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Alternative Corrosion Protection Pre-treatments for Aluminium Alloys

Aluminium alloys are extensively used in space programs for both structural and non-structural applications. As well known, the corrosion resistance of these alloys is quite limited and anticorrosion treatment is needed.

The most used treatment currently used for improving the corrosion resistance of aluminium alloys are usually chromate (CrVI-based) conversion coatings (CCC). Due to the high environmental impact of these compounds, the REACH Regulation of the European Union decided to limit/restrict the use of hexavalent chromium. A sunset date of mid-2017 has been already set.

For the time being many chromate-free alternative products are available but they have found to be significantly inferior in terms of corrosion protection performances with respect to the chromate options. In this regard there is a great need to develop high performance hexavalent chromium-free anti-corrosion coatings with low environmental impact and conformity with the EU regulations.

The European Space Agency (ESA) is currently involved in a TRP contract with Instituto de Soldadura e Qualidade (ISQ) that is currently on-going. The objective of this study is to evaluate the anticorrosion behaviour of the different alternative pre-treatments applied to the most used aluminium. The outcome of this activity will be the identification and the optimization of the most promising anticorrosion pre-treatment.

Several commercial Cr(VI) free processes were applied onto aluminium alloys (2024-T3 and 2024-T81) used in the construction of ESA spacecraft, in order to investigate their anticorrosive properties compared with Alodine 1200, a widely used conventional CCC. One of these commercial processes (PreCoat A32) presented good anticorrosion performance, even better than Alodine 1200 and these results are presented in this paper.

Salt spray resistance is included in the testing program as well as metallurgical coating evaluation that include microscopy (SEM) observations before and after testing and electrochemical impedance spectroscopy (EIS), in order to evaluate surface and microstructural modifications due to degradation mechanisms. Further studies must be performed with the this promising alternative, modifying application parameters, in order to achieve improved corrosion protection efficiency.

Key Words: Aluminium alloy, Conversion coating, Anti-corrosion coatings, SEM, EIS

Source: Whitepaper Springer.com,Journal of Coatings Technology and Research, pp 1–14, Alternative corrosion protection pretreatments for aluminum alloys

Interested in PreCoat A32 passivation or the full whitepaper? Contact chemicals@adinternationalbv.com

precoat_a32_bare_corrosion_protection

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Innovative chromium (VI)- free processes (AD Chemicals/Weert Group)

 

PreCoat Z31 for galvanized steel: First in Europe

AD Chemicals (chemical supplier) and Weert Group (galvanizer and powder coating applicator) are introducing an innovative chromium (VI)- free pretreatment system prior to powder coating on galvanized steel (Duplex-system). Weert Group is the first galvanizer in Europe to implement this new technology that complies with both the GSB and Qualicoat (Approval No. A-119) standard.

For making this innovation possible, there has been a joint research and development trajectory of more than 8 years. The uniqueness of the PreCoat Z31 pretreatment lies in the fact that it is a 1-on-1 replacement for chromium (VI), meaning that all the qualitative properties are sustained (corrosion protection, paint adhesion, passivation). This results in a corrosion protection and paint adhesion of more than 2000 hours of NSS, a performance to be proud of. The expectation of AD Chemicals and Weert Group is that this new system will become the (global) market standard in chromium (VI) free pretreatments on galvanized steel.

 

More innovations from AD Chemicals: PreCoat F31/20 and Z31/20 for grit blasting

AD Chemicals launches a revolutionary new product on the global grit/sand blasting market. Namely, PreCoat F31/20 suitable for treatment of steel and PreCoat Z31/20 for aluminum and galvanized steel. PreCoat is a chemical treatment applied directly after grit/sand blasting or metallization(also referred to as metal spraying). It has two main benefits; by applying the product directly after blasting, a conversion layer is created that substantially improves the adhesion of the painting system (suitable for wet painting and powder coating) and significantly enhances the corrosion-protection resistance properties of the paint system as a whole. The application procedure of PreCoat is very easy and can be integrated in every business process. Furthermore it is developed in compliancy with the Qualisteelcoat, Qualicoat and GSB quality standards. The innovative aspect is that it combines the worlds of mechanical and chemical pre-treatment, enabling a longer product lifetime.

 

AD Chemicals present at EUROFINISH 2017, 10+11/05 2017

AD Chemcials will be present at EUROFINISH 2017.  AD Chemicals will demonstrate its new innovations for chromium(VI) free pretreatment of galvanized steel. Furthermore we will show our PreCoat F31/20 and Z31/20 for grit blasted steel.

 

eurofinish surface treatment exhibition

Eurofinish surface treatment fair 2017

Eurofinish is organized bij VOM (Belgian association for surface finishing techniques) and takes place the 10th and 11th of May 2017 in Leuven, Belgium.

