following section.
Temperature Controllers.Controllers are best determined bythe heat exchanger manufacturer.Ronatec prefers a controller that hasboth a high and low set point. Iffunds are available, using a “timercontroller” can save on energy costsand avoid plate out in that they canbe set to lower when the bath is notgoing to be in use. Wrap controllersin clear plastic to avoid internal cor-rosion (steam, splash, etc.).
Pump. Electroless nickel pre-treat-ment (soap, deox, etc.) agitation andturnover ratios should be deter-mined by their specified manufactur-er (mostly not required). Make sureto check with the pump manufactur-er for requirements based on tanksize and material suggested by thechemistry being pumped. On tanksthat require a pump, intake shouldbe from the center bottom of thetank for maximum circulation.
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BY JIM WETHERALD, TECHNICAL SALES REPRESENTATIVE,RONATEC C2C, INC., CARLSBAD, CALIF.
vides added brightness, preventsshadowing, eliminates contami-nants, etc.). Use CPVC plumbingalong the bottom of the tank topump filtered solution back into thebath. In this instance, more is better,as some parts require more agitationthan others.
Tank Placement. Provide plenty ofspace for tank maintenance (filteralterations, etc.). If possible, limitexposure to the exhausts of otherbaths as contamination will shortenbath life. (Please contact Ronatec fora schematic of our prefered electro-less nickel tank design.
Electroless Nickel Tank Line Order.The ideal electroless nickel line, forthe purposes mentioned above,should have 18 tanks (less tanks canbe used by “doubling up” on tanks,but this is not recommended.Contact us for additional options).The scenario below assumes a roomtemperature of 70°F:
1. Aluminum Soak 2. Rinse3. Aluminum Etch (Caustic basedor Acid based)4. Rinse5. Deoxidizer (Chrome Free)6. DI Rinse7. Non-Cyanide Zincate8. Rinse9. Zincate Strip10. DI Rinse11. Non-Cyanide Zincate12. Rinse13. DI Rinse14. Alkaline Electroless NickelStrike15. DI Rinse16. RoHS, Mid Phosphorous,Bright Electroless Nickel 17. Rinse18. Hot DI Rinse
Many have asked why an alkalineelectroless nickel strike and a secondnon-cyanide zincate bath are so vital,and how adding these additionaltanks to a line might save money.The answer: double zincating is nowthe standard in electroless nickelplating, allowing superior adhesion
Filtration. For the most part, theonly tank on an EN line that requiresfiltration should be the electrolessnickel tank. There are typically twotypes of filtration for electrolessnickel tanks: filter bag or filter cham-ber. For the purpose of this article,Ronatec prefers the filter bag optionas it is the most cost effective, isreusable, limits pump pressure, andallows for continual operator inspec-tion. Ronatec prefers to mount thefilter bag system on the rear of theelectroless nickel tank—off a shelf asto maximize tank surface usage area.Contact Ronatec to see the recom-mended design.
Plumbing. Ronatec prefers CPVCplumbing. Make sure to use a techni-cian who understands your heatexchanger system, while taking intoconsideration the chemistryinvolved.
Ventilation. Electroless nickel shouldbe ventilated. Check with localauthorities to make sure ventilationrequirements are being met. Mosttank manufacturers provide a com-patible ventilation/exhaust system.
Electroless Nickel Feeder/Controller.While not required, an electrolessnickel feeder can save money in thelong run in that it can eliminatehuman error. At the same time, onmany occasions, they can cause prob-lems. The choice comes down tofunds available. Contact Ronatec forinformation regarding the varioustypes of controllers.
Splash Wall. Separate all electronics,plumbing, and sensors from chemi-cals with a splash wall to prolongequipment life. It is a very inexpensiveway to maximize equipment value.
Agitation. Again, refer to the pre-treatment chemistry’s manufacturerfor agitation requirements.Electroless nickel should always haveagitation. For EN tanks, Ronatecprefers “solution agitation” (pro-
and eliminating pitting/blistering.You can reuse the initial zincate tankif space is limited, but be sure toavoid cross contamination with zin-cate strip.
The alkaline electroless nickelstrike is the most cost-effective bathon the aforementioned EN line. Atypical RoHS-compliant bright elec-troless nickel bath should reach 8-9turnovers over aluminum, if runproperly, without the use of an alka-line strike. (Please contact Ronatecfor the proper turnover calculationbased on your material used).However, by adding the alkine strike,that same RoHS EN bath shouldreach 10-13 turnovers. That’s a hugeincrease in bath length. The reasonmost EN tanks over aluminum onlylast to 8-9 turns is because of theirbuild up of zincate and conversion ofhypophosphite to orthophosphate.The strike eliminates zincate build upin the final EN bath. The best part isthat alkaline strikes are fairly inex-pensive to run, while the RoHS elec-troless nickel tank is the most expen-sive on the line. By adding an alkalinenickel strike the value of the RoHSelectroless nickel tank has doubled.
Pre-Treatment Chemical Choices.Choosing proprietary pretreatmentover “home brews” can be a difficultchoice. For obvious reasons (disclo-sure: Ronatec supplies proprietarychemistry), Ronatec prefers propri-etary pretreatment chemistries.There are some huge cost advantagesto using proprietaries vs. home brewalternatives. These include tech sup-port (priceless), chemistry advan-tages, and Mil-Spec approvals(required). With that said, initialstart-up costs are much less expen-sive when if one makes their ownetch, deoxidizer, and zincates. Pleasecontact Ronatec for a list of homebrew formulations, which can also befound in the metal finishing hand-book and/or online.
If it is decided to go the proprietaryroute, choose suppliers wisely:
• Is the supplier’s pricing secure or do they raise it often? (i.e., right after they secure the business)
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Carlsbad, Calif. He works closely with direct customers and dis-tributors addressing issues with a “hands-on” approach.
Wetherald graduated from San Diego State University withdegrees in Integrated Financial Systems andApplied Mathematics, and he has studied chemical engineeringand JIT systems management. His six years in the metal finishingindustry, combined with excellent training from ShawnWetherald, Mike Aleksinas, Joe Zabielski—as well as other well-known industry experts—has made him a valuable asset in elec-troless nickel problem solving and its related applications.
Jim may be reached via e-mail at [email protected] orby telephone: cell: (858) 401-3374; office: (760) 451-9081; or fax:(760) 946-7862.
ABOUT RONATECRonatec has been a leader in the electroless nickel industrysince the 1980s. Ronatec works with facilities across theUnited States, Mexico, Canada, China, Brazil, Thailand,and Ireland. Ronatec operates warehousing facilities ineight convenient locations, providing shipping and analy-sis on a same-day basis.
• Does the supplier offer quality customer service? (i.e., ease to order, stock material, etc.)
• Does the supplier offer technical support/expertise or refer to another supplier/manufacturer? THIS IS IMPORTANT! The chemical supplier should, in most cases, be able to provide tech service!
Electroless Nickel Chemical Choices. The most impor-tant part of the chemical selection process should be thechoice of an electroless nickel supplier. This shouldinclude the non-cyanide zincate, alkaline electroless nick-el strike, and the RoHS-compliant electroless nickel. Workwith a direct manufacturer or a stocking distributor. Bothhave huge advantages and each situation is unique.
A good supplier will:
• Provide around-the-clock technical support• Back up their chemistry financially• Keep chemistry in stock• Provide free sample analysis• Provide free salt-spray testing• Provide a list of notable electroless nickel platers who
they work with
Always remember that less expensive EN is not alwaysthe best, while more expensive EN does not always make itbetter.
