Anodizing 101

A primer for Anodizing today

 Anodizing 101

Wiki-Pedia says:
Anodizing, or anodising, is an electrolytic passivation process
used to increase the thickness and density of the natural oxide
layer on the surface of metal parts.

This process is of no use on carbon steel because rust puffs up

and flakes off, constantly exposing new metal to corrosion. But
on many other metals, anodizing increases corrosion resistance
and wear resistance, and provides better adhesion for paint
primers and glues than bare metal.
 Anodizing 101

Wiki-Pedia says:

Anodic films can

also be used for a
number of cosmetic
effects, either with
thick porous
coatings that can
absorb dyes or with
thin transparent
coatings that add
interference
effects to
reflected light.
 Anodizing 101

Wiki-Pedia says:
Anodization changes the
microscopic texture of
the surface and can
change the crystal
structure of the metal
near the surface.

Coatings are often

porous, thick ones
inevitably so, so a sealing
process is often used to
improve corrosion
resistance.
 Anodizing 101

Wiki-Pedia says:
The process derives its name from the fact that the
part to be treated forms the anode portion of an
electrical circuit in this electrolytic process.

Anode + (pos) Work piece

Cathode (neg) Cathode (neg)

Acid Electrolyte
 Anodizing 101

Wiki-Pedia says:
Anodizing can prevent galling of threaded components.
Anodic films are generally much stronger and more
adherent than most paints and platings, making them less
likely to crack and peel. Anodic films are most commonly
applied to protect aluminum alloys, although processes
also exist for titanium, zinc, magnesium, and niobium.
 Anodizing 101

An overview
Materials Anodized Chemical Finishing Sealing

Assemblies Bright Dip Teflon Seal

Brake Metal Etching (Caustic) Dichromate Seal
Castings Etching (Acid) Boiling DI Water
Coil Material Type I (Chromic) Nickel Acetate
Extrusions Type II (Sulfuric) Mid-Temperature
Sheet & Plate Type III (Hardcoat) Trivalent Chrome Seal
Small Parts
Other

Mechanical Finishing
Fabrication Services
Special Services
Conversion Coat
Coloring
Anodizing 101

Introduction
Economics and Environmental concerns
Productivity and Efficiency
Support and Troubleshooting
Understanding the process is key to success
 Anodizing 101

Steps to a Quality Anodized Finish

Raw Aluminum Anodize
Mechanical Finishing Rinse
Racking Color
Cleaning Rinse
Rinse Seal
Etch/Bright Dip Rinse
Rinse
 Anodizing 101

Raw Aluminum
Problems Effect
Die Lines Too deep, hard to remove
Buffing Burning, too much
compound, comet pits
Different Soils Cleaner not Effective
Corrosion Pitting, staining
 Anodizing 101

Alloy and/or Material Temper

Problems Effect
Zinc Spangling
Fe, Si, Mg ratio Bright surface or Rough
Surface
T-52 (overaged) Smutting
Soft Metal Bad etch, smut or grainy
appearance
 Anodizing 101

Racking
Used to transfer from
tank to tank.
Acts as an electrical
conductor to deliver
power to parts.
It is consumable.
Problems not always
where it appears.
 Anodizing 101

Racking Practices
No worn out
racks
Clean Contacts
Uniform
Distribution of
Parts
Rack of Similar
Alloy
Load Bars
Anodizing 101

Rack Types
Spline, Twist, Stack, Welded
Bolt Clamps, Spring Clamps.
Anodizing 101

Soil
Rinsing Residue

Breaking
Surface
Soil Tension
Soil
Dissolving Soil Lift
Off

Clean
Surface
 Anodizing 101

Cleaning
Problems with Cleaners
A clean surface will be soil Does not clean
free and water break free Spent Solution
You need the right cleaner Low concentration
Wrong chemistry
for the soil, environment Too cold
and materials involved. Etching
High Temperature
Alkaline cleaners Temp beyond cloud point
Acid cleaners Redeposits soil
Both???? Dirty bath
Crystal on Surface
Bath life factors High concentration
Bath is spent
 Anodizing 101

Etching
Purpose
Uniform surface
Esthetically appealing
Types of etching
Conventional
Recovery
New generation recovery
Acid Etching
Tank maintenance
Critical controls
Additive levels
Temperature
 Anodizing 101

