January 2009 Vol. 107 No. 1: The Plating and Coating Industries' Technology Magazine

January 2009
Vol. 107
No. 1
The Plating and Coating Industries’ Technology Magazine

www.metalfinishing.com
Decorative Coatings
TriChrome® –
For Environmentally
Responsible TriChrome® processes improve productivity
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Deposits plated from TriChrome® have

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From bright to dark:

TriChrome® White,
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ers freedom of choice,
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High covering power for Various ﬁnishes for consumer Features and Benefits
automotive application electronics articles # Higher productivity and faster
deposition rate
# Advanced throwing and covering power
# Reduced burning and “white wash” effects
# Suitable for PoP and metal substrate
applications (incl. White-Bronze)
# High corrosion resistance – superior
against CaCl2 attack
# Cr(VI)-free processes – simple handling
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# Reduced air-borne mists and use of
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TriChrome® is a tried and trusted technology

in use at approximately 350 customer loca-
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Atotech USA Inc.
1750 Overview Drive · Rock Hill, SC 29730
USA · Tel.: +1 803 817 3500 · Fax: +1 803 817 3666
usainfo@atotech.com · www.atotech.com
Circle 038 on reader information card or go to www.metalfinishing.com/advertisers
ULTRASONICS
ULTRASONICS
IMMERSIBLE TRANSDUCERS
5 YEAR GUARANTEE
ON WELDING
5 DAY DELIVERY ON CUSTOM
IMMERSIBLE TRANSDUCERS
5 YEAR GUARANTEE ON
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Phone (609) 883-4000 • Fax (609) 883-6452
P.O. Box 7266 • Scotch Road • Trenton, NJ 08628
WHAT’S
inside
Technically Speaking
27 Next Generation Trivalent Chromium:
New systems meet or exceed all decorative
thickness requirements and corrosion
standards
34 Investigation into the Corrosion Resistance

of Nanocoatings
Organic Finishing
43 Time, Cost, and Space Considerations Fully Equipped
When Prepping for a New Paint System
Investing in equipment
49 COATING WEST 2009 Preview: pays big dividends .
Technical Conference Schedule,
Plus Preliminary Exhibitor Listing
Case Study
43
Photo courtesy of Professional Plating
42 Cost-Saving Solutions Via Used
Finishing Equipment
Business Spotlight
13 Year in Review: Metal Finishing Recaps Columns
the Top News and Events of 2008
4 Tucker’s Take
Countdown to SUR/FIN 2009 Analysts Temper Industrial Outlook
12 You Have to be in it to Win
47 Painting Problem Solver
Departments Ensuring Proper Grounding When Using
5 News & Briefs Electrostatic Spray Guns
55 Product Showcase: Conveyors & Equipment

48 Ask Joe Powder NEW!
56 New Products Powder Coating Laser-Cut Surfaces
58 UV Curing Spotlight
52 Cleaning Times
60 Directory: Polishing & Buffing Parallels Between Fishkeeping & Cleaning
63 Calendar of Events
54 Sherwood on Management
64 Advertisers’ Index The Power of Confident Speaking
wwwebinar:
Alternative Pretreatment Technologies
for Steel and Aluminum Surfaces
Date: Live Thursday, January 29, 2009
Time: 3pm (EST)
Duration: 60 minutes
Moderator: Ron Joseph, Metal Finishing Organic Editor
Panelists: Allen Miskowiec, General Industry Surface Treatment Market Manager;
Gary Nelson, General Industry Surface Treatment Product Manager; and
Daniel Yankovich, General Industry Manager, Chemetall.
Description: IN ASSOCIATION WITH
Increasing regulatory pressures are forcing metal finishers

to seek out options to conventional pretreatment processes.
That has led to the development of several novel pretreatment
processes with which finishers might not be readily familiar.
This informative webinar will cover current environmentally
acceptable alternative processes, particularly those impacting
the steel and aluminum fabrication industries.
This Webinar will:

I Identify and define conversion coatings
I Discuss the basics of a zinc phosphate process for ferrous
and aluminum surfaces
I Outline the advantages and disadvantages of zinc phosphate
I Delve into the pros and cons of alternative technologies,
such as zirconium, titanium, and silane
Registration Details:
Information will be available at www.metalfinishing.com/webinars
approximately two weeks prior to the event launch date.
metal finishing
January 2009
tuckerstake
Volume 107 - Number 1
Publisher
Greg Valero
g.valero@elsevier.com
Editor
Analysts Temper Outlook for ’09 Reginald Tucker
re.tucker@elsevier.com
B
Managing Editor
usiness conditions are likely to es, and a shrinking number of jobs Drew Amorosi
worsen before they get better. made individuals poorer and look- d.amorosi@elsevier.com
That seems to be the prevailing con- ing for ways to build some savings. Organic Coatings Editor
sensus of a chorus of economic The slide continued. MAPI’s Ron Joseph
experts when queried about not only Institute of Supply Management rjoseph@exponent.com
the likelihood of an economic recov- Index (ISM) for November fell to its Publisher Emeritus
ery in the U.S. No surprise, then, that lowest level since May 1982, on the Eugene B. Nadel
so many analysts have tempered their heels of a negative durable goods Art Director - Production Manager
outlook on the U.S. industrial sector report for October. “The 12th consec- Susan Canalizo-Baruch
s.canalizo@elsevier.com
specifically. utive decline in new orders to the low- Advertising Sales Manager
A recently released report from the est level since June 1980 reflects the William P. Dey
Manufacturers Alliance/MAPI, offers fact that the key demand drivers for w.dey@elsevier.com
a sobering assessment: With the U.S. manufacturing growth—exports and Advertising Sales Manager
economy in the midst of a severe business investment—are weakening Lawrence A. Post
l.post@elsevier.com
recession, it will likely face serious significantly,” said Cliff Waldman, Sales Operations Coordinator
and unrelenting challenges through- economist for MAPI. Eileen McNulty
out 2009. Specifically, according to More reasons to be concerned: e.mcnulty@elsevier.com
Daniel J. Meckstroth, MAPI’s chief MAPI’s 2009 forecast calls for indus- Marketing/Circulation Manager
economist, manufacturing produc- Jason Awerdick
trial equipment expenditures to j.awerdick@elsevier.com
tion is likely to fall by 4.2% this year. plummet by 15.4% this year, with a Metal Finishing
Furthermore, he predicts inflation- 20.2% drop in spending on trans- 360 Park Avenue South
adjusted GDP growth will decline 1%. portation equipment. Furthermore, New York, NY 10010-1710
The prognosis represents an inflation-adjusted expenditures for (212) 633-3100
FAX: (212) 633-3140
abrupt “about-face” from a report information processing equipment http://www.metalfinishing.com
MAPI released at the start of the sec- are expected to decline by 4.6%.
Metal Finishing (ISSN 0026-0576) is published monthly, with the
ond quarter of 2008 that initially Amidst all the gloom, many are exception of July and August that combines into 1 issue and with
special issues in September and December by Elsevier Inc., 360
forecast production to grow by 1.6% wondering if there any bright spots . Park Ave. South, New York, N.Y. 10010. Metal Finishing is free to
in 2009. At the time, MAPI noted In truth, MAPI does expect to see a qualified metal finishers in North America. For others related to
the field the subscription rate per year, including a copy of the
that, since the fourth quarter of 2007, surge in the computers and electron- “Metal Finishing Guidebook and Directory Issue” and the
“Organic Finishing Guidebook and Directory Issue” is:
seven industries enjoyed strong, dou- ics products sector, with high-tech 1-year subs for 2009
ble-digit year-over-year growth. This industrial production expected to USA $107.00
was led by mining and oil and gas rise 6.6% in 2009. Additionally, Canada/Mexico $149.00
Europe & Japan $238.00
field machinery (31%); communica- export growth should continue to Rest of World $238.00
tions equipment and aerospace parts outpace that of imports, which may
Metal Finishing Customer Service, P.O. Box 141, Congers, N.Y.
(15%); steel (13%); and electronic offer some marginal economic relief, 10920-0141. Toll free (U.S. only): (800) 765-7514. Outside
computer/electrical equipment experts say. the U.S. call (845) 267-3490, fax (845) 267-3478. E-mail:
Metal@Cambeywest.com. Periodicals postage paid at New
(12%). That same report predicted In next month’s column, we’ll look York, N.Y. and at additional mailing offices.
Change of Address: Postmaster—send address changes
that 20 of 24 industries were expected at additional economists’ perspectives to Metal Finishing, P.O. Box 141, Congers, N.Y. 10920-0141.
Toll-free (for U.S. customers) (800) 765-7514. Outside of the
to show growth in 2009, with only on industry, including recommenda- U.S. call (845) 267-3490, fax: (845) 267-3478. E-mail:
two sectors remaining flat. tions for a long-term recovery. In the Metal@Cambeywest.com, 45 days advance notice required.
Please include both new and old address.
Then trouble came knocking. interim, I would like to know how Copyright by Elsevier, Inc. Permission for reprinting selected
portions will usually be granted on written application to the
“The financial crisis worsened dra- you’re coping with this downturn. publisher.
Articles on pertinent subjects are invited. For further
matically in the [second half of Please e-mail your comments to information, please contact the Managing Editor at 360 Park
2008] and consumers suffered a re.tucker@elsevier.com. Hang in there! Ave. South, New York, NY 10010, d.amorosi@elsevier.com.
Publication does not necessarily imply endorsement.
major decline in wealth from falling Microfilm Edition: Available from University Microfilms,
300 N. Zeeb Rd., Ann Arbor, Mich. 48103. Our publication
housing prices and the plummeting number is 342180.
stock market,” Meckstroth noted.
“High inflation, lower wage increas-
January 2009 I metalfinishing I 4 www.metalfinishing.com

NEWS&
briefs MICHAEL
SIEGMUND
APPOINTMENTS Wahlin, AAA Plating & Inspection as it copes with stalling vehicle sales.
The National Association for Inc., Compton, Calif. The board was During the autumn 2008 selling
Surface Finishing (NASF) has elected by the general membership in season, vehicle sales in China were
announced the names of the new elections held this fall, with officers flat or slightly negative—this after
officers and board members for chosen at the annual board meeting six years of 20% or more annual
2009. The appointments are as fol- on Nov. 19, 2008, in Washington, D.C. growth. Citing the $25 billion in
lows: Michael Siegmund, loans that Congress has already
MacDermid Inc., Waterbury, Conn., PPG Industries has announced, approved to help their American
has been selected to serve as the pres- effective immediately, that Charles counterparts increase green
ident of the trade association for F. Kahle II, vice president, coatings research, Chinese executives are
2009. He will succeed Ray Lucas, research and development, is taking now telling the government in
Valley Chrome Plating, Inc., Clovis, on additional responsibility as chief Beijing that they also need emer-
Calif., who has completed a two-year technology officer for PPG. Kahle gency measures. Specifically, they
term. Other officers for 2009: Tony will report to Charles E. Bunch, are seeking lower taxes on new cars,
Revier, Uyemura International chairman and CEO, and join PPG’s lower fuel prices and increased
Corporation, Ontario, Calif., vice Operating Committee in his new grants for research into hybrid cars
president; Pat Gleason, Microfinish combined role. He will continue to and new technology.
Co., Inc., St. Louis, Mo., be based at PPG’s coatings research
secretary/treasurer; Rick Delawder, center in Allison Park, Pa., and will NEW FACILITIES
SWD, Inc., Addison, Ill., executive work closely with PPG’s business Rohm and Haas declared on Nov. 21
committee member at-large; and Ray leadership and the board’s technolo- the opening of the initial phase of a
Lucas, past-president. gy and environment committee. new manufacturing facility in the
Results from NASF’s recent board While retaining direct responsibility Ramenskoye region of Moscow,
of directors election were also for coatings research and develop- Russia—its largest investment in
announced. Newly elected to the ment, Kahle also will assume func- Russia to date. The new polymer
board for a two-year term beginning tional responsibility for glass and emulsions facility, which will focus
January 1, 2009, was Blair Vandivier, chemicals research as well as global on additives for paint and coatings
Benchmark Products, Inc., product development. materials and adhesives, is planned
Indianapolis, Ind.; Bob Burger, KC to have an eventual capacity of
Jones Plating Co., Warren, Mich.; Wayne Boeckman, president and 70,000 metric tons upon completion
Peter Gallerani, Integrated CEO of Quick-Way Stampings Inc. of the final stage. According to
Technologies, Danville, Vt.; Tom of Euless, Texas, has been named the Rohm and Haas, the facility was
Gerhardt, General Super Plating Precision Metalforming developed from a greenfield site with
Co., E. Syracuse, N.Y.; Pat Gleason, Association’s (PMA) 2009 chairman close proximity to key customers and
John Kinne, Xtalic Corp., of the board of directors. Boeckman with good access to local and import-
Marlborough, Mass.; Ray Lucas; Bill is an advocate of expanding opportu- ed raw materials and all key utilities.
Wiggins, Automation Plating Corp., nities for members through product It has been designed with the capa-
Glendale, Calif; and Joelie Zak, innovation, exploring new markets bility to make a wider range of poly-
Scientific Control Labs, Chicago, and ensuring that the new mers for coatings and detergents at a
Ill.—all serving two-year terms. Administration and Congress make later date.
Other members of the board the recovery of the manufacturing
include: Tony Alcaro, Alcaro & sector a priority in 2009. NEW WEBSITE
Alcaro Plating Co., Montclair, N.J.; DYMAX has streamlined its website:
Rick Delawder; Ken Hankinson, CHINESE AUTOMOTIVE www.dymax.com. The site focuses on
KCH Services, Forest City, N.C.; Jim BAILOUT PLEA education with more easy-to-find
Jones, Dixie Industrial Finishing, It seems the major American auto- information, including download-
Tucker, Ga.; Mike Kelly, Asko motive manufacturers are not the able literature, selector guides, and
Processing, Inc., Seattle, Wash; only ones seeking a massive multibil- product bulletins. A new FAQs page
Charles Remied, SERFILCO, Ltd., lion rescue package from the govern- is searchable by market and provides
Northbrook, Ill., Tony Revier, ment. China’s car industry is quietly product-specific answers to the most
Michael Siegmund; and Jerry pressing Beijing for government help commonly asked questions pertain-
www.metalfinishing.com January 2009 I metalfinishing I 5

