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Surface Finishers PDF
Surface Finishers PDF
SURFACE FINISHING
USER’S GUIDE
Aluminium Federation of
ALUMINIUM
Light, Strong & Beautiful Southern Africa
Introduction
Aluminium the Material
INDEX Aluminium is a remarkable material. It has a unique
combination of properties that make it suitable for many
different applications in various alloy forms.
Introduction 3
Aluminium is a light metal whose strength, corrosive and
decorating properties can be improved by alloying with various
ASFA 3 other metals. It has good tensile strength over a wide range of
temperatures and has excellent corrosion resistance. When
aluminium is exposed to air, a thin, glass-hard oxidised film
Surface Finishing defined 3 forms on the surface. This oxide film clings tenaciously to the
metal's surface, presenting an effective barrier to the elements.
Surface coating can make corrosion resistance even more
Types of Surface Finishing 4 effective.
Anodising 11
Powder Coating 15
Wet Coating 18
Contact Details 20
References 20
2
Introduction
ASFA
Extruded Fine lines on extruded surface Decoration, Guidelines to future positioning, Fine lines cover small imperfections.
Mechanical Grinding / brushing Fine lines in the direction of grinding. Gives a silk or matt appearance.
Produces a flat even surface.
Polish and buffing The grinding lines partly disappear with polishing. Reduces “stress risers”.
Removes die lines and tool marks and surface blemishes.
Vibration polishing Yields a matt to shiny surface suited to small batches and mass produced parts.
Shot / grit blasting For cast aluminium components to remove cast skin and improve appearance.
Chemical Milling Removes surface to desired depth. Can be used for signwriting.
Brightening (prior to anodising) Removes surface texture and gives a mirror finish. Film usually < 15 microns
Electrochemically plating with Improves corrosion resistance / gives good soldering surface /
copper, tin, nickel or silver conductivity and reflectivity.
Electrochemical Decorative anodising Gives a hard, natural or coloured oxide layer up to 25 microns.
Mainly for decoration - resists pitting corrosion but also adds wear resistance
and electrical insulation.
Hard anodising Gives a grey to brown coloured hard oxide layer of 75 - 125 microns.
Mainly used for engineering purposes to resist abrasion / wear.
Wet coating Mainly used in capital intensive operations for coil coating, effective and
efficient. Mainly for building industry.
4
Finishing Processes
Type of Finish to be Specified Grinding requires a rotary grinder with a bonded adhesive cup
wheel or canvas wheel faced with suitable abrasives. Low speed
grinding (1500mm/min) using aluminium oxide is preferred to
There are a number of factors to consider when specifying avoid overheating the surface.
surface finishes. Different finishing processes may be specified
depending on the use or application of the final product. Some Machine polishing requires wheels or belts that have abrasives
of the factors to be considered are: either bonded to them or sprayed onto the wheel at regular
z Appearance: bright, matt, coloured, brushed, other intervals. Both contact and mush polishing methods are used,
z Environment of use: the latter being more common. Polishing can include a buffing
z Interior (architectural, commercial, decorative, other) operation to remove emery marks.
z Exterior (architectural, marine)
z Industrial / Automotive (corrosive or non-corrosive z Chemical finish in preparation for anodising
application, resistance to wear or abrasion, other) Chemical treatment of an item significantly affects its
z Underground (mining, cabling, piping) mattness or brightness (specularity). Chemical treatment is
z Aerospace (corrosive resistance, dielectric, emissivity, done prior to anodising and is a very important factor in the
fatigue strength, other) final appearance of the anodised part. The pre-anodise
chemical treatment of aluminium is often called the cleaning,
clean-up or pre-treatment phase of the process.
Criteria for Specifying Finish the surface not to be etched is covered with a coating such as
wax, that does not react with the reagent. The areas to be
attacked are then exposed or exposed in order if different
The performance of surface treatments depends directly on the degrees of attack are required. Both alkaline and acid etchants
quality of the surface preparation. Anodising and powder can be used. The former are more common as they are
coating are complex processes that are constantly being cheaper and easier to handle.
improved. Specifiers should insist on adherence to SANS or
International Standards to ensure that the surface finish z Anodic oxide requirements
performs in the expected manner. The anodic finish is the result of carefully controlled electro-
chemical oxidation of the aluminium surface. There are
When specifying surface finishes for aluminium products, the various types of anodic finishes. Each finish is specified to obtain
following specific criteria should be addressed: certain appearance and/or performance characteristics desired
according to the end use of the product.
