www.fictiv.com Open in urlscan Pro
172.67.151.39 Public Scan

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URL:
https://www.fictiv.com/articles/alternatives-to-chromic-acid-anodizing
Submission: On September 13 via manual (September 13th 2024, 2:21:56 pm UTC) from US — Scanned from DE

Form analysis
12 forms found in the DOM

GET https://www.fictiv.com/search/

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GET https://fictivloc:8890/search/

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GET https://www.fictiv.com

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GET https://www.fictiv.com/filter/

<form method="GET" action="https://www.fictiv.com/filter/" id="filter-form" data-cb-wrapper="true">
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ALTERNATIVES TO CHROMIC ACID ANODIZING

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Samson Olanrewaju

08.30.2023 Engineering & Design



Time to read: 6 min

One technique in modern cycles and surface modifications is a small but
effective player — chromic corrosive anodizing. This finish isn’t a basic
method; rather, it’s a groundbreaking metal surface transformation that upgrades
toughness and prevents degradation while providing an appealing aesthetic.

From aviation to consumer gadgets, chromic acid anodizing is popular for its
useful and extraordinary applications and its one-of-a-kind elements — but
chromic acid anodizing is dangerous and bad for the environment. 

This article discusses chromic corrosive anodizing, its complexities, and wide
scope of uses, then details some excellent chromic acid alternatives. 


WHAT IS ANODIZING?

Anodizing is an electrochemical cycle that forms a defensive oxide layer on
aluminum. This deposited surface layer improves erosion obstruction and strength
and can be colored for decorative purposes. There are different sorts of
anodizing, including chromic corrosive, sulfuric corrosive, and hard coat
anodizing. Each method has its own advantages and applications.

To learn more about anodizing, check out our guide, Aluminum Anodizing: All You
Need to Know.


BASICS OF CHROMIC ACID ANODIZING

Chromic corrosive anodizing occurs by submerging aluminum in a chromic ion
electrolytic bath and applying an electrical current — chromic acid acts as both
an electrolyte and a reactant. The process produces an oxide layer in a
controlled way that coordinates with the metal substrate to further develop
erosion obstruction and aid with color assimilation.

Chromic acid anodizing also improves: 

 * Corrosion resistance
 * Aesthetic appearance
 * Wear resistance
 * Paint and adhesive bonding
 * Lubricity
 * Plating adhesion

Chromic acid anodizing is specified and carried out through a few industry
specifications, including: 

 * MIL-A-8625 US Military Specification: Anodic Coatings For Aluminum And
   Aluminum Alloys 
 * NASA/JSC PRC-5006 Process Specification for the Anodizing of Aluminum Alloys 

Both specifications include 2 types of chromic acid anodizing. Type I are
conventional coatings produced from an electrolytic chromic acid bath (3.4.1).
Type IB are coatings produced in low voltage chromic acid anodizing (22 ± 2 V).


ANODIZING SUBSTRATES AND APPLICATIONS

Chromic acid anodizing is ordinarily applied to aluminum and aluminum composites
because of their widespread use in aviation, automotive, consumer electronics,
and structural industries. Aluminum’s lightweight and naturally occurring oxide
layer makes it ideal for chromic acid anodizing. 


PRE-ANODIZING CLEANING

Surface cleanliness is critical for effective anodizing, and the term cleaning
includes eliminating toxins, oils, and existing oxides from the aluminum
surface. Soluble or dissolvable cleaning is often followed by an etching cycle,
where the aluminum surface is synthetically treated to remove all pre-existing,
naturally occurring aluminum oxide and to roughen the surface texture — all to
ensure uniform anodic covering development.

When a smooth, shiny, or glossy surface is required, parts are pre-treated in a
deoxidizing bath and then mechanically polished, while parts are blasted or
milled to achieve a matte finish. 


ANODIZING PROCESS HARDWARE 

The anodizing process requires tanks, rectifiers, and racks. Tanks hold the
anodizing fluid and allow for part submersion, while rectifiers control the
electrical voltage and current. Racks hold the aluminum parts to guarantee a
thorough immersion in the solution. All of this equipment must be properly
arranged and maintained to reliability deliver top-notch anodized coatings.


ANODIZING PROCESS STEPS AND CONSIDERATIONS

The stages of chromic corrosive anodizing are: 

 1. Cleaning 
 2. Etching/deoxidizing/mechanical surface modification 
 3. Anodizing 
 4. Coloring (if desired)
 5. Rinsing
 6. Sealing (either via chemical or hot water) 

The timing of each step, temperature, voltage, current, and thickness of the
coating influence the quality of the finish, so close control of these variables
is necessary to get good results consistently. 


NATURAL ALUMINUM OXIDE VS CHROMIC ACID ANODIZED ALUMINUM OXIDE

Aluminum has a high affinity for oxygen, so a natural aluminum oxide layer
instantly builds on the surface of aluminum after it’s been exposed to air.
Chromic acid anodizing also produces an aluminum oxide layer on the surface of
aluminum, but there are differences between the oxide layers: 

Thickness (nm)HardnessCorrosion ResistanceAbility to be ColoredPaint
AdhesionFatigue ResistanceNaturally Occurring2-3GoodGoodNoGood when cleaned and
preppedStandardChromic Acid Anodized5-15Harder than natural aluminum oxide, but
the film is easily damagedExcellent (Increases with thickness)Naturally gray (or
green when sealed) in color but can be dyed black Excellent when cleaned and
preppedSuperior (Inversely proportional to thickness, though)

The formation of the chromic acid-induced anodized oxide layer is dependent on
electrolyte concentration, bath temperature, immersion time, voltage supplied to
parts, and solution flow. As with any other electrolytic coating process,
current density impacts the local thickness of the anodized coating. 