• Check nickel concentrations (g/l) in the A component vs. price. Most EN formulations today use an 8 g/l “A” component formulation.
• Check proven turn-over levels. Does the EN reach 8-10 turnovers over an aluminum substrate with out the useof a strike? It should.
• Does the formulation utilize “1 to 1” (A to C*) replenishment combination or “1 to 2”? Ronatec prefers the “1 to 1” replenishment model, as it:
1. Costs less to transport (Never pay to ship excess waterwhen possible).
2. Is easier to use.3. Usually costs less when compared to the same replen-
ishment of a “1 to 2,” by volume added.
CONCLUSION This article is meant to assist with a new line design. If aline is already in place and assistance is required, pleasefeel free to contact Ronatec. We are available to help makesome suggestions. This information is based on a collec-tive analysis of our team. We are always looking to expandour knowledge and appreciate you suggestions.
BIOJames “Jim” Wetherald serves as a technical sales representativefor the Electroless Nickel Division of Ronatec, C2C, Inc., based in
TECHNICALLYspeaking
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program helps finishers sharpen their online acts.
For much of Van Nuys Plating’s50-plus years in existence, the
focus first and foremost was on theart: providing expert services rang-ing from cadmium and chrome plat-ing, all the way up to electrolessnickel, passivating, phosphating, etc.But in recent years the company real-ized—that in order to maximizeawareness, particularly online—itneeded to do a much better job innot only communicating itsstrengths and expertise to potentialclients but also in coming up withnovel ways to “virtually” attract endusers in the market for quality fin-ishing services.
Sure, Van Nuys Plating alreadyoperated a “functional” website,which offered the basics: list of serv-ices, location, contact information,and so on. Unfortunately, it was“tiny” as Linda Boyer, the company’sgeneral manager, described it—placed on the Web “just to get some-thing up there.”
Then, back in September of 2010,Boyer received a fortuitous “courtesycall” from a Thomas IndustrialNetwork sales agent, touting a newWeb-based marketing and advertis-ing initiative called Custom SPEC, aprogram designed to assist industrialclients via website development andInternet exposure (see screenshot onthe next page). While Boyer wasalready familiar withThomasNet.com—Van Nuys Platingalready enjoyed a free listing on thesite—she was very intrigued by theconcept.
“I had been keeping a mental track
of the calls that were coming in fromthe Thomas.net search engine whenThomas Industrial Network called toask if we were interested in pursuingdoing more advertising,” Boyerrecalled. “I did not know the name‘Custom SPEC’ before then, but I didlook at some other websites thatThomas Net built for platers andthought they were very attractive.”
It wasn’t too long after that pointthat Van Nuys Plating “got with theprogram,” so to speak. Soon afterrevamping its website utilizingThomas Industrial Network’s guid-ance and technical expertise, Boyerbegan to realize the benefits ofCustom SPEC. For one, she says,potential customers calling on VanNuys Plating for quotes had alreadyobtained a wealth of information
casestudyBY REGINALD TUCKER
from the site, which had been signif-icantly upgraded. Among theimprovements: a catalog of portfo-lios and past project case histories;high-quality images reflecting thetypes of finishing services offered;and detailed information on stan-dards and specifications.
“Customers are getting a lot ofinformation from the website thatthey weren’t getting before, and it’smuch more user-friendly,” Boyerexplained. “I’m finding that callersare only getting in touch with me toperhaps ask one more little questionor two. The site is now doing what itwas meant to do: provide as muchinformation as possible to allow thecustomer to make a decision whetheror not we’re someone they want towork with.”
For Thomas Industrial Network,that’s precisely how the plan wasdrawn. According to Charlie Watts,director of marketing, Web SolutionsGroup, Custom SPEC is designed tofill clients’ pipeline by “helpingindustrial operations better marketthemselves and generate leads,” heexplained.
The mechanics of achieving those
Van Nuys Plating Co. AT A GLANCE
14611 Bessemer St. • Van Nuys, CA 91411Tel.: (818) 785-5885 • Fax: (818) 785-4421
32 I metalfinishing I April/May 2011 www.metalfinishing.com
goals entails in-depth consultationwith the client. And for very special-ized industries such as surface finish-ing, customization can make a worldof difference.
“Platers, traditionally, have done agreat job at showing pictures of fin-ished goods on their sites, but theyfall short in providing case historiesof what they’ve done,” said ThomasIndustrial Network’s Joe Nieckarz,applications engineer manager, whomakes it a point to visit as manyshops as possible for research pur-poses. “With Custom SPEC, they canfocus on their core capabilities, plusthe past work they’ve done.”
Additionally, Nieckarz notes, fin-ishers enrolled in the Custom SPECinitiative can also benefit via greateropportunities to generate businessoutside of their core sectors. (Forexample, if a plater is seeking toexpand beyond automotive and intomore high-margin sectors such asmilitary/defense and aerospace.) Butperhaps the biggest benefit ofCustom SPEC, he says, is its symme-try with ThomasNet.com. “It’s assimple and turnkey as possible, andthe two work together very efficient-ly to grow sales.”
MEASURABLE RESULTS Custom SPEC converts attest to thepositive impact the program has had,not only on leads generated but alsoactual “conversions.” In Van NuysPlating’s case, Boyer estimates thatabout 10% of leads identified actual-ly resulted in sales within a relativelyshort time frame.
Another satisfied customer isWheeling, Ill.–based KeatsManufacturing Company, a customproducer of small metal stampings,wire forms and assemblies. MattEggemeyer, vice president and chiefoperating officer, reports that saleshave increased by 30%, with quotesmore than doubling from 600 to1,400 in one year, as a direct result ofemploying Custom SPEC’s newInternet marketing strategy.
“Thomas Industrial Network
casestudy
helped us to reach qualifiedprospects who would not otherwisehave considered us, including onewho placed a million-dollar order,”Eggemeyer said. “Keeping ourpipeline full like this is criticalbecause our sales cycle can be long—anywhere from six months to twoyears.”
For Keats Manufacturing Co.—which adopted the Custom SPECprogram back in 2009—the timingcould not have been better. It was atthe height of the economic down-turn, and the impact on the industri-al market was palpable. AsEggemeyer noted, 50 years of word-of-mouth references from satisfiedand repeat customers was still notenough to carry the company, espe-cially when many long-time cus-tomers were forced to cut back or,worse, close their doors.
As revenues began to shrink, thecompany looked to make changes torecapture lost revenue. In short,Keats needed to widen the net ofprospects and delve into other indus-tries to find new business.Essentially, a fresh approach to salesand marketing was in order.Traditional forms of advertising andprospecting, Eggemeyer surmised,weren’t going to cut it anymore.
To that end, Keats’ managementrecognized that a growing number of
their customers—primarily designengineers working for the OEMs—were routinely turning to theInternet as a starting point toresearch and evaluate custom manu-facturers. “Our potential buyers aregoing online, [so] we needed a strate-gy to reach those customers there, onthe Web,” Eggemeyer stated.
This approach resonates particu-larly well with companies lookingbeyond their own backyard and intoexport markets. “With the reach ofCustom SPEC, I’m seeing requestscoming in from all parts of the[globe],” Van Nuys Plating’s Boyersaid. “It’s very exciting to see what’sgoing on internationally.”
For more information on the CustomSPEC program, please send an e-mail to:[email protected].
www.metalfinishing.com April/May 2011 I metalfinishing I 33
cleaningtimes
Over several years, this columnhas covered parts cleaning as if
there were only two major types—aqueous and solvent.