z Alloy and temper of aluminium to be used Some of the characteristics of anodised surfaces are:
The alloy and temper of the product to be anodised will affect z Decorative
both the strength and appearance of the part after it is treated. z Abrasion resistance
Various combinations of constituent elements cause each z Reflective
aluminium alloy to react differently in the coating process; this z Dielectric, insulating
is particularly evident between alloy series. As a result, each z Corrosion resistance
alloy or alloy series yields a different appearance, even if z Colour
treated to identical coating processes. z Absorption / emissivity of heat
5
Atmospheric Corrosion
Aluminium and Atmospheric The Concept of Corrosivity
Corrosion The corrosivity of an atmosphere can be defined as the ability
Aluminium enjoys the advantage of a hard, inert oxide film that of the atmosphere to cause corrosion in a given metal or alloy.
forms instantaneously when the metal is cut or abraded. This ISO 9223 specifies the key factors in the atmospheric corrosion
oxide film inhibits corrosion and as a result, in some uses such of metals and alloys and defines categories of corrosivity on
as industrial and agricultural roofing and cladding, aluminium is the basis of the constituents of the atmosphere, and in
routinely supplied in mill finish. Even windows, doors and particular the levels of chloride and sulphur dioxide present,
casements can be supplied in mill finish. in combination with the time-of-wetness of metal
surfaces.
The demands of corrosion resistance, surface protection
and aesthetics have however relegated mill finish to those ISO 9223 also allows the classification of corrosivity to be done
situations where corrosion is slow and the product does using corrosion rate measurements of standard specimens of
not have to be finished in a specific brand colour or where common metals and provides a table relating the corrosivity
dulling and roughening of the surface is not important. category to these corrosion rates for the first year of exposure.
Description Type of corrosion Mild steel* corrosion Galvanised steel Aluminium sheet
rate µm/yr sheet** life in years^ life in years
KEY:
* Higher corrosion rate usually indicates proximity of sea. ++ Industrial implies pollution present in atmosphere.
** Commercial grade Z 275g/m² (unpainted). Temperate marine & Sub-tropical marine usually from 5km inland
^ Life in years - until 5% of surface area showing red rust. up to first mountain range.
6
Atmospheric Corrosion
NOTE:
z Metal corrosion depends
on time of exposure to
moisture and relative
humidity and temperature.
z Rate of corrosion reduces
rapidly the greater the
distance from the sea.
z For aluminium, aggravating
conditions can be a strong
sulphurous atmosphere, the
occurrance of chloride salts
and stagnant water - but the
right aluminium alloy still
outperforms copper, zinc
and carbon steel! Regular
cleaning and surface coatings
reduce the affect on
aluminium.
z Pitting corrosion in
aluminium may be unsightly,
but it is not structurally
significant.
7
Atmospheric Corrosion
8
Surface Finishes Comparison
TABLE 6: Finishing Comparisons
Parameter Anodising Powder Coating Wet Coatings
Specifications SANS 999, 1407 and 10322 SANS 1578, SANS 1274, ASTM D3663 for PVDF
(ensure relevant use of most apply. Also Qualanod. SANS 1796 and SANS 10322 fluorocarbon. AAMA 605.2.92
current revision) BS EN 755 applies to surface apply. Also Qualicoat. for baked organic coating.
characteristics of extrusions. BS EN 755 applies to surface
characteristics of extrusions.
Colour range Extensive range but not Full range available for Dependent on type of
all are suitable for exterior either interior or exterior coating used, a large range
use. Inorganic and organic use. Critical to specify is available. PDVF colours are
dyes used. SANS 1091 the type of powder to be limited
applies. used.
Appearance Anodising gives a crisp, clean, Powder coated aluminium may
metallic appearance - in lose that crisp appearance due
natural or colour finish to the flow of the powder
during curing.
Installation Anodising is prone to attack Powder coating is less prone Long lasting mortar resistance
by wet mortar and certain to attack by mortar, but is
acid attacks. also prone to certain acid
attack.
Abrasion resistance Hard surface, long lasting Not abrasion resistant, but Inert coating with good
abrasion resistance. long lasting. chemical resistance and
seawater attack.
Maintenance Wash down with a neutral Wash down with a neutral Roofs and vertical cladding
detergent every 3 to 6 detergent every 3 to 6 require minimal
months. months. maintenance. For other
areas, wash regularly
with a neutral detergent
Corrosion Resistance If correct microns are Protects the underlying Good corrosion resistance if
specified, excellent substrate if correctly treated correct design, fixing,
resistance against marine prior to coating. Also crevice joining, etc.
and industrial atmosphere resists UV degradation if principles are adhered to.
attack. correct powder has been
used.