Current tends to flow in the same pattern that you would expect to see heat
distribute, with higher areas of thickness building on edges and lower thickness
building on the center of a part. This resource has more on the technical
details of the anodizing process, including an explanation of the
electrochemical reaction. 


VERSATILITY AND SIGNIFICANCE: APPLICATIONS OF CHROMIC ACID ANODIZING

The excellence of chromic corrosive anodizing lies in its flexibility. The thin
oxide layer increases corrosion resistance, perfect for applications exposed to
the elements — like airplanes flying through the sky and ships sailing ocean
waters.

Anodized coatings are also compatible with cement and paints, providing a
surface for good paint or adhesive contact. It also improves electrical
insulation, making anodized parts ideal for capacitors and connectors. 

In short, chromic corrosive anodizing is incredibly useful in various
industries, from architecture and medicine to consumer electronics and military
gear.


CHROMIC ACID ANODIZING: THE UGLY TRUTH

For all its beneficial uses, chromic acid anodizing comes with a high price in
terms of health risks for workers. The byproduct of this process, airborne
hexavalent chromium, is a known carcinogen 500 times more toxic than diesel gas
that can lead to various health issues: 

 * asthma
 * eye irritation/damage
 * perforated eardrums
 * respiratory cancer
 * contact dermatitis
 * septum perforation

That’s why many industries, including the automotive industry, are phasing out
processes that produce hexavalent chrome. The automotive industry began its
phase-out of hexavalent chrome-containing chemicals with the adoption of the
European Union’s End of Life Vehicle Directive in 2020. 


ALTERNATIVES TO CHROMIC ACID ANODIZING

Because it’s such a useful process, chromic corrosive anodizing remains a part
of product development, but because of the toxic byproducts, it creates, the
mission to find greener, safer options proceeds. 

Here are some excellent alternatives to chromic acid anodizing: 


TYPE II, MIL-A-8625 – SULFURIC ACID ANODIZING, CONVENTIONAL COATINGS PRODUCED
FROM SULFURIC ACID BATH

Sulfuric acid anodizing is an excellent alternative to chromic acid anodizing.
Here’s why:  

 1. Sulfuric acid anodizing is safer. The process uses no hexavalent chromium
    and does not create it as a byproduct. 
 2. Sulfuric acid anodizing produces a thicker and more durable anodized layer
    than chromic acid anodizing. This makes it better suited for use in harsh
    environments where the part may be exposed to abrasion or corrosion. 
 3. Sulfuric acid anodizing is much more cost-effective than chromic acid
    anodizing. It requires fewer steps and chemicals to produce the same
    high-quality results. 
 4. Sulfuric acid anodizing can be used on a wider range of materials. It can be
    used on aluminum, titanium, and magnesium parts. Chromic acid anodizing is
    for aluminum only. 
 5. Sulfuric acid anodizing produces a more uniform and consistent finish than
    chromic acid anodizing — it’s easier to control and maintain the process
    parameters, so you get more predictable outcomes.


TYPE III, MIL-A-8625 – HARD ANODIC COATINGS

Type III anodizing is a hard sulfuric acid anodizing applied with the same
general process as Type II sulfuric acid anodizing, but creates a much thicker
oxide layer. Type III coatings provide increased resistance to wear, corrosion,
and other general environmental effects and are also known as hard or hardcoat
anodizing. The protective oxide layer must be thicker than >= 0.0005”, with
coatings up to 0.004”. 

While the thicker coating of Type III offers greater physical protection, it
costs more due to extra processing and immersion time, and the increased
thickness may require more quality control for tight tolerances. 


TYPE III, MIL-A-8625 WITH PTFE – HARD ANODIC COATINGS WITH PTFE

Type III with PTFE is a more recent anodizing process designed to offer the
benefits of both hard coat anodizing and Teflon (aka PTFE). The addition of PTFE
improves lubricity and wear resistance and prevents galling failure — adding
PTFE lowers the coefficient of friction by as much as 50%. 

--------------------------------------------------------------------------------

If you’re looking for a safer and more environmentally friendly alternative to
chromic acid anodizing, then sulfuric acid anodizing is a great solution.

At Fictiv, we have experts with extensive experience using sulfuric acid
anodizing to finish a variety of parts — so we can deliver high-quality parts
with excellent corrosion resistance and color options without the harmful health
and environmental risks associated with chromic acid. Upload your design today
for a free instant quote for our anodizing services!



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Samson Olanrewaju Samson is the Technical Applications Engineer (TAE) at Fictiv
for CNC manufacturing. He has a decade of experience in the Aerospace industry
as an aircraft design engineer working in R&D, design, and manufacturing of
aircraft mechanical, structural, and aerodynamic components and assemblies.
Samson earned his degree from the National Aerospace University (XAI) in
Kharkiv, Ukraine. At Fictiv, he works with clients across various engineering
industries to help optimize designs for manufacturing
Learn More »


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