Metal Finishing NovDec2012

November/December 2012
Vol. 110
No. 9
The Plating and Coating Industries Technology Magazine
www.metalfinishing.com
Feature Focus
Update on accelerated
corrosion testing methods
Technically Speaking
Role of environmental exposure
simulation in predicting failures
Ask the Experts

The trouble with plating baths
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WHATS
inside
Feature Focus
12 Update on Accelerated Corrosion Testing
Technically Speaking
20 Corrosion and ExposuresAn Ounce of Testing
is Worth a Ton of Recalls
Organic Finishing
25 Hard Chromium Replacement Candidates for
Non-Line-of-Sight Landing Gear Applications
At Convention
8 FABTECH 2012 Recap: Mega-Manufacturing
Industry Event Pleases Show Organizers and
Exhibitors Alike
Cover image courtesy of Singleton Corp.
Columns
3 Tuckers Take
Testing Your Metal
31 Adhesion and Bonding

How High Temperatures Affect Adhesives
and Sealants
34 Cleaning Times
Type Industrial FirstUsing the Internet
to Investigate Parts Cleaning Equipment
36 Quality Control
Run Charts as a Test of System Performance
39 Ask the Expert

The Trouble With Plating Baths
Departments
4 News & Briefs
43 Product Showcase/New Products
53 Finishers Directory
54 Classifieds
55 Calendar of Events
56 Ad Index
Photo courtesy of Guyson
metal finishing
tuckerstake
Testing Your Metal
his months issue puts the magnifying glass on testing and controls, with topics ranging from accelerated corrosion simulation procedures for both organic and inorganic coatings, to getting to the source
of common (and some not-so-common) electroplating bath problems.
Take, for instance, Corrosion
and ExposureAn Ounce of Testing
is Worth a Ton of Recalls, the
instructional article from Anderson
Laboratories (page 20). In this highly informative piece, complete with
helpful illustrations, the authors
effectively demonstrate how accepted laboratory testing methods can
help operators evaluate the efficacy
of their coating materials as well as
their overall finishing processes.
Another gem is Singleton
Corporations updated tutorial on
the fundamentals of accelerated corrosion testing (page 12). In this comprehensive refresher, the author, Ray
Singleton, underscores the usefulness
of accelerated corrosion tests in comparison to real-world exposure, while
focusing on the consistency of the
test results. Its a pretty thorough
read, but stick with it and youll be
rewarded with essential knowledge of
the prevailing theories behind accelerated corrosion testing. (Disclosure: I
had the fortunate opportunity to
observe this wealth of knowledge
firsthand, when I visited Singleton
Corporations headquarters in
Cleveland, Ohio, earlier this year.)
I was pleasantly surprised to learn
that Singleton Corporation is much
more than just a fabricator/manufacturer of testing chambers and
barrel plating systems. The firm also
does double duty as an educator,
teaching not only existing clients,
but also providing instruction to
students and established plating

shops alike. Mr. Singletons credentials speak volumes. He serves as
chairperson for the ASTM Cabinet
Corrosion
Tests
(committee
G.01.05.03), vice-chairperson for
ASTM Corrosion of Metals (committee G.01), vice-chairperson for
ASTM Laboratory Corrosion Tests
(committee G.01.05), and composer/instructor for the ASTM TPT
(Technical Professional Training)
Corrosion Testing course for the last
14 years.
Other major players in the field of
corrosion testing equipment are also
putting just as much emphasis on
education and theory as they are on
making stuff. During the aforementioned tour, I made a pit-stop in
Strongsville, Ohio, where fabricators
and designers at the newly expanded
Auto Technology Company headquarters were busy at their craft.
Kevin Smith, the companys president, provided an in-depth look at
its capabilities. As chairman of
ASTM B117 (G01.05.03.01) Task
Group on Salt Spray Testing; cochair of the SAE Automotive
Corrosion & Prevention Committee;
and U.S. voting member for ISO
TC35, Smith also administers corrosion testing courses for clients and
students right on the premises.
Now, thats what I call one-stop
shopping.
For more information on the aforementioned training programs and courses, including customized educational
opportunities, please contact the respective companies.
Volume 110 - Number 9
Publisher
David Hopwood
Editor
Reginald Tucker
re.tucker@elsevier.com
Art Director - Production Manager
Susan Canalizo-Baruch
s.canalizo@elsevier.com
Advertising Sales Manager
Arnie Hoffman
Ph: (847) 559-0909
E-mail: arnie@edmancompany.com
Advertising Sales Reps
Donald Moeller
512-585-2391
E-mail: moeller.donald@gmail.com
Lynne Arons
847-853-7001
E-mail: Lynne.lyongroup@comcast.net
Annabelle Jacobson
847-256-6850
E-mail: Annabelle.lyon@comcast.net
Gabe Jacobson
E-mail: lyongroup1@comcast.net
Tel: 847-256-6818
Sales Operations Coordinator
Eileen McNulty
e.mcnulty@elsevier.com
Marketing/Circulation Manager
Caroline Champney
c.champney@elsevier.com
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November/December 2012 I metalfinishing I 3
NEWS&
briefs
APPOINTMENTS
Rebecca Harding has been promoted to the position of marketing manager at Columbia Chemical
Corporation, effective immediately.
She will report to Brett Tilberg,
European sales manager.
As marketing manager, Harding
will take a more active role in global
marketing functions, including marketing strategy, brand development,
and marketing communications in
support of the companys strategic
initiatives for continued growth and
development. She will continue to
coordinate foreign and domestic
communication campaigns, promotions, marketing collateral and website content.
Harding has been a key member of
Columbia Chemicals marketing
team for eight years, originally joining the company in 2004 as a marketing assistant and most recently
holding the position of marketing
coordinator. She holds a Bachelors
degree in Education with a concentration in Biology from BaldwinWallace College. Harding also serves
as chairperson to Columbia
Chemicals Charitable Committee.
For more information, please visit
www.columbiachemical.com.
Coventya, based out of Cleveland,
Ohio, recently appointed Rick
Rauppius International product
manager, protective technologies.
Rick has more than 21 years in the
metal finishing industry, working
primarily in product management
and technical support for protective
and functional coatings. He holds a
BS in Chemical Engineering from
Georgia Tech.
Pneu-Mech
Systems
Manufacturing recently named
Jerry Trostle its new sales manager,
with responsibility for the North
4 I metalfinishing I November/December 2012
American region. Trostle brings

more than 30 years experience in the
finishing industry, most recently
serving as general manager at
Wagner Systems.
"Pneu-Mech
Systems Manufacturing and our customers will greatly benefit from
Jerrys extensive background in finishing," a company press release stated.
"We are excited about Jerry joining
our company. He will be a great asset
to our team."
Pneu-Mech
Systems
Manufacturing of Statesville, N.C., a
member of the Brawtus Group, provides paint finishing system engineering, design, manufacturing,
installation and project management to the industrial market. PneuMech Systems Mfg. has more than
20 years of experience in providing
quality equipment and services to
the industry.
Metabo Corporation, a leading
international manufacturer of professional grade portable electric
power tools and abrasives for industrial, construction and welding
applications, announced it has hired
Jere L. Geib, Jr. as its new marketing
manager. Geib will be responsible for
marketing, advertising, and sales
promotions as well as supporting the
development efforts for the companys distribution channel.
Over the past 16 years, Jere has
held an array of positions in the field
of marketing and communications,
said Martin Cross, president of
Metabo. As a result, he brings wellrounded experience to our team and
company. His vast knowledge of
sales, marketing and communications will help us develop strategies
to meet the changing needs of our
customers as well as our sales network.
Before joining Metabo, Geib was
the director of marketing for
REBECCA
HARDING
Translogistics, Inc., Birdsboro, Pa.,

where he served as a member of the
executive management team developing and executing strategic marketing, business and development
plans for the company.
Prior to that, Geib held various
marketing and public relations positions for a variety of global electronics manufacturers and distributors,
including Tyco Electronics, Phoenix
Contact, TVC Communications and
Harsco Corporation.
Geib
holds
a
B.A.
in
Communications with concentrations in Public Relations and
Corporate
Media
from
Elizabethtown
College,
Elizabethtown, Pa.
EXPANSIONS
Chemetall, an innovator in surface
treatment and metal processing
technologies, opened a new cuttingedge facility in Blackman Township,
Mich., on Oct. 24. The $25 million
chemical manufacturing plant covers 200,000 square feet to house

administrative,
manufacturing,
warehousing operations, and a physical testing laboratory. More than
900 Chemetall products will be produced at the 40-acre Blackman site
for applications in surface treatment,
metal fabrication, cleaning and sanitizing.
"The labor force, as well as the
strong support from Blackman
Township and the State of Michigan,
NEWS&
briefs
made Blackman Township the most
logical choice for our new plant,
said Dr. Ron Felber, CEO of
Chemetall NAFTA. "We have selected the best area talent to support our
growing operations."
Automation
advancements,
including bulk material handling
systems, mixing vessels, and packaging lines, have been incorporated
into
Chemetall's
Blackman
Township facility to increase productivity as well as improve product
yield and quality for customers. As a
measure of its dedication to environmental sustainability, Chemetall has
installed a semi-automated waste
treatment system to reduce process
wastewater by 90%.
"High-tech additions to the new
Blackman Township site ensure the
efficiency of operations for the
manufacture of the finest quality
chemistries," Dr. Felber stated.
"Customers can be assured of
Chemetall's commitment to their
satisfaction through our innovations and service from all of our
facilities. Our mission is to integrate our decades of experience in
close cooperation with our customers, employees, and communities to produce customized solutions that enhance processes as well
as the environment."
Americas Center in downtown St.

Louis, Mo. The manufacturer of
coating thickness devices edged out
more than 20 COATING 2012
exhibitors that took part in the
Powder Coating Institutes annual
awards program.
DeFelskos award-winning product
was the PosiTector 6000 Coating
Thickness Gage. The unit accepts all
DPM, SPG and UTG probes, easily

converting from a coating thickness
gage to a dew point meter, surface
profile gage or ultrasonic wall thickness gage.
The Product Showcase display featured products launched in the last
12 months. Visit the Powder Coating
Institutes website, www pci.org., for
more information on the showcase
Flexible Measurement
Solutions for your
Plating Applications
AWARDS
DeFelsko took home the Product
Showcase Award at COATING 2012,
which took place Oct. 811 at The
Electroplating Electroless Coatings Anodize

Thin Film Measurement Compositional Analysis
Solution / Bath Analysis Coating Applications
Mike Wittenhagen (right), technical manager at

the Powder Coating Institute, presents the 2012
Product Showcase Award to DeFelskos Terry
LaRue (left), during the close of the COATING
2012 show in St. Louis, Mo.
NEWS&
briefs
contest or the COATING 2012 show
in general.
PARTNERSHIPS
Integran
Technologies
and
Dynatronix, Inc., recently developed a cooperative sales and marketing agreement designed to further strengthen their ongoing relationship in the area of electrodeposition of nanostructured materials.
Under the new agreement,
Dynatronix will continue to provide industry-leading pulse plating
power supplies specifically optimized for Integran's proprietary,
patent-protected electrodeposition
processes. Together, these processes
and power supplies will be deployed
into Integran's global production
facilities as well as by Integran's
licensees.
Dynatronix engineers have been
instrumental in the development of
state-of-the-art process equipment,
enabling the low-cost production of
our nanostructured and nano-laminated materials at high production
speeds, said Dr. Gino Palumbo,
Integran's president and CEO. I
am very pleased that, as part of the
new agreement, Dynatronix personnel will play a much more active
role in the further development and
commercialization of our nanotechnology."
David Osero, vice president of
sales and marketing at Dynatronix,
concurred. Dynatronix is honored
and excited to be involved in the
cutting-edge technology that
Integran continues to bring to market, he said. Their efforts to
remain at the forefront of metallurgical nano-technology development
have driven Dynatronix to continually improve our products and services to meet Integran's needs. We
look forward to strengthening our
relationship with Integran and
helping both companies enjoy continued success in the metal finishing industry.
CERTIFICATIONS
Coventya is pleased to announce

the addition of GMW16730 to its
impressive and continually expanding list of global zn/ni approvals.
COVENTEC P7755B surpasses all of
the strict requirements defined within GM's cosmetic black multi-layer
zn/ni standard.
Products covered include: PERFORMA 285; FINIDIP 728.2; and
FINIGARD 113.
The latest GM approval joins previously obtained approvals for VW,
Renault, PSA, Audi, Toyota, Fiat,
Honda, Ford, Volvo, Nissan and GM.
www.coventya.com.
ANNIVERSARIES
Osborn, a leading supplier of surface
treatment solutions and high-quality
finishing tools for hundreds of
industrial and commercial applications, celebrates 125 years in the
business.
Founded by John J. Osborn in
1887, Osborn originally made horse
and butcher block brushes as well as
street cleaning brooms. Now, 125
years later, Osborn--a unit of Jason,
Inc., offers more than 10,000 standard finishing products and more
than 100,000 customized solutions
to customers in more than 120 countries. Throughout its growth,
Osborn maintained its headquarters
in Cleveland while adding locations
in 15 countries to better serve its
diverse group of customers.
At Osborn, were extremely proud
of our 125-year history of providing
our customers worldwide with superior products that meet their finishing needs, said Luis Hereza, vice
president of marketing at Osborn.
Under Osborns new brand identity,
introduced earlier this year, were a
unified team that focuses on a history of quality, innovation, excellence
and service.
In celebration of its 125th anniversary, Osborn is publishing the companys history in a coffee table book.
The book captures a valuable piece of
brush making history, and takes the
reader from the companys beginning to present day.
Pangborn Europe, a leading manufacturer in the surface preparation

industry, celebrates 50 years of successfully development and engineering in an increasingly diverse and
technologically challenging industry.
"With the right strategies, we have
effectively grown over the years and
gone through good and difficult
times," said Pangborn Europe general manager Renzo Boarino, who
actively engaged the daily business of
Pangborn Europe since 1988. "In
fact of our consistent focus on continuous development and market
introduction of new and pioneering
plant and machinery has set new
standards for surface treatment in
miscellaneous industries."
Pangborn Europe, part of the
umbrella Pangborn Group organization, was founded in 1962. Since
then the company has been providing some of the most well designed,
engineered and durable wheel blast
and air blast equipment, Boarino
stated. "Our excellence in design and
engineering has earned us a stellar
reputation across a number of industries through our unmatched combination of custom products and services, particularly those for heavy duty
applications in the foundry, forge,
automotive and steel industries. In
addition, our on-site foundry allows
us to assist our customers with a
variety of parts."
TRAINING
Enthone, Inc. recently hosted a comprehensive one-day training session
on
the
recently
re-issued
Automotive Industry Action
Group (AIAG) CQI-11 Plating
System Assessment, Second Edition.
Enthone Automotive Industry
Managers, Linda Wing and Richard
Lynch chaired the training session.
Ms. Wing was also a member of the
AIAG CQI-11 technical committee.
Over the last decade, the Continual
Quality Improvement (CQI) assessment has become an industry benchmark that is extensively employed by
component coating applicators to
assess their suppliers, with the key
objective of defect prevention and
reduction, and supply chain optiwww.metalfinishing.com
NEWS&
briefs
mization. Furthermore, major automotive OEMs require compliance
with CQI guidelines.
The training was conducted by a
trio of industry experts who were all
active members of the AIAG technical committee that issued the second
edition. Mr. Ron Lash, CQI-11 technical committee chairman and a
retired senior engineer for Chrysler,
detailed the document changes. Ms.
Elizabeth Hanna, a Six Sigma master
black belt and ASQ quality engineer,
provided her experiences with supplier assessment as a quality manager. Mr. Jeff Szotek, a plating and surface finishing specialist with
Chrysler, provided an OEMs perspective and expectations for supplier use of the CQI-11 assessment, as
well as the influence of the assessment on future specifications. More
than 50 OEMs and tier suppliers participated in the training program.
2012 NEW ENGLAND SURFACE

FINISHING REGIONAL
More than 120 metal finishing professionals attended the New
England Surface Finishing Regional
on November 2 in Sturbridge, Mass.
The Host Hotel was the site for the
annual one-day event, which featured technical presentations, a table
top trade show and a social hour
with entertainment.
Christian Richter, NASF executive director, opened the meeting
with an update on the organization's
activities and efforts at strengthening the association and increasing
membership. He was followed by
eight other speakers who presented
on technical topics such as surface
preparation of copper and copper
alloys, water purification and alternative coatings for aerospace and
defense applications.
Other regulatory and management
issues covered included an presentation by a local OSHA representative
and a presentation on state and federal employment laws. A very thor-
ew
N
COATING THICKNESS GAGES
ough presentation on the use of

computer software tracking for
chemical use, cost and inventory was
included.
Personal interest topics were covered as the details and story of the
impact of a massive business disaster
had everybodys attention. Attendees
also listened to a very well-received
presentation on stress and energy
management in the workplace.
Marc Pelissier of Valley Plating of
Springfield, Mass., was the master of
ceremonies and once again got a
round of applause for all his efforts.
John Gilbert of Gilbert and Jones,
Marko
Duffy
of
Marathon
Manufacturing Services, Chris
Capalbo of New Method Plating and
Chris and Ed Ondrick of Poly Plating
were presented with Certificates of
Appreciation for al their hard work
in making this day a success.
The Regional Meeting for next year
will be held in November 2013 with
the location to be determined. Please
visit www namf-ne.org for more
information.
Now smarter, faster and more

powerful than ever before and still ...
Rugged, weatherproof,
ergonomic design

Simplified paperless QA
no software required
Simple.
Durable.
Accurate.
www.PosiTector.net
45 Years of Quality
atconvention
atconvention
BY REGINALD TUCKER
FABTECH 2012:
Mega-manufacturing event pleases
show organizers and
exhibitors alike.
he organizers of FABTECH
2012, which took place at the
Las Vegas Convention Center Nov.
1214, kicked off a well-rounded,
heavily attended event that lived up
to its pre-show billing. Exhibitors
enjoyed robust traffic, particularly
on the first two days, with some
vendors reporting purchasing activity. More importantly, attendees
representing various sectors of the
North American manufacturing
community got the opportunity
network with peers as well as vendor partners while reviewing the
latest innovations in equipment,
automated systems, and surface
forming/finishing technologyall
under one great, big roof.
According to show organizers,1
FABTECH 2012 drew 25,903 attendeesan 18% increase compared to
the last time the show was held in
Las Vegas.2 The sheer volume,
observers say, is indicative of not
FABTECH 2012 consumed more than 450,000

net square feet of floor space at the Las Vegas
Convention Center. Wheelabrator enjoyed
prime space in Hall C.
only the vitality of the U.S. manufacturing sector, but also the willingness of job shops and captive operations to invest in capital equipment
and training.
Weve received great feedback
from attendees and exhibitors, said
John Catalano, FABTECH show comanager. Attendees were impressed
with the size and scope of the show
and the vast array of new products
and technologies on display (see
Product Showcase in this issue).
Exhibitors were enthusiastic and
report that sales activity was brisk
and the leads plentiful.
The heavy activity was especially
palpable in the Finishing Pavilion,
which made its debut at FABTECH
2010 in Atlanta. According to Anne
Goyer, executive director of the
Chemical Coaters Association
International, or CCAI, a FABTECH
co-sponsor, this years Finishing
Pavilion occupied its largest show
floor space in the
three years that it
has been a part of
the show. (More
than 25,000 net
square feet, to be
more precise.)
By all accounts,
this was the best
Finishing Pavilion
& Conference at
FABTECH to date,
Goyer told Metal
Finishing. She said
CCAI was pleasantly surprised that its
show floor square footage surpassed
that of FABTECH 2011, which was
held at the sprawling McCormick
Bruce Dunham, marketing manager, Dubois

Chemicals, demonstrates the capabilities of the
company's new treo jel D pretreatment line.
Conference and Convention Center

in Chicago. In fact, Goyer said CCAI
had to expand its exhibit space three
times to accommodate the requests
for booth space in Las Vegas.
Likewise, Goyer said CCAI also saw
a big jump in this years Finishing
Conference sessions. By her count,
CCAI more than doubled its sessions
sold to 384 this year compared to
187 in Atlanta in 2010. Conference
participation was up by more than
30% over the Chicago event last year.
As we were tearing down, I had the
chance to talk to quite a few conference attendees who told me the conference sessions they attended provided great information, said Goyer,
citing conference evaluations reflecting very high marks.
SOLID ALL AROUND

Finishing Pavilion exhibitors, not to
be outdone, providing some generous scoring of their own. Cases in
point: Kathy Wilson, marketing
manager for AkzoNobel, was
extremely pleased by the number of
legitimate leads generated at her
booth, while Mark Schmidt Jr., technical support specialist, Finishing
Brandsrepresenting DeVILBISS,
Ransburg, BGK, and BINKSsaid
the traffic through his booth was
rock steady. Similarly, Paul Lomax of
Fischer Technology had his hands
full with a stream of curious attendees interested in demonstrations of
atconvention
Spray equipment demonstrations at the

Wagner Industrial Systems booth.
Coral Chemical talking up its environmentally

friendly pretreatment technologies.
All smiles. Chemetall's Suresh Patel (left), David

Gotoff (center), and Gary Nelson.
thickness testing equipment.