Pre-treatment Finishes Etched, polished, Matt, satin, gloss speckled, Standard gloss level or by
brightened, brushed, structured, metallic, etc. special arrangements.
sanded, shot blasted, etc.
NOTE: All anodised and powder coated surfaces need regular care depending on the location and installed life. After installation, the
surfaces should only be cleaned with suitably approved cleaning materials. Site repair or changes to colour or finishes requires
expert opinion.
9
Surface Finishes Comparison
Overall, anodising is the most common surface finish (having
been in use for more than 60 years), but powder coating is What makes a Quality Powder Coating?
increasing its market share, especially opposite paint coatings.
The main requirements of a quality coating are:
Anodising and Powder Coating
z A uniform and even appearance, properly cured
The main debate on the merits of different finishes is really
between anodising and powder coating as applied to z Excellent adhesion
extruded aluminium. Some members of ASFA are both
powder coaters and anodisers and do not see the two z Excellent weatherability and durability
finishes as competitors. They have different roles to play in
enhancing the metal’s decorative visual experience and z No fading or chalking when used for exterior or
improved corrosion resistance. interior conditions
For decorative and corrosion resistant surface finishes a Following and adhering to these basic guidelines can
number of polyester, acrylic and fluorocarbon coatings have assure the customer/asset owner of a coating that will
been developed and used successfully - with service lives deliver optimum performance while also limiting the
exceeding 20 years. These finishes command a price premium chances of coating failure.
over mill finish price.
TABLE 7: Main Types of Anodising Treatment - for different aluminium alloy series
Alloy Treatment Properties of the anodic layer Typical applications
Series
1000 Surphuric acid anodising, Transparency, reflectivity, brilliance. The lower Decoration, optical
continuous or static the Fe and Si content, the more transparent reflectors.
the layer.
3000 Degreasing, chemical conversion, food quality Alloys easy to anodise. Cans, buildings,
lacquering. Protection, decoration, good corrosion domestic utensils.
Degreasing, chemical conversion, continuous resistance, resistance to scoring.
lacquering.
Surphuric acid anodising.
Hard anodising. The layer has a grayish tint. Engineering
5000 Sulphuric acid anodising, continuous or static. Durable aspect, corrosion protection. Architecture, building.
Colourless or electrolytically coloured. Most alloys easy to anodise. The layer is milky
or greyish depending on composition.
2000 Chromic acid anodising, sealed with Surface preparation for adhesive bonding. Aeronautics.
bichromate on 2024 and 2618A.
Sulphuric acid anodising, sealed with The thickness of the layer is limited and more Mechanical applications.
bichromate on 2017A. or less porous due to dissolved copper.
Provides limited corrosion protection.
7000 Chromic acid anodising on 7075. Most alloys easy to anodise, those containing Aeronautics, mechanical
Suphuric acid anodising on 7020. copper, less so. applications, sports
Hard anodising on 7075, 7049A. Protection, decoration, harness. goods.
6000 Sulphuric acid anodising, continuous or static; Most alloys easy to anodise. Metal fittings, buildings,
colourless or electrolytically coloured. Working and heat treatment parameters must boat masts, transport
Electrostatic powder coating. be controlled to achieve consistent appearance and many others.
mong batches.
Decoration, durable aspect, good corrosion
protection.
10
Anodising
What is Anodising?
Typical Anodising Process Flow Chart
Anodising successfully combines science with nature to (performance additives not detailed)
create one of the world's best metal finishes that is also
environmentally safe.
RACKING
It is an electrochemical process that thickens and toughens the
CLEANING / DEGREASING (optional)
naturally occurring protective oxide layer in aluminium. The
SOAK CLEANER @ ±60°C
resulting finish, depending on the process, is the second
hardest substance known to man, second only to the diamond.
ETCHING -
The anodic coating is part of the metal, but has a porous
CAUSTIC SODA @ ±60°C, 5 - 10 min
structure that allows secondary infusions (organic and
inorganic colouring, etc.)
COLD WATER RINSE x 2
Anodising is commercially unique to aluminium and its alloys.