EUROFINISH will be much more than an assembly of technologies. It will be a gathering of congenial entrepreneurs and a juncture for networking, a source of inspiration for the future and a nursery of new ideas. EUROFINISH is a professional niche exhibition in the field of surface treatment and focusses on following themes:

  • Creation of added value: innovative coatings with focus on durability
  • Materials technology: attention to functional and smart utilisation of materials
  • Valorisation and durability: balancing technology and environment
  • Precision & engineering:  concurrent evolution and development
  • Future oriented: know‐how and skills under one roof

Free tickets? Contact us through chemicals@adinternationalbv.com

More information: http://eurofinish.be/

AD Chemicals en Weert Groep winnen de ION Borghardt Award 2016

Tijdens de opening van Surface 2016, de vakbeurs voor oppervlaktetechniek, is de ION Borghardt Award 2016 uitgereikt aan AD Chemicals in partnership met Weert Groep. Ze hebben een innovatie geleverd op het gebied van chroom(VI)-vrije voorbehandeling op verzinkt staal voor poedercoaten en natlakken.

Deze innovatie won de prijs omdat zij volgens de jury over de gehele breedte van de gestelde criteria op het gebied van ‘people-planet-profit’ bijzonder hoog scoort. “Niet alleen marktbelang en ketenoptimalisatie, maar ook zaken als maatschappelijk verantwoord ondernemen, kostenreductie, arbeidshygiëne en ontzorgen van de klant zijn nadrukkelijk meegewogen in ons oordeel”, aldus Arjan Mol namens de jury.

Chroom(VI)-vrije voorbehandeling op verzinkt staal Weert Groep en AD Chemicals hebben de afgelopen zes jaar een intensief partnership opgebouwd om tot een chroom (VI)-vrije voorbehandeling voor poedercoating (Duplex systeem) te komen die qua eigenschappen op het vlak van corrosiebescherming en lakhechting vergelijkbaar is met het toxische chroom (VI). Uitgebreide laboratorium- en praktijktesten, zoals het machubad (versnelde corrosietest) en de zoutsproeitest geven minimaal dezelfde resultaten en zodoende worden alle goede eigenschappen behouden. De oplossing laat tevens zien dat intensieve ketensamenwerking leidt tot nieuwe innovaties.

AD Chemicals, 2x genomineerd voor de ION Borghardt Award 2016

Om vooruitstrevende initiatieven in het vakgebied industriële oppervlaktetechnieken te stimuleren wordt op Surface 2016 de ION Borghardt Award uitgereikt. De ION Borghardt Award wordt op de openingsceremonie, op dinsdag 4 oktober om 9.15 uur.

AD Chemicals is genomineerd met:

  1. AD Chemicals: PreCoat Z31/20 en F31/20, Innovatie in de straalwereld!  AD Chemicals introduceert een revolutionair nieuwe productlijn op de markt die zorgt voor corrosiebescherming en extra lakhechting na stralen of metalliseren. Deze productlijn bestaat uit PreCoat F31/20 (substraat staal) en PreCoat Z31/20 (substraten verzinkt staal en aluminium)
  2. AD Chemicals & Weert Groep: Verzinkerijen: de reis naar een chroom (VI)-vrij poedercoatproces. Weert Groep en AD Chemicals hebben de afgelopen 6 jaar een intensief partnership opgebouwd om tot een chroom (VI)-vrije voorbehandeling voor poedercoating (Duplex systeem) te komen die qua eigenschappen op het vlak van corrosiebescherming en lakhechting 1 op 1 vergelijkbaar is met het toxische chroom (VI).

Meer informatie op: http://www.surfacevakbeurs.nl/bezoeker/activiteiten-programma/ion-borghardt-award

THE CHROME-FREE PRETREATMENT

It is well known now that some well described Qualicoat pretreatment procedures are very critical in obtaining good adhesion of powder coating and sufficient corrosion protection.

Proper etching/pickling to remove the most sensitive Aluminium top layer and sufficient rinsing are two of these important pretreatment steps.

Even though job coaters are following Qualicoat procedures most of the time when adhesion or corrosion issues occur the failure can be found in the pretreatment steps and not in the conversion bath or in the powder coating cycle. It seems that the newly developed Cr (VI) free conversion coatings are less forgiving than former chromate conversion coatings.

AD Chemicals and her customers are working closely together to determine the critical pretreatment steps. Pickling, racking and rinsing procedures can be optimized to guarantee the best performance possible with Cr(VI) free conversion coatings.

In this presentation we will discuss some factors

that might influence the quality of your powder coated aluminium.

Introduction

Each powder coating line has it´s own challenges. You have to be aware of the best processes prior to the painting of Aluminium objects. The starting point must be that a

The ultimate goal is to work with Chromium (VI) free pretreatments while maintaining the quality properties between Aluminium and paints. Also to meet the required specifications of Qualicoat.