Desmutting &
Deoxidizing
Purpose
A desmut will remove residue from the finishing process.
An oxidizer will remove oxides in addition to smut.
All desmut/oxidizer solutions are acidic with proprietary
additives.
Usually run at ambient.
Problems usually are caused by low concentration.
Drag out not brought up to strength
Neutralization Drag in of alkaline residue
Excess usage Parts in bottom of tank consuming chemicals
 Anodizing 101

Desmutting &
Deoxidizing
If the smut or oxides are
not removed, you may
create stains in the finished
product.
Deoxidizing for too long
will create acid etching and
will form smut which is not
soluble in acid. This often
results in a stain.
 Anodizing 101

Anodizing
A controlled electrochemical process in which the surface
of the aluminum is oxidized producing a porous
aluminum oxide.
Anode + (pos) Work piece
Cathode (neg) Cathode (neg)

Acid Electrolyte
 Anodizing 101

Anodizing
This step in the process is critical for coloring. Inconsistency in
managing this step will lead to failures and non-uniformity at
other steps in the process.
 Anodizing 101

Anodizing

As you see in this

photograph, the surface is
very porous. The pores
can be filled with organic
or inorganic color and
sealed to provide an anodic
oxide coating that protects
the aluminum substrate.
 Anodizing 101

Anodizing
The thickness of the
resulting anodic oxide is
controlled by time and
current density. The
structure, i. e. cell size,
pore diameter and the
barrier thickness are
determined by voltage.
Faradays Second Law: Film thickness ASF * T
is proportional to Current and Time. Thickness in mils =
720
 Anodizing 101

Anodizing
Guidelines for maintaining uniformity throughout the process:

1. Concentration levels must be maintained within narrow

specifications.
Acid: +/- 5 gram/liter
Aluminum: 8 12 grams/liter
2. Temperature fluctuation will affect uniformity most. H2 SO4
conductivity changes dramatically with temp changes.
Uniform coloring requires consistency between multiple
anodizing tanks.
Temperature: +/- 2 degrees Farenheit
 Anodizing 101

Anodizing
Guidelines for maintaining uniformity throughout the process:

3. Additives reduce the dissolution

effect of H2 SO4 on the anodic
film.

4. Electrical connections tend to

corrode with time. Acidic
corrosion can lead to uneven
current distribution and uneven
anodic films. Cleaning and
monitoring connectivity must be a
regular practice.
 Anodizing 101

Anodizing
Problems in this step are usually seen in the color or seal steps.

1. Burn Marks
Current density too high or
no additive
Bad or dirty contacts
To quick of a ramp on the
rectifier.
 Anodizing 101

Anodizing
Problems in this step are usually seen in the color or seal steps.

2. Uneven Coating
Worn out cathodes
Too quick of a ramp.
Anode to cathode ratio off.
Too much load for tank.
Bad part distribution on
the rack.
 Anodizing 101

Anodizing
Problems in this step are usually seen in the color or seal steps.

3. Pitting
Contamination of solution, chlorides, nitrates or sodium.
 Anodizing 101

Anodizing
Problems in this step are usually seen in the color or seal steps.

4. Soft Coating
Low current density.
Temperature too
high.
No additives to
protect coating.
 Anodizing 101

Coloring

Coloring is created by depositing material or

dyes in the pores of the anodic coating or by
dispersing particles in the coating. There are 3
basic methods used for anodized aluminum.

1. Electrolytic coloring
2. Organic or inorganic dyes
3. Integral
 Anodizing 101

Electrolytic Coloring

In this process, parts are

immersed containing a metal
salt such as tin. AC power is
supplied and the metal is
deposited at the bottom of the
pore.
 Anodizing 101

The Electrolytic Cell

Power Supply Alternating
Anodized Aluminum work Current or Modified AC.
piece with anodic coating. Negative/Positive (+-)
Counterelectrode Counterelectrode
Positive/Negative (+/-) Positive/Negative (+/-)

Stannous Sulfate +
Acid Electrolyte
 Anodizing 101

Electrolytic Coloring
Electrolytic coloring is
accomplished by the
electrical disposition of
metallic particles near the
base of the anodic pores.