Well, there is a third—one that isbecoming more common in the fin-ishing industry. And I want to coverit in detail in this piece and the suc-ceeding two columns.
This third type of cleaning entailsapplying rapidly evaporating clean-ing fluids to a surface through anaerosol delivery system, and thenwiping the soil and cleaning fluidfrom the surface.
As I researched materials for thisarticle, I was surprised to find howversatile aerosol-dispensed cleaningcan be in terms of the diversity ofsoils that can be removed. Thosefindings will be covered in the sec-ond part of this series.
In this column, I describe whataerosol-dispensed cleaners are, andhow they are used.
SOME HISTORYPrior to the 1990s, aerosol-dis-pensed cleaners were noted for theirlow cost and high flammability. Thereason for both aspects was theircomposition—volatile low-costhydrocarbons, alcohols, ethers, andthe like. The propellant was usuallyalso a volatile and flammable hydro-carbon, such as propane.
The value provided by theseaerosol-dispensed products wasthreefold, in that:
• They applied cleaning fluid by spray only to locations on a surface where it was wanted
• The cleaning agent had been
selected to wet the soiled surface,penetrate/dissolve the soil structure, and to fulfill the needed cleaning requirement, and
• The cleaning agent was immediately evaporated without operator action, leaving a dry surface
Almost none of these productswas/is based on water, because of itsextraordinarily high surface tension(even combined with detergents),and its slow evaporation rate.
THE PERFECT AEROSOLThe second defect in these productswas that the surface tension of thecoalesced solvent droplets (~25dynes/cm) was high so surfacesweren’t well-wetted—outside of theobvious defect with solvent-basedaerosols of concern about fires.(This will be covered in the thirdpart of this series).
In the 1980s and 1990s the globalsearch for non-ozone-depletingreplacements for CFC-113 and likechemicals led to the development ofthree new and different generationsof solvents: HCFCs, HFCs, andHFEs. These solvents: weren’t flam-mable as they didn’t have measuredflash points; displayed little polarand hydrogen-bonding intermolecu-lar forces; were compatible withother more useful solvents that dis-played significant polar and hydro-gen-bonding intermolecular forces;and left dry surfaces because theyevaporated rapidly.
The new defect was that they werevery expensive relative to previousofferings.
Aerosol-Dispensed Cleaners and Cleaning—Part I
34 I metalfinishing I April/May 2011 www.metalfinishing.com
So, the perfect aerosol single-com-ponent solvent possessed the virtuesof these HCFCs, HFCs, and HFEswhile displaying substantial polarand hydrogen-bonding intermolecu-lar force, dried by evaporation “in aheartbeat,” and being priced morecheaply.
In the absence of the perfect, thepresently accepted “good aerosol”solvent product is a blend of theseHCFCs or HFCs or HFEs withanother solvent that possesses sig-nificant polar and hydrogen-bond-ing intermolecular forces, andwhose packaged selling price is lessthan a twenty-dollar bill.
HOW AEROSOL DELIVERY WORKSThe condition that produces anaerosol is a high velocity of propel-lant relative to liquid. Here, tinydroplets of liquid are produced viashearing of larger droplets usingthe force released when the pres-
surized propellant is allowed toexpand when the control nozzle inthe aerosol can is opened (SeeFigure 1)1.
Lower propellant velocities, rela-tive to liquid, produce larger liquiddroplets; higher relative propellantvelocities shear the liquid moreeffectively (and often) and producesmaller droplets.
Only to a modest extent is propel-lant velocity controllable by adjust-ing the position of the top plungerof the aerosol can. This means thatthe quality of surface coverage
Figure 1
cleaningtimesmight not be at the level of consis-tency as desired by the user.
HOW AEROSOLS CLEANEffluent from an aerosol can is nota high-velocity moving stream ofliquid solvent (see Figure 3.), whichcould flush a surface. Rather, anaerosol is a suspension of fine liq-uid droplets in a slowly moving gasstream. These droplets can be sub-microscopic in size (< 1 micron inmajor dimension) to just a few or afew dozen microns in size at ambi-ent pressure and temperature.Other aerosols can supportdroplets significantly larger in size.(The droplets visible in Figure 1must be above ~50 to 60 micronsin size, as that is the limit of visualresolution.)
So the aerosol spray does not applyforce to a surface to liberate soils.Sprays from aerosol cans do notapply significant impact to surfaces,which could displace or dislodge soilmaterials. Sprays from aerosol cansonly wet surfaces.
Don’t confuse a high-velocity sprayfrom a nozzle connected to a pumpin a spray cleaning machine with alow-velocity spray connected to asmall can.
In solvent cleaning with aerosols,the purpose of these droplets is towet a surface so soils on it may beswollen (or possibly dissolved) andliberated from surfaces by latermechanical action, usually with ahand-applied wiper.
• Wetting is done when the submicron-to-micron-size drop lets coalesce on the soiled surface(see Figure 2).
• Swelling is done by diffusion of solvent molecules into the large volume of voids within a polymeric structure, and absorption of the solvent within those voids. This weakens the bonds between the polymeric structure and a surface (see Figure 3)3.
So the prime mechanism by which
blends (and single solvents) dis-pensed from aerosol cans clean is bywiping of wetted surfaces where thebond between the soil and the sur-face has been weakened via wetting,and the soil may have been dis-solved/softened via solutioning.
Contact time is certainly a variablein cleaning with aerosol sprays. In animmersion cleaning machine, itmight be seconds to a few minutes;with aerosol sprays, it could be manyminutes.
In the contact within the immer-sion machine, diffusion of the sol-vent(s) through the soil matrix isaided by the elevated temperature—which raises diffusion coefficients—and continued agitation, whichavoids static concentration gradients.
Application by hand of mechani-cal force with a wetted wiper, andextended contact time of the sol-vent(s) on the soiled surface, are theonly variables that can enhance soilremoval.
Often after spray wetting of asoiled surface, and short-time appli-cation of mechanical force with awiper to spread the droplets, opera-tors allow 5 or 15 minutes of timefor the solvent to diffuse into thesoil matrix, before starting the sub-stantial wiping operation.
www.metalfinishing.com April/May 2011 I metalfinishing I 35
THE AEROSOL CANAn aerosol can may be any sealedcontainer that contains a liquidunder gas pressure, and has aninternal fixture that is externallyactivated to allow a controlled
release of pressure so as to allowemission of the liquid suspended inthe gas being expanded through thefixture (See Figure 4)4. The fixture isthe heart of the aerosol delivery sys-tem—it’s called the actuator valve,or crimp valve.
CONTENTS OF THE AEROSOL CANThe aerosol can contains twochemical components: the cleaningsolvent(s) and a propellant. Ideally,the propellant should be a liquidwhose boiling point is slightlylower than the temperature of use.This allows the can to contain theliquid solvent and have the propel-lant be in the vapor phase under amodest (not high) pressure, suffi-cient to expel the can’s contents ondemand. In use, as the propellantgas expands, its volume is replacedby evaporation (and cooling) of thecleaning solvent.
To avoid management of a two-phase blend, the propellant is cho-sen to be miscible with the cleaningsolvent (or blend).
After World War II, chlorofluoro-carbons (CFCs) were commonly usedas propellants because of their com-patibility with other solvents, and(then) low price. In the 1970s, it wasdiscovered that emitted CFCs collect-ed in the Earth’s stratosphere andacted as catalysts to destroy the ozonein that region. To that end, their
Figure 2
Figure 3
Figure 4
cleaningtimesmanufacture was banned by a globalfiat (the Montreal Protocol) in 1988.