First let’s focus on the variables of the pretreatment line and the quality of the Aluminium.

Concerning the quality of the Aluminium, an assessment of the quality is essential. However, jobcoaters have no influence on this question. They are depending of the Aluminium quality which they received from their sources. The only thing the jobcoater can do is to ask for a quality certificate of the Aluminium or a certificate of analysis of the formation of the Aluminium. Only the structure of the pretreatment line and the chemicals is in control of the jobcoater.

For example: Structure of a Pretreatment line(spraying), chromium (VI) free application

  1. Degreasing /Acid pickling >1.0 g/m2
  2. Rinse
  3. Rinse
  4. D.I. Rinse
  5. Chromium (VI) free pretreatment

 

Stage 1: Pretreatment tunnel, Pickling phase

Due to the increasing demands from Qualicoat (for example, sea-side > 2 g/m2), the pickling rate (etching-rate) has to be increased in the pickling (etching) phase. This means that you have to increase the aggresivity of the chemicals in the pickling phase. Important note is that when there is a stop in the line speed aluminium profile will be exposed by wet pickling solution and aggressive acid vapor. This “pollution” can dehydrate on the Aluminium surface. It is highly recommended to use a water curtain in case of an outage, as this will prevent acid drying effects. Experience has shown that dried-acid residues on the aluminum surface will not be removed totally in the rinsing phases. Residues can be a possible influence for the chromium (VI) free pretreatment. The formulation of the acid pickling is also a factor to prevent acid drying problems. AD Chemicals monitors it’s formulation at costumers to prevent undesirable effects. Other important items to prevent undesirable effects are good maintenance of the spraying nozzles, temperature, spraying pressure, contact time and the build up of the Aluminium content in the pickling solution.

Stage 2 and 3: Pretreatment tunnel, 2x normal rinse (tapwater)

The both rinsing phases are very important. The difficulty in these phases is that the rinsing water reaches all shapes and surfaces. Especially the seams of insulated profiles have to be rinsed well. In the seams acid residues stick and the rinse water flows over the pollution, this effect results in a minimum mixture with rinse water. The temperature of the rinse water is recommended to 18- 20oC, lower temperatures of the rinse water result in more viscous water and the rinsing effect will be less. The quality of the rinse water will be controlled by pH and conductivity.

Stage 4: Pretreatment tunnel, D.I. rinse water

The best rinsing quality will be if the conductivity is < 30µS and with a pH between 4,5 and 6,0.

At these parameters the risk of contaminations on top of the aluminium surface is minimized. This phase is highly important because any pollution can influence the last phase, the chromium (VI) free pretreatment phase.

 

Stage 5: Pretreatment tunnel, Chromium (VI) free pretreatment

The chromium (VI) free preatreatments of AD Chemicals are based on a precipitation reaction, where the conversion layer will be made. This layer is a cross linking layer for organic coatings. The thickness of this layer is very important. A layer that is too thick, results to bad adhesion and will be humidity sensitive.

A layer that is too thin, influences the adhesion at the bending tests. By guaranteeing the parameters like conductivity, pH and concentration, the chromium (VI) free layer can be assured. There are several types of chromium (VI) free pretreatments available for Aluminium. The most common types are based on the reactive groups titanium/zirconium (marked named by chromium free pretreatments) and chromium (III). All those Chromium (VI) replacements confirm the 1000hours Salt Acid Spray, corrosion resistance test requirements of Qualicoat.

 

One very important question bothers AD Chemicals:

“Is the requirement of 1000 hours corrosion resistance which Qualicoat prescribes enough?”

AD Chemicals doubts this statement of Qualicoat. When you only focus on the 1000 hours corrosion resistance, that has been described in the past, Qualicoat is right. However, the corrosion resistance of chromium (VI) based pretreatments fulfills the 2500 hours. This was a fair value for Chromium (VI) based pretreatments on Aluminium. AD Chemicals has investigated their chromium-free systems on the corrosion resistance of 2500 hours and compared it with the traditional chromium(VI) systems.

 

Internal research shows that the chrome free pretreatment of AD Chemicals precoat CR-FREE A-021, that has been approved since 2003, achieved a corrosion resistance of 2500-3000 hours.

 

The following reaction takes place on the surface:

When there is a good etching in the way that all the oxides are removed of the surface and the alloys are complexed then the layer is ready for the interaction with our PRECOAT CR-FREE. So there will be a interface bonding between our precoat and paint.

By proper process optimizations and pursuing the parameters and variables with fine chemicals, Chromium (VI) free pretreatments are perfect replacements of Chromium(VI) based pretreatments.

precoat chrome free pretreatment qualicoat