AC power is used to deposit

metal at the bottom of the
pore.
 Anodizing 101

Electrolytic Coloring

The depth of the metal

deposit within the pores
determines the color of
the film that ranges from
Champagne through
various Bronzes to Black.
Anodizing 101

Electrolytic Coloring

Various metals can

be used such as:
 Anodizing 101

Electrolytic Coloring
The thickness and pore structure of the anodized film regulates the coloring
rate and distribution. If the anodic film is not produced properly, color
uniformity and color ability will be compromised.
 Anodizing 101

Electrolytic Coloring

Most problems arise from Coloring additives and sulfuric

improper anodizing, although
problems can occur from the
coloring system itself. These
problems are usually
controlled by keeping bath
chemistry constant.
acid concentrations must be
maintained, the temperature
can not fluctuate and electrical
power must be programmed
correctly.
 Anodizing 101

Electrolytic Coloring Problems

Extrusions Not Colored
Bad Contacts
Broken Contacts
Dark Ends
Uneven Coating
Wrong voltage on coloring power
Wrong program on coloring power
Non-uniform Color Across Extrusions
Wrong ramp
Chemistry of bath incorrect
Uneven coating
Color Wrong Shade
Temperature of bath is wrong
Time
 Anodizing 101

Dyeing
The pores of the anodic film produce a capillary action
and will absorb easily. This property allows the use of
organic or inorganic dyes to color anodized aluminum.
Inorganic Organic
Dying Dying
 Anodizing 101

Dyeing
Most dyes are designed so that dyeing is done by saturation of
the pore to get the proper color and stability. To achieve this,
temperature, pH, concentration and time must be controlled.
Inorganic Organic
Dying Dying
 Anodizing 101

Dyeing
Dyes need a certain depth of the pore to achieve the colors, which
makes the anodizing step critical. Uniformity of thickness and
pore structure is very important for uniform results.
 Anodizing 101

Organic & Inorganic Dyes

The inorganic dye (FAO or FSO) or the organic dye will
absorb into the pores of the anodic coating.

Inorganic Organic
Dying Dying
 Anodizing 101

Dyeing Problems
Non-Uniform Color
Uneven anodic film
pH of rinse too low
Dye pH wrong
Dye activity too high
White spots of surface
Pits
Holding sulfuric acid from anodize
Poor rinsing
Airborne contaminants
Color not dark enough
Film thickness too thin
Rate of Dye off
Concetration wrong; pH off
Dye bath is old with aluminum
build up
 Anodizing 101

Electrolytic Coloring
combined with Dyeing

By combining Electrolytic
Coloring and Dyeing, you
have more color options.

Dye

Electrolytic Deposit
 Anodizing 101

Integral Color Anodizing

An Organic Acid such as
Sulfophthalic Acid, is used in
anodizing to produce anodic
coating. The color results from
insoluble particles within the
anodic pores. A color range
from light bronzes to black can
be obtained. The depth of color
is dependent on the thickness of
the anodic coating and bath
conditions.
 Anodizing 101

Integral Color Anodizing

This process makes use of the intermetallics (alloying material)
in the metal to give color. As the anodic film is grown, particles
are exuded into the film and color is dependent on the thickness.
The process is usually done under
cold conditions and high power.
The alloy and temper play a major
role in color uniformity and
thickness determines color depth.
Because of the cost, only 5 systems
remain in the US. The main
products are handrails and push
plates where heavy wear occurs.
 Anodizing 101

Sealing of Anodic Coatings

Sealing of anodized Sealing can be
aluminum changes the accomplished by:
anodic coating to make Physically plugging with
it: oils, waxes, paints or
Non-Staining aqueous sealing chemicals
Non-Absorbing Chemical change of the
oxide layer through
Non-Reacting hydration
Non-Corroding Combining both using
metal-based sealing salts
 Anodizing 101

Sealing of Anodic Coatings

This is the final step in the 1. Hydrothermic Sealing
process. A good rinse
prior to the sealing step
will reduce contamination
and allow the pore to be
closed.
Here are the 3 most
common methods of
sealing the anodic film:
Hot water @ 210 Deg. F
Emersion in hot water
with a pH of 6.0 6.4
Film hydrothermically
sealed converting the
AL2O3 to AL2O3*H2O
Larger hydrated
molecules fills the pores
and seals it.
 Anodizing 101
Sealing of Anodic Coatings
2. Nickel Acetate Low Temp
Hot water @ 175 - 185
Deg. F
Nickel co-precipitates into
pores accelerating the
hydrothermic sealing.
3. Cold Sealing
Water @ 90 - 94 Deg. F
Nickel, the accelerator
and the aluminum react
to form a compound that
plugs the pores.
 Anodizing 101