Replacements for CFCs havechiefly been volatile and flammablelow-cost hydrocarbons, typicallypropane, n-butane and isobutane;compressed gasses, such as carbondioxide or occasionally nitrogen; andsubstantially more expensive HFCs,such as HFC-134a, HFC-365mfc,and HFC-227. Hydrocarbons, carbondioxide and HFC-365mfc are themost commonly employed today inaerosol cans used to dispense clean-ing solvents.
Under certain circumstances, bothcarbon dioxide and HFC-365mfc areuseful solvents for some soils. In useas propellants, one assumes they donot act only as carriers and do con-tribute solubility performance to thedispensed cleaning solvent.
MARKETING 101The solvent contents of an aerosolcan of cleaning solvents is onlyrarely a single component—such asisopropanol, aliphatic hydrocar-bons, or HFC-43-10mee.
This enables suppliers to differen-tiate their respective offerings from
competitors. That’s the main reason solvents
dispensed from aerosol cans areblends or azeotropes containing atleast two chemical components—tomake offerings unique.
There is a second and commonlyaccepted reason, which is—unfortu-nately—not technically sound.
The reason is a belief that when
one component of binary azeotropesor blends has no measured flashpoint (such as HFC-43-10mee, HFE-7100/7200, HCFC-225ca/cb, HFC-365mfc, etc.), and if it is present insufficient amount, the azeotrope orblend can’t be ignited. That can be amost valuable outcome. It’s just notcertain—that’s all!
(The next column—which willappear in the June issue of MetalFinishing—will provide further infor-mation about the difference betweentwo measures of ignitability flashpoint and flammability limits.)
There is a third reason: solventblends dispensed from aerosol cansare often used in a less-than-scientificfashion. For example, the label on theaerosol can almost never reveals theingredient list. Instead, the print isusually consists of just a name chosenby marketers—and some rudimentarysafety warnings. The formulation ofaerosol products is highly proprietary,which is why their ingredients areconcealed to the extent consistentwith federal and local regulations.
There are many types of aerosolproducts. Each is formulated with abase solvent (such as the four picturedabove) whose unique properties oftenengender formation of an azeotropewith an additional one or more com-
36 I metalfinishing I April/May 2011 www.metalfinishing.com
ponents, or a base solvent whoseproperties can be made more versatileby addition of another one or morecomponents to form a blend.
The base solvent is undoubtedly onein which the manufacturer has astrong financial interest. It is likelythey are the only global supplier. It islikely they hold patents on its methodof manufacture, molecular structure,and azeotropic compositions.
PREVIEW OF COMINGATTRACTIONSIn next month’s column we’ll coverthe many applications for aerosol-dispensed cleaners, and how theyare specified for success.
BIO John Durkee is the author of the bookManagement of Industrial CleaningTechnology and Processes, published byElsevier (ISBN 0-0804-48887). He is anindependent consultant specializing inmetal and critical cleaning. You can con-tact him at PO Box 847, Hunt, TX 78024or 122 Ridge Road West, Hunt, TX78024; 830-238-7610; Fax 612-677-3170; or [email protected].
REFERENCES1. The image of Figure 1 is courtesy
of featurepics.com.2. The image of Figure 2 is courtesy
of the Koc University Nano-Optics Research Laboratory(nano-optics.ku.edu.tr). Themagnified image depicts dropletsthat have yet to coalesce.
3. The image of Figure 3 is courtesyof the Martin Luther Universitatof Halle Wittenberg (physik.uni-halle.de/fachgruppen/nmr/research/).
4. The image of Figure 4 is courtesyof boxvox.net.
HFC-43-10mee
HFE-7200
HCFC-225ca
HFC-356mfc
Commercial Products
sherwoodonmanagement
The Great Depression No. 2 is notcompletely over, but at least it
has bottomed out and started toclimb on the positive side. I wouldsurmise that most managers areoperating leaner and meaner compa-nies these days.
Specifically, you have feweremployees, lower sales and reducedprofits (dare I say no profits?). Whatproactive steps should you now taketo improve, not just survive?
One step is to increase the educa-tion and capabilities of both man-agement and employees—you nowhave to do more to cover all thebases by taking on more functionsrather than rehiring. It’s amazinghow much all of you can now dowithout all those terminatedemployees.
Under present economic circum-stances, I propose you find anemployee capable of conductingclasses for both employees and man-agement to improve their knowledgeand, consequently, their supervisoryabilities. With a little assistancefrom self-training books¹, even theowner/manager of small companieshas the capabilities.
Suggested requirements for Do-it-yourself Supervisory Training. Theeffort in this approach is directed tothose companies that have both thefacilities and personnel capable ofconducting their own supervisorytraining programs. The title“Supervisors” as used here applies toall levels from lead man through topmanagement.
• Instructors must be good writers, articulate and easily understood. They must be fluent in the first
language of the students.• A quiet meeting area equipped
with table, chairs and visual equipment, e.g., overhead projectors, flip chart and blackboard. A flip chart should be considered the minimum requirement.
• Students should attend during
working hours and should be paid for their attendance at regular wage rates. If time is not availableduring working hours, attendance can be managed either before or after working hours.
• The course content must be analyzed with top management before starting classes. Company
Do-It-Yourself Management Training
www.metalfinishing.com April/May 2011 I metalfinishing I 37
problem areas must be reviewed with both high priority and off-limit topics established in advance.
• Incentives should be established for good attendance and course completion, e.g., wage increases, promotion or paid time off. In the absence of these incentives, job security can be considered suffi-
ciently motivating.• Adapt the selected subject to the
company needs. Select those needing emphasis and those that are irrelevant.
• Prepare a detailed course outline approved by top management.
• Class length of one to two hours.
The following are detailed out-lines for each specific subject in thecurriculum: Leadership. Characteristics of agood leader. Difference between aboss and leader. Functions of the supervisor. Planning,organizing, scheduling, teaching, com-municating and disciplining.Responsibilities of a supervisor.
sherwoodonmanagement
38 I metalfinishing I April/May 2011 www.metalfinishing.com
Production, quality, cost and safety.Discipline. Good and bad tech-niques, fact finding, penalties,rewards and positive reinforcement.Motivation. Bad methods and goodmethods. Merit wage reviews, man-agement by objectives and recogni-tion techniques. Problem-solving techniques.Methods for solving both technicaland personnel problems.Personal time management. Innovation and creativity.Methods of motivating originalthinking and solutions.New employee and subordinatetraining. Company policy, on-the-job training and follow-up.Special problems of family busi-ness (optional). Course summary. Student input,certificates of completion. Messagefrom top management.Reading/courses/workshops for thefuture.Party time. Pass out certificates.
On-site supervisory training is aproven procedure for improving thequality of supervision and teamspirit in your organization. It canhelp solve some of the most diffi-cult problems management faces.An example of the curriculum isshown below with the suggestedfirst subject—leadership.
LESSON 1—LEADERSHIPThe class picks a leader for thegroup. What is the basis of theirselection?
Ask the following questions anddiscuss the answers:• How do we become a boss?
Appointed.• How to become a leader? Natural
and acquired characteristics.• Difference between a leader and
a boss.