This surface finish is used for a number of reasons including: DESMUTTING with 20% NITRIC ACID
5 - 15 min
z For decoration, through a variety of colours
z For a long-lasting appearance
z For protection against weathering COLD WATER RINSE
z For surface hardness
z For abrasion and wear resistance ANODISE (using DC at18V)
z To reduce friction and improve repellency 10% SULPHURIC ACID
z To improve the adhesion of organic coatings (adhesives, TEMP. 18-22°C
varnish, paint) COOLING & AGITATION
z To modify electrical properties (insulation) 2 TO 3 min. PER MICRON
z To modify visual properties (reflectivity)
COLD WATER RINSE x 2
Anodising Definitions
There are five main types of anodising, each with a range of
possible processes: ELECTROLYTIC INORGANIC or
z Barrier anodising, used for refined aluminium only, for COLOURING (AC) ORGANIC
electrical applications TIN or DYEING ABSORPTIVE
z Sulphuric acid anodising, used mainly as protection against COBALT SOLUTIONS
weathering
NATURAL
z Chromic acid anodising for aerospace applications
z Hard anodising which increases the surface hardness of COLD WATER RINSE COLD WATER RINSE
the metal, mainly for engineering applications
z Phosphoric acid anodising, used to prepare surfaces for HOT SEALING in DE-IONISED WATER
adhesive bonding Temp: 92°C min. / 3min per micron
or COLD SEAL
While the chemical anodising process remains the same for all
applications, the mechanical methods vary according to the DE-RACKING & PACKING
physical types and shapes of metal used.
11
Anodising
12
Anodising
Note: The various forms of semi-fabricated aluminium have their own characteristics affecting the anodising finish. Different alloys
anodise to slightly different shades.
The thickness of the aluminium oxide coating can be varied by the anodising process time. The following figures
are usual:
10 Micron Suitable for internal applications, and outdoor applications where cleaning is very
frequent, for example, caravan trim. Also for reflectors.
25 Micron plus to 250 Micron 25 Micron to 250 Micron is achieved by Hard Anodising of wrought alloys done by
(125 Microns max. is more usual) varying the electrolyte composition and modulating the process parameters. Hard
anodic films are used to provide abrasion resistant surfaces on bearings, pistons,
gears and other components.
14
Powder Coating
Introduction Range of Colours
Powder coating is an advanced method of applying a decorative
Polyester powder coatings are available in a vast range of
and protective finish to aluminium - creating a wide range of
colours. These may be specified from the international RAL
products that are used by both industries and consumers. The
colour chart, SANS 1091 or the individual colour ranges of
process result is a uniform, high quality and attractive finish.
powder manufacturers and coaters. Specifiers should also
The powder coating industry continues as the fastest growing
specify the gloss level required, with a matt surface being
finishing technology in North America. Powder costs less to
preferable for most architectural finishes.
apply than equivalent performance liquid paint.
For exterior use, specifiers should at least opt for finishes in
Attributes of Powder Coating accordance with SANS 1578 and 1796, as these not only
protect the substrate metal against corrosion, but also resist
z Tough and durable UV degradation as well.
z Excellent corrosion resistance
z
z
Impact resistant
Attractive and colourful
Versatile Finishes
z Excellence of finish
z High quality and versatile Powder coated surfaces are more resistant to chipping,
z Solvent free and environmentally friendly scratching, fading and wearing than other finishes. Colour
selection is virtually unlimited with high and low gloss, metallic
The list of products powder coated is extensive and includes and clear finishes available. And colours stay bright and vibrant.
automotive parts, industrial piping, appliances, sports goods, Texture selections range from smooth surfaces to a wrinkled or
outdoor furniture, power tools, aircraft parts, office equipment matt finish and rough textures designed for hiding surface
and architectural fittings such as windows, doors, showers, etc. imperfections. Powder coating is a technology of the future!
15
Powder Coating
There are many advantages that make the choice of applying 2. Jigging Points
thermosetting powder coatings attractive to the coating To apply polyester powder it is necessary to hang each item on
company. These include: to a conveyor and so one or more jigging points are required.
These are best in the form of drilled holes or suitable jigging
z Powder is immediately ready for use edges, where the contact point does not affect the appearance
z Less powder wastage during the application process of the finished product.
z Reduced health hazard in case of exposure of operators
z Superior cured-film properties 3. Pretreatment Drainage
z Lower capital investment costs All of the approved pre treatments require immersion in
SPECIFY...