NEWS&
briefs CERTIFICATIONS
Waterbury, Conn.-based Hubbard-
Hall, Inc., a privately held distributor
chemicals in products shipped to any
EU country.
ing to those markets. In addition, a and manufacturer of commodity GREEN RECYCLING EFFORTS
new, informative glossary explains and specialty chemicals, has fulfilled Belmont Metals, Inc., a diversified
the acronyms and often-used terms compliance requirements with the and recognized source for a large
that might be unfamiliar to some vis- Registration Evaluation and variety of nonferrous metal composi-
itors. The improved navigation Authorization of Chemicals
enables customers to easily find a (REACH) by registering more than
product or application from the 130 products. The new law, enacted
Adhesive Products, Applications, or on June 1, 2007, required manufac-
Industries Served drop-down menus turers and importers to the EU to
on the top navigation bar. There are register specific chemical informa-
also new sections on thermal inter- tion in excess of 1 metric ton per year
face materials and medical adhesives by Nov. 30, 2008 (EC 1907/2006).
for bonding tube sets and fittings. This also affects the sale of common
Visitors to the site will now find products, including air fresheners
detailed, product-specific Web pages and tires, which contain regulated
that contain pertinent information substances. Failure to register neces-
on each product, including features, sary substances by the deadline tions and forms, is doing its part to
applications, suitable substrates, and would have resulted in delayed ship- ensure its products are manufac-
package sizes available. There is also ments and reduced productivity. By tured with a certain percentage of
a link on each of those pages for complying with REACH, Hubbard- recycled content. Although this is
Product Data Sheets (PDS) and Hall is committed to providing unin- not a new initiative—as far back as
Material Safety Data Sheets (MSDS) terrupted supply of products to their 1896, Belmont Metals has been
and no registration is required to European customers, in addition to involved in green technology, utiliz-
download those documents. customers who incorporate these ing reclaimed copper for alloying as
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Circle 029 on reader service card or go to www.metalfinishing/advertisers
6 I metalfinishing I January 2009 www.metalfinishing.com

NEWS&
briefs these rates and make sure you let them
know you are with the “Powder
Coating Academy.”)
Board (PCB) Statistical Program.
Other findings: Year-to-date, rigid
PCB shipments are up 3.2% and
bookings are down 2.5 %. Compared
es, please contact Paul Fisher by phone PCB INDUSTRY RESULTS to the previous month, rigid PCB
at (828) 245-3482, or by e-mail at Rigid PCB shipments are down 5.9% shipments decreased 12.8% and rigid
info@surfacefinishingacademy.com. and bookings are down 17.4% year bookings decreased 17.6%. The book-
You may also visit www.surfacefin- over year for the month of October to-bill ratio for the North American
ishingacademy.com, for registration, a 2008—the most recent period for rigid PCB industry in October 2008
detailed itinerary and hotel informa- which figures are available. That’s slipped slightly to 0.95.
tion for each course. (Hotel rooms are according to newly released data Flexible circuit shipments for
not included, but a discounted rate is from the Association Connecting October 2008 were up 8.8% and book-
available for those who register in Electronics Industries’ (IPC) month- ings were up 25.9% compared to
advance. Call the hotel directly for ly North American Printed Circuit October 2007. Year-to-date, flexible
circuit shipments are up 9% and book-
ings are down 2.4%. Compared to the
previous month, flexible circuit ship-
Moving? Upgrading? Renov ating? ments are up 10% and flex bookings
increased 2.5%. The North American
flexible circuit book-to-bill ratio in
Call the Experts! October 2008 jumped up to 1.00.

For rigid PCBs and flexible circuits
combined, industry shipments in
OUR SERVICES: October 2008 decreased 4.8% from
October 2007 and orders booked
Relocations, New Installations, Turnkey Projects, decreased 14.6% from October 2007.
Waste Treatment Plant Installations - Year to date, combined industry ship-
All handled smoothly & efficiently ments are up 3.6% and bookings are
down 2.5 %. Compared to the previ-
OUR GOAL - YOUR SATISFACTION ous month, combined industry ship-
ments for October 2008 are down
NATIONWIDE INSTALLATION CORP. 11.3% and bookings are down 16%.
4499 Cascade Rd. S.E. • Grand Rapids, MI 49546 The combined (rigid and flex) indus-
616-575-9300 • Fax: 616-575-9322 try book-to-bill ratio in October 2008
www.finishing.com/nationwide • E-mail: tlkeizer@aol.com increased slightly to 0.96.
To view the complete report, as
well as the bellwether book-to-bill
ratios, please visit www.IPC.org.
NOVEMBER U.S. AUTO SALES

U.S. automotive sales in the month
of November plummeted by more
than 40% at three automakers—47%
at Chrysler, 42% at Nissan, and 41%
at General Motors—and by high dou-
ble digits at Toyota, which sold 33.9%
fewer vehicles than in November
2007; Honda’s sales declined 31.6%;
and Ford’s revenues fell 30.6%. BMW
said its sales dropped 26.8%. The
declines are in line with October’s
automotive performance: Sales at
G.M. fell off by 45%, while Toyota,
Honda, and Nissan sales dropped by
23%, 25.2%, and 33%, respectively.
LAYOFFS
Circle 001 on reader service card or go to www.metalfinishing/advertisers DuPont plans to cut 2,500 jobs—

NEWS&
briefs sales team derives its foundation
from years of service in the industry.
Bob Lavorgna, its cleaner and chem-
which kicks off June 16–17 at the
Kentucky International Convention
Center in the city of Louisville.
about 4.2% of its workforce—amid ical specialist who sold and Specifically, the association is asking
steep drops in construction, car sales designed buffing wheels and com- potential speakers to give exclusive,
and consumer spending. The slump pounds for Lea Manufacturing, has informative presentations on the lat-
in the U.S. automotive markets in 30 years in the industry; Craig est technologies impacting the sur-
particular has hurt DuPont badly, as Hoffheimer, COO, has 35 years face finishing industry. Presenters
it is one of the largest suppliers of designing compounds and Buffs for may include: researchers in the
paints to car makers. The company Buckeye Products then for chemical engineering, material sci-
has also been stymied by the collapse JacksonLea; Rich Clouse has 25 ence, and/or surface finishing fields;
in the U.S. housing market, since it years with Matchless; Lyndon Posh companies having developed a new
supplies coatings, countertops and has six years, previously working process or equipment that provides
insulation products used in home with Divine in buff and compound significantly improved results; shop
building. DuPont said it was target- sales; and Mike Plescia, who was owners, managers, supervisors or
ing cost cuts of $600 million for formerly sales manager at Divine for engineers that have developed suc-
2009, up from its previous goal of 15 years manufacturing buffing cessful business strategies; and end
$200 million. wheels and compounds. For more users who wish to give a presentation
information, call (773) 924-1515. on the needs of a specific surface fin-
ANNIVERSARIES ishing area. Abstracts are due
Chicago-based Matchless Metal LAST CALL FOR SURFIN PAPERS January 30, 2009, with final papers
Polish Company announces the The National Association for due May 1. Please submit your
one-year anniversary of its new ded- Surface Finishing (NASF) is inviting abstract for consideration to: Cheryl
icated sales team, which provides recognized experts from around the Clark, SUR/FIN 2009, c/o National
new product, process, and technical globe to submit technical papers for Association for Surface Finishing,
help to customers. The company’s presentation at SUR/FIN 2009, 1155 Fifteenth Street, NW, Suite 500,
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NEWS&
briefs Show & Conference will take place
April 12-15, 2010, at the Charlotte
Convention Center in Charlotte,
Hanover, Germany. Nürnbergmesse
North America (Atlanta) organizes
the show.
Washington, DC 20005. You may N.C. The combined event will kick- The FABTECH International &
also call (202) 457-8404 or e-mail her off with the conference, which will AWS Welding Show—which includes
at cclark@nasf.org. For more infor- open its doors on Monday, April 12, METALFORM—announced plans to
mation about the conference—as well and close on April 14. The show will partner with the Association for
as a list of recommended paper begin on Tuesday, April 13, and run Manufacturing Technology (AMT).
themes and categories—please visit through April 15. The American The purpose, according to the associ-
www.nasf.org. trade show for the paint and coat- ation, is to combine the efforts of
ings industry is hosted by the several trade associations to produce
FUTURE EVENTS National Paint & Coatings an annual event designed to appeal
Following its successful June 2008 Association (NPCA), Washington, to the full range of metal forming
premiere, the American Coatings D.C., and Vincentz Network (VN), and fabricating industry profession-
als. (The first official combined exhi-
bition will take place in November
2009 at McCormick Place in
Chicago.) AMT joins the Society of
Manufacturing Engineers (SME),
Fabricators & Manufacturers
Association, International (FMA),
Precision Metalforming Association
(PMA), the American Welding
Society (AWS), and industry partner
the National Association of
Manufacturers (NAM), to provide
domestic and international support
for the FABTECH International &
AWS Welding Show including MET-
ALFORM.
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SeekMultibillion-dollar Cash
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Business

Big things come in the
SUR/FIN Package
Bold ideas. Best practices. New product innovations. Networking To reserve your booth or register,
and educational opportunities. These are just some of the big things contact
you can expect from SUR/FIN 2009, North America’s premier surface Cheryl Clark, NASF
finishing event. Whether it’s SUR/FIN’s first-class technical conference or 1155 15th Street, NW, Suite 500
its highly acclaimed automotive, aerospace and management sessions, Washington, DC 20005
you’ll be empowered with knowledge that you can immediately apply Phone: 202-457-8404
back in the office or on the shop floor. What’s more, this year’s host city Fax: 202-530-0659
is Louisville, recently named by Manufacturers’ News magazine as the e-mail: cclark@nasf.org
“Southeast’s leader in manufacturing.” And it’s all within an easy drive www.sur-fin.net
or direct flight to the automotive heartland--strategically located near
some of the world’s largest OEMs and applicators. So come to Louisville June 16-17
and be a part of something big. Kentucky International
Convention Center
SUR/FIN 2009. Think big. Win big. Louisville, KY.
Call for Papers. Abstracts now being accepted.

Submissions due January 15, 2009.

Countdown to count on SUR/FIN 2009 to continue
to provide the industry’s best ses-
SUR/FIN ’09
BY REGINALD TUCKER
sions on technological innovations,
chemical engineering, materials sci-
ence, airline/aerospace, management
sessions, and so much more.
Professionals from around the
world—and across various key chan-
You Have to be in it to Win nels—will be on hand to share ideas
and experiences to help finishers
Exhibition, technical conference provide fertile ground, solve surface finishing and manufac-
turing challenges while improving
and captive audience, for sure-fire lead generation. productivity.
Likewise, the show floor area is
A s past SUR/FIN exhibitors will

attest, there are many benefits in
attending the show. Of course,
OEMs and applicators. For finish-
ers, that translates into, potentially,
critical access to an important cus-
expected to be brimming with
excitement and enthusiasm, organ-
izers say. In fact, according to Cheryl
there’s the invaluable networking tomer base for metal finishers. Clark, NASF’s director of events, sev-
component, an exhibition show Additionally, Louisville—with its eral companies have increased their
floor teeming with product demon- full-service convention center and booth spaces this year to convey a
strations, and an educational confer-
ence that’s second to none. But
another important aspect of the
show, particularly for vendors, is the
opportunity to capture leads among
the hundreds of attendees combing
the trade show floor.
“We had a lot of people stop by the
booth, particularly international
attendees,” Mark Schario, executive
vice president of Mentor, Ohio-based
Plating Process Systems, told Metal
Finishing following the event. “We
loved the show, we obtained a lot of
quality leads.”
Schario’s experience was in keeping
with other vendors. One company
told MF is generated 75 leads—and
that was all in one day! Sounds com-
pletely possible—and repeatable—
given the more-than-900 visitors For many exhibitors, SUR/FIN provides a bonafide opportunity for lead-generation.
who came to last year’s show in
search of new products, equipment, downtown amenities and attrac- more dramatic presentation.
and answers to address their day-to- tions—offers ease of access and navi- As an added incentive to come out
day finishing challenges. gation. So not only is the city a hub to the show, NASF is offering regis-
The National Association for for manufacturing, but it is also a tration discounts to those who regis-
Surface Finishing (NASF) is looking place abuzz with activity, develop- ter early. For example, NASF mem-
forward to a similarly strong ment and commerce. bers have the opportunity to save
turnout when SUR/FIN 2009 kicks Yet another draw for SUR/FIN more than 20% on a full conference
off June 16–17 at the Kentucky attendees is the show’s highly package just by getting a jump on
International Convention Center in acclaimed technical program. In signing up. Organizers are also pro-
the city of Louisville. The associa- fact, the show’s respected Technical viding potential attendees various
tion is doing its part to make a com- Committee is already busy at work options to attend the show via sever-
pelling case for not only visitors to developing a comprehensive educa- al registration deals—single-day vs.
particpate but also vendors. tional program to offer the tremen- exhibits only, for example—for the
The primary draw is the location dous value attendees have come to time-strapped finisher.
itself. Louisville is strategically locat- expect. Show organizers are driving For additional information about
ed near some of the world’s largest home the point that attendees can the event, please visit www.nasf.org.

2008
Year in Review body fillers, putties, primers and
other vehicle refinish products.
PPG Industries completes its $3.2
billion acquisition of SigmaKalon