What makes a natural leader? Getclass answers. Supplement theiranswers with the following subjects:
Articulate
AssertivenessCharacterOne of the “guys”Physically superiorSocial status (wealth, position)Superior experience, backgroundSuperior knowledge
Major problems facing the newleader. Ask the class. Discuss theanswers and add the following ifneeded:
• Wants to remain one of the gang• When I get to be boss, I will be
better than my boss.• Doesn’t stop being the “chief
worker”
Characteristics of a good leader.Discuss the following after askingfor class suggestions:
• Knows his craft• Plans his work and work of others• Knows his people and their
capabilities• Is fair – no favoritism or
nepotism• Practices positive reinforcement –
explain• Teaches as well as supervises• Makes prompt decisions. No
procrastination.• Controls his temper and emotions• Rarely depressed. Sets the tone
for all.• Casts a good shadow over
subordinates.• Sets attainable goals• Good sense of humor• Follows up!
REFERENCESSherwood B.J. Metal Finishing, A
Secret Method for IncreasingProfits on the Cheap. P. 48-49,Vol. 103, No. 2.
BIOBert J. Sherwood, M.S. in Ch.E., is a con-sultant who has provided business andtechnical advice to surface finishing andmanufacturing companies for 35 years.He can be reached via e-mail at: [email protected].
Promote your company in
Metal Finishing’sNEW Finishers’
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Get your company listed
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www.metalfinishing.com April/May 2011 I metalfinishing I 39
DECORATIVE NICKEL PLATING COVENTYA, Inc., a specialty chemi-cal company that manufactures andmarkets processes for the metal fin-
ishing and water treatmentIndustries, introduces the newestaddition to its line of decorativenickel plating technologies: theSATIN CRYSTAL 230 Process. Thedistinguishing feature of the processis its ability to provide remarkablyuniform white-silver satin depositsat all current densities, even thosecorresponding to recessed areas onproduction parts.
The process is a “perfect fit” forthose installations that require flexi-bility in the satin appearance due toprocessing a variety of work, fromexterior rand interior automotivetrim, to furniture, plumbing, andshelving. COVENTYA, Inc. has along and successful history of pro-viding high-performance “decorativetechnologies” and now have perfect-ed “Satin Nickel.”
For more information, please con-tact COVENTYA, Inc. at (216) 351-1500 or [email protected].
NEWproductsBURNISHERMetabo Corporation, maker ofprofessional-grade portable electricpower tools and abrasives for indus-
trial, construction and weldingapplications, now offers the SE12-115 burnisher. It is ideal for finish-ing and polishing stainless steel andmetals in applications as diverse ascommercial kitchen equipment,architectural ornamental iron, andequipment and fixtures found inpetrochemical and pharmaceuticalfacilities.
Due to its extensive line of acces-sories, the SE12-115 can be used in avariety of applications, such asgrinding, polishing, sanding, andremoving scratches and rust. Theburnisher can accommodate abra-sive wheel diameters from 4 inchesto 4.5 inches and widths from 5/8inches to 4 inches.
The new burnisher includesMetabo’s VTC (Vario TachoConstamatic) electronic speed stabi-lization for increased productivityunder the heaviest operating condi-tions. The SE12-115 features a long-lasting 10 A motor with 1,200 W ofpower, 98 inch-lbs. of torque and ano-load speed of 900 rpm to 2,800rpm. For more information, pleasevisit www.metabousa.com.
CURING SYSTEMSDavid Weisman, LLC has intro-
duced its latest HorizontalConveyorized Infrared Preheatand Curing Systems designed forcustomers to preheat or cure liquidand powder coatings on a widerange of products processed hori-zontally. The system features fastresponse, electric infrared or gas cat-alytic infrared heaters and controlsand complete energy efficient insu-lated oven enclosure, with optionsfor side and bottom heat, and roomfor integral supply or recirculated airplenums. The system can be used asa stand-alone complete horizontalconveyorized drying or cure ovensystem or in conjunction with coat-ing application equipment andincoming and outgoing conveyors.
GRINDERSMetabo Corporation add theW24-230, a new large angle grinder,to its Metabo Metal Masters series.The W24-230 comes equipped witha 9''-wheel guard and delivers 150inch-lbs. of torque.
This large angle grinder is one ofthe most efficient on the market,with a rated speed of 6,600 rpm andloaded speed of 4,600 rpm, the com-pany said. The tool features 2,400watts of power and is rated at 15A.Its robust Marathon motor extendsthe tool’s service life up to five timesover other grinders in its class.
The new angle grinder featuresMetabo’s VibraTech (MVT) three-position side handle that signifi-cantly reduces vibration levels up to60%. The grinder's ergonomic rearhandle includes a vibration dampen-ing system and pivots 90 degrees left
NEW products
or right for comfort during cuttingor vertical grinding.
Also new from MetaboCorporation is the WE14-125 InoxPlus grinder, a high-powered anglegrinder with high torque andadjustable speed. This new anglegrinder is ideal for working on stain-less steel under the most extremeoperating conditions.
Capable of removing a substan-tial amount of material in a finiteamount of time, the WE14-125Inox Plus offers 1,400 watts, 12Amps of power, 35.4 inch-lbs oftorque and a variable speed range of2,000–7,000 rpm. With its robustMetabo Marathon motor, the newWE14-125 Inox Plus is ideal forheavy-duty cutting, grinding andpolishing applications in the metalworking and mechanical mainte-nance industries.
The tool features advanced motorprotection, including current inter-ruption protection, thermal over-load protection, electronic speed sta-
bilization and an electronic softstart that helps to extend tool lifesignificantly.
Lastly, Metabo Corporation nowoffers the KNSE 12-150 Fillet WeldGrinder, ideal for finishing variousmetals, including stainless steel. Thenew extended nose grinder is usedfor finishing and polishing hard-to-access fillet welds typically found onhandrails or inside welds on enclosedareas. Standard features include awinding protection grid, auto-stopcarbon brushes and thumbwheel forspeed preselect.
For more information, please visitwww.metabousa.com.
GAUGESElcometer has launched the nextgeneration Elcometer 456 digitalcoating thickness gauge. Fast, reli-
able and accurate, the new Elcometer456 sets new standards in coatingthickness measurements. Availablein a range of models for measuringdry film thickness on ferrous andnon-ferrous metal substrates, thenew Elcometer 456 is even morepowerful, rugged and easier to use.
For more information, visitwww.elcometer456.com.
HEAT RECOVERY SYSTEMACE Equipment Company has
developed a Heat Recovery Systemthat can be installed on burn offovens. This system will recover heatfrom the exhaust stack and reclaim itfor use as supplemental buildingheat. This compact overhead heatingsystem provides free infrared warmthand can be extended out through anetwork of radiant tubes. Infraredenergy travels independent of airmovement and the warming effectcovers critical areas by directing theenergy downward in a uniform pat-tern. The system has heat extractionefficiency in excess of 90% andalmost instantaneous delivery ofheat after the burn off oven is start-ed. Heat is drawn into the network ofradiant tubes from the afterburnerexhaust stack. The network of tubesis under a vacuum, which helps todisperse the heat throughout thework area.
For more information, please visitwww.armaturecoil.com.
INDEX SPINNER HANGERViking Blast & Wash Systems hasreleased the new Indexing SpinnerHanger, the SH 1545. This machineprovides versatility in blasting a widerange of part sizes and shapes on acontinuous basis. The SH 1545removes scale, flashing, corrosion,rust and paint by indexing two, 15-inch diameter x 45-inch high workenvelopes on a continuous basis. Asthe chambers rotate, one compart-ment is being blasted while the otherchamber is being loaded with partswithout the need to shut down themachine.