Colour RAL / NCS SANS Standards
or SANS
or Mfr’s Powder coated finishes to be in accordance with SANS 1578.
range Organic powder coatings for external architectural aluminium
Finish Gloss
or Satin Powder Coater
or Matt
To be a certified markholder of SANS 1796 and / or an applicatior approved by the
Powder Coating powder manufacturer who must be a certified markholder of SANS 1578: Organic
Film Thickness 60 - 80µ powder coatings for external architectural aluminium.
Protective Coating Low tack Guarantee of coating given by the Powder Coating manufacturer is only valid
during adhesive provided the applicator is approved by the coating manufacturer.
installation tape
16
Powder Coating
6. Heavy Masses
Heavy components require a longer heating cycle due to the
metal temperature being the important criterion.
Consequently, these are more expensive to coat. The surface
appearance (but not colour) of the finished item may be
slightly different between substrates of differing mass due to
variations in "heat-up" and cool down times.
7. Exposed Surfaces
All drawings should indicate the area where the coating is
required.
17
Wet Coating
Colour
from coil coater’s range
Gloss
18
Care and Maintenance
Introduction
As with all materials exposed to the elements, regular
maintenance is required to ensure maximum life and
performance from the product.
Cleaning Procedure
Guidelines for the Protection of Aluminium
A regular cleaning and maintenance system is essential for two
reasons: DO'S:
z Protect exposed aluminium surfaces until all the trades
z To maintain decorative appearance; and
etc. have been completed.
z To reduce any chemical attack, if applicable.
z Any cement or acid should be removed as soon as
practical. This will prevent any chemical attack.
The cleaning procedure may be broken down into three
z When cleaning, wash down all surfaces with a neutral
distinct categories, namely:
detergent and rinse thoroughly.
z Remove stubborn deposits on ANODISED aluminium
1. Primary Cleaning:
with a suitable nylon abrasive cleaning pad or brush, plus
Primary cleaning is the initial cleaning that should occur after
neutral detergent and then rinse.
installation / completion to remove atmospheric dust, deposits
z Remove stubborn deposits on POWDER COATED
of dirt, possible cement deposits, glues, etc.
aluminium with a suitable soft cloth or nylon brush, plus
a neutral detergent and then rinse.
2. Secondary Cleaning:
z To clean long neglected areas, it is advisable to use
This is normally a heavy duty clean that is carried out on a
proprietary cleaners specifically formulated for
surface that has not been cleaned for some time.
aluminium surfaces. These products contain residual
waxes etc. and can substantially improve the appearance
This is carried out by companies that specialise in the cleaning
of worn or weathered surfaces.
of facades, windows, doors, curtain walling, etc.
DONT'S
The most important criteria of an aluminium cleaning agent is
z Use wire brushes, steel wool, blades or emery paper.
that it should not be toxic, have a pH within 4,5 and 9 and it
These are NOT recommended under any circumstances.
must be free of fluorides, chlorides or sulphates.
z Avoid mechanical damage from scaffolding and bad
handling.
3. Periodic Cleaning: z Allow cleaning with pool acid on anodised finishes (as it
This is the cleaning cycle that should be done on a regular basis contains chlorides).
AFTER the primary and secondary phase (in the case of a new z Allow cleaning with abrasive pads on powder coated
installation, it follows after the primary). The intervals of each surfaces.
cleaning cycle are dependent on the atmospheric pollutants, z Allow mortar cleaning chemicals to come into contact
area, region, corrosion levels, etc. for a particular region - with powder coated and/or anodised surfaces, unless
approximately three months at the coast and six months inland. the cleaning company gives a warranty for its product.
z Aluminium should not be in direct contact with brass or
copper, which may be wetted.
z Allow strong alkalis such as caustic soda, lime etc. to
come into contact with aluminium or finished aluminium.
19
Acknowledgements for the contribution of ideas, material and/or pictures to:
AFSA Library E.S. Mowat and Sons
Akzo Nobel / Interpon Powder Coatings Hulett Aluminium
Astro Anodizing cc Hulett-Hydro Extrusions
Cascolor Aluminium Finishing Lite-Epoxy Coating cc
Continental Anodisers Polynam (Pty) Ltd
C.S.I.R Standards SA (SABS)
Design Anodising Wispeco (Pty) Ltd
AFSA has a number of reference sources on surface finishing of aluminium and its alloys. Members and non-members
are welcome to contact AFSA for more information (which is free to members).
Aluminium Federation of
Southern Africa
This revised edition was compiled by AFSA (in conjunction with There Be Dragons)
and published by the Aluminium Federation of Southern Africa. © 2004