Sealing of Anodic Coatings

It is critical to manage the seal

bath. Time, temperature,
concentration and pH have
dramatic impact on the finished
seal properties. Improper seals
lead to smut or a non-sealed
part.
 Anodizing 101

Sealing of Anodic Coatings

Smut was once a necessary evil.
Quality standards and increased
production rates require no
smut. Seal baths must be
maintained to control the
process. Use as recommended
with regular dumping and
recharging.
 Anodizing 101

Sealing of Anodic Coatings

White powder (Yellow tint) Eliminate problems with the proper
Electrolytic color dirty processing steps
White powder (Greenish tint) 1. Proper racking
Nickel seal 2. Good chemical management of
the baths
Rinse after nickel seal dirty
3. Good rinsing
pH too high on Nickel seal
4. Proper drainage of parts
Foam on seal tank
5. Understand the function of each
Iridescent easily wiped off. bath
Desmut tank not working
Iridescent hard to wipe Off
Too long of seal time
Too soft coating
Too low pH, rinse before seal
Anodizing 101

Sealing
Anodizing 101

Anodizing Line Safety

It is everyones responsibility to
see that the anodizing line runs
safely. The 3 areas of concern:
Anodizing 101

Anodizing Line Safety

1. Employee Training
2. Safe design of facilities and
equipment
3. Adequate safety equipment
readily available
 Anodizing 101

Anodizing Line Safety

Employee Safety and Training
Safety consciousness is mandatory for anyone working around an anodizing line. You
must be aware of the potential risks and be able to react in case of an emergency.

The employer must ensure that the equipment is appropriate for the job, is within easy
access and that training is provided for new employees and refresher courses for
existing employees.

Management should assign a safety person who will be responsible for maintenance,
supplies and monitoring the day to day operations. Equipment should be inventoried
and readily available.

One tool is a checklist. This outlines all of the checks needed as well as the time and
the person conducting the activity. Studies show that 7 areas result in 80% of the
reported citations.
 Anodizing 101

Anodizing Line Safety

1. General Housekeeping 17% of citations. Blocked doors, improper storage and
clutter, improper posting of signs and exits.
2. Mechanical Guards 16% of citations. Lack of adequate guards and shields
around abrasive wheels, exhaust fans, belts and pulleys.
3. Electrical Problems 14% of citations. Improper grounding and potential
exposure to live current.
4. Safety Equipment 12% of citations. Lack of adequate eye wash and safety
showers, along with worker failure to wear personal protective gear.
5. Railings and Platforms 8% of citations. Slippery platforms and inadequate or
missing safety rails.
6. Signs and Labeling 6% of citations. Failure to identify hazards, particularly
open tanks.
7. Others 6% of citations. Availability of fire extinguishers and lack of poor
ventilation.
 Anodizing 101

Anodizing Line Safety

Principles

1. Safety is first
2. Understand the risks
3. Provide Safeguards
4. Train for Action

Laws and Guidelines

Ontario Occupational Health & OSHA Regulations

Safety Act and Regulations for 29CFR 1910-1001 and
Industrial Establisments 29 CFR 1910-1200
 Anodizing 101

Anodizing Line Safety

1. Understanding the risks
2. Hazard Characteristics
1. Toxicity
2. Corrosivity
3. Flammability
4. Spontaneous combustion
5. Explosivity
6. Reactivity
3. Information Sources
1. MSDSs
2. Container labels
3. Process tank labels
4. Chemical Manufacturers
5. Plant Management
Anodizing 101

Anodizing Line Safety

Wear Protective Clothing

Goggles, face shields,
rubber gloves, aprons,
rubber boots and a
respirator as required.
Anodizing 101

Anodizing Line Safety

Store Chemicals Safely
Avoid high traffic areas
Allow for good ventilation
Identify Risks with placards
 Anodizing 101

Anodizing Line Safety

Adopt Safety Habits

1. Never eat, smoke, drink or wear
contacts in chemical environments
2. Know where the nearest safety shower,
eye wash and emergency equipment is
located.
3. Wear personal protective equipment
4. Avoid breathing fumes
 Anodizing 101

Anodizing Line Safety

Emergency Procedures
1. Eye contact: Flush immediately with water for 15 20 minutes.
Take other follow-up care as required by MSDS.
2. Skin contact: Flush with water for 15 -20 minutes. Seek additional
care as required by the MSDS.
3. Inhalation: Leave area immediately and seek treatment as required
by MSDS.
4. Ingestion: Contact medical personnel immediately with MSDS
information.