Parts are presented on removable,manganese rotating parts trees witha 185-pound capacity that expose theparts to the two, 7.5 HP VC9 blastwheels. An adjustable control cage inthe wheel allows for control of theabrasive pattern, achieving the high-est percentage of shot impact on thework. This machine is rugged anddurable with each blast chamberconstructed of manganese chromealloy steel and lined with 1/4-inchmanganese alloy liners that protectsthe cabinet from abrasive wear; safetylight curtains protect operators fromthe rotating drum. The SH 1545 also
40 I metalfinishing I April/May 2011 www.metalfinishing.com
NEW products
www.metalfinishing.com April/May 2011 I metalfinishing I 41
utilizes a heavy-duty abrasive recy-cling system with an air wash separa-tor that cleans the abrasive prior toblasting..
For more information, visitwww.vikingcorporation.com.
AIR KNIFEPrecision Process, a custom processequipment designer and turnkey fab-ricator for electroplating and relatedprocess equipment, has launched anew product for reel-to-reel electro-plating plating lines designed toreduce compressed air consumptionand resultant energy costs for platingline operations.
The new air knife is designed forplacement at exit locations ofprocess cells and has been tested atthe company’s manufacturing facili-ty and trialed in the field. Dataobtained during testing has shownless than 3.5 cfm of continuous airconsumption per unit at 80 psi linepressure was used when compared toa range of 8-15 cfm for other- off-the-shelf air knife designs.
A reduction in costs in energy con-sumption for this product on anelectroplating line using this air
knife product could approach 1.5kW-h per air knife. Companies look-ing to enhance green technology intheir electroplating operations canretrofit this air knife into their exist-ing cells via custom mounting hard-ware provided with each unit.
LITERATUREALMCO unveils four-color literaturedetailing key features of a three-spin-dle finishing machine and points tothe company’s custom design andmanufacturing capabilities.Developed for a long-standing cus-tomer, the Model 3SF-72RA providesfast processing of large quantities ofcomplex metal parts that requireexceptionally accurate deburring.
The three spindles—rather than thenormal one or two on other ALMCOmachines—can be automatically low-ered into the spinning media mass orcan be manually operated if desired.
The 72-inch-diameter finishingtub provides adequate space for largeor small parts. A 10-HP drive motorpowers the variable speed tub, andfour solenoid valves control variousparts rinsing operations followingexit from the rotating tub processchamber.
The literature emphasizes theimportance and functions of ahydraulic power package positionedimmediately adjacent to the spindlefinisher. The package controls therotary actuator feature and thehydraulically activated tooling, andis complete with a cooling unit foroil temperature management.
For more information, visitwww.almco.com.
Spraying Systems Co., has releasedthe new TankJet® Tank CleaningProducts Catalog, which providescomplete information on automatedtank cleaning equipment thatreduces cleaning time and returnstanks to service more quickly. Userscan increase production time andreduce labor costs without compro-mising cleaning effectiveness.
The 72-page catalog reviews keyselection factors such as spray dis-tance, impact, flow rate, and cover-age, offering guidelines to ensureproper specification. Several opti-mization tips are provided as well toensure users maximize equipmentcleaning efficiency.
Also included are technical specifi-cations on high-impact fluid-driventank cleaners, motor-driven tankcleaners, a wide range of tank clean-ing nozzles and spray balls for clean-ing tanks with diameters up to 100'(30m). Tank cleaning accessoriessuch as fluid delivery systems,retractable tank washers, flanges,lances and strainers are featured inthe catalog as well.
For more information, visitwww.tankjet.com.
Heatbath Corporation has revised
NEW products
its Rust Preventative Brochure toincorporate seven new products andupdated salt spray data. This newcatalog features an overview of itshigh-performance lines of water-based rust inhibitors, water displac-ing oils, emulsifiable oils and waxemulsions all—designed to providesuperior corrosion protection and tomeet final finish requirements. Visitwww.heatbath.com to order.
VOC-FREE CLEANER A new VOC-free formulation of D-Zolve 917 from Solvent Kleeneprovides safe removal of organicpaints, varnish, Mil-spec CARCpaints, cured powder coatings,multi-layer coatings and E-coatings.Designed for energy efficient use atlow temperatures, D-Zolve 917 isused in an immersion tank.Environmentally friendly D-Zolve917 is non-flammable, has very lowodor toxicity, and does not containany ozone-depleting components orcarcinogenic compounds.
D-Zolve 917 penetrates paints andcoatings to break the bond betweenthe paint layer and the substrate.Severing this bond causes a paint orcoating to delaminate and fall off thesubstrate and drop to the bottom ofthe tank. D-Zolve completelyremoves even the most difficult-to-strip paints and coatings, eliminat-ing the need for processes such assand blasting and burn off.
D-Zolve is ideal for reworkinghigh-value parts with paint or coat-ing defects. It will not damage intri-cate surface details or polished sur-faces. D-Zolve 917 has an NSN num-ber and provides safe stripping ofpaints and coatings from ferrous andnon-ferrous metals, including alu-minum, copper, brass, stainless steelsand carbon steels, as well as plasticand silicon substrates.
OVENSThe No. 991 is an electrically heated350°F (~177°C) bench oven fromGrieve, currently used for heatingparts including flammable solvents.Workspace dimensions are 28'' widex 24'' deep x 18'' high. TheNichrome wire heating elements areinstalled with 4 KW.
This Grieve bench oven features 2''insulated walls, leg stand, Type 304,2B finish stainless steel interior,whereas the exterior is a brushed #4stainless steel. To accompany theexhauster, a powered forced airflowsafety switch shuts down heat ifthere is an exhauster failure. A purgetimer provides a time period toexhaust four volumes of fresh airprior to turning the heat on.
Series CLD is a new line of standardelectrically heated cabinet ovens fromGrieve, specially designed for use in aClass 100 cleanroom environment.They are typically utilized for dryingcoatings onto printed circuit boards.The unit has a maximum operatingtemperature of 260 C (500 F) andworkspace dimensions of 36 W x 36D x 39 H.
A 20 KW total heat input isinstalled in Incoloy sheathed tubularheating elements. A 10,000 CFM, 1-1⁄2
HP recirculating blower provideshorizontal airflow across theworkload, inside 4 insulated walls.
For more information, please visitwww.grievecorp.com.
Precision Quincy’s model#49C 650D is an electrically heatedoven, available in NFPA 86 Class ‘A’or Class ‘B’ configuration. Known forits ability to successfully process awide range of materials, the49C 650D is a popular choiceamong heat processors for most cur-ing/drying/pre-heating needs. The
49C 650D’s compact design featurestwo independent oven chambers(stacked one above the other), eachwith separate controls and sharing asingle dampered exhaust system.
The 49C 650D weighs in at 1,180lbs. with two internal working spacesof 32'' x 18'' D x 18'' H and exteriordimensions of 43'' W x 29'' D x 45''
42 I metalfinishing I April/May 2011 www.metalfinishing.com
NEW products
www.metalfinishing.com April/May 2011 I metalfinishing I 43
H. The oven is capable of reachingand maintaining a maximum tem-perature of 650°F. An optionalmatching heavy-duty stand providesa stable base that adds an extra 24''to the overall height of the oven—auseful feature making for easierproduct loading and removal.
All of Precision Quincy’s ovensmeet or exceed NFPA 86, NFPA 70,OSHA and UL requirements, and arefactory wired, tested and balancedbefore shipping to ensure quick,trouble-free start-ups.
For more information, please visitwww.precisionquincy.com.
WHISKER PREVENT TECHNOLOGYUyemura International Corp., aworld leader in high-performingplating processes, has announced anew technology that preventswhisker formation in electroplatedtin for 22,000 hours and longer.
To be marketed under its beta testname, GHS-51, this unique, high-speed electrolytic process representsa breakthrough in the control of tin
whiskers, the most common culpritsin the short circuiting of electroniccomponents. Most often, the causeof tin whisker formation is compres-sive stress. The proprietary technolo-gy developed by Uyemura dissipatescompressive stress, thereby prevent-ing whisker formation.
GHS-51 uses a high purity anode,and is ideally suited for connectorsand semiconductor lead frames. Itoffers high deposition speeds forrackless and reel-to-reel processing,and high deposition efficiency over awide current density range. The bathis lead and fluoride free, and foam-resistant. Operating range is 113-131°F, with 122°F the optimum.
The GHS-51 film has a uniformwhite matte appearance; appearanceafter reflow is excellent. Carbon andsulfur concentrations in the film arevery low, and control over liquid levelis easy. The film is heat-resistant,with excellent solderability.
For more information, please visitwww.uyemura.com.
SOUND ABATEMENT ALMCO now makes sound hoods forautomated deburring and finishing
equipment to help industrial compa-nies provide a safer, more comfort-able environment for workers whileachieving noise levels that meet regu-latory agency requirements. Thesound hoods are available as stan-
dard or custom units.Designed for spindle finishers and
continuous thru-feed vibratory sys-tems, including both new and exist-ing machines, the hoods keep noiseunder 85 dbA.
Made of sheet metal, the light-weight ALMCO hoods are lined withopen-cell urethane sound-deadeningmaterial, which also is installed onundersides of covers of other types offinishing machines from the manu-facturer. For more information,please visit www.almco.com.
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directoryaerospacefinishersFollowing is a sampling of U.S.-based fin-ishers and captive shops serving the aero-space/aircraft market. Please visit MetalFinishing’s online Finishers’ Directory atwww.mffinishersdirectory.com.
ALABAMAPrecision Finishing, Inc. United Plating
ARIZONAAlpha Tech CoatingsCapitol Metal Finishing
ARKANSASPM Industries, Inc.
CALIFORNIAAno-Tech Metal Finishing Arthur S. Kushner & Associates Black Oxide Industries, Inc. California Technical PlatingChemsolv International Coastline Metal Finishing Coast Plating, Inc. Electronic Chrome & Grinding Co. Inc.Electroplating SpecialtiesEME, Inc. Hudson Plating Works Mult ichrome-Microplate-Cert i f ied-Processing Lab, Inc. Precision Control Finishing Primo Powder CoatingReliance Plating and Coating, Inc. Semano, Inc. Southwest Plating Co., Inc. Surface Finishing Technology Plating Technical Metal Finishing Thermal Vac Technology Tiodize Company, Inc. Valley Plating Works Valmont/George Industries West Coast Specialty Coatings
COLORADOIndustrialex
FLORIDAAbsolute Powder Coating Poly Coatings of the South
GEORGIADelong Equipment Co.Frohn North America, Inc. Performance Coatings, Inc.Team Metal Finishing
IDAHOAdvanced Electrochemical Technology
ILLINOISAdvanced Powder Technology Bellwood Industrial, Inc. Berteau Lowell Plating Works Britt Industries, Inc.
Chem Processing, Inc. CRW Finishing, Inc. Imperial PlatingJH Benedict Co. KVFQUAD Corporation LA Metal Polishing Micron Metal FinishingMeyer Metal Systems Morgan O’Hare Powder Parts Precise Finishing Co. QC Finishers, Inc. Reliable Plating Corp. Saporito Finishing Company
INDIANABeacon Industries C&R Plating CompanyMuncie Precision Hard Chrome Protech Metal Finishing
IOWACycle Country Accessories Triple E Mfg.
KANSASBontrager Powder CoatingChrome Plus International, Inc. NMFAmerica True Spec Finishes, LLC
KENTUCKYTri-State Plating, Inc.
LOUISIANAA-1 Powder Coating Martin Specialty Coating
MARYLANDMil-Spec Painting, Inc.
MICHIGANApex Rack & Coating Co. Delta-Chem Technologies, Inc.Diamond Chrome Plating, Inc. DST Industries Kalamazoo Metal Finishers K C Jones Plating McNichols Polishing & AnodizingPeninsula Powder Coating Wolverine Plating Corp.
MINNESOTAMidwest Finishing, Inc.
MISSISSIPPIProcess Engineering Co., Inc. T&T Plating
NEW YORK Anoplate Corporation C.H. Thompson Company, Inc.Control Electropolishing Lawrence Ripak Company
NORTH CAROLINAAllied Metal Finishing Matlab, Inc.
OHIOAdvance Paint Technology, Ltd. Architectural & Industrial Metal Finishing Burton Metal Finishing Plating Technology, Inc.
OREGONApex Anodizing
PENNSYLVANIAArmoloy of Western Pennsylvania Great Lakes Metal Finishing J.K. Metalworks Lane Enterprises
SOUTH CAROLINAPossehl Connector Services
TENNESSEEVolunteer Finishing
TEXAS3D Powder Coating Aerotech Metal FinishingCybershield Delta Specialty Coatings Dixie Electroplating DuPont Industrial Coating SolutionsEnhanced Powder Coating Harrison Electropolishing Industrial Metal FinishingLane Plating Works Royalty Metal Finishing, Inc. Schumacher Company Vanguard Metal Technologies
VIRGINIA East West DyeCom, Inc. Greystone Plating Group
WASHINGTONASKO Processing, Inc. Esterline Hytek Finishes HYTECH Finishing
WISCONSINArtistic Plating Crystal Finishing Systems, Inc.Hartford Finishing OPI, Inc. PM Plating, Inc. Quality Coatings, Inc. Reliable Plating Works River City Powder Coating Wisconsin Plating Works of Racine
44 I metalfinishing I April/May 2011 www.metalfinishing.com
Ready ReferenceServicesCLASSIFIED
ADVERTISING RATES: 1 Time - $117.00, 3 Times - $114.00, 6 Times - $109.00, Yearly - $102.00 per column inch per insertion
www.metalfinishing.com April/May 2011 I metalfinishing I 45
Promote your company in
Metal Finishing’s NEW Finishers’ Directory!Listings start at $19.99 per year
The Finishers’ Directory is an online resource that enables potential customers to quickly identify surface finishers based on a range of
variables, including company name, business served, finishing operations performed, and geographical location.
Get your company listed today at www.mffinishersdirectory.com
212-633-3100
46 I metalfinishing I April/May 2011 www.metalfinishing.com
U.S. POSTAL SERVICE STATEMENT OF OWNERSHIP, MANAGEMENT AND CIRCULATION
(Required by 39 U.S.C. 3685)
1. Title of Publication: Metal Finishing2. Publication No. 342-1803. Date of Filing: April 6, 20114. Metal Finishing (ISSN 0026-0576) is published 10
times per year in January/February, March,April/May, June, July/August, September,October, November, November/December, andDecember
5. No. of Issues Published Annually: 126. Annual Subscription Price: $107.007. Location of Known Office of Publication: Elsevier Inc.,
360 Park Ave. South, New York, NY 100108. Location of the Headquarters or General Business
Offices of the Publishers (not printers): Elsevier Inc.,360 Park Ave. South, New York, NY 10010
9. Names and addresses of Publisher and Editor, GregValero: Metal Finishing, 360 Park Ave. South, NewYork, NY 10010. Managing Editor: Reginald Tucker:Metal Finishing, 360 Park Ave. South, New York, NY 10010.
10.Owner. (If owned by a corporation its name andaddress must be stated and also immediately there-under the names and addresses of stockholdersowning or holding 1 percent or more of total amountof stock. If not owned by a corporation the namesand addresses of the individual owners must begiven. If owned by a partnership or other unincorpo-rated firm its name and address as well as that ofeach individual must be given.)Elsevier Inc., 360 Park Ave. South, New York, NY10010. Wholly-owned subsidiary of Reed ElsevierU.S. Holdings, Inc., 4520 East-West Highway, Suite800, Bethesda, MD 20814.
11.Known bondholders, mortgagees, and other securityholders owning or holding 1 percent or more of totalamount of bonds, mortgages or other securities:None.
12.Does not apply.13.Publication Name: Metal Finishing14. Issue Date for Circulation Data Below:
Vol. 108, #10 October 201015.Extent and Nature of Circulation:
Average Actual No.No. Copies Copies ofEa. Issue Single IssueDuring PublishedPreceding Nearest to12 Months Filing Date
A. Total No. Copies 18,205 18,064(Net Press Run)
B. Paid and/or RequestedCirculation1. Paid/Requested Outside
Country Mail SubscriptionsStated on Form 3541 15,967 16,058
2. Paid In-Country/SubscriptionsStated on Form 3541 None None
3. Sales Through Dealers andCarriers. Street Vendors, CounterSales and Other Non-USPSPaid Distribution 264 242
4. Other Classes MailedThrough the USPS None None
C. Total Paid and/or Requested 16,231 16,300D. Free Distribution by Mail
1. Outside County as Stated on Form 3541 1,208 1,127
2. In-County as Stated on Form 3541 None None
3. Other Classes Mailed Through the USPS None None
4. Free or Nominal RateDistribution Outside the Mail(carriers or other means) 527 456
E. Free Distribution Outside the Mail None NoneF. Total Free Distribution 1735 1583 G. Total Distribution 17,966 17,883H. Copies Not Distributed 239 181I. TOTAL (Sum of 15g and h) 18,205 18,064J. Percent Paid and/or Requested
Circulation (15c ÷ 15g x 100) 90.3% 91.1%
I certify that the statements made by me above are correct and complete.
Laure Ballu, Marketing Communication Manager
HELP WANTED
SERFILCO, Ltd., an industry leader in pumpsand filtration systems, is seek-ing qualified applicants for itsSales and Customer Serviceoperations located in North-brook, IL. Experience in thesurface finishing industries andthe ability to travel is requiredfor Sales. Technical degree
and/or experience with pumps and filtrationsystems are a plus. SERFILCO is an Equal Op-portunity Employer.
Visit us at www.serfilco.com and email resume to [email protected] or
fax to (847) 509-2911.
As a global specialty chemicals companyserving the diversified needs of theElectronics, Industrial, Offshore andPrinting industries MacDermid solutionsenhance and protect the products peo-ple use every day. From PCs to automo-biles to oil rigs and newspapers.MacDermid, Inc. is always looking forsmart and energetic people to help uscontinue our tradition of success. We are actively seeking experiencedindustry sales professionals with aproven track record of sales success forthe Texas Region as well as for our Kentucky/Tennessee Region. If you meetthese criteria, please
www.metalfinishing.com April/May 2011 I metalfinishing I 47
MAYMay 9–13. Missouri S&T Introduction to PaintFormulation Course, Rolla, Mo. For more information,please visit http://coatings.mst.edu/introduc.html.
May 10–12 Porcelain Enamel Institute Technical Forum,Nashville, Tenn. Visit www.porcelainenamel.com.
May 11–13 2011 SFEXPO, Guangzhou, China. For moreinformation, please visit www.sf-expo.cn/en/
May 17–19 EASTEC 2011, Springfield, Mass. Please visitwww.easteconline.com for more information.
May 24–25 Cleveland Coatings Society Symposium,Cleveland, Ohio. For more information, please visitwww.clevelandcoatingssociety.org.
JUNEJune 13–16 SUR/FIN 2011 Manufacturing & TechnologyConference, Rosemont, Ill. For more information, pleasevisit www.nasfsurfin.com.
JULYJuly 18–20 Missouri S and T Introduction to CoatingsComposition and Specifications Course, Rolla, Mo. Pleasevisit http://coatings.mst.edu/introcoatcomp.html formore information.
AUGUST Aug. 23–24 2011 “Old School Meets High Tech” PowderCoating Workshops, East Windsor, Conn. Please visitwww.itwgema.us/powdercoatingworkshop for more infor-mation.
SEPTEMBER Sept. 6 NESHAP Subpart 6H Training Program, spon-sored by DeVilbiss, Binks, and Community College,Toledo, Ohio. To register online, please visit the website:www.owens.edu/workforce_cs/spray2011-flier.pdf or call(800 466-9637, ext. 7320, for more information.
Sept. 7–9 Spray Finishing Training, sponsored byDeVilbiss, Binks, and Community College, Toledo, Ohio.To register online, please visit the following website:www.owens.edu/workforce_cs/spray2011-brochure.pdf orcall (800) 466-9637, ext. 7320, for more information.
OCTOBEROct. 4–6 2011 North American Industrial Coating Show(NAI), Cincinnati, Ohio. For more details, please visitwww.thenaicoatingshow.com.
UPCOMINGevents
ADVERTISERS’index April/May 2011
48 I metalfinishing I April/May 2011 www.metalfinishing.com
Large-Capacity Walk-In OvensStandard sizes to 786 cu. ft.
Special sizes to your specs
Gas & Electric models
Choice of air flow patterns
Temps to 1200ºF
Large-Capacity Walk-In OvensStandard sizes to 786 cu. ft.
Special sizes to your specs
Gas & Electric models
Choice of air flow patterns
Temps to 1200ºF
www.metalfinishing.com/advertisers
JULY/AUGUST (Cleaning & Pretreatment)A quality final finish begins with a thorough, controlled cleaning and surface preparation process. Papers soughton emerging advancements in Procedures,Materials & Technologies.
SEPTEMBER(Coating Application Methods& Finishing Systems)Essential reading for the organic finishingspecialists. subjects to range from paintand powder coating tips to robotic paintautomation to curing and drying. bonus distribution at the 2011 Nai CoatingShow!
2011/12 Metal FinishingGuidebookMechanical and Chemical SurfacePreparationPlating Troubleshooting & SolutionsAlternatives to Cadmium, Hex-Chrome
Gain Valuable Insights You Won’t Find on the Internet.
Though NASFsurfin.com is a Good Place to Start.
SUR/FIN’s reputation for innovation and inside industry knowledge is what keeps exhibitors and attendees coming back each year. In just three days, you’ll be able to meet face-to-face with key
decision makers, listen to industry experts, and build relationships with knowledgeable suppliers in an environment that stimulates idea and information sharing.
NASFsurfin.com (302) 436-5616
Making Connections that Change the World |
Presented By: Held in Conjunction With:
Presented By:
Making Connections that Change the WJune 13-15 Donald E. Stephens Convention Center
Held in Conjunction With:
Making Connections that Change the WJune 13-15 | Rosemont, ILDonald E. Stephens Convention Center
Held in Conjunction With:
orldMaking Connections that Change the W Rosemont, IL