And lets not forget about the consuming publicthose attendees
comprising shop owners and managers who made the trip in search of
innovative tools and new equipment
to boost efficiency/profitability in
their operations. That description
fits those like Tony Sclafani, general
manager of ARI Iron, LLC and AR
Powder Coating, who primarily came
to touch base with both existing and

potential suppliers. In recent years,
Sclafani expanded into the finishing
business and wanted to meet with
his cleaning and pretreatment vendor partners, as well as suppliers of
turnkey finishing systems.
Were very loyal, Sclafani told
Metal Finishing. When we find a good
supplier, we tend to stick with them.
MANUFACTURING PULSE
FABTECH 2012 represented much
more than a venue for suppliers to
showcase innovations in manufacturing. The event also provided a
snapshot of the state of the manufacturing sector itself, which was
reflected in the lineup of educational
sessions. For instance, the conference portion featured a special State
of the Industry roundtable with
manufacturing chief executives
many of whom concurred that modest growth in U.S. industrial production should continue in 2013. At the
same time, many cited the lack of
skilled workers in manufacturing as
a major stumbling block to hiring.
To remedy that situation, members
of the CEO panelcomprising firms
such as Jay Industries, Inc.; Ohio
Laser,
LLC;
Trans-Matic
Manufacturing Co.; Metcam, Inc.;
and SunDial Powder Coatings
emphasized that manufacturers
need to be more aggressive in influencing parents of students, having
students influence each other and
have school be a more active voice in
recruiting potential workers.
One panel member, Patrick J.
Thompson, president of Trans-Matic
Manufacturing Co., told the audience that qualified labor is closer
than one would think. The best
source of labor is in your own backyard, he said. Thompson suggested
companies work more closely with
community colleges, vocational
schools, and even trade associations.
Other feature presentations proved
just as timely and relevant. With the
show occurring only five days after
the presidential election, FABTECH
also featured a Post-Election Analysis
panel featuring Omar S. Nashashibi,
partner
with
The
Franklin
Despite Challenges,
Metalformers Expect Slow
and Steady Growth Over
the Short Term
The November Precision Metalforming
Association report shows that 19% of
participants anticipate that economic
activity will improve during the next
three months, up from 15% in
October, while 45% predict that activity will remain unchanged, down from
55% last month. By comparison, 36%
report that activity will decline (compared to 30% in October).
At the same time, metalforming companies expect a slight uptick in incoming orders during the next three
months, with 28% anticipating higher
activity, up from 24% in October, while
39% forecast no change (compared to
41% last month). One-third of respondents predict a decrease in orders
(down from 35% in October).
Metalforming companies clearly
anticipate continued softening for the
balance of 2012 and are looking ahead
to 2013 with very modest expectations
for an uptick in business conditions
during the first few months of the new
year, said William E. Gaskin, PMA
president. Results of the presidential
election, negative stock market performance, significant concern over how
Congress will address income taxes on
Sub-S and LLC pass-through companies, and low expectations for how
Congress will address the fiscal cliff are
major concerns. There also is a growing
concern for resurgent regulatory
enforcement by EPA, OSHA and other
federal regulatory agencies.
Partnership, LLC, and David Goch,

partner with Webster, Chamberlain
& Bean. The panelists discussed the
ongoing political gridlock in
Washington as well as impending tax
reform and other issues that stand to
impact manufacturers. Still, there
was a general consensus that the
manufacturing sector has gained
influence in Washington over the
past two years, and panel members
strongly encouraged manufacturers
to get involved in advocacy efforts for
atconvention
I heard both on the show floor and at

the seminars was thatwhile challenges and uncertainties remain
most manufacturers believe that
their businesses are headed for continued growth in 2013.
FABTECH 2013 will be held Nov. 1821 at McCormick Place in Chicago, Ill.
REFERENCES
1. FABTECH 2012 is jointly spon-
sored by the American Welding

Society, Fabricators &
Manufacturers Association
International, Society of
Manufacturing Engineers,
Precision Metalforming
Association, and the Chemical
Coaters Association
International.
2. Attendance as measured by the
number of people who actually
picked up a badge on site.
Magic Rack's Dan Davitz (front right) explains

how the company can customize racking systems for a particular part or component.
CONFERENCE & EXHIBITION

EXHIBITION
February
F
ebruary 1921, 2013
Convention
vention Center
San Diego Con
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to keep our company on the leading edge. The ability to learn and
communicate with suppliers along with IPC experts at the same place makes
IPC APEX EXPO a must-attend event.
David Gale
Manufacturing Manager
MJS Designs, Inc.
Bill and Brendan Johnsee manning the Walther
Pilot booth in the Finishing Pavilion.
3Ms Jeff Simmons (front right) and Bob

Hamilton (far right) explain the benefits of the
companys new Cubitron II technology for
grinding wheels.
the industry via their trade associations.

All things considered, the overall
outlook was generally positive. If
you can take the pulse of the economy by whats happening in manufacturing, then you have to be optimistic
that we are headed for economic
growth, said Mark Hoper, FABTECH
show co-manager. A constant theme
INFORMATION that
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design | printed boards | electronics assembly | test

and printed electronics
feature
focus
BY RAYMUND SINGLETON, SINGLETON CORP., CLEVELAND, OHIO
Accelerated Corrosion Testing
ccelerated corrosion testing of

metals and coatings was first
developed in the late 1890s and early
1900s for testing products to
increase their useful performance
and service life. This method of testing the corrodibility of ferrous and
nonferrous metals and organic and
inorganic coatings has since been
improved and variations added to
better test new materials and help
operators understand how they may
perform in, and withstand, a wider
range of real world environments.
Accelerated corrosion testing has
also evolved from providing information to help determine durability of
products, and their quality assurance
during manufacturing, to use in
product research and development.
Professional trade, industry, military
and standards organizations, such as:
ASTM International (American
Society for Testing and Materials),
the Society of Automotive Engineers
(SAE), the Federation of Societies for
Coatings Technologies (FSCT),
NACE International (National
Association for Corrosion Engineers
), Society for Protective Coatings
(SSPC) and others have developed a
number of accelerated corrosion tests
to meet the demands of changes, and
advances, in technology, materials,
and other performance requirements
and environmental regulations.
For instance, water-based coatings
have been developed as replacements
for solvent-based liquid coating
materials in response to environmental concerns. Some powder coatings
and their application methods reduce
the use of solvents and ease application. In addition, the automotive
industry has improved coatings and
increased the number of surfaces
coated as part of the response to market pressures for longer warranties.
Some of the more widely used tests

are the representative ASTM
Standards detailed in this article and
well known industry cyclic corrosion
tests such as: General Motors
GMW14872 (formerly GM9540P),
and SAE J2334. There are many other
tests in use; however, those mentioned also exhibit wider applicability
and versatility and are, therefore,
some of the more popular procedures. Other than the ASTM B117
Salt Fog test, most widely used for
on-line process and product quality
control, no other single corrosion test
is as dominant because of the wide
variety of service conditions, product
industries and specific issues such as
various materials, applications methods, properties, and varying surfaces.
Other considerations to consider
when choosing or specifying a particular accelerated corrosion test
include the multitude of environments and customer demands faced
by a product and industry. A variety
of standard tests has been developed
to address these issues.
One of the firstand still most
widely utilizedaccelerated corrosion tests developed is ASTM B117
Operating Salt Spray (Fog)
Apparatus. Early development of
corrosion tests was initiated in order
to evaluate the corrodibility of metals and protective properties of coatings in a marine or near shore environment. As corrosion testing was
increasingly used also to evaluate
product quality and materials used
in product development, variations
on the basic, or original, corrosion
test standards have been added to
increase their usefulness for a wider
range of environments and materials. This process has resulted in the
development of the various representative accelerated corrosion tests
to be discussed in this update.

The usefulness of testing coatings
for resistance to water, or high
humidity, as a good indicator of their
service life in service environments of
that type resulted in the ASTM
D1735 Standard Practice for Testing
Water Resistance of Coatings Using
Water Fog Apparatus and the ASTM
D2247 Standard Practice for Testing
Water Resistance of Coatings in 100%
Relative Humidity. Demand for
improved evaluation of decorative
copper/nickel/chromium
or
nickel/chromium coatings on steel,
zinc alloys, aluminum alloys, and
plastics designed for severe service
resulted in the ASTM B368 Standard
Test Method for Copper Accelerated
Acetic Acid-Salt Spray (Fog) Testing,
widely known by its acronym as the
CASS test.
Additional needs for testing of
product resistance to harsh industrial environments led to the development of the ASTM G85 Standard
Practice for Modified Salt Spray (Fog)
Testing with its 5 included corrosion
test variations and the ASTM G87
Standard Practice for Conducting
Moist SO2 Tests. The ASTM G85
variations (tests): Annex 2, Annex 3,
Annex 4, and Annex 5 along with
ASTM G87 were developed to subject
test pieces to cycles of differing environments to more closely resemble
the changes occurring in pertinent
real-world environments. See Table I
for information on static versus
cyclic environment tests.
With the wide variety of materials
and coatings, their uses, and the service environments in which they may
be used, manufacturers and product
development personnel now can
select an accelerated corrosion test
that best suits their particular product and applicable environmental
conditions. Table I is provided to give
a guide to which ASTM test standard
can be used for the representative situations listed. Along with the development of new accelerated corrosion
tests ASTM Standards have been
developed to give direction and
resources for the preparation of test
pieces prior to testing and evaluation
of post test results. A good example is
featurefocus
ASTM D609 Standard Practice for

Preparation of Cold-Rolled Steel
Panels for Testing Paint Varnish,
Conversion Coatings and Related
Coating Products. This standard provides guidelines for the preparation
of test pieces before they are introduced into the accelerated corrosion
test. ASTM Standards: D1654
Standard Test Method for Evaluation
of Painted or Coated Specimen
Subjected
to
Corrosive
Environments; D610 Standard
Practice for Evaluating Degree of
Rusting on Painted Steel Surfaces,
and; D714 Standard Test Method for
Evaluating Degree of Blistering of
Paints were developed to provide
common standards for analyzing and
reporting the results obtained from
the corrosion tests and observed on
the tested specimens. These standards are summarized below.
ISSUES
Primary issues that arise when discussing the usefulness of accelerated corrosion tests are comparison to
real-world exposures and the consiswww.metalfinishing.com
tency of test results. Accelerated corrosion tests are performed under

controlled conditions with a limited
number of variables, which generally do not duplicate the vast variety
of variables that occur in any one
location in a real-world environment. Comparison standards can be
used to compensate for this.
Comparison standards are properly
prepared, representative test pieces
from a product with a known track
record of exhibiting acceptable performance from exposure in applicable real-world environments and/or
also acceptable corrosion resistance
after being exposed to the specified
accelerated corrosion test(s). They
then can be used as standards
against which other tested pieces are
compared. This process helps especially product developers and also
quality professionals predict how a
new product or production run of
an existing product will perform
when used. It is usually not possible,
unless additional long-term, realtime, comparative outdoor or inservice exposure data is available,
to directly compare any given number of hours in an accelerated corrosion test with a given number of
years exposure in real-world environments. The development of
additional variations on basic accelerated corrosion tests have allowed
engineers, technicians, and quality
professionals to better evaluate
durability of products to be used in
a wider variety of environments,
under multiple corrosive influences,
and under constantly changing
service conditions.
The issues are: consistency in the
accuracy of test results from subsequent runs of the same test in a single test chamber; and consistency for
comparison of test results obtained
from the same test run in other
chambers. These issues have been
addressed with the development of
ASTM methods for evaluating this
necessary consistency. This verification is called repeatability of results
from subsequent runs of the same
test in a single test chamber and
reproducibility of results from subsequent runs of the same test in
other test chambers (regardless of
how many other corrosion test
chambers are involved). These
important verification procedures
are covered in Section X3 of the
Appendix of the ASTM B117 test
standard and incorporate Mass
Loss Corrosion Coupons described
in that section. A similar variation of
this Mass Loss Corrosion Coupon
procedure is described in Paragraph
8.7 of ASTM B368, using nickel
coupons for the CASS test.
CRITERIA FOR CYCLIC TESTS

The American Iron and Steel
Institute, in cooperation with the
Automotive
Corrosion
and
Prevention Committee of the SAE,
conducted a study of existing cyclic
corrosion tests (completed in 2003,
revised in 2007) in order to develop
tests that could be used to rank performance of materials used in automotive cosmetic applications.
Approximately 20 existing corrosion
tests were selected for study. These
included static exposure condition
tests (tests where the exposure conNovember/December 2012 I metalfinishing I 13
featurefocus
Fig. 1. Schematic drawing of a typical salt fog

test chamber.
ditions do not vary over the duration of the test), such as ASTM
B117, and cyclic exposure condition tests such as ASTM G85 Annex
5 and GMW14872 (formerly
GM9540P), (tests which subject test
pieces to a variety of different exposure atmospheres and conditions
over the duration of the test). Ten
different test materials were
exposed in each test. The results of
the tests were compared to realworld exposure results from 10 sites
around the globe utilizing duplicates of the same materials. It was
concluded from results that an
acceptable corrosion test must: (1)
simulate the rank order of performance of coatings in actual service; (2)
produce the same type (character)
of failure as found in real-world
experience (example: blistering); (3)
be reproducible; (4) be of relatively
short duration; and (5) be feasible
and cost effective.
The test established as a result of
this effort is the SAE J2334
Laboratory Cyclic Corrosion Test.
The SAE J2334, GMW14872 (formerly GM9540P), and ASTM G85,
Annex 5 meet the above criteria
and are some of the more commonly used cyclic corrosion tests in
the U.S. and around the world. The
SAE J2334 and the GMW14872
were originally developed for testing cosmetic finishes on automotive components. Fortuitously,
they have been shown to produce
more realistic corrosion results
and, therefore, are used to test a
much wider variety of materials,

finishes, and applications. ASTM
G85, Annex 5, is known to be particularly useful for testing both:
architectural coatings and industrial maintenance paints as well as
other applications.
TYPES OF TESTS
In this case, ASTM B117 is described
first. The other ASTM Corrosion
Test Standards discussed are
described in terms of how they vary
from the basic B117 Standard. Only
those aspects of these standards,
which are different from the B117
standard, will be discussed.
ASTM B117 Standard Practice

for Operating Salt Spray (Fog)
Apparatus
The ASTM B117 Standard is primarily used to test the corrosion resistance of organic and inorganic coatings on metals. Examples are paint
or plated finishes on metal items
and exposure of products to
marine or near-shore environments. This standard will also be the
base against which this article will
describe other corrosion tests. The
B117 Standard is a static (constant) condition, continuous test,
preferably run in multiples of 24hour periods. The test pieces are
featurefocus
Fig. 2. Typical water-jacketed-type corrosion

test chamber, mostly used for static condition
tests.
Fig. 3. Typical large-size, drive-in-type corrosion

test chamber.
exposed to a salt fog atmosphere

from atomized solution made up of
5% sodium chloride and 95% ASTM
D1193 Type IV water by mass and
held to purity standards specifying
that it contain: not more than 0.3%
by mass total impurities. Halides
(Bromide, Fluoride, and Iodide)
other than Chloride, shall constitute
less than 0.1% by mass of the salt
content. Copper content shall be less
than 0.3ppm by mass. Sodium
Chloride that has had anti-caking
agents added shall not be used
because such agents may act as corrosion inhibitors. This solution is
then atomized into the chamber
exposure zone, which is maintained
at a temperature of 35 +/- 2C (95 +/
- 3F) and a relative humidity of at
least 95%, creating a fog that has a
condensate collection rate of 1.0
to2.0 ml/hr per 80 m2 of horizontal
collection area. To maintain

these conditions, the chamber is heated and best maintained with a wet bottom
condition in the exposure
zone. The equipment needed to maintain these test
conditions will meet the
requirements described in
Table II and be made such
that all component parts
that come in contact with the exposure zone, water, or solutions are
made of, or coated with, inert materials. Typical test chamber components and operational connections
are illustrated in Fig.1.
ASTM D1735 Standard Practice
for Testing Water Resistance of
Coatings Using Water Fog
Apparatus
The ASTM D1735 Standard uses a
standard fog-generating chamber as
used for the ASTM B117 Standard.
The primary variations are the
chamber temperature, which is held
at 38C (100F) and the elimination
of the corrosive salt (electrolyte).
The fog is created by atomizing
ASTM D1193 Type IV water without
any salt whatsoever. This test
method is used to gauge the life
expectancy of coating systems by
measuring their resistance to water
penetration.
ASTM D2247 Standard Practice
for Testing Water Resistance of
Coatings in 100% Relative
Humidity
The ASTM D2247 Standard is used
to investigate how a coating resists
water, which can help predict its useful life. This is generally a pass/fail
test; however, the time to failure and
degree of failure can be measured. A
coating system typically passes if
there is either no sign of water-related failure after the specified test
period or less than an established
specified amount of failure.
For the ASTM B2247 Standard
the ASTM D1193 Type IV water is
placed in the bottom of the exposure
zone to a depth of 6 to 8 in. and then
heated. The area of the exposure
zone above the water is not heated
Fig. 4. Humidity test chamber schematic

drawing.
directly in order to cause condensation on the test pieces. The water is

introduced into the chamber before
the test pieces and maintained at a
temperature approximately 5 to
10C (1020F) higher than the
temperature of the vapor above it.
The major variation in the chamber
is the elimination of the fogging
tower. The 100% humidity results
from the vaporization of the heated
water in the bottom of the chamber
and/or having heated humidified air
pumped through the water. The
humidifying tower is used when the
option of having air pumped
through the heated water is chosen.
The exposure zone is maintained at
38 2C (100 4F) and 100% relative humidity. This test method is
performed in water-jacketed chambers (see Fig.2) with the 6 to 8 in. of
water mentioned above in the bottom of the exposure zone and the
water jacket filled to 12 in. above the
bottom to ensure that the immersion heaters are submerged. It can
also be run in larger chambers, such
as walk-in or drive-in size units (see
Fig. 3), equipped with heated water
tanks in the exposure zone to generate the required humidity. A primary
concern when conducting the ASTM
D2247 test is that the chamber be
sufficiently insulated. Figure 4 is a
schematic of a typical ASTM D2247
humidity test chamber configuration. To ensure that the ASTM
D2247 test is being performed consistently, it is recommended that a
control test piece with known durability be included in each test run.
ASTM B368 Standard Test
Method for Copper Accelerated
featurefocus
Acetic Acid-Salt Spray (Fog) Test
(or CASS Test)
The ASTM B368 Standard, originally developed by the National
Association for Surface Finishing
(NASF), is used primarily in the
development of coated metal products, including decorative coatings,
which will be exposed to severe service and more corrosive environments and also to evaluate the performance and protective properties
of more durable coatings which
would not be affected by the typical
ASTM B117 type salt fog test. This
test method is particularly applicable to the evaluation of the performance
of
decorative
copper/nickel/chromium or nickel/chromium coatings on steel, zinc
alloys, aluminum alloys, anodized
aluminum and plastics designed for
Fig. 5. Typical cyclic-type corrosion test

chamber with PLC control for automatic
operation of changeable atmospheres,
temperatures, and durations of various steps
in cycle.
severe service. This test meets the

challenges of providing a simulated
service evaluation to test product
specifications in research and development and provide manufacturing
controls for environmental changes
caused by human intervention.
The B368 Standard is a variation
on the basic ASTM B117 Salt Spray
(Fog) Test. For this variation, adjust
the pH of the 5% salt solution into
the range 6.0 to 7.0, and then add
0.25 grams of reagent-grade copper
chloride per liter of salt solution.
The test is not considered to start
until the temperature within the

exposure zone has reached 49C +/1C (120 +/- 2-F) and is then run
continuously for 6 to 170 hours as
agreed upon between purchaser and
seller prior to the start of the test. It
is required that the temperature
within the exposure zone be
checked twice a day only on regular
business days when the chamber
may be periodically opened for
short durations (preferably less
than 5 min) to work with test pieces
and/or replenish solution.
Another variation from the standard salt spray (fog) test is in the
mandatory verification for consistency of test exposure conditions. In
ASTM B using Nickel Mass Loss
Coupons rather than steel (as used
in the B117 Practice, Section X3
[non-mandatory]).
The
B368
Standard uses corrosion test chamber apparatus that meets the requirements for the ASTM B117 Standard
and will withstand the increased temperature and stronger electrolyte
solution used for this test.
ASTM G85 Standard Practice
for Modified Salt Spray (Fog)
Testing
Five variations of this standard have
been developed to accommodate its
use to different purposes. The variation that is used by interested parties
in any situation must be agreed upon
prior to the start of testing. Following
are brief explanations of each of the
five individual test variations:
Annex 1Acetic-Salt Spray (Fog)
Testing
The Acetic Acid-Salt Spray (Fog)
Test is used to test ferrous and nonferrous metals and inorganic and
organic coatings for resistance to
additional and more corrosive environments than the ASTM B117
Standard. This test is designed as a
continuous exposure test without
interruptions. It uses a 5 1 part by
mass solution of sodium chloride in
95 parts of ASTM D1193 Type IV
water. The pH of the solution is
adjusted with the addition of glacial
acetic acid to be within the range of
3.1 to 3.3. This solution is then
atomized into the exposure zone to

create a fog that has a condensate
collection rate of 1.0 to2.0 ml/hr per
80 m2 of horizontal collection area
while the temperature of the exposure zone is being held at a constant
35 +/- 2C (95 +/- 3F). This variation is particularly useful in
research when evaluating the effect
of altering the parameters of an
electroplating process or evaluating
the quality of the process on decorative chromium plating. It is used primarily for steel and zinc die-casting
substrates. It should be noted by
users that even though this test is
utilized as a more severe alternative
to the ASTM B117 Salt Spray (Fog)
test, the type of actual corrosion
produced is not necessarily of a
like-kind to that resulting from
the B117 test on the same test specimen material.
Annex 2Cyclic Acidified Salt Fog
Test
For this variation the pH of the test
solution is adjusted to a range of 2.8
to 3.0, the exposure zone temperature is raised to 49C (120F), and
the humidifying tower temperature
is raised to 57C (135F); however,
the most significant change is the
wet and dry cyclic nature of the test.
This change in the test requires that
the test chamber be equipped with
apparatus to produce differing
atmospheres for the various steps in
the test cycle and timing apparatus
that will cause the atmosphere within the chamber to vary as follows.
Every 6 hours, the test pieces will be
exposed to 3/4 of an hour spray of
atomized salt solution, then a 2-hr
dry period, during which the chamber is purged of humidity. The final
cycle is 1 hours of high humidity
as described by the temperature and
collection rates specified. Adding
the cycles to this test increases its
effectiveness if evaluating how products perform in a continuously
changing environment.
Annex 3Acidified Synthetic Sea
Water (Fog) Test
The addition of 42 g of synthetic sea
salt and 10 ml of glacial acetic acid
featurefocus
per liter of solution, in this variation, is to increase its usefulness for
production control of exfoliationresistant heat treatments used in
producing 2000, 5000, and 7000
series aluminum alloys. The pH is
adjusted into the range 2.8 to 3.0
and the test is performed at a temperature of 49C (120F). When
using this variation to test organic
coatings on metallic substrates the
test is performed at a pre-selected
temperature in the range 24 to 35C
(7595F). The collection rate specification for fog cycles of this test is
unchanged from the B117 Standard
at 1 to 2 ml/hr of operation; however, 2-hr cycles are used throughout
the test period. Because of the cyclic
nature of this test, prior to starting
the test a separate 16-hour salt fog
test is necessary to establish and verify proper condensate collection
rates. The test chamber must be
equipped with apparatus and controls that will cycle the exposure
zone repeatedly through a -hr
spray step then 1 hours of soak
time at 98% relative humidity (see
Fig. 5).
Annex 4Salt/SO2 Spray (Fog)
Test
In this test either a sodium chloride
or synthetic sea salt solution can be
used. The determination of which
will be used is dependent on the
product being tested and the
requirements of the interested parties. A primary difference in this test
procedure is the addition of sulfur
dioxide (SO2) to the exposure zone
using a predetermined cycle. The
requirement of the ASTM G85,
Annex 4 standard is that all the
cycles during the test period be equal
in length. Introducing SO2 into the
exposure zone on a periodic basis
requires additional apparatus. The
chamber can be equipped with a
device that will disburse the SO2
evenly throughout the chamber
without directly impinging on any
test pieces. The SO2 supply source
attached to the chamber must have a
regulator, flow meter, and timer to
allow for accurate introduction of
SO2 in accordance with any set cycle.

It is imperative to address all safety
issues: equipment, personnel, apparatus, and procedures prior to testing with SO2, since it is a very hazardous highly toxic gas. Note that
the primary changes to the chamber
are to allow for the correct introduction of the SO2. All parts of the
chamber that come into contact
with the SO2 must be made of materials that are inert to SO2 gas.
Annex 5Dilute Electrolyte Cyclic
Fog/Dry Test
For this test the electrolyte solution
contains 0.05% sodium chloride and
0.35% ammonium sulfate in 0.60%
by mass of ASTM D1193 Type IV
water. This solution is much more
dilute than the standard salt spray
(fog) test and is run using 2-hr cycle
times comprised of 1-hr fog at ambient 24C 3C and relative humidity below 75%, followed by 1-hr dry
off at 35C. That is, the test pieces
are exposed to 1 hour of spray fog at
controlled room temperature,
then 1 hour dry-off time at 35C
(95F). The collected condensate
shall have a pH within the range of
5.0 to 5.4. Because of the cyclic
nature of this test, a separate 16-hr
salt fog test is necessary to establish
and verify proper condensate collection rates prior to starting the cyclic
test. Because of the differences in
humidity in this test method and
the cyclic nature of the test, the
chamber will need to have a separate
air line and valve to allow the atomizing air to bypass the humidifying
tower and timing apparatus to control the cycle times, temperature
changes, spray, and airflow. This test
is a modification of the British Rail
Prohesion test developed in the
1960s for the industrial maintenance coatings industry. This test is
best suited for the testing of paints
on steel.
ASTM G87Conducting Moist
SO2 Tests
The ASTM G87 standard is an adaptation of the sulfur dioxide tests
used in Europe and is particularly
effective in producing easily visible
Fig. 6. Custom-sized, computer-controlled corrosion test chamber for cyclic testing.
corrosion on metals as would be

observed in an industrial or marine
environment. This test requires 2
0.2 L (122 in3 12 in3) Type IV
water in the bottom of the test chamber and does not use a fogging apparatus. The apparatus used to generate the necessary humidity is the
same used in the ASTM D2247 test.
The gas introduction apparatus is
the same as used in the ASTM G85
Annex 4 test. Once the test pieces are
placed in the chamber 0.2, 1, or 2 L
(12, 61, or 122 in3 12 in3) of sulfur
dioxide (SO2) with a purity of 99.9%
(liquid phase) is introduced. Then
the temperature of the chamber is
raised to 40 C (104 5.4F) in 1
hours and remains at this level for
the duration of the test cycle. One
test cycle is 24 hours. A test can be
run for as many cycles as are agreed
upon between the purchaser and seller; however, the SO2 and water must
be changed for each 24-hr cycle.
The 24-hr test cycles are executed
in one of the following ways: 1.
Continuous change of water and
SO2 with as little disturbance as possible 2. Alternating Exposure 8-hr
exposure; drying in ambient for 16
hours with 2030C (6886F) and
75% relative humidity The variations
differing from the B117 practice are
that for this test method all test
pieces be placed on the same horizontal plane and all test pieces in a
given test run be of similar reactivity.
NOTE: While adding corrosive gases
may expedite degradation of the protective properties of the coating on
the steel substrate, the purpose of
the test must be kept in mind. This
gas introduction may be acceptable
when testing materials used in an
environment that may include similar acids, such as roofing materials,
featurefocus
that could be exposed to acid rain.
EQUIPMENT
With continued developments in
accelerated corrosion testing, basic
changes and improvements have
been made to the equipment. The
basic requirements for accelerated
corrosion testing equipment are listed on Table II under the ASTM B117
Standard. The adjustments required
for each variation on the accelerated
corrosion-testing model are then
listed next to the appropriate ASTM
standard. Typical applications are
listed in Table III. Along with the
basic operating requirements,
improvements have been made in
the materials used in the construction of the chambers, the hardware
and software controls, and data
meets their specific needs.
recording
capabilities.
Programmable logic controller
(PLC) systems provide for increasingly sophisticated data acquisition,
manipulation, and display (see Fig.
6). As a result, both test chambers
with manually entered settings for
automatic operation, and test chambers with increasingly sophisticated
programmable controls for automatic temperature changes; varying
levels of controlled humidity; automatic changes for different environmental atmosphere cycles; and automatic data logging/accumulation,
record keeping, and output with
graphic data display, are available
through a variety of suppliers. These
comprehensive capabilities allow
each laboratory to find accelerated
corrosion testing equipment that
TEST PIECE PREPARATION/

CLEANING
In order for any of the above accelerated corrosion tests to obtain comparable results, all test pieces must
start the test in a similar condition
without contaminants present on
the surface of interest. The ASTM
test standards discussed above indicate reference standards to be used
for the preparation and cleaning of
test pieces. Particular attention
must be paid to the wide variety of
materials being cleaned and recognition of differing specialized material
and coating operations. ASTM test
standards state that the cleaning
method is to be dependent on the
product being cleaned and then
refer to ASTM D609 Standard
Practice for Preparation of ColdRolled Steel Panels for Testing Paint,
Varnish, Conversion Coatings and
Related Coating Products where
required. This standard describes
five cleaning and preparation methods. The preparation methods
described
are: Procedure
A
Conversion Coating; Procedure B
Vapor Degreasing; Procedure C
Solvent Brushing; Procedure D
Solvent Wiping; and Procedure E
Alkaline Cleaning. Procedure A
(Conversion Coating) addresses the
issue of ensuring that the test piece
be protected from rusting between
the manufacturing process and the
corrosion test. Procedure B (Vapor
Degreasing) exposes the test pieces
to solvent vapors within controlled
conditions to remove contaminants.
This procedure is currently discouraged for environmental reasons.
Procedures C (Solvent Brushing)
and D (Solvent Wiping) both use
Mineral Spirits as the cleaning
agent. Procedure E (Alkaline
Cleaning) describes methods for
cleaning with an alkaline cleaning
agent that is appropriate for the
product. The cleaning method and
cleaning agent chosen for any test
run should be as agreed upon
between the purchaser and seller.
ASTM D609 refers to the water break
test as a method of checking test
featurefocus
pieces for contaminants. The procedure is simply to run a small amount
of water over the surface of the test
piece. If it is free of oils and contaminants the water will run over it in a
sheet and off in one fall with no
breaks. Finally, ASTM D609 discusses the handling of cleaned test pieces
and storage in paper impregnated
with volatile corrosion inhibitor
(VCI) if the test pieces are not to be
run immediately after cleaning.
EVALUATION OF RESULTS
Some primary ASTM Standards that
have been developed to assist in the
evaluation of corrosion test results
are: ASTM D1654Standard Test
Method for Evaluation of Painted or
Coated Specimen Subjected to
Corrosive Environments; ASTM
D610Standard Test Method for
Evaluating Degree of Rusting on
Painted Steel Surfaces; ASTM D714
Standard Test Method for Evaluating
Degree of Blistering of Paints; and
ASTM B537Standard Practice for
Rating of Electroplated Panels
Subjected to Atmospheric Exposure.
Irrespective of the title wording, the
text of ASTM B537 states that it is
also used to evaluate panels subjected
to laboratory accelerated corrosion
tests. Other standards are also available for evaluation of specific materials and finishes.
ASTM D1654 is used for the evaluation of substrates, pretreatments,
coating systems, or a combination
thereof. This standard is also used
when the coating has been scribed
prior to exposure to the corrosive
environment. ASTM D1654 recommends a straight-shank tungsten
carbide tip or equivalent scribing
tool to produce a cut through the
coating to the substrate of the test
piece. The scribe serves as a deliberate failure of the coating system
prior to corrosion testing. Once the
test piece has been through the
selected accelerated corrosion test it
is then cleaned by rinsing with a gentle stream of water at 45C (110F).
Loose coating is then removed using
compressed air to blow it off or a
scraper to scrape it off. The creepwww.metalfinishing.com
back (perpendicular distance of

failure from the scribe line) of the
coating is measured at uniform
intervals and the rating system
described in the standard applied.
ASTM D610 provides a series of
photographic reference standards
that demonstrate degrees of rust on
the surface of a test piece. The test
pieces are first gently cleaned then the
amount of rust observed is reported
from comparison to the photographic standards and the additional use of
established standardized terminology
from the test standard. It is important
to compare only rust and not surfaces
stained by rust.
ASTM D714 is used to evaluate
coating adhesion by observing the
amount of blistering that has
occurred. The test pieces are first gently cleaned then compared to the
series of included photographic references and the additional use of the
appropriate standardized terminology indicated in the test standard.
They are graded
first by the size of
the blisters that
appear on the
surface and then
the number of
blisters
that
appear per unit
area.
products and materials. These standards have been developed, evolved

and refined through cooperative
efforts of experts and interested parties from: ASTM International,
industry, government, and other
trade organizations worldwide.
ABOUT THE AUTHOR

Ray Singleton is the Chairperson for the
ASTM Cabinet Corrosion Tests (committee G.01.05.03) and Vice-Chairperson for
ASTM Corrosion of Metals (committee
G.01) and Vice-Chairperson for ASTM
Laboratory Corrosion Tests (committee
G.01.05) as well as the composer/instructor for the ASTM TPT (Technical
Professional Training) Corrosion Testing
course for the last 14 years. He has written various magazine articles and contributed to industry directories on this
topic over the years. Singleton was also
presented with the Francis L. LaQue
award by ASTM in 2010 for contributions corrosion testing and the field of corrosion technology.
Clean Parts.
CONCLUSION
The corrosion
tests discussed
in this article are
some of the
most
utilized
tests of this type.
They
also
demonstrate the
diversity of the
tests and some
of the advancements in accelerated corrosion
testing and complexity of the
subject.
They
also provide a
solid basis for
evaluating the
performance of a
wide variety of
Clean Lines
I Passivation Lines
I Aqueous Chemistries
I Data Management
I
Tel. 716.763.4343
www.miraclean.com
TECHNICALLY
speaking
BY BENJAMIN CARDENAS, ICP ANALYST/SALT SPRAY
SPECIALIST; PHILIP SCHMIDT, CHEMICAL
ANALYST/CORROSION SPECIALIST; AND MICHAEL
PORFILIO, DIRECTOR OF OPERATIONS, ANDERSON
LABORATORIES, INC., GREENDALE, WIS.
Corrosion and Exposures

An Ounce of Testing Is
Worth a
Ton of Recalls
INTRODUCTION
There are many options for surface finishes when it comes
to metal products. Chemical coatings and paints are common in metal parts (Figure 1). Surface preparation and
coating options range from polishing and blasting to
pickling, passivating and plating. Application of the coating adds another layer of complexity to the finishing
process. So, how do you know if your coating is going to
hold up over time and exposure to the elements before
going into production? The answer is simple; environmental simulation and/or accelerated corrosion testing.
Corrosion Costs to America. The products of corrosion
that are at times an aesthetic annoyance cannot be compared to the potential of failure to many corrosion
modes. The numerous hidden costs of corrosion structures, equipment, bridges, proactive coatings, specialty
materials, cathodes, anodes, and other manufactured
parts are just some of the items that suffer the effects of
corrosion.
The coatings industry is experiencing pressure from
environmentalist groups, corporate sustainability pro-
grams and individuals to produce greener products.

Environmentally friendlier coatings usually have less corrosion resistance over the lifetime of the coating or finish.
This had left the industry, in some situations, struggling
to come up with new alternative formulations that perform as well as their less environmentally friendly counterparts.
The price of corrosion is staggering. Some quick costs
for corrosion include $108 billion in protective coatings,
$7.7 billion for Corrosion Resistant Alloys (CRA), and
$1.1 billion spent on corrosion inhibitors, to name a few.
The total direct cost of corrosion in America is $276 billion in 2012. To emphasize how large this number is in
2012, it is projected to be 3.1% of the United States GDP.
Cabinet Salt Spray and Humidity Testing. Tests such as
neutral salt spray testing (NSS) and humidity testing can
help a manufacturer or end user determine the efficacy of
their coating/finishing process. By examining test specimens throughout the duration of the test, obvious surface effects are noticeable sometimes within a single day
or two, preventing expensive and time-consuming rework
and recalls. This comparison to an unfinished, or control
specimen will help to determine the best surface finish for
the intended application (Figures 1-5). The following
images illustrate failures of coating application and/or
performance.
There are many specifications and standards written to
help perform this testing and, equally as importantly,
evaluate the results. The most common specifications for
performing an NSS test are ASTM B117 and ISO 9227,
which outline the test conditions required for the neutral
salt spray test. These specifications unify the test parameters across the globe in the effort to evaluate the efficacy
of paints, coatings and finishes.
Figure 1 (left): Painted Power Transfer Assembly Prior to Exposure to Neutral Salt Spray (NSS). Figure 1a (right): Salt Spray Exposure IAW ASTM B117-11 in
Process.
TECHNICALLYspeaking
Figure 4. Failed Galvanized Plating on a Spring After 48 Hours of Exposure

to NSS.
Figure 2. Failed Painted Power Transfer Assembly After Exposure to NSS.
Figure 5. Failed Powder Coating on a Ductile Iron Casting After 72 Hours

Exposure to NSS.
Figure 3. Base Metal and Surface Corrosion in Galvanized Steel
Construction Stud After 24 Hours of Exposure to NSS.
These specifications unify the test parameters worldwide in order to evaluate the efficacy of paints, coatings
and finishes. In this test, an atmosphere of a 5% solution
of sodium chloride is atomized and introduced at a constant rate throughout a sealed chamber. (see Figure 1a)
Test specimens are inclined and placed in the cabinet so
that the test surface is parallel to the primary direction of
flow of the sodium chloride mist. The mist wets the surface, and the excess solution runs off into the cabinet.
Humidity testing is another measurement of the effectiveness of the corrosion resistance properties of a metal
part. This test can be performed is several ways. The first
takes place in an unused NSS cabinet by simply turning
off the salt solution flow and plugging the drain. The second test takes place in an environmental simulation cabinet specifically designed for this type of test. The requirements for this test can be laid out in a manufacturers
specification or in an ASTM publication such as ASTM
D2247. This type of testing helps to evaluate primarily
paints and their tendencies to bubble and blister.
These two types of cabinet corrosions testing can also
be very effective as free iron detection tests. Free iron testing can be an excellent predictor of corrosion resistance
properties and surface finish success. Locations on a casting or finished part, which are high in free iron, can
become epicenters for corrosion while in service. In most

cases, a free iron test can be done via salt spray testing in
about 2 hours or in a humidity chamber in about 24
hours (see Figure 6).
These different combinations of coatings and hours of
exposure have led to a number of different conclusions
for these companies. The most important being cost
effectiveness of coating and surface finishes vs. corrosion
resistance.
Additional Free Iron Detection Tests. In addition to
these two cabinet style tests, another procedure that can
effectively detect free iron is a potassium ferricyanidenitric acid (Ferroxyl) test, in accordance with MIL-STD753 and ASTM A380. The ferroxyl test will illuminate
even the lowest levels of iron contamination. In this test,
a reaction with the chemicals in the test solution yields a
chemical reaction in the form of a bluish coloration,
demonstrating the presence of free iron (see Figure 7).
Once the testing has begun, the challenge becomes the
evaluation of the constantly changing surfaces of interest.
Sometime it is helpful to add a point of certain failure to
the test specimen, or scribe, to see just how bad a failure
becomes if it should occur via damage or deficiency of the
coating. There are many evaluation procedures such as
ASTM D610, D714 and D1654 that oversee the evaluation of test results. These specifications use numerical
TECHNICALLYspeaking
Figure 8. Conforming and Non-conforming G48C Corrosion Coupons.

Pitting indications correspond to dark spots on left-hand samples.
Figure 6.
Figure 7. Free Iron Indications after Ferroxyl Test on High Alloy Stainless
Steel Casting. The blue coloration indicates presence of surface free iron.
values to evaluate the severity of the corrosion, blistering

and/or creep.
These laboratory tests have one goal in common: to
assist the surface preparation industries evaluate the efficacy of their coating material and/or process. Corrosion
testing can help everyone from epoxy powder coating
companies to chemical coating operations to zinc/cadmium/chrome plating providers, and everyone in between.
The ultimate goal in applying a coating or perform surface treatments is to protect surfaces providing the highest quality product with the least amount of overhead in
order to yield maximum profit.
Accelerated Corrosion Testing. Accelerated corrosion
testing allows base material verification prior to final
application of surface treatments such as plating or polishing. Unwanted corrosion in stainless steels and other
related alloys is of significant concern in their engineering. Rough surface finishes, elevated temperatures and
corrosive environments encountered in service can accelerate corrosion and lead to material early failure.
Different forms of corrosion are commonly encountered in service, and many can be strongly influenced by
heat-treating. Fortunately, there are many types of standardized test methods, which seek to qualify materials
and quantify the rates corrosion that the alloy may experience. Some examples are noted below:
Pitting corrosion is a localized form of corrosion found
in stainless steels and other related alloys, which do not
typically experience uniform corrosion. Pitting corrosion
is typically caused by the breakdown of a passivating surface layer and results in small areas of corroded pits.
These pits can act as sites of crack initiation and are detrimental to a materials performance.
Intergranular corrosion in stainless steels is usually
associated with a precipitated inter-metallic phase found
at the grain boundaries of a material. For example,
chromium carbide precipitation at the grain boundaries
can deplete the surrounding material of corrosioninhibiting chromium. In the presence of a corrosive environment, these grain boundaries are preferentially
attacked and are subsequently weakened.
Stress corrosion cracking is another form of corrosion
that can cause normally ductile materials to fail in a brittle manner. When a material is both stressed (especially at
elevated temperatures) and also exposed to a corrosive
environment, the grain boundaries can be attacked and
the materials mechanical properties can be compromised. Stress corrosion cracking (SCC) is very alloy-specific in that certain alloys may only experience SCC in the
presence of specific chemical environments. Austenitic
stainless steels in particular are susceptible to SCC in the
presence of chlorides.
Sensitizing heat treatments in stainless steels can aggravate problems associated with intergranular corrosion.
(Sensitization is a process in which a material is heated to
a temperature in which chromium carbides, for example,
can precipitate out of solution at the grain boundaries
and create a chromium depleted region which adversely
affects corrosion resistance). Austenitic stainless steels are
susceptible to sensitization after heating to ~500C
800C. The addition of carbide-stabilizing elements such
as niobium or titanium can help to ameliorate the problem; however, processes such as welding a susceptible
material can still detrimentally affect its microstructural
integrity.
There are many standardized methods for testing a
materials susceptibility to one of the three forms of corwww.metalfinishing.com
TECHNICALLYspeaking
Figure 9. Intergranular Corrosion of Metallographic Cross Section of 304

Stainless Steel.
Figure 10. Lab technician conducting the ASTM G48 test, a common procedure for detecting pitting corrosion.
rosion addressed. A common test for pitting corrosion is

the ASTM G48 test. How it works: A sample coupon is
polished, dimensioned and weighed prior to testing. It is
then placed in a ferric-chloride solution for a specified
period of time. The sample is re-weighed after testing and
visually examined for signs of pitting corrosion. This test
can also quantify the mass loss rate of certain materials
and can be very useful in ranking a materials ability to
resist this form of corrosion.
ASTM A262 Method E is a common test for intergranular corrosion. In illustration: Two samples are polished for
testing, with one as a control. One of the two samples is
boiled in a copper/copper sulfate sulfuric acid solution for
a specified period of time while the other is desiccated.
After testing, the two samples undergo a U-bend test;
the apex of the bend is examined by microscope to look

for evidence of intergranular fissures. The presence of
these fissures indicates the materials susceptibility to
intergranular corrosion, and can be used to determine if
a sensitizing heat treatment has affected a materials susceptibility to intergranular corrosion.
The ASTM G36 test is another commonly used test to
look for susceptibility to stress corrosion cracking. In this
method, samples are polished and bolted into a U-bend
configuration. These samples are boiled in a magnesium
chloride solution for a specified period of time, and the
apex of the bend is microscopically evaluated to look for
evidence of crack formation. The presence of cracks indicates susceptibility to stress corrosion cracking.
Other common forms of testing and their applications
areas of interest are listed in Table 1.
Although corrosion can be detrimental to the service
life of many stainless steels and related alloys, there are,
fortunately, many methods available to help predict a
materials expected performance. The American Society
for Testing Methods has standardized many of these
methods, which are part of the standard toolkit designed
to help minimize the costly effects of corrosion in metals.
Corrosion Societies and Technical Committees. There
are a few organizations in the United States to assist manufacturers in matters that regard corrosion. The most
prominent is NACE International, the National
Association of Corrosion Engineers, based out of
Houston, Texas, which focuses on corrosion of numerous
grades of steel and surface treatments. Most of the specified material types are austenitic stainless steel, duplex
stainless steel, and nickel-based alloys as dependent upon
the
environment or exposure to sour gas
and corrosive
environments.
NACE works
with individual
members
as
well as organizations.
More
support can be
found for manufacturers from
ASTM,
the
American
Society
for
T e s t i n g
Materials. The
organization
has hundreds
of committees
and sub-committees
on
technical topics
www.metalfinishing/advertisers
TECHNICALLYspeaking
ASTM Test Method
Applicable Forms and Alloys
Relevant Type of Corrosion
ASTM A262 Method A
Cast and Wrought Austenitic Stainless

Steels
Detection of Sigma Phase
ASTM A262 Method B

(Streicher Test)

Steels
Intergranular Corrosion
ASTM A262 Method C

(Huey Test)

Steels
ASTM A262 Method E

(Modified Strauss Test)

Steels
ASTM A923 Method A
Cast and Wrought Duplex Austenitic /

Ferritic Stainless Steels
Detecting Detrimental Intermetallic

Phases
ASTM A923 Method B

ASTM A923 Method C


Phases (Utilizing Charpy V-Notch
Impact Testing)
Phases
ASTM G28 Method A
Wrought Nickel-Rich,
Chromium-Bearing Alloys
ASTM G28 Method B
Wrought Nickel-Rich,
Wrought Cast and Welded Stainless

Steels and Related Alloys
Stress Corrosion Cracking
ASTM G48 Method A
Stainless Steels, Nickel-Based and

Pitting Corrosion
ASTM G48 Method C
Stainless Steels, Nickel-Based and

Pitting Corrosion
ASTM G36
Table 1. Common Forms of Testingand Their Associated Applications.
from testing, to material specifications, to manufacturing

practices and parameters. Technical committee G01 was
formed in 1964, meets twice per year and has more than
350 members. This committee has many manufacturing
members to drive the process for the specifications contained in the corrosion testing volume 3.02 of the ASTM
family of standards and specifications.
On a global level, theres the World Corrosion
Organization (WCO), which is based out of the European
Union (EU) and discusses, attends, and drafts many
NACE-type material codes and testing protocols. The
mission of the WCO is to: alert and make industry aware
of the problems and solutions associated with corrosion;
identify best practices to deal and prevent corrosion; facilitate corrosion-related control through the industry; and
normalize world corrosion standards. As the ISO and
other EU states begin to solidify their stances of corrosion
and its by-products, the WCO is making a unified
approach.
Final Thoughts. The application of corrosion tests can be
a complicated subject. If you know your specific goals, the
usefulness of the process can be informative and value
added. To have a solid concept of the product life and use24 I metalfinishing I November/December 2012
fulness before elemental degradation is key for the selection of materials, coatings and/or manufacturing
process. Better products can be achieved through proper
testing selection.
ABOUT ANDERSON LABORATORIES, INC.

Anderson Laboratories, Inc., was established in 1939 in
Milwaukee, Wis. Currently located in Greendale, Wis., the company is an independent materials testing laboratory specializing
in chemical analysis, mechanical testing, welding procedure and
performance qualification, failure analysis, environmental and
corrosion testing, as well as on-site evaluations. Anderson
Laboratories, Inc. has quality and system programs accredited or
compliant to ISO/IEC 17025, 10CFR50 Appendix B, ASME
NQA-1, 97/23/EC PED, RoHS, NORSOK M-650, ISO 9001, to
name a few. For more information, please contact Anderson
Laboratories, Inc. at (800) 950.6330, via e-mail at sales@andersonlabs.com, or online at www.andersonlabs.com.
ORGANIC
finishing
BY MELISSA KLINGENBERG, PH.D., AND CLAYTON DREES, CONCURRENT

TECHNOLOGIES CORPORATION JOHNSTOWN, PA., AND FAIRBORN, OHIO
ELIZABETH BERMAN, PH.D., AIR FORCE RESEARCH LABORATORY,
WRIGHT-PATTERSON AIR FORCE BASE, OHIO
NATASHA VOEVODIN, PH.D., UNIVERSITY OF DAYTON RESEARCH
INSTITUTE, DAYTON, OHIO
Hard Chromium Replacement

Candidates for Non-Line-of-Sight
Landing Gear Applications
ntroduction. Electroplated hard

chromium (EHC) is a proven coating process, but many environmental, health, and safety (EHS) issues
and regulations are associated with
its use. As a result, the Department
of Defense (DoD) has investigated
and implemented thermal spray
coatings to replace EHC in its maintenance facilities. High velocity oxygen-fuel (HVOF), a type of thermal
spray process, deposition of tungsten carbide-17 percent (%) cobalt
(WC-17Co) has largely replaced EHC
in line-of-sight (LOS) applications;
Metal
CAS #4
Chromium
18540-29-9
Nickel
7440-02-0
Cobalt
7440-48-4
however, it has been incapable of

repeatedly depositing uniform coating thicknesses on complex (i.e.,
non-LOS [NLOS]) geometries[1].
Therefore, the United States Air
Force Research Laboratory
Advanced Power Technology Office
(AFRL APTO), in conjunction with
Concurrent
Technologies
Corporation (CTC), sought both
electroless and electrochemically
deposited chromium- (Cr-) free coatings that could treat NLOS parts.
Most suitable candidates contained
nickel (Ni), which has other health
concerns, denoted in Table 1. It also
PEL
IDLH
REL
TLV
OSHA
NIOSH
NIOSH
ACGIH
0.005
Units of mg/m3
15
0.001
is listed on the Environmental

Protection Agencys list of hazardous
substances and is on the watch list as
an emerging contaminant by the
Office of the Deputy Under Secretary
of Defense for Installations and
Environment Chemical and Material
Risk Management Directorate
(CMRMD).1 As a result, Ni-based
products are expected to become
more heavily regulated and, thus, not
suitable for mid- to long-term solutions. To address this problem, the
team investigated non-Cr and nonNi technologies (i.e., largely cobaltbased coatings), with fewer health
concerns and potentially reduced
restrictions as compared to EHC (see
Table 1).
Background. Numerous electroless
and electrochemically deposited
alternatives to EHC were evaluated
and found to be successful candidates for replacement; however, none
were transitioned to the Air Logistics
Centers (ALCs) largely due to changing workloads or priorities, additional qualification testing requirements,
and/or potential reduced bath life
and hence increased generation of
F00612 waste [2]. To facilitate transition at the original equipment manufacturer (OEM) level, a landing gear
(LG) manufacturer was added to the
Carcinogenicity
IARC5
ACGIH6
NTP7
US EPA8
Group
0.019
A1
10
0.01510
1.5
N/A
Class 2A
0.1
20
0.05
0.0210
2B
A3
N/A11
N/A
Table 1. Metal exposure limits and carcinogen groupings listed by associated agencies. 3
1CMRMD was formerly known as the Materials of Evolving Regulatory Interest Team
(MERIT).
2Exposure limits: PEL = permissible exposure limit; IDLH = immediately dangerous to
life or health; REL = recommended exposure limit; TLV = threshold limit value
3Agencies: OSHA = Occupational Safety and Health Administration; NIOSH =
National Institute for Occupational Safety and Health; ACGIH = American Conference
of Governmental Industrial Hygienists; IARC = International Agency for Research on
Cancer; NTP = National Toxicology Program; US EPA = United States Environmental
Protection Agency
4CAS = Chemical Abstracts Service
5Group 1 carcinogenic to humans; Group 2B - the agent (mixture) is possibly carcinogenic to humans
6Group A1 carcinogenic to humans; Group A3 - known animal carcinogen, unknown
human relevance
7Group 1 - Known human carcinogen; Class 2A - suspected carcinogen
8Group A - Known human carcinogen
9Reference points are for insoluble compounds
10Reference points are for soluble compounds
11WC/Co powders and hard metals are reasonably anticipated to be human carcino-
gens according to the NTPs Report on Carcinogens (RoC), Twelfth Edition (2011). This
is based on limited evidence of carcinogenicity from studies in humans and supporting
evidence from studies on mechanisms of carcinogenesis. Nevertheless, there is no
reported file within the RoC on cobalts capacity to act as a lone carcinogen.
12F006 wastes are wastewater treatment sludges that result from metal finishing
processes.
ORGANIC
finishing
Test
Test Method
EHC Baseline
Nano-Co-P
Benchmark
Ni-P + SiC
Co-P + SiC
AMS 2460
PASS
MARGINAL
PASS
PASS
Thickness
(mils; target = 5 mils)
ASTM
B 487
12.6
6.3
5.1
7.9
Surface Profile
(in)
ANSI
B 46.1
As-Plated: 28.9
Ground: 5.7
As-Plated: 7.1
Ground: Not tested
As-Plated: 15.9
Ground: 6.7
As-Plated: 37.1
Ground: 11.2
Adhesion
ASTM
B 571
FAIL
PASS
FAIL
FAIL
Hardness
(VHN)
ASTM
E 384
PASS
900
616
633
580
Porosity
(number of pits)
AMS
2460
FAIL
25
80
11
118
120 Hr Corrosion
Resistance
(hr to red rust/rating13)
Taber Wear Resistance
(Taber Wear Index)
ASTM
B 117
0-24 hr
Rating: 6.4
0-24 hr
Rating: 8.0
0-24 hr
Rating: 4.6
0-24 hr
Rating: 6.2
ASTM
D 4060
2.5
14.8
3.1
2.2
Block-on-Ring Wear
Resistance
(block scar depth mils)
ASTM
G 77
0.57 mil
3.43
6.00
3.35
Coefficient of Friction
ASTM
G 77
0.704
0.580
0.660
0.801
Quality
Table 2. Phase I Test Results

Evaluation criteria: Green Pass; Yellow Marginal pass; Red Fail
project team to perform evaluation

of new emerging alternatives for
EHC replacement. In Phase I of this
project, formerly evaluated, yet successful alternatives were reviewed to
identify coatings for aircraft landing
gear use. Two candidate coatings
emerged: a mid-phosphorus electroless nickel phosphorus (Ni-P) coating with occluded silicon carbide
(SiC) particles and an electrolytic
cobalt phosphorus (Co-P) coating
with occluded SiC particles. The NiP+SiC coating is amorphous at 1013% by weight P, microcrystalline at
3-5% by weight P, and exhibits crystalline variations thereof occurring
in intermediate P concentrations.
SiC content is approximately 11% by
weight, and the average size of the
SiC particles ranges from 3 to 5 m
[3,4].
The
hybrid
nanocrystalline/amorphous Co-P+SiC
coating contains 6 to 12% by weight
P and 5 to 11% by weight SiC content. The coating is reported by the

vendor to display increased homogeneity with increased P content. SiC
particles are 1 to 10 m, with average
particle sizes between 3 and 5 m
(less than 10% of the particles under
2 m and less than 10% of the particles above 7 m)[5]. EHC was chosen
as the baseline, and a nanostructured
cobalt-phosphorus
(nano-Co-P)
coating was selected as the industry
benchmark. The nano-CoP coating is
reported by the vendor to contain
approximately 2% to 3% phosphorus
and exhibit crystal sizes of 20 nm or
less [6].
Phase I screening test results
(shown in Table 2), compared to
EHC baseline results (shaded grey
in the table) and AMS 2460 criteria,
were quite unexpected. Reduced
performance was shown by all coatings as compared to previous test-
ing. Therefore, additional, Phase II,

testing was required to determine
the suitability of any alternative or
the benchmarkthe subject of this
article.
Experimental Details. AMS 2460
and USAF and the LG manufacturer
requirements were used as acceptance criteria for testing, as shown in
Table 3, with the most stringent
requirements taking precedence. All
testing was conducted in accordance
with ASTM International, the
American National Standards
Institute (ANSI), ASME, and/or
Federal Specifications.
Most landing gear parts are fabri13ASTM
D 1654 Standard Test Method for Evaluation

of Painted or Coated Specimens Subjected to Corrosive
Environments ratings: 10=No failure; 9=0-1% failure
(by area); 8=2-3%; 7=4-6%; 6=7-10%; 5=11-20%;
4=21-30%; 3=31-40%; 2=41-55%; 1=56-75%; 0=over
75% failed.
ORGANIC
finishing
Test
Quality
Test Method
AMS 2460
Sample Size
Specimens
per Coating
All Specimens
Acceptance Criteria
Per AMS 2460; must be easily reproduced.
Fatigue Debit
ASTM E 466
Per Section
5.2.1.1
of ASTM E 466
Fatigue debit must be less than or equal to

that of the EHC baseline data, and no
coating failure must be exhibited.
Hydrogen
Embrittlement
ASTM F 519
Type 1a.1 per

ASTM F 519
Must be non-embrittling.
Fluid Corrosion
Resistance
(5 fluids)
ASTM F 483
1 x 2 x 0.100 in
15
Equal to or better than EHC when subjected

to reagent grade water (ASTM D 1183),
synthetic sea water (ASTM D 1141), solventbased paint stripper (TT-R-2918, Type 1),
peroxide-based paint stripper, water-saturated hydraulic fluid (MIL-PRF-5606)
EVALUATION OF COATINGS DEPOSITED ON A COMPLEX GEOMETRY

Thickness
(sectioned and mounted)
ASTM B 487
ASTM B 499
3 mils 10%; capable of 8-10 mils
Hardness
ASTM E 384
ASTM B 487
Tube
cross-section
100-gram load, 10-15 seconds; avg. 5

measurements/panel. 850 VHN or greater,
900 KHN and/or 68-74 HRC are acceptable
(USAF).
Knife Adhesion
ASTM B 571
Tube half
Salt Fog Corrosion

Resistance
(120 hr)
ASTM B 117
Tube half
No separation of the plate from basis metal

at the interface at 4X magnification; no
cohesion failures.
No red rust after 120-hr exposure to salt
fog. Reject the lot if any specimen fails.
Table 3. Test Matrix
cated from high-strength steel (e.g.,

300M and 4340). Due to high cost,
4340 steel test specimens were used
only for critical requirements including fatigue and hydrogen embrittlement (HE) testing. Test specimens
were machined from 4340 steel and
heat treated to 5153 Rockwell
Hardness Scale C (HRC) to obtain
ultimate tensile strength (UTS) values between 260280 kilopounds per
square inch (ksi). Fatigue specimens
were procured from Westmoreland
Mechanical Testing & Research
(WMTR) of Youngstown, Pa., who
subsequently shot peened the specimens per AMS 2430 (100% coverage)
at an intensity of 6-10 A14 to alleviate
stress concentrations. WMTR also
performed the high cycle fatigue
tests after coating. HE test specimens
were
procured
from
Dirats
Laboratories in Westfield, Mass.,
which also performed testing. All

other specimens were fabricated
from 4130 steel.
Again, the Ni-P+SiC particles and
Co-P+ SiC particles were the candidate coatings. The nano-CoP was the
benchmark and EHC was the baseline.
All specimens were labeled with
specific identifications, and vendors
were requested to apply coatings to a
minimum thickness of 0.005 inches
(5 mils) to one side of flat specimens
and the test portion of the axial
fatigue specimens and a minimum
thickness of 3 mils 10% on the
inside diameter of the tubes and on
the test region of the HE bars. All
coatings received a standard HE
relief bake at 375F for 24 hours (hr)
within 4 hr of deposition and were
visually inspected for quality purposes. Coatings deposited on flat
coupons were ground by R&M

Machining of Latrobe, Pa., while
fatigue bars were ground by WMTR,
to a thickness of 3 mils and a surface
profile average (Ra) of 16 micro-inches (in) or better. Coatings deposited
on HE bars and on the inside diameter of tubes were not ground due to
grinding difficulties with these
geometries and the risk associated
with damaging the coatings and/or
substrates during grinding.
Fatigue specimens were cycled
under load-controlled conditions
and examined visually every 10,000
cycles up to 150,000 cycles maximum. A stress ratio of R=0.1 was
used at a common maximum stress
of 185 ksi and frequency of 10 hertz
14A
corresponds to the measure of intensity determined using Type A Almen strips.
ORGANIC
finishing
Performance
Rating
further development and/or evaluation. As a result, a performance rating scale shown in Table 4 was developed, which is different from the
pass/marginal/fail scale used previously.
Coating Performance Assessment
Demonstrated significant potential to meet performance criteria
Some developmental work is required to improve performance
Requires significant research and development efforts to improve

performance
EXPERIMENTAL RESULTS AND

DISCUSSION
Visual inspections were performed
by the same laboratory analyst to
assess coverage, boundaries, finish,
Table 4. Coating Performance Rating Methodology
Test
EHC Baseline
Nano-Co-P
Benchmark
Ni-P + SiC
Co-P + SiC
Coating performance assessment, rating or comments

3
23,693 2,275
72,179 64,819
3 samples below EHC
All fluids pass
3 fluids failed
1 fluid failed
2 fluids failed
Quality
Fatigue Debit
(Cycles to Failure)
As-plated Hydrogen
Embrittlement
Fluid Corrosion
Resistance
49,914 9,070
14,795 3,976 All samNo samples below EHC
ples below EHC avg.
Evaluation of Coatings Deposited on a Complex Geometry

Thickness
(mils)
5.2 to 12.4
3.5 to 3.9
2.9 to 3.2
4.7 to 6.0
Hardness
(Vickers)
835
1 failed panel
552
All panels failed
663
All panels failed
752
All panels failed
2
1 tube failed
Rating: 0
Rating: 10
Rating: 916
Rating: 1017
Knife Adhesion
120hr Corrosion
Resistance
(Corrosion rating)
Table 5. Summary of Phase II Test Results
(Hz). HE specimens were loaded to

75% of the notched tensile strength
for up to 200 hr without failure. If
failure of one specimen occurred, the
remaining three samples were incrementally loaded to 90% UTS for 2
hrs. If no failure occurred, then the
process was considered non-embrittling. However, if any specimen failed
to achieve 90% UTS, then the results
were considered to be inconclusive,
requiring the test to be repeated with
4 new specimens. Fluid corrosion
specimens were cleaned with reagent
grade acetone, dried in an oven at
150F for 2 hr, placed in a desiccator
for 16 hr, weighed to the nearest 0.1
milligram (mg), and immersed in the
respective test solution (maintained
at a temperature of 100F) for 24 hr.
Specimens were removed, cleaned

and dried again, and visually inspected for discoloration, dulling of the
coating, etching, and the presence of
accretion, pitting, selective or localized attack. Specimens were
immersed in the respective solutions
again for 144 hr, after which they
were again cleaned, dried, placed in a
desiccator for a minimum of 16 hr,
reweighed, and visually examined as
mentioned previously. Test specimen
appearance was rated per ASTM F
1110 corrosion severity scale. 15
Although the ultimate criteria for
acceptance were the alternatives performance in comparison to EHC, it
was critical to compare the alternatives and the benchmark to each
other to identify the most viable for
and plating characteristics. Table 5

shows that all sample sets received
overall passing ratings according to
AMS 2460 quality inspection criteria
for all four tested coatings. All coatings showed even and smooth coverage; however, many flat EHC and
some Co-P+SiC samples demonstrated beading, edge build-up and pitting. All EHC, flat panel/bar NanoCo-P, and fatigue Co-P+SiC specimens were bright and/or shiny.
15Corrosion
severity scale: 0=none; 1=very slight or

discoloration noted (up to 5% of the surface area corroded); 2=slight (5-10%); 3=moderate (10-25%);
4=extensive or pitting present (>25%)
16All three tubes exhibited pitting and each were rated
9
17Only one tube was rated a 9 and the other two tubes
were rated 10.
ORGANIC
finishing
Coating
Coating
Thickness
(mils)
Fluid
Average ASTM F 1110 Corrosion Severity Rating
Reagent-Grade
Water
Synthetic
Sea Water
Methylene
Chloride Paint
Stripper
Peroxide Paint
Stripper
Water-Saturated
Hydraulic Fluid
Exposure Time (hr)
24
168
24
168
24
168
24
168
24
168
EHC
3.84
0.3
0.7
0.0
0.3
0.0
0.0
0.0
0.0
0.0
0.0
Nano-Co-P
4.31
3.0
3.0
1.0
1.0
0.0
0.0
1.7
4.0
0.7
0.7
Ni-P + SiC
3.27
0.0
1.0
0.0
1.0
0.0
0.0
1.0
1.0
1.0
4.0
Co-P + SiC
4.28
1.0
1.0
1.0
1.0
0.0
0.0
1.0
2.0
0.0
1.0
Table 6. Fluid Corrosion Resistance Details

*The row that is shaded grey indicates baseline data.
However, Nano-Co-P tubes, all nonfatigue, Co-P+SiC specimens, and all

fatigue Ni-P+SiC specimens were a
matte finish. The non-fatigue NiP+SiC specimens were a dull grey finish. Most Co-P+SiC and many EHC
and Nano-Co-P flat panels samples
exhibited contact marks, while only
one Ni-P+SiC panel did. All coatings
demonstrated some level of staining
in flat specimens, but a few Ni-P+SiC
HE specimens and several Co-P+SiC
fatigue specimens also exhibited
staining. Most EHC flat panels
exhibited haziness near the contact
mark, and several flat panels displayed water marks. A couple NanoCo-P tubes were discolored and displayed streaking in the discolored
area, and a couple Co-P+SiC flat panels and fatigue specimens also
showed discoloration.
The column in Table 5 that is shaded grey indicates baseline data that
were gathered for comparison to the
benchmark and candidate coatings.
p
In terms of HE testing, only the
Nano-Co-P had a specimen that
failed prior to 200 hr. As a result, the
remaining three specimens were subjected to the standard 5% incremental step load. However, all three specimens failed prior to reaching the
required ultimate tensile strength. In
accordance with ASTM F 519, four
additional specimens were subjected
to the test. All additional specimens
achieved 200 hr in testing, meeting
the requirement for HE testing.

Fluid corrosion resistance was conducted to determine whether the
alternative coatings could undergo
routine exposure to typically used
maintenance fluids. As shown in
Tables 5 and 6, only EHC coatings
passed all fluid testing. Of the alternative coatings and benchmark, NiP+SiC performed the best, only performing worse than EHC in a watersaturated hydraulic fluid, but 168-hr
exposure to the fluid was significantly worse than EHC. Although the CoP+SiC performed worse than EHC in
two fluids, the margin of difference
was less at the 168-hr exposure than
the Ni-P+SiC in the single fluid at
168-hr exposure. The benchmark
coating performed significantly
worse than EHC in three separate
fluids at both the 24- and 168-hr
exposure limits.
As was seen in Table 5, there was a
large range in coating thickness for
EHC on a complex geometry, as is
typical for the EHC coating. As
expected, the coating thickness for
the electrolessly deposited Ni-P+SiC
was closely controlled. However,
both electrolytic Nano-Co-P and CoP+SiC maintained consistent control
of coating thickness (although
beyond the 10% limit), which may
be able to be further optimized into a
fully
acceptable
range.
Unfortunately, no process fully met
the hardness requirements in all
specimens, including EHC. However,
ORGANIC
finishing
only one EHC specimen failed hardness. Because the Co-P+SiC had the
highest hardness, it might have good
potential for meeting other wear
requirements, as long as suitable
adhesion and low coating stress is
maintained.
As expected, EHC failed 120-hr salt
fog corrosion resistance testing, with
pitting appearing at 48 hr and red
rust at 72 hr, with over 75% of the
surface failing. The Nano-Co-P coating performed the best with no pitting or corrosion observed after 120
hr, followed by the Co-P+SiC coating
that exhibited 2 pits at 48 hr, but no
failures for red rust or other pitting
observed. The Ni-P+SiC coating
exhibited a pit on one tube at 48 hr
and two pits on one tube and one pit
on another tube at 120 hr. As a
result, it was rated a 9 (less than 1%
failure) after 120-hr exposure, with
no red rust being observed.
CONCLUSIONS
Based on Phase II testing, the NiP+SiC coating performed the best of
the alternatives, the benchmark, and
EHC. However, there is still concern
that substantial hardness cannot be
achieved unless a high temperature
heat treatment is used, which is not
permitted for high strength steels.
This, combined with reduced sliding
wear resistance observed in Phase I
testing, is cause for concern.
However, previous test efforts had
shown the contrary in wear testing,
performing even better than EHC[7].
Upon review of historic test data, it
was observed that EHC performed
substantially better (i.e., a nearly
four-fold improvement) in fatigue
testing in the more recent Phase II
evaluation.14 Consequently, although
the Co-P+SiC coating had shown
exceptional abrasive wear resistance
in previous testing and met most
other requirements, there are still
concerns with the fatigue life of the
coating. As with the other alternatives, Co-P + SiC also demonstrated
less sliding wear resistance than EHC
in the block-on-ring test performed
during Phase I.
As a result, the team investigated
potential differences in processing
between the more recently deposited
EHC coatings (i.e., Phase I and Phase
II test coatings) and those deposited
for previous evaluations to determine differences in vendor, processing conditions, and/or chemistry.
The team found that the most
notable difference between the two
data sets was related to shot peening
of the fatigue specimens. The original fatigue data were obtained for
specimens that were not shot peened
prior to plating, while all fatigue
specimens evaluated during this
effort were shot peened prior to plating. This led to the significant differences in the EHC baseline fatigue
data. Another notable difference was
that different plating vendors were
used to prepare the EHC baseline
specimens for the historical and current baseline data [8]. However, upon
review of processing conditions, it is
not clear that differences in processing had occurred to warrant differences in EHC baseline results.
Nevertheless, it has been observed
previously, that slight modifications
in process conditions or chemistry
can result in profound differences in
coating structure and the resulting
performance
characteristics.
Optimization of processing parameters for the candidate coatings is recommended to obtain more consistent results.
ACKNOWLEDGMENTS
This work was conducted under
AFRL APTO tasking. The authors
would like to express thanks to Mr.
Tom Naguy, AFRL-APTO, for his
support of this work. Additionally,
the authors would like to thank the
stakeholders at the LG OEM for
their technical input, time and consideration in support of this effort.
REFERENCES
1. Legg, Keith, Chrome-Free Aircraft
Finishing, Paint and Coatings
Industry, March 1, 2008.
2 Concurrent Technologies
Corporation, Requirements
Analysis Report, Weapon System
Technical, Logistical, and

Sustainment Support Contract
FA8601-05F-0011, Subtask 041,
Topic 1: Transition of Advanced NonLine-of-Sight (ANLOS) Engineering
Coatings, September 30, 2007.
3 Feldstein, Michael, The
Environmental Benefits of
Composite Electroless Nickel
Coatings: Eliminating Chrome
and Reducing Nickel, unpublished report provided by Surface
Technology, Inc.
4 Communications with Michael
Feldstein, Surface Technology,
Inc.
5 Carpenter, John; Kertesz, Al; and
Datta, Amit; Electro-Composite
Coating, Advanced Materials and
Processes, March 2009.
6 Prado, Ruben; Facchini, Diana;
Mahalanobis, Neil; Gonzalez,
Francisco; and Palumbo, Gino;
Electrodeposition of
Nanocrystalline Cobalt Alloy
Coatings as a Hard Chrome
Alternative, 2009 Department of
Defense Corrosion Conference.
Corporation, Phase II,
Demonstration and Validation
Test Report, General Services
Administration Task Order
5TS5703D035U, Contract Number
GS-23F-0061L, August 30, 2005.
Corporation, Phase II, Level 2
and 3 Screening Test Report,
General Services Administration Task
Order 5TS5703D035U, Contract
Number GS-23F-0061L, March 24,
2005.
18Previous
fatigue testing performed on EHC resulted

in an average of 6,401 cycles to failure, compared to
an average of 23,693 cycles to failure obtained during
this effort.
adhesion&bonding
How High Temperatures Affect
Adhesives and Sealants
or an adhesive bond to be useful,

it must not only withstand the
mechanical forces that act on it, but
it must also resist the environmental
elements to which it is exposed during service. One of the most degrading elements for organic adhesives is
heat. All polymeric materials are
degraded to some extent by exposure to elevated temperatures. Not
only are short-term physical properties lowered by elevated temperature,
but properties will also degrade due
to prolonged thermal aging.
Much has been accomplished in
recent years to develop and commercialize high-temperature structural
adhesives. Such adhesives are finding
use in demanding aerospace, automotive, and industrial applications.
This article will review the factors
that are important when considering
an adhesive or sealant for elevated
temperature exposure.
FACTORS AFFECTING ELEVATED

TEMPERATURE RESISTANCE
Several important questions need to
be asked of an adhesive or sealant if
high service temperatures are
expected:
1.What is the maximum temperature that the bond will be exposed
to during its life?
2.What is the average temperature
to which a bond will be exposed?
Ideally, one would like to have a

definition of the entire temperature
versus time relationship representing
the adhesives expected service history. This data would include time at
temperatures and rates of temperature change.
Certain adhesives will have excellent resistance to high temperatures

over short duration (e.g., several
minutes or hours). The short-term
effect of heat on a polymeric adhesive is primarily one of increasing
molecular mobility or flexibility.
Thus, adhesives with relatively high
temperature resistance may actually
show increased toughness and elongation but lower shear strength.
Adhesives with lower temperature
resistance will show softness and a
high degree of creep on exposure to
elevated temperatures.
Prolonged exposure to elevated
temperatures may cause several
reactions to occur in the adhesive
or sealant that will weaken the
bond. The mechanisms that affect
the bulk material (adhesives tensile
strength, modulus, etc.) are oxidation and pyrolysis. Thermal aging
can also affect adhesion by causing
dimensional changes in the adhesive or adherend, or by reducing its
ability to absorb stress by evaporation of plasticizer.
Generally, excessive heat may have
the following effects on an adhesive:
Softening of the adhesive,
resulting in flow or excessive
creep
Split polymer molecules, causing
lower molecular weight, degraded
cohesive strength, and
by-products
Oxidation (if oxygen or a metal
oxide interface), resulting in lower
cohesive strength and weak
boundary layers.
Most thermally resistant structural adhesives and sealants are capable
of withstanding temperatures up to
150C on a long-term basis.
However, there are relatively few that
can tolerate higher temperatures. To
use these materials, the end-user
must generally pay a premium in
adhesive price and also be able to
provide long, high-temperature curing conditions, sometimes with
pressure exerted on the adhesive
bond during cure. Long-term temperature resistance greater than
250-300C can only be accomplished with ceramic, metal, or other
non-organic materials.
Thermal Softening. The effect that
high temperatures have on an adhesive bond will depend primarily on
whether the adhesive is crosslinked
(thermosetting) or not. Most structural adhesives are based on
crosslinked polymers. Crosslinking
is a reaction that chemically or
physically binds the adhesive molecules together and inhibits their
separation due to mechanical or
environmental forces. The degree of
crosslinking is indicated by the
adhesives glass transition temperature, Tg. The Tg is the temperature
where a glassy polymer begins to
exhibit rubbery characteristics and a
noticeable change in properties
such as thermal expansion coefficient and moisture resistance
(Figure 1).
If heating brings an adhesive above
its glass transition temperature, the
molecules will become less immobile
so that the cohesive strength will
decrease. In this condition, the adhesive is susceptible to flow under
stress (creep) and greater chemical
or moisture penetration.
For an adhesive to withstand elevated-temperature exposure, it
must have a relatively high glass
transition
temperature
(Tg).
Materials with a low Tg, such as
adhesion&bonding
Figure 1. Effect of increased temperature and Tg on properties of an adhesive.
dependent on
the specific
formulation
and is usually
an indicator
of the degree
of crosslinking. Because
of
this
c r o s s l i n ke d
structure,
adhesives
show relatively little creep
at elevated
temperature
and exhibit
relatively little loss of
mechanical
function
when exposed
Figure 2. The effect of 550F (274C) aging in air and nitrogen on a high-temperature epoxy phenolic
adhesive.1
many of the thermoplastic or hot

melt adhesives, may prove excellent
adhesives at room temperature.
However, once the service temperature approaches the Tg of the adhesive, plastic flow results in deformation of the bond and degradation of
cohesive strength.
Thermosetting adhesives, such as
those based on epoxy chemistry, are
chemically crosslinked and exhibit
no melting point. The Tg will be
to moderately elevated temperatures.

Some of these materials are suitable
for high-temperature applications.
When considering thermosets, the
critical factor is the rate of strength
reduction due to thermal oxidation
and pyrolysis rather than softening.
Oxidation. Thermal oxidation is a
mechanism resulting from an adhesives longer term exposure to elevated temperatures. Oxidation ini-
tiates a progressive chain scission

of molecules, resulting in loss of
weight, strength, elongation, and
toughness. Figure 2 illustrates the
effect of oxidation by comparing
adhesive joints aged in both hightemperature air and inert-gas environments.
The rate of bond strength degradation due to thermal oxidation will
depend on the temperature, the
adhesive formulation, the rate of airflow, and even the type of adherend.
Some metal-adhesive interfaces are
chemically capable of accelerating
the rate of oxidation. For example, it
has been found that nearly all types
of structural adhesives exhibit better
thermal stability when bonded to
aluminum than when bonded to
stainless steel or titanium (as shown
in Figure 1).
Adhesive and sealant formulators
have extended the thermal
endurance of their products by
incorporating additives into the formulations. Chelating agents and
antioxidants are commonly found
in the formulations of high-temperature adhesives to forestall, as best as
possible, the effects of oxidation.
Usually, concentrations of less than
1% by weight are effective. Catalyst
poisons may also be incorporated
into the system to react directly with
the metallic substrate, thereby
inhibiting its catalytic effect on oxidation.
Pyrolysis. This is simple thermal
destruction of the molecular chain
of the base polymer in the adhesive
or sealant formulation. Pyrolysis
causes chain scission and decreased
molecular weight of the bulk polymer. This results in both reduced
cohesive strength and brittleness.
Resistance to pyrolysis is predominantly a function of the intrinsic
heat resistance of the polymers
used in the adhesive formulation.
Many of the base resins used in
high-temperature adhesive formulations are rigidly crosslinked or are
made up of a molecular backbone
referred to as a ladder structure.
The rigidity of the molecular chain
decreases the possibility of chain
adhesion&bonding
Figure 3. Degradation of a ladder polymer (top)

and a straight chain polymer (bottom) due to
thermal aging.
scission by preventing thermally

agitated vibration of the chemical
bonds. The ladder structure (Figure
3) provides high bond dissociation
energy and acts as an energy sink to
Property
Continued crosslinking due to elevated temperatures, resulting in

adhesive shrinkage and internal
stresses on the joint.
Thermal expansion differences
between the adhesive and the
substrate, resulting in internal
stress on the joint.
Evaporation of plasticizer or other
low molecular weight component
from the adhesives, resulting in
bond embrittlement and reduced
capability of absorbing external
stresses.
Polymers for High Temperature

Service. High-temperature adhesives
are usually characterized by a rigid
ing candidate for high-temperature

applications, an adhesive or sealant
must provide all of the usual functions necessary for good adhesion
such as wettability, low shrinkage on
cure, thermal expansion coefficient
matched to the substrates, and so
forth. But it must also possess:
1. A high glass transition temperature
2. Resistance to oxidative degradation
3. Resistance to thermally
induced chain scission
These factors will affect the cohesive strength of the bulk adhesive.
However, the nature of the overall
adhesive joint (i.e., adhesive and
adherends) is also important. The
Modified Epoxy
Epoxy-Phenolic
Polyimide
Silicone Rubber
Pressure
Sensitive Silicone
-55 to 177
-251 to 260
-251 to 315
-73 to 232
-40 to 260
Optimum Cure
Condition
- Time, min
- Temp, C
- Pressure, psi
60
177
10-50
60
177
10-100
90
288 to 371
50
24 hours
Room Temp
Contact
5-10
100
Minimal
Tensile shear, psi at

- 20 C
- 175C
- 260C
4330
2300
--
3800
2500
2000
3300
-2300
275
-275
3-10 piw
-3-10 piw
Temperature
Range, C
Table 1. Short-Term Strength and Cure Properties of High Temperature Structural Adhesives
its environment. Notice in Figure 3

that to have complete chain scission
resulting in a decrease in molecular
weight, two bonds must be broken
in a ladder polymer, whereas only
one needs to be broken in a more
conventional polymeric straight
chain structure.
Other Important Factors. The factors described above generally affect
the bulk properties of the adhesive
material within the joint. However,
there are also interfacial properties
that are important when considering elevated temperature service.
These properties are dependent on
the combination of the adhesive and
the adherends, and mainly consist of
the following:
polymeric structure, high glass transition temperature, and stable chemical groups. The same factors also
make these adhesives very difficult
to process. Only certain polymers
(i.e., epoxy-phenolic, bismaleimide,
polyimide, polybenzimidazole) can
withstand long-term service temperatures greater than 177C. However,
modified epoxy and even other
adhesives have moderately high
short-term temperature resistance.
Silicone adhesives also have excellent high-temperature properties
but exhibit lack of high shear
strength. Properties of these adhesives are compared in Table 1.
SUMMARY
In order to be considered as a promis-
adhesive joint must show dimensional stability after long-term elevated temperature service.
REFERENCES:
1 Krieger, R. B., and Politi, R. E.,
High Temperature Structural
Adhesives, in Aspects of Adhesion,
vol. 3, D. J. Alner, ed., University
of London Press, London, 1967.
BIO
Edward M. Petrie is the sole proprietor of
EMP Solutions, a Cary, N.C.based consulting firm focused on solving problems
in the adhesives and sealants industry. He
also works as a technical expert for
SpecialChem.
Visit www.specialchem4adhesives.com
for more details.
cleaningtimes
Type Industrial First
n 1996, speaking at the late John

Dennis Mr. Clean Conference, I
made the then-seemingly ludicrous
forecast that within five years one
would be able to shop for, and purchase, cleaning goods using the
Internet.
While one may argue about the
wisdom of such a forecast, or criticize its timing, there is no question
that in 2012 one can fulfill the
promise of that forecastand so
much more.
This column is about the experiences of others (and my own) in
using the Internet to investigate,
manage, and purchase parts cleaning
equipment, supplies, and facilities.
THE KEY PROBLEM

The key problem is that the word
cleaning can be associated with:
Cleaning the carpets and
upholstery in your home
Cleaning home facilities with
steam
Cleaning of diapers
Cleaning floors, drains, toilets
and other maintenance work
Cleaning of commercial and
home septic tanks
The consequence of this problem

is that ones search engine returns a
considerable amount of information
in which one presumably has no
interest. There is a second aspect to
this problem. It is that the search
not been disappointed with foreignsourced purchases.
engine returns URLs for firms providing cleaning services.
SOLUTION OF THE KEY PROBLEM

It's simple! Limit Internet searches
to those of interestthose associated with INDUSTRIAL cleaning.
More importantly, use the - character1 in search strings. This indicates that the search engine is not to
return results containing whatever
word follows the - character.
THE SEARCH FOR USED STUFF
A client, despite my advice against it,
purchases and uses used cleaning
equipment. This firm never purchases new equipment. It is their organizational belief that there is little or
no valuable technology currently
being developed and implemented
in new parts cleaning equipment. So
they believe they miss little or no
new technology by purchasing used
cleaning equipment.
Their strategy is to purchase preowned cleaning machines, use them
for two years or so, consign them to
scrap, and repeat the same.
One can find firms re-selling cleaning equipment with this search
string: used industrial cleaning equipment -service -carpet -floor.
FOREIGN AFFAIRS I
It is absolutely certain that this
search will identify foreign firms
selling used equipment. Firms in
India and China are commonly identified.
One clients firm has purchased
pre-owned equipment from these
sources. While travel costs and difficulties have made pre-purchase
inspection unlikely, in general they
have found good bargains and have
One to two decades ago this

approach would never have been
considered, or recognized. One to
two decades ago no user would have
considered purchasing cleaning
equipment without the post-purchase support and service available
from domestic suppliersbut generally not from foreign suppliers.
Thats one manifestation of the
changes in the industrial cleaning
marketplace globalization, and contraction of support.
ANOTHER PROBLEM
The search string aboveand almost
all others related to cleaning technologyreturns useful results in an
unexpected place.
Search engines generate revenue by
listing advertisements adjacent to
the information returned as results
of the search. It is likely that the
information contained in the advertisements might be more valuable.
This information will often be more
focused on the needs expressed in the
search than will be the results of the
search.
There is nothing wrong, per se,
with this outcome. Its existence simply means that one has to look for
results in an unexpected location.2
THE SEARCH FOR EQUIPMENT
SUPPLIERS
The same search strategies can be
used to find new cleaning equipment. To enhance the chance for
success of a single search, one might
add the phrase -used to the search
cleaningtimes
string noted above.3 To still further
enhance the chance for success, one
should also add the appropriate
word aqueous or solvent.
It is likely that some or many of the
firms identified as suppliers will be
unknown to the searcher. This is
because some smaller firms depend
upon the Internet to reach potential
customers. Larger, more well-known
firms have distributors, salespersons,
and showrooms.
Despite substantial market consolidation over the last decade, small
regional firms still abound in the
marketplace. Disclosure: This author
believes this situation is a positive
characteristic of the market for
cleaning machines.
Cleaning machines are generally
assembled from a standard design of
commercially available parts, and
often do not represent differentiable
offerings. Small firms with limited
resources can compete in supply of
these goods.
THE SEARCH FOR SUPPLIERS OF

CLEANING AGENTS
Searches for these products are simpler. Two useful search strings are:
aqueous cleaning products and aqueous
cleaning agents. Both of these search
strings will return information4
about both cleaning juice (fluids
or agents) and cleaning iron
(equipment).
While it can be difficult to differ-
entiate among offerings of cleaning

machines, so it can be with cleaning
agents. Product names reveal little.
Suppliers can reveal on their website
a slate of products, each targeted for
a different application. This presentation should be sought. A useful
search string is: industrial cleaning
degreasing agents line.
If one searches for reviews of these
products, by using the search string
below, they will find white papers

and general analyses about the
industrial cleaning market (specific
cleaning agents arent reviewed):
review aqueous cleaning agents.
FOREIGN AFFAIRS II
Users seeking to purchase chemicals
for any purpose via the Internet will
a plethora of suppliers located in
China. At least four web sites integrate access to these companies. For
the most part these are firms selling
bulk chemicals and almost never are
firms selling formulated products.5
WARRANTY SERVICE
Simply put, there isnt any, as one
normally anticipates receiving with
the purchase of, say, an automobile.
This author is aware of only one
firm which provides a five-year warranty with purchase of a cleaning
machine. One may identify them
with this search string: 5-year warranty cleaning machine -washing.
INFORMATION RULES!
That is what mattersgood and
understandable information. The
Internet is an excellent source. But
there are others. This magazine and
its weekly e-mails, frequent podcasts
and webinars provide topical and
detailed information. Some clients
rely on the latter; others have come
to rely on the Internet.
SUMMARY
My clients and I use and have used
the Internet to research opportunities and make purchases. A decade
ago, not many users would have had
the confidence to take the risk of
purchase without specific human
experience. What can fortify that
confidence is competitive pricing
and the depth of information available through the Internet.
REFERENCES
1. Characters to be inserted in
search strings between quotation
marks in this column to highlight their presence. Obviously,
the question marks are not to be
used in search strings.
2. Actually, some search engines
provide results as commercial

advertisements in two locations
on their output page. The normal location for advertisement is
on the right or left side of the
output pages. However, some
sponsored results are often
placed at the top of the output
page. It is important to note that
the parameters in the search
string noted with a - are not
considered in selection of these
sponsored advertisements. So
some of the real estate of the output page may be wasted.
3. Other words which might be
used are pre-owned or replacement.
4. Often the user must register with
their business credentials in
order to receive a copy of an
MSDS without purchase of the
cleaning agent.
5. Each of these companies offers
best price and respond to an
inquiry with an e-mail from
Alice, Joan, or Mary.
Surprisingly, prices do seem to
greatly depend upon the competitive nature of the initial inquiry.
BIO
John Durkee is the author of the book
Management of Industrial Cleaning
Technology and Processes, published by
Elsevier (ISBN 0-0804-48887). In 2012,
Elsevier will publish his landmark book
21st Century Solvent Cleaning (ISBN
185617-4328 ). He is an independent
consultant specializing in metal and critical cleaning. You can contact him at PO
Box 847, Hunt, TX 78024 or 122 Ridge
Road West, Hunt, TX 78024; 830-2387610;
Fax
612-677-3170;
or
jdurkee@precisioncleaning.com.
qualitycontrol
Run Charts as a Test of System
Performance
run chart, also known as a runsequence

plot,
displays
observed data in a time sequence.
Typically, the data displayed represents some aspect of the output or
performance of a manufacturing or
business process. Simply put, run
charts are a straightforward way to
summarize a single variant data set
graphically.
Single variant data sets are commonly understood to:
Behave like random data
Have a fixed distribution
Have a common location
Employ a common scale
Figure 1 shows a simple run chart

that displays data collected over
time. The median of the observed

data (73) is also shown on the chart.
Figure 2 is a run chart showing
eight random walks starting at 0.
The plot shows the current position
on the line (vertical axis) versus the
time steps (horizontal axis).
Examples might include measurements of the fill level of bottles filled
at a bottling plant, or the water temperature of a dishwashing machine
each time it is run. Time is generally
represented on the horizontal (x)
axis and the property under observation on the vertical (y) axis.
Oftentimes, some measure of central
tendency (mean or median) of the
data is indicated by a horizontal reference line.
Run charts are evaluated to find
Figure 1. Illustration of a simple run chart displaying data collected

over time.
incongruities in data that suggest

shifts in a process over time or point
out factors that might be impacting
the variability of a process. Typical
factors considered include unusually long runs of data points above
or below the average line, the total
number of such runs in the data set,
and unusually long series of consecutive increases or decreases.
Run charts are similar in some
regards to the control charts used in
statistical process control, but do
not show the control limits of the
process. They are, therefore, simpler
to produce but do not allow for the
full range of analytic techniques
supported by control charts.
Run charts display process performance over time. Upward and
downward trends, cycles, and large
aberrations may be spotted and
investigated further. Run charts can
also be used to track improvements
that have been put into place, check-
Figure 2. Run chart showing eight random walks, starting at 0.
qualitycontrol
ing to determine their success. Also
an average line can be added to a
run chart to clarify movement of the
data away from the average.
Alternatives with run charts:
1. An average line, representing
the average of all the y values
recorded, can easily be added to a
run chart to clarify movement of
the data away from the average.
An average line runs parallel to
the x axis.
2. Several variables may be
tracked on a single chart, with
each variable having its own line.
The chart is then called a multiple run chart.
3. Run charts can also be used to
track improvements that have
been put into place, checking
their success.
Questions to ask about a run
chart:
1. Is the average line where it
should be to meet customer
requirements?
2. Is there a significant trend or pattern that should be investigated?
Two ways to misinterpret run
charts:
1. You conclude that some trend
or cycle exists, when, in fact, you
are just seeing normal process
variation. (No process will ever be
without some variation.)
2. You do not recognize a trend
or cycle when it does exist.
Both of these mistakes are common, but people are generally less
aware that they are making the first
type, and are tampering with a
process that is really behaving normally. To avoid mistakes, use the following rules of thumb for run chart
interpretation:
1. Look at data for a long enough
period, so that a usual range of
variation is evident.
2. Is the recent data within the
usual range of variation?
3. Is there a daily pattern?
Weekly? Monthly? Yearly?
Using run charts to detect special causes of variation:

If you have 25 points or more in
your data series, you can use run
charts to detect special causes
something beyond the usual variability of the processacting on the
process.
1. Shifts: If you see eight or more
consecutive points on one side of
the centerline that indicates that
a special cause has influenced the
process. Points on the centerline
don't count; they neither break
the string, nor add to it.
2. Trends: Six consecutive jumps
in the same direction indicate
that a special cause is acting on
the process to cause a trend. Flat
line segments don't count, either
to break a trend, or to count
towards it.
3. Patterns: If you see a pattern
that recurs eight or more times
in a row, it is a good idea to look
for a special cause.
For more robust monitoring of a
process, and better information
about when your process is showing
variation beyond what is expected,
try using a control chart. It will
detect special causes more quickly,
and with more accuracy.
RUN CHART STATISTICS

For each line in the run chart, the
following statistics are calculated:
Mean The average of all the data
points in the series.
Maximum The maximum value in
the series.
Minimum The minimum value in
the series.
Sample Size The number of values
in the series.
Range The maximum value minus
the minimum value.
Standard Deviation Indicates how
widely data is spread around the
mean
What is it?
By collecting and charting data
over time, you can find trends or
patterns in the process. Because they
do not use control limits, run charts

cannot tell you if a process is stable.
However, they can show you how the
process is running. The run chart
can be a valuable tool at the beginning of a project, as it reveals important information about a process
before you have collected enough
data to create reliable control limits.
Use run charts when you can
answer yes to these questions:
1.Is the data collected over time?
2. Is the time order of the data
preserved?
GETTING THE MOST

Run charts should be used as a quick
test of system performance. Start-ups
and short runs in manufacturing
settings often produce insufficient
data for conventional control chart
analysis, but are easily analyzed in a
run chart. Inspection data generated
in these situations should be plotted
immediately on a run chart to
enable quick diagnosis of system
changes over time or to identify
signs that the process has begun to
stabilize.
Run charts are good way to illustrate
and share information with other
departments. They are often used to
post sales figures for all to see.
Patterns and trends are much easier
to see on a run chart than in a matrix
of rows and columns.
Because run charts can be easily
constructed, they are especially useful for one-time analysis of historical
data.
When to Use a Run Chart. If data
analysis focuses on statistics that
give only the big picture (such as
average, range, and variation), trends
over time can often be lost. Changes
could be hidden from view and
problems left unresolved. Run
charts graphically display shifts,
trends, cycles, or other non-random
patterns over time. They can be used
to identify problems (by showing a
trend away from the desired results)
and to monitor progress when solutions are carried out.
November/december 2012 I metalfinishing I 37
qualitycontrol
of various kinds, and their order by

connecting these with arrows (see
Figure 3). This diagrammatic representation can give a step-by-step
solution to a given problem. Process
operations are represented in these
boxes, and arrows connecting them
represent flow of control. Data
flows are not typically represented
in a flow chart, in contrast with data
flow diagrams; rather, they are
implied by the sequencing of operations. Flow charts are used in analyzing, designing, documenting or
managing a process or program in
various fields.
Figure 3. Example of the flow chart diagram.
RULES FOR INTERPRETING A RUN

CHART
The following provide some guidance in interpreting a run chart:
Eight consecutive points above (or
below) the center line (mean or
median) suggest a shift in the
process
Six successive increasing (or
decreasing) points suggest a trend
Fourteen successive points alternating up and down suggest a cyclical process
Scales must be in regular intervals
Charts that are to be compared
must also use the same scale and
symbols
Charts should be easy to read.
Use caution. Be careful not to use too

many notations on a run chart. Keep
it as simple as possible and include
only the information necessary to
interpret the chart.

Do not draw conclusions that are
not justified by the data. Certain
trends and interpretations may
require statistical testing to determine if they are significant.
Whenever possible, use a run
chart to show the variation in the
process. Do not assume that the
variation is so clear and obvious that
a run chart is unnecessary.
A run chart must not lie or mislead! To ensure that this does not
happen, follow these guidelines:
Often, in literature, a run chart
may be called a flow chart, but
these are two entirely different
types of chart and serve very different purposes.
A flow chart is a type of diagram

that represents an algorithm or
process, showing the steps as boxes
BIO
Leslie W. Flott, Ph.B., CQE, ASQ Fellow,
is certified as an IDEM Wastewater
Treatment Operator and Indiana
Wastewater Treatment Operator. He
received his Bachelor of Science Degree in
Chemistry
from
Northwestern
University and his Masters Degree in
materials engineering from Notre Dame
University. Most recently, Flott served as
the environmental program director and
instructor at Ivy Tech Community
College. Prior to that, he was the health,
environment, and safety manager at
Wayne Metal Protection Company.
askthe
expert
MATT STAUFFER, PAVCO, INC. IN CHARLOTTE, N.C.
The Trouble with Plating Baths
Q:
I am getting excess sulphate in my

chrome tank. Due to this excess, I'm
getting dull plating. Can you please tell
me how to solve this problem? Also, in my
cyanide copper tank the solution becomes
dark after 4-5 plating rounds. Can you
offer some advice?
: You mention a chrome bath
and a copper bath, so Ill go out

on a limb and assume youre plating
copper-nickel-chrome. If so, the
usual source for excess sulfate is
insufficient rinsing after nickel plating. A typical Watts nickel bath will
contain upwards of 35 opg (263 g/l)
of nickel sulfate. Even a simple sulfate catalyzed hex chrome has only
0.32 opg (2.4 g/l) sulfate. Based on
those relative quantities, it is pretty
easy to get a fair amount of sulfate
from a nickel bath into your chrome
if rinsing is insufficient. Use barium
carbonate to remove excess sulfate
and consider additional rinse tanks
(counterflowed) after nickel plating,
and/or use of spray rinsing for blind
holes, etc.
As far as the dark copper, I need a
little more information to go on, but
I will throw out the general advice
that more cleaning is always good.
You may be contaminating your copper with oils or buffing compound
due to insufficient cleaning. Carbon
treatment of your cyanide copper is
an effective way to remove contaminants. Make sure your parts have a
water break free surface before you
attempt to plate them.
Q:
Our nickel metal is high in our

bright nickel bath. [My vendor]
tells us the only way to bring it down is to
decant. Is there a way to bring it down
slowly without wasting solution?
A:
The increase in nickel metal

growth in most acidic plating
processes is caused by the difference
in anode and cathode plating efficiencies. In the case of Watts nickel
baths, you have 100% anode efficiency and approximately 93% cathode
efficiency. The remaining 7% is
directed towards the reduction of
hydrogen into hydrogen gas. This
hydrogen is a common source of gas
pitting. So, basically, you are dissolving more metal than you are plating
out. Most platers dilute their baths
to correct them. Some platers look
towards insoluble anodes. Care
must be taken to avoid the creation
of harmful oxidation products when
using insolubles.
There are products on the market
that utilize a membrane system to prevent this reaction. These can be expensive and do require maintenance.
The other options to consider
involve nickel recycling. This can be
done by working with a company
that recycles nickel solutions (plating
or stripping) into nickel metal or by
finding another plater, usually a barrel plater, who has a regular need for
nickel salts in his process. Usually, an
arrangement can be made to be beneficial to both parties.
The final option would be what I
would call home-grown recycling.
Set up a small plate out tank with
insoluble carbon anodes. A good
alternative for cathodes is nickel
anode chips, which can be readily
barrel plated.
Occasional adjustment may be
required to raise the pH due to the
use of insoluble anodes. Fresh solution can be added as the nickel is
depleted from the plate out cell. The
plated anodes can now be reused in
the anode baskets.
Q:
I am plating semi-brilliant nickel

bath over steel; my customer is heating parts (after nickel plating) up to 1250
degress celsius, and they are having blistering problems. What can I do to solve
this problem?
A:
This situation may be caused

by either base metal preparation
or conditions (i.e., stress) in your
nickel plate. The problem needs to be
isolated in order to solve it.
I would recommend that you plate
a zinc-coated steel hull cell panel in
the tank using the same semi-bright
nickel solution. Strip the zinc with
fresh hydrochloric acid, then remove
the panel from the acid immediately
after stripping is complete to avoid
over pickling. Ensure that there is no
water break film before you plate in
your nickel.
Heat treat the plated panel and
check for blistering. If you see blistering, it would appear you have an
issue with the semi-bright nickel. If
you do not see blistering, chances are
your problem is related to surface
preparation. You can repeat the plating test for confirmation in the lab
by running hull cell panels of your
nickel and a newly made nickel, and
heat treating both panels. If you confirm that the existing solution blisters and the new solution does not,
you will then need to investigate several potential factors, using the hull
cell to confirm appropriate corrective action.
1. Excess semi-bright brightener
additive. Semi-bright nickel does
use leveling agents. Excess class 2
nickel brightener will impact
stress levels. This can be removed
by electrolysis.
2. Organic contaminant caused
askthe
expert
by brightener breakdown or
soils/oil from poor cleaning.
Look at peroxide/carbon treatment for improvement.
3. Stress can be monitored
through stress tabs or spiral contractometer. This will allow a
more direct evaluation of treatments.
4. Certain metals can co-deposit
and cause stress. Look for low
current density darkness in the
hull cell. These metals can be
dummy plated to remove.

5. Check iron levels and peroxide
treat if necessary. Iron can cause
HCD defects. Keep below 20 ppm
for your application.
6. Always make sure basic chemistry is correct. Low nickel, low
boric, high pH can all cause high
current density issues. Start here.
If you find there is no blistering on
a test panel, then it is likely that your
issue is related to preparation.
Investigate to ensure parts are free of
water breaks. Check for sufficient
oxide removal as well as excess pickling. As Yogi Berra used to say about
plating, 90 percent [of the plating
game] is half preparation.
I have alkaline-free cyanide zinc

plating baths; the temperature is
now 35C. How can we cool down the
solutions in order to have better conditions? Is there a product that works at
high temperatures, or what kind of equipment should we use?
A:
Cooling coils in the plating

tank or a heat exchanger connected to an industrial chiller are recommended for alkaline zinc plating.
There are zinc brighteners on the
market that work well (enough) at
elevated temperatures, but none are
as bright across all current densities
as a lower temperature bath operated
at 25 degrees Celcius. Different additive levels and bath parameters are
required at the higher temperatures.
You can expect to use more brightener, and you will find that some low
current density areas tend not to be
as bright as the lower temperature
process.
This may not be objectionable once
the parts are bright-dipped and chromated, as both steps will tend to polish out dullness in the deposit. A
stronger (or longer) bright dip step
will help compensate for poor low
current density brightness in the zinc
plating bath. High polishing blue
chromates are also available to further your cause.
Your ability to produce acceptably
uniform brightness may depend
upon, to some degree, the geometry
of the parts. Large flat surfaces tend

not to polish nearly as well as round
surfaces. Air agitation during polishing and chromating will tend to help
compensate, but areas of the part
that remain unagitated (interiors)
may remain dull.
In general, much of your success
will depend on the nature of the
work you are doing, (small parts vs.
large flat parts) as well as the degree
of brightness or uniformity desired.
Q:
Do you know of any solution to

prevent oxide after nickel plating?
The coating is nickel on steel, and the
thickness is 5 microns average. It is a
bright nickel solution, and we need to protect uncoated parts of low current density.
A:
The oldest answer to your question is the use of a chromic acid

passivation step after nickel plating.
Use 20-40 g/l of chromic acid, preferably hot, 35-40C. This has the
added benefit of removing any flash
rusting that may have occurred in
any of the process steps, such as acid
rinse or nickel rinse. There are
options on the market for similar
processes that are free of hexavalent
chrome. There are also many waterbased lacquers or topcoats that can
be used over nickel plating to supplement corrosion protection in thin
coverage areas.
Q:
We are doing Zn alkaline with

trivalent passivation + topcoat for
our products, and these are packed in
cardboard boxes and dispatched to the
customers. However, once the customers
open these boxes, the plated parts are
found rusty. Our quality checks before
dispatch: 1. Neutral salt spray test on the
plated parts and they answer for resistance as per our customers requirement. 2.
Plating thickness is within the specification of 6 to 10 microns Zn. What could be
the probable reasons for this corrosion?
A:
You do not mention the salt

spray requirements nor the
details of the current process so I will
make general observations on potential causes.
Premature corrosion failures are
the result of several factors:
askthe
expert
1)Storage and shipping conditions. High humidity and/or
temperature during shipping
may overwhelm a lower-end chromate. Many low-end blue chromates offer only 12-24 hours of
protection. If you are in a high
humidity environment or are
shipping product over saltwater,
consider an upgrade to a higher
salt spray chromate that is suitable for your application. Blue
trivalent chromates are available
that readily exceed 120 hrs to
white corrosion.
2) Insufficient plating thickness.
While you do mention that thickness is satisfactory, be sure that it
is sufficient in the areas where
the failures are occurring.
Depending on the type of zinc
plating technology used, you may
have critical areas of the part that
are not well covered, even though
a prominent area tests to the
desired thickness specification.
This could dictate which zinc

plating technology you should
specify, as well as thickness
requirements. Use of a post chromate sealer helps improve salt
spray in low thickness areas, as
well as with parts that have issues
with base metal porosity.
3) Poor cleaning/preparation causing poor adhesion of deposit.
Non-adherent zinc does not offer
protection. Poor adhesion may not
be immediately apparent. Bake
parts at 300F for 30 minutes and
inspect for blisters to confirm
acceptable adhesion.
4) Proper parts packaging after
plating can also improve chromate coating performance. This
includes proper drying, as parts
that are not thoroughly dried are
prone to failures.
ABOUT THE EXPERT

Matt Stauffer is the Director of Technical
Service at Pavco, Inc. in Charlotte, N.C.
He leads a group that specializes in helping
customers maintain, optimize, and troubleshoot a wide variety of metal finishing
processes. He has 23
years of experience in
metal finishing R&D
and technical service.
Matt has research
experience in zinc
alloys and high corrosion-resistant finishing systems in addition to extensive formulation experience in antimicrobial electrodeposited coatings, bright nickel, trivalent chrome, acid copper, and cleaning
chemistries.
Submit your questions to Matt by visiting www.metalfinishing.com/mf/ask-theexperts.
Accelerated
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PRODUCT
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This technology is the most
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Conventional ceramic abrasive
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fracture to form sharp points and
edges. This technology helps
Cubitron II abrasives slice cleaner
and faster, stay cooler, and last
longer than conventional wheels.
FABTECH 2012
Cubitron II abrasives offer performance that dramatically surpasses that of traditional grinding
wheels made with aluminum oxide,
alumina zirconia or ceramic grain.
Some competitive products require
up to three times the amount of
pressure to match the cut of
Cubitron II abrasives, according to
3M. With the advantages of 3Ms
technology, operators are subjected
to less wear and tear, and can remove
more material with the
same amount of
effort. It all
adds up to
improved
productivity, achieved
in a way
that
is
good for
the business and for
workers.
Operators
have a tough job,
so its our hope
that 3Ms new
Cubitron II bonded
abrasives can make it easier on them,
while still performing exceptionally
on the shop floor, Cunningham
noted.
A wide variety of industries stand
to benefit from these advancements,
including: ship building, structural
steel, general metal fabrication, oil
and gas, and agriculture, industrial
and
construction
machinery.
Cubitron II abrasives offer potential
for operators in all of these fields to
easily increase efficiency.
To learn more about Cubitron II
abrasives, visit www.3M.com/cubitron2. In addition, 3M has created a
tribute video to grinder operators,
Grindstone Cowboy, which can be
seen at www.3mcubitron2.com/rocks
or www.youtube.com/3Mabrasives.
DeFelsko
Corporation
has
launched the fifth generation
PosiTector
200
Ultrasonic
Coating Thickness Gage from

DeFelsko is ideal for measuring the
thickness of polyurea and other coatings on concrete. The NEW
PosiTector 200 has been redesigned

with more features, additional measuring ranges and new models.
Additional features include a NEW
polyurea probe for measuring thickfilm coatings up to 300 mils.
Importantly, the new PosiTector 200
has the ability to accept all coating
thickness, surface profile, environmental and wall thickness probes.
Advanced models feature WiFi wireless technology and enhanced graphics mode with screen capture for
detailed analysis of the coating system. With each successive generation, the PosiTector 200 has become
more economical and easier to use.
Call DeFelsko at (800) 448-3835
or visit our website at www.defelsko.com to get assistance selecting
the optimal instrument for your
application.
Nordson Corporation, a recognized
leader in liquid dispensing technology, is launching a line of new nonelectrostatic guns, stainless steel
pumps and plural component metering systems for liquid applications.
The new products complement
Nordsons existing portfolio of airless equipment, rotary atomizers,
electrostatic spray guns, voltage
PRODUCT
SHOWCASE
As seen at
blocking systems and nozzles,

rounding-out a complete line of
products for most any liquid coating
need. The investment represents the
largest liquid product line expansion
to date and
Nordsons commitment to the longterm growth of its liquid coatings business.
Nordson brings nearly 60 years
of expertise to liquid applications
and this market is key to the longterm growth of our Industrial
Coating Systems group, said Brad
Syrowski, global liquid business
development manager, Nordson
Liquid Systems. For the last 18
months, weve been laying the
groundwork for this expansion, and
we are excited to offer customers in
all of our geographies a more comprehensive line of liquid coating
equipment.
The newest additions to
Nordsons liquid coating line
include:
Trilogy Non-Electrostatic Spray
Guns: Encompass air assist airless,
air spray and low volume/low pressure technologies. These guns
incorporate the latest in design
technology, providing excellent
spray quality, the durability to
FABTECH 2012
withstand harsh manufacturing

environments and ease of handling
and maintenance.
StediFlo Pumps: With pressure
ratios from 3:1 to 57:1, StediFlo
pumps provide versatility and high
performance to meet a wide range of
pressure and volume requirements.
OptiMix Plural Component
Metering Systems: High-performance pneumatic and electronic plural-component mixing and proportioning units
process both solvent- and waterbased paints, and are designed for
flexibility and efficiency.
As we move forward, we will

continue to add new products
when opportunities for expansion are identified, Syrowski
said. Our complete liquid line
combined with Nordsons powder coating, adhesive and sealant
dispensing, and curing systems
allow us to bring our customers a full range of solutions
that improve efficiency, flexibility
and productivity in their operations.For more information, please
visit www nordson.com.
Fischer Technology, an innovator
in the field of
coating thickness measurement, material testing, and material
analysis instrumentation, showcased
its complete
product
range
at
FABTECH
2012. Fischer
offers a complete
range of handheld coating
thickness
gauges ideally
suited
for
measurements of
paint, powder coating,
plating and anodize. The new FIS-
CHER DataCenter software, for

quick and easy data transfer to your
PC and personalized inspection
reports, is included with Fischers
handheld instruments. All Fischer
units and foils come certified at no
additional charge.
The FMP Series product line
include the DUALSCOPE, DELTASCOPE, and ISOSCOPE coating
thickness gauges. The gauges measure over ferrous, non-ferrous, or
both substrates with automatic substrate recognition. They can measure thin, thick, soft, and duplex
coatings and can adapt to any measuring application using the large
selection of interchangeable Fprobes which yield extreme accuracy
and a wide measurement range.
Probes are available for hard to
measure areas such as inside, curvature, and surface roughness.
Bluetooth wireless technology is
available. Fischer also offers the
pocket sized MP0 and MP0R Series,
which has two large displays and
integrated wear resistant hard metal
tip probe. These instruments give
fast, precise, repeatable readings and
are very easy to use.
FISCHERSCOPE
X-Ray
Fluorescence Instruments for
Coating
PRODUCT
SHOWCASE
As seen at
Thickness
Measurement
and
Material Analysis. Fischers X- Ray
fluorescence instruments utilize
an energy dispersive X-ray fluorescence analysis (ED-XRFA) method.
The measurement and control software allows for the simultaneous
thickness measurement and analysis
of even complex coating systems,
with or without calibration standards. The broad assortment of
instruments can determine single or
multiple coatings on the smallest
structures or large components, trace
analysis required by RoHs, or testing
of jewelry and gold.
For additional information
regarding the measurement of coating thickness, hardness measurement, or material analysis contact
Fischer Technology at 860-683-0781
or visit www.fischer-technology.com
PPG Industries industrial coatings
business took the wraps off ULTRAPAX(TM) packaged pretreatment
and powder coatings solutions, as
well as its
FABTECH 2012
coupled with PPG powder coatings as

part of a cost-effective, comprehensive, single-source coatings solution.
PPG pretreatment products
encompass traditional spray and
immersion zinc- and iron-phosphate
systems, multi-metal cleaners, lowtemperature cleaners, low-temperature phosphates and high-technology zirconium-based products. Highperformance powder coatings by
PPG are based on polyester, urethane, epoxy, acrylic and hybrid
technologies. Because PPG formulates, produces and tests pretreatment and powder products together,
the Ultrapax package will offer customers effective and economical
coatings solutions backed by PPGs
experience, technology and technical
service expertise, according to Randy
Brent, PPG director, pretreatment
and engineered products technology. For more about Ultrapax packaged coating solutions and other
PPG industrial coatings products,
please visit www.ppgindustrialcoatings.com or call (888) 774-2001.
Wagner Systems unveil its R
HiCoat manual gun. According to
the company, the new gun generation achieves greater efficiency and
perfection, both in manual and in
automatic coating applications. The
Wagner manual units are the result
of concentrating development
efforts on greater gun performance.
A user-friendly design simplifies

usage while offering improved
speeds. for the operator.
Wagner R HiCoat manual guns
are constructed for high coating
output, high efficiency and a long
service life. They offer the user optimal handling that is achieved
through the use of robust materials,
a weight-optimized design and a
high performance charging and
atomization system.
The new Wagner manual gun
PEM-X1 sets the standard and trend
for all kinds of surfaces used today
in powder coating. The new gun
generation improves perfection and
precision even furtherthe product
philosophy combines a balanced
finesse on all levels with long life
expectancy and optimal handling.
Advantages of the new generation guns include:
High transfer efficiency
Perfect coating results
Well balanced ergonomic handling
Simply and easy maintenance
Robust and lightweight design
Wide range of accessories
The powder cup laboratory set is a

useful, handy, flexible but yet highperformance equipment for powder
coating component parts and small
amounts.
www Wagnersystemsinc.com.
s
ce
xy,
.
service expertise
h icalfull
range of liquid, powder, pretreat-
ment and electrocoat products, at

FABTECH. The new Ultrapax packaged technology program will provide PPGs customers with a full
range of pretreatment products to be
NEW
products
BLACK TRIVALENT PASSIVATE
Challenging surface finishers to get
black to work, Haviland Products
Company unveils Jet Black B2,
the industrys blackest black trivalent black passivate for alkaline and
acid chloride zinc. Jet Black B2 is the
culmination of four years of rigorous
R&D, with the collaboration of
numerous zinc plating facilities
throughout the United States and
South America.
Made in the USA, Jet Black B2 is
an easy-to-prepare and easy-tomaintain completely trivalent conversion process that produces a deep
black, lustrous finish. Designed to
cover the first time and every time,
Jet Black B2 works equally well over
alkaline and acid chloride electroplated zinc deposits. The process
will withstand up to 250 hours to
white corrosion in 5% neutral saltspray solution, when correctly
applied in conjuction with Prodigy
ECP or Prodigy Seal 3000 topcoat.
Jet Black B2 has excellent shelf-life
and bath stability.
For more information, please call
800-456-1134 or visit www.havilandusa.com.
COPPER PLATING CHEMISTRY
MacDermid unveils CuMac Royal,
the latest innovation in bright acid
copper plating.
CuMac Royal is a dye-based system formulated to produce a bright,
level deposit over a broad range of
current densities. Among the key
features and benefits:
Low use cost
Bright, ductile deposit
Outstanding leveling over a broad
range of current densities
High temperature tolerance
Easy to operate

www.macdermid.com or call (203)

575-5700.
POWDER COATING COLORS

AkzoNobel Powder Coatings
launched the new Interpon F 2013
trend range, featuring colors chosen
specifically for indoor and outdoor
furniture. The 2013 collection features 15 colors carefully chosen for
the interior furniture market and 15
colors that have been selected specifically for exterior furniture. The
trend range is the perfect complement to the standard Interpon color
ranges and every shade is available in
high quality, sustainable powder
coatings.
The exciting 2013 trend range is

taken from the AkzoNobel Colour
futures collection. Once a year, the
AkzoNobel Aesthetic Center meet
with an international group of creative specialists from the fields of
color, design, architecture and fashion to discuss and develop the hues
that will be key for the following
year.
Interpon F for furniture offers the
ultimate in protective, durable and
design driven powder coatings.
Created with the tough performance
requirements and aesthetic qualities
demanded specifically by the furniture industry, the Interpon F range
offers a sustainable, quality coating
alternative. Interpon F powder coatings offer increased scratch resistance and hardness as standard for
the interior and exterior furniture
markets.
www.colourfutures.com.
CGW INTRODUCES SURFACE

PREPARATION WHEELS AND
DISCS
CGW-Camel Grinding Wheels
expanded its surface conditioning
offerings, adding a line of surface
preparation aluminum oxide and silicon carbide wheels and discs. The
surface conditioning line is specially
designed for blending, smoothing
and finishing stainless steel, steel,
aluminum and nonferrous metals.
Made from nonwoven material
impregnated with abrasive grains,
CGWs new surface preparation
products remove paint, rust, and
welding and cutting discoloration
from stainless steel. The marooncolored aluminum oxide products
have a fine grit size, making them
ideal for cleaning, blending and finishing stainless steel. The gray-colored silicon carbide products are
very fine in grit size, and provide
light finishes on metal, wood, composites and satin-finish aluminum.
The new type 27 shape surface
preparation wheels are available in
aluminum oxide and silicon carbide
grains with 4-, 4 1/2-, and 7-inch
diameters. The type 27 wheels are
NEW
products
designed with reduced backing to
minimize work piece scratches and
allow for full use of the wheel material. The surface preparation discs
have a roll-on attachment and are
available in 2- and 3-inch diameters
in aluminum oxide and silicon carbide grains.
www.cgwcamel.com.
INERT ATMOSPHERE CABINET

OVEN
Grieve offers No. 873, a 650F,
electrically-heated inert atmosphere cabinet oven used for processing corrosive materials at the
customers facility. Workspace
dimensions of this oven measure
38" W x 50" D x 38" H. 40KW are
installed in Incoloy-sheathed tubular elements to heat the oven chamber, while a 2000 CFM, 2-HP recirculating blower provides horizontal
airflow to the workload.
This Grieve cabinet oven has 6"
insulated walls, aluminized steel
exterior, Inconel 600 interior with

continuously backwelded seams and
special exterior paint. The oven also
features full inert atmosphere construction, including pressure regulator, flow meter, pressure gauge,
internal high-temperature gasket,
all-welded expansion connection in
the doorway throat, air jacket on
inner oven for cooling, " thick cellular silicone rubber atmosphere
seal, blower shaft seal, positive latching door hardware, adjustable offset
door hinges, outlet with pressure
relief, interior seams welded gastight and all wall penetrations fitted
with compression fittings.
No. 873 has a 650 CFM blower to

pull air through the air jacket on the
inner oven for cooling, plus automatic dampers. A hinged door jacket with 4" diameter connector to
allow the jacket to be ventilated is
also provided.
Sixteen pairs of shelf supports to
support thirty-two Inconel 600
pans, with two pans on each level,
plus loading truck tracks on the
floor of the workspace, are built into
this Grieve oven.
Controls on this inert atmosphere
cabinet oven include a programming
temperature controller, manual
reset excess temperature controller,
SCR power controller
www.grieve.com.
ROBOTIC GLASS BEAD PEENING

MACHINE
Guyson Corporation has introduced a robotic blast system that is
designed and specially adapted for
glass bead peening in NADCAPcompliant manufacturing and overhaul operations that must perform
the surface enhancement process
according to AMS 2432 peening
specifications, including peening of
stage one titanium fan blades.
The 7-axis RB-9 glass bead peening
machine incorporates a Fanuc M10iA or comparable robot as a blast
gun manipulator and a servomotor
drive that orients the machines
turntable as a coordinated auxiliary
axis of robotic motion. During a
peening cycle, the robotic blast system constantly maintains the correct
nozzle angle, offset and surface speed
as it traces the contours of the part.
The Fanuc robot design features a
hollow wrist that allows the air and

media hoses of the suction-blast gun
as well as the air supply hose for the
separate blow-off nozzle to be routed
through the arm of the robotic nozzle manipulator.
A 36-inch diameter, 500-pound
weight capacity rotary table is provided with T-slots and mounted on a
powered transfer cart to facilitate
installation and changing of component-holding fixtures. The 48 x 48 x
48-inch glass bead peening cabinet is
also provided with a rubber-flapped
and covered channel in the roof of
the blasting enclosure and a 500pound capacity roof-mounted jib
crane to ease loading and unloading
of heavy components.
In addition to a cyclone separator
for removal of dust and fines, the
peening shot reclamation system of
the RB-9 glass bead peening
machine includes a vibratory screen
classifier to maintain strict control
over shot sizing and a spiral separator to prevent non-spherical or fractured beads from being fed to the
blast gun.
CHEMICAL AGITATORS
Chemineer, Inc. offers a broad range
of high quality, field-proven HT
Agitator models for application versatility in a variety of industries such
as chemical, pharmaceutical, water
and wastewater treatment, ethanol
and biofuels, FGD, food processing,
general industrial and many more.
The Chemineer Model 20 HT
agitators feature a high-efficiency
gearbox designed specifically for agi-
NEW
products
tator service. Models are available in
right angle configurations to meet
specific application requirements
from critical chemical reactor systems to routine storage. The agitators incorporate a modular design
package that reduces the number of
replacement parts that need to be
carried in inventory by the customer.
The rugged and versatile
Chemineer Model 20 HT Turbine
Agitator is capable of handling virtually any process. Its unique design
results in high strength, low wear,
quiet operation, and minimal maintenance. HT Agitators are ideal in
harsh, demanding environments
where reliability is a key consideration. Thousands of Chemineer
Model 20 HT agitators have logged
years of dependable, field-proven
performance in blending, agitation,
solids suspension and gas dispersion
applications.
www.chemineer.com.
XRF ANALYSER
Oxford Instruments is pleased to
announce the new X-Strata920 X-ray
fluorescence (XRF) analyser for coating thickness measurement and
materials analysis. It combines a
large area proportional detector and
Oxford Instruments micro-focus Xray tube, providing a high-intensity,
small spot X-ray beam for superior
sample excitation. This combination
guarantees the best accuracy in its
class, with analysis results obtained
in seconds to ensure better process
control and cost efficiency.

So whether you analyse solder
alloys as part of your quality control
process, or assay gold jewellery for
valuation, or plating thickness in
component manufacture, we believe
the X-Strata920 is an ideal solution
for your business, providing reliable
analysis you need at a price youll
like.
X-Strata920 performs excellent
analysis and characterization of
multi-layer analysis across a wide
range of industrial markets, including electronics, metal finishing,
alloys and precious metals assay. For
these industries, the X-Strata920
offers a number of benefits:
Increase productivity with better
process control
Minimise production cost of the
plating process and maximize
production output
Rapid, non-destructive analysis of
jewellery and other alloys
Rapid analysis of up to 4 coating
layers
Field-proven technology and
better reliability ensuring value
for money year after year
Easy to use, with minimal user
training required
The X-Strata920 is designed with
ease of use, accuracy and value for
money in mind. A large sample area
can be analysed in one measurement
cycle using the X-Stratas multipoint analysis function. If a problem
area is identified the operator can
return to specific points with pin
point accuracy for detailed investigation. With the analysers embedded
camera and live video imaging, precise sample placement is assured.
The X-Strata920 even allows unattended operation to ensure minimal
downtimes of your production
process.
www.oxford-instruments.com.
DUST CONTROL
FilterSense offers B-PAC series of
Baghouse Performance Analyzers
& Controllers feature a combination of features to help powder pro48 I metalfinishing I November/December 2012
cessing, air pollution control and

dust collection users meet regulatory
compliance while simultaneously
reducing operating costs and
improving the process.
The controllers tightly integrate
control, sensing and high speed digital signal analysis to provide time
and money saving diagnostics
including:
the
ability
to:
detect/locate filter leaks weeks
before emissions are visible;
detect/locate failed pulse solenoids
that can lead to plugged filters; and
instantly detect/locate ruptured or
frozen pulse-jet diaphragms.
The controller also provides intelligent filter cleaning which extends
filter life and lowers emissions while
reducing compressed air use by 1540% over traditional PLC programming and up to 90% over continuous cleaning.
Optional software provides
enhanced process control features
and further automation of compliance record keeping. A series of
models for small cartridge collectors
to large multi-compartment baghouses are available. The controllers
are easy-to-use, high quality, heavy
duty products designed for long-life
in harsh process environments. A
range of analog and digital I/O are
available as well as all major fieldbuses, including Ethernet IP,
Modbus TCP, DeviceNet and
Profibus etc.
wwwfiltersense.com.
IMMERSION HEATER
Durex Industries, a leading North
American designer and manufacturer of heaters, temperature sensors,
temperature controls and process
systems, recently announced the
release of their Standard Flange
Immersion Heaters. In response to
increasing customer requirements
NEW
products
for fast delivery, Durex Industries

developed a standardize process for
manufacturing and delivering
Flanged Immersion Heaters. In two
weeks, Durex Industries can now
ship hundreds of options for Flange
Immersion Heaters ranging from 3
inch to 14 inch flanges. These
heaters are available in various
sheath materials including 316 passivated stainless steel, steel, copper,
and Incoloy 840. Available standard voltages and wattages range
from 60 W/in2, 6 kW, 240 V/1 Phase
to 16 W/in2, 167 kW, 480 V/3 Phase.
Flange immersion heaters are typically used for larger volume and
higher power applications or where
flange tank or pipe vessel connections are preferred. Tubular heater
elements are brazed or welded to the
flanges for convenient mounting.
These immersion heaters are used in
process temperature control applications ranging from car washing to
heavy industrial applications in
chemical, petroleum, water, metals
and other process industries. Durex
Industries supports all Flange
Immersion Heaters with application
support and field service.
Visit www.durexindustries.com
for more information.
ANTICORROSION COATINGS
NEI Corporation unveils a new flexible coating product specifically
designed to protect oxidizing steel
and aluminum exposed to corrosive
chemicals or harsh environmental
conditions. The technology was
developed in New Zealand and has
been used throughout the South
Pacific for over 40 years. In collaboration with the Goldseal Group, NEI is
now offering the product for sale in

North America under the name
NANOMYTE TC 3001. Unlike
conventional paint, which will chip
or crack when exposed to stress from
vibration, expansion, or flexing,
TC 3001 will move, bend and conform to the substrate that it covers.
The coating can last 10 to 15 years, or
more, in the field with little or no
maintenance.
NANOMYTE TC 3001 is unique
in that traditional solvents and
binders are replaced by a high-solids
carrier. The material is heated until
liquefied, then applied by hot airless
spray. The result is a smooth, uniformly thick coating. Cracks and
crevices in pre existing paint, and
even spalled concrete, can be filled as
the metal surface is covered.
TC 3001 is able to protect the metal
substrate by adapting to changing
environmental conditions. The coating maintains its resiliency and
structural integrity over time, better
than conventional anticorrosion
paints and coatings.
TC 3001 is formulated as a single
pack, single application encapsulating barrier coats that are corrosion
neutralizing and lubricating. The
compound is a niche solution in
extreme environments, often associated with aggressive chemicals and
marine deposits such as encountered in factories and refineries,
boats and barges, as well as on
bridges and wharfs.
Adding this new coating product
to its portfolio is part of NEIs
efforts to develop corrosion resistant coating systems, including pretreatments, primers and topcoats, to
protect customers metal assets. The
coatings are economical, easy to use
and provide excellent corrosion
resistance compared to state-of-theart offerings.
www.neicorporation.com.
XRF ANALYSIS TECH SUPPORT

Thermo Fisher Scientific Inc., has
announced 24 hours a day, seven
days a week telephone support for its
Thermo Scientific portable x-ray fluorescence (XRF) analyzers. The new
24 x 7 telephone service consists of

the following programs:
Flat Rate Repair Program, which
offers budgeted pricing and shortened repair times. Customer service
representatives first try to resolve
any instrument issue over the
phone. If the problem cannot be
resolved and the analyzer must be
sent in for repair, Thermo Fisher will
assess the level of repair as Tier 1,
Tier 2 or Tier 3 and provide a quote
in real time. Pricing levels are fixed;
once a rate is quoted, that initial
quote will be honored throughout
the entire repair process, even if
further repairs are required.
Service Care Program, which provides a way for customers to protect their investment in their
Thermo Scientific portable XRF
instrument with the benefit of predictable costs. They can choose
from four support agreement
options, Service Care Premium,
Service Care Plus, and Service Care
Basic as well as Service Care Share
specifically for the Niton XL2 precious metal analyzer, all designed
with business needs and budgets in
mind.
We expanded our telephone support as part of an ongoing effort to

respond to the growing customer
need for access to technical expertise
regardless of the day or time, said
Paul Pazareskis, manager of global
services for Thermo Scientific
Portable Analytical Instruments.
Our skilled support staff recognizes that any downtime for customers can result in missed deadlines or lost revenue, and by providing continuous availability we can
help troubleshoot the issue and give
them some answers.
For more information, contact a
local Thermo Scientific portable
XRF analyzers representative or
Thermo Fisher directly at 800-8751578 (toll-free U.S.), +1 978-6707460 (choose Technical Support,
option 2, from the menu), via email
at niton@thermofisher.com or by
visiting http://www.thermoscientific.com/niton.
NEW
products
MASKING
MOCAP's threaded plugs are
designed to protect threads, fittings
and ports from moisture, contamination and damage during production, shipping and storage. These
plugs are produced in an assortment
of styles and materials and are avail-
able for Standard, Metric, BSP and

NPT Threads, as well as other types
of threads and fittings. These plugs
are available in mini-pack, box and
bulk quantities and are stocked for
immediate delivery.
www.mocap.com.
BRIGHT COPPER PROCESS
Enthone introduces UPROSTAR NC
alkaline, cyanide-free bright copper
process. A cost-effective and environmentally sound alternative to tradi-
tional cyanide-containing processes,

CUPROSTAR NC process is engineered for use on all commonly used
base materials, including zinc die cast.
The process exhibits exceptional
throwing power on complex part
geometries, ensuring that complete,

consistent and uniform coverage is
achieved.
Specifically, the CUPROSTAR NC
process provides high yields and significantly reduced rejects when plated on aluminum, brass, steel and zinc
die cast parts. The production proven
process is completely cyanide-free,
reducing regulatory burdens and
exposure to government restrictions.
CUPROSTAR NC process offers a
robust operating window that plates
uniform, fine-grained, ductile and
adherent deposits. The patented
process does not require a specialized
pretreatment cycle and uses virtually
the same process sequence as a
cyanide-based system.
CUPROSTAR NC is the only
cyanide-free process that is being successfully used in a wide range of
industries, markets and applications, said Maja Brandes, Enthone
Global Product Line Manager
Plating on Plastics and Decorative
Base Metals. Unlike existing
cyanide-based coppers, CUPROSTAR
NC maintains exceptional metal
adhesion.
CUPROSTAR NC is an extremely
versatile and easy-to use process. By
making simple adjustments to the
temperature, pH and copper content,
the CUPROSTAR NC process can be
quickly modified to meet specific
brightness, current density, adhesion
and throwing power application
requirements.
www.enthone.com.
SYSTEM FOR HIGH-SPEED REEL-TOREEL CONNECTOR PLATING
Technic, Inc. has announced the commercial release of its Goldeneye
Barrier Layer System specifically
engineered for improved corrosion
resistance in high-speed, reel-to-reel
connector applications.
Goldeneyes Barrier Layer System
is a newly developed universal metal
stack designed to enhance functionality of subsequent precious metal
deposits. The system enables the deposition of application specific
options from a universal base electrolyte through the use of specifically
designed additives.
Metal Stack options include: .1 .
Goldeneye Nickela low stress, highly corrosion-resistant nickel plating
process capable of operating at high
current densities from a proprietary
electrolyte; 2. Goldeneye Nickel ORC,
which protects over-plated bright tin
from discoloration during thermal
exposure (e.g., reflow); and 3.
Goldeneye Level Nickel, which
enables deposition of a leveled, fully
bright nickel deposit at high current
densities. Deposit properties, such as
hardness and corrosion resistance,
are further enhanced with use of
Goldeneye Level Nickel.
Our Goldeneye technology platform continues to receive universal

acclaim in our target markets, said
Rob Schetty, vice president, global
technology sales and marketing. The
Goldeneye Barrier Layer System is a
significant step forward in providing
superior end product performance in
an extremely easy to use electrolyte
platform. This technology enables
significant advancement in precious
metal reduction goals for high reliability applications.
Visit www.technic.com for information on Technic & Technic products, or call (401) 781-6100.
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Directory!
This interactive Web-based tool is available at
www.mffinishersdirectory.com
Helps manufacturers, suppliers, and OEMs seek out surface
finishers according to specialty (anodizing, blackening,
conversion coating, and electrocoating, etc.); region of the
country; or simply by company name. Search results provide
pertinent background information on each finisher, with direct
links to websites and contacts, pdf brochures, and even videos
and demos, in some cases.
Visit www.mffinishersdirectory.com today to begin your
search for the right finisher!
Anodizing Electrocoating Powder Coating

Precious Metals Plating Phosphating
Physical Vapor Deposition Pretreatment
Automotive Aerospace Electronics
Military
finishersdirectory
Following is a sampling of North American job shops and captive
operations listed in Metal Finishings online Finishers Directory.
For contact details on each company, or to view a complete listing, please visit www.mffinishersdirectory.com.
ALABAMA
MICHIGAN
United Plating
A T Industrial Products
California Technical Plating
Gardena Specialized Processing
Precision Stampings, Inc.
Tiodize Co.
Almond Products
Cadillac Plating Corp.
Delta-Chem Technologies, Inc.
Depor Industries, Inc.
Great Lakes Finishing, Inc.
KC Jones Plating
Master Finish Co.
Parts Finishing Group
CANADA
MINNESOTA
CALIFORNIA
OHIO
Electro Metallics Co.
MPC Plating
Olymco, Inc.
Sifco ASC
Techmetals, Inc.
SOUTH CAROLINA
CAPSCO, Inc.
Roy Metal Finishing Co., Inc.
TEXAS
3D Powder Coating
Cybershield
Sifco ASC
Vanguard Metal Technologies
Aegis Industrial Finishing Ltd.

WestChem Technologies
Engineered Finishing Corp.
VIRGINIA
MISSOURI
CONNECTICUT
Superior Coating
Alexandria Metal Finishers

Global Metal Finishing, Inc.
Sifco ASC
NEBRASKA
WASHINGTON
Sifco ASC
FLORIDA
Plating Resources, Inc.
Lincoln Industries
NEW JERSEY
Delong Equipment Co.

Peening Technologies of Georgia
Paramount Metal Finishing

Quality Metal Finishing Corp.
Shining Surface Systems, Inc.
ILLINOIS
NEW YORK
GEORGIA
Arlington Plating Co.

Chem Processing, Inc.
Iosso Metal Process
Mark-it Company
Rockford Metal Polishing Co.
The Finishing Company
Triton Industries, Inc.
Unitech Industries, Inc.
Control Electropolishing
Esterline Hytek Finishes
WISCONSIN
Engineered Finishing Corp.
Powder Finishers, LLC.
Professional Plating, Inc.
Quality Coatings, Inc.
Wisconsin Plating Works of
Racine, Inc.
INDIANA
C & R Plating Co.
DeKalb Metal Finishing
Protech Metal Finishing
KANSAS
Chrome Plus International, Inc.
MEXICO
CENSA/Compaia Estaadora
Nacional S.A. de C.V.
GDO/Galvanizadora de Occidente
S.A. de C. V. Mexico
Recubrimientos Metallicos de
S.A. de C.V. Mexico
CLASSIFIED
Ready Reference
Services
ADVERTISING RATES:
1 Time
- $117.00,
3 Times
- $114.00,
6 Times
- $109.00,
Yearly -Yearly
$102.00- $107
per column
inch perinch
insertion
ADVERTISING
RATES:
1 Time$123.00,
3 Times
- $120.00,
6 Times
- $114.00,
per column
per insertion
Filter Presses 1-100 cu. ft.

Clarifiers 2-300 gpm
Sludge Dryers 2-75 cu. ft.
Waste Treatment Systems
Used Equipment
Polyproducts, Evaporators
Bags, Cloth & Media
Anode Bags
We
BUY, SELL and
RECONDITION
Used Equipment
Call: 216-881-7900
info@metchem.com
Fax: 216-881-8950
NICKEL SOLUTION WANTED

Will purchase excess
semi/brights/watts nickel
baths and nickel sulfate from
IX recovery.
Go to
www.ewmetals.com
Nationwide Installation Corp.

Finishing Installations,
Renovations & Relocations
60 hp steam boiler 3 years old. Boiler is
prepackaged with an IRI burner with:
1) Automatic boiler feed system
2) Water softener
Boiler new would $38,000 now $7,900
Oberlin Filter Press - $4,600
Tanks stainless/FRP 30 x 72 x 67
deep also dryer tank $9,900
E-mail: Keizer.terry@gmail.com or
ph 616 883 6144
Northern PA plating company looking for a great hands on foreman/

floor manager. To help grow a
small silver, tin, nickel, electroless
nickel plating company. Weve
been doing great work for years
and need a great floor manager to
help grow the company. Please
send resume and pay history and
why you want to be part of our
team to:
chriscsb4300@hotmail.com
212-633-3100
NEW USED REBUILT SELL LEASE
WASTE TREATMENT EQUIPMENT SPECIALTIES
P.O. Box 40382, Cleveland, OH 44140
(440) 808-8844
Clarifiers Filter Presses Plates Cloths

Parts Washers Ovens Dryers Tanks Mixers
Air Scrubbers Plating/Finishing/Equipment
www.wescoequip.com
U.S. POSTAL SERVICE STATEMENT OF OWNERSHIP,

MANAGEMENT AND CIRCULATION
(Required by 39 U.S.C. 3685)
1.
2.
3.
4.
Title of Publication: Metal Finishing

Publication No. 342-180
Date of Filing: October 1, 2012
Metal Finishing (ISSN 0026-0576) is published 9
times per year in January/February, March, April,
May, June, July/August, September, October,
November/December
5. No. of Issues Published Annually: 12
6. Annual Subscription Price: $123.00
7. Location of Known Office of Publication: Elsevier Inc.,
360 Park Ave. South, New York, NY 10010
8. 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, David Hopwood:
Metal Finishing, 360 Park Ave. South, New York, 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 and
address must be stated and also immediately thereunder the names and addresses of stockholders
owning or holding 1 percent or more of total amount
of stock. If not owned by a corporation the names
and addresses of the individual owners must be
given. If owned by a partnership or other unincorporated firm its name and address as well as that of
each individual must be given.)
Elsevier Inc., 360 Park Ave. South, New York, NY
10010. Wholly-owned subsidiary of Reed Elsevier
U.S. Holdings, Inc., 4520 East-West Highway, Suite
800, Bethesda, MD 20814.
11.Known bondholders, mortgagees, and other security
holders owning or holding 1 percent or more of total
amount of bonds, mortgages or other securities:
None.
12.Does not apply.
13.Publication Name: Metal Finishing
14.Issue Date for Circulation Data Below:
Oct. 2011 - Sept. 2012
15.Extent and Nature of Circulation:
Average
No. Copies
Ea. Issue
During
Preceding
12 Months
A. Total No. Copies
11,514
(Net Press Run)
B. Paid and/or Requested
Circulation
1. Paid/Requested Outside
Country Mail Subscriptions
Stated on Form 3541
9,015
2. Paid In-Country/Subscriptions
Stated on Form 3541
0
3. Sales Through Dealers and
Carriers. Street Vendors, Counter
Sales and Other Non-USPS
Paid Distribution
470
4. Other Classes Mailed
Through the USPS
0
C. Total Paid and/or Requested
9,485
D. Free Distribution by Mail
1. Outside County as
Stated on Form 3541
1,578
2. In-County as
Stated on Form 3541
0
3. Other Classes Mailed
Through the USPS
0
4. Free or Nominal Rate
Distribution Outside the Mail
(carriers or other means)
287
E. Total Nonrequested Distribution
1,865
F. Total Distribution
11,350
G. Copies Not Distributed
164
H. TOTAL (Sum of 15f and g)
11,514
I. Percent Paid and/or Requested
Circulation (15c f x 100)
83.6%
Actual No.
Copies of
Single Issue
Published
Nearest to
Filing Date
11,215
9,024
0
FEBRUARY 2013
Feb. 1921 2013 IPC APEX EXPO Conference &
Exhibition, San Diego, Calif. Please visit
www.ipcapexexpo.org for more information.
Feb. 2428 NASF Management Conference, Key West, Fla.
For more information, please visit www.nasfmanagementconference.com.
MARCH
March 68 Spray Finishing Training Sponsored by Owens
Community College and Finishing Brands (Binks, DeVilbiss,
Ransburg, BGK), Toledo, Ohio. For more information, call
800-466-9367, ext.7320, or e-mail
sprayworkshop@netscape.net.
APRIL
April 911NASF Washington Forum, Washington, D.C. For
more information, please visit
www.nasfwashingtonforum.com.
April 2025 SVC TechCon 2013, Rhode Island. Please visit
www.svc.org for more information.
MAY
May 68 Intertech Conference, Baltimore, Md. Visit
www.intertechconference.com for more information.
May 1416 EASTEC 2013, West Springfield, Mass. Visit
www.easteconline.com/eastec2013/public/enter.aspx for
details.
386
0
9,410
1,234
0
JUNE
June 1012 SUR/FIN Manufacturing & Technology
Conference, Rosemont, Ill. Pease visit www.nasfsurfin.com
for more details or to register.
OCTOBER
476
1,710
11,120
95
11,215
84.6%
16. Publication is required and will be printed in the

Nov/Dec 2012 issue of this publication
17. Signature of Publisher on PS form #3526, filed
October 1, 2012.
UPCOMING
events
Oct. 810 Powder Coating 2013, St. Louis, Mo. Visit

www.coating-show.com for more information.
NOVEMBER
Nov. 1821 FABTECH, Chicago, Ill. Please visit
www.fabtechexpo.com for more details.
ADVERTISERS
index
AmeriChem
Engineering Services ...............54
Apex Expo...........................................11
Cornerstone Systems, Inc. ........23
Lanco Corp. ......................................54
Matchless Metal Polish .............40

Metalline Corp. ..............................54
Met-Chem ..........................................54
Miraclean Aqueous
Cleaning Systems.......................19
M.W. Watermark, LLC .................54
Defelsko Corp. ...................................7
SERFILCO, Ltd.....................................1
Singleton Corp...............................41
Techton America, Inc. .................29
Waste Treatment Equipement

Specialties Co...............................54
Nationwide Installation Corp....54
EW Metals, LLC...............................54
Quantum Plating, Inc.................54
Fischer Technology, Inc. ..............5
Happy holidays
and best wishes for
the New Year!
Metal Finishing
Elsevier, Inc.
metal
finishing
WANTS YOUR
TECHNICAL PAPERS
Metal Finishing is currently seeking
technical papers and articles for
upcoming editions. Issue themes
and special editions are as follows:
JANUARY/FEBRUARY 2013
(Finishing for Electronics)
mate-free conversion coatings; CARC

coatings
Applications for printed circuit boards,

hard drives, connectors, photovoltaic
and more!
JULY/AUGUST
(Cleaning & Pretreatment)
MARCH/APRIL
(Automotive)
Ultrasonics, vapor degreasing, aqueous

and solvents, phosphorus-free
chemistries, and manual surface prep
Techniques for plating on plastics and

fasteners; zinc/zinc alloys; and auto
body coatings; E-coating.
MAY/JUNE
(SUR/FIN 2013 Preview, plus
Aerospace & Defense)
Alternatives to cadmium;
aluminum/titanium anodizing; chro-
SEPTEMBER/OCTOBER
(POWDER COATING 2013, plus
FABTECH PREVIEW )
Best Paint/Powder coating practices;
spray booth design; irs curing ovens.
Special Supplement: Finishing Equipment:
Racks, Barrels, Tanks, Hoists, Spray
Guns, Robots, Turnkey Systems.
Please submit abstracts or deadline inquiries to

Reginald Tucker, editor, at re.tucker@elsevier.com
or call (212) 633-3885.
The Metal Finishing Network

Your Global Surface Finishing and Coatings
Research and Development Resource
Multi-media marketing and advertising opportunities

Broad portfolio of lead-generation products and services
Targeted online programs reaching more than 250,000 users worldwide
Proven lead-generation solutions include:
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What is the Metal Finishing Network?
The Metal Finishing Network offers you an opportunity to connect with more than 250,000 researchers and
industry professionals involved in the science or application of surface finishing as well as the specification of coatings
development, processes, and procedures. The family of products and services within the Metal Finishing Network
can help you reach targeted audiences that matter most to your business. These include: original equipment
manufacturers; chemical design and mechanical engineers; coating products and systems developers, as well as
providers who specify, buy, or authorize the usage of relevant products, equipment and services. You can choose from
a wide range of magazines, journals, branded websites, conferences and trade shows from ReedElsevierthe worlds
foremost publisher of scientific and technical informationto reach your target demographics.
Access to the readers of more than 20 Elsevier peer-reviewed journals on

ScienceDirect.com, including:
Aerospace Science & Technology, Applied Surface Science, Computers & Electrical Engineering, Corrosion Science,
Dyes & Pigments, Inorgranic Chemistry Communications, International Journal of Minerals, Metallurgy & Materials,
International Journal of Refractory Metals & Hard Metals, Journal of Alloys & Compounds, Journal of Materials Processing
Technology, Materials Characterization, Microelectronic Engineering, Nano Today, Precision Engineering, Progress
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Metal Finishing NovDec2012

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November/December 2012

The Plating and Coating Industries Technology Magazine

Ask the Experts

Your Metal Finishing Subscription Service is FREE!

OR scan this QR code with your smartphone!

GLOBAL PRODUCTS, LOCAL SERVICE AND ADVICE YOU CAN RELY ON

(800) 323 - 5431

Cover image courtesy of Singleton Corp.

31 Adhesion and Bonding

39 Ask the Expert

Photo courtesy of Guyson

students and established plating

November/December 2012 I metalfinishing I 3

American region. Trostle brings

Translogistics, Inc., Birdsboro, Pa.,

chemical manufacturing plant covers 200,000 square feet to house

Americas Center in downtown St.

DPM, SPG and UTG probes, easily

Electroplating Electroless Coatings Anodize

Mike Wittenhagen (right), technical manager at

November/December 2012 I metalfinishing I 5

Coventya is pleased to announce

Pangborn Europe, a leading manufacturer in the surface preparation

2012 NEW ENGLAND SURFACE

COATING THICKNESS GAGES

ough presentation on the use of

Now smarter, faster and more

November/December 2012 I metalfinishing I 7

FABTECH 2012 consumed more than 450,000

Bruce Dunham, marketing manager, Dubois

Conference and Convention Center

SOLID ALL AROUND

Spray equipment demonstrations at the

Coral Chemical talking up its environmentally

All smiles. Chemetall's Suresh Patel (left), David

thickness testing equipment.

to touch base with both existing and

Partnership, LLC, and David Goch,

I heard both on the show floor and at

sored by the American Welding

Magic Rack's Dan Davitz (front right) explains

CONFERENCE & EXHIBITION

IPC APEX EXPO allows me and my colleagues to evaluate new technologies

3Ms Jeff Simmons (front right) and Bob

the industry via their trade associations.

thousands of your colleagues

Scan for your chance to win

design | printed boards | electronics assembly | test

November/December 2012 I metalfinishing I 11

BY RAYMUND SINGLETON, SINGLETON CORP., CLEVELAND, OHIO

Accelerated Corrosion Testing

ccelerated corrosion testing of

Some of the more widely used tests

to be discussed in this update.

ASTM D609 Standard Practice for

tency of test results. Accelerated corrosion tests are performed under

CRITERIA FOR CYCLIC TESTS

Fig. 1. Schematic drawing of a typical salt fog

much wider variety of materials,

ASTM B117 Standard Practice

Fig. 2. Typical water-jacketed-type corrosion

Fig. 3. Typical large-size, drive-in-type corrosion

exposed to a salt fog atmosphere

collection area. To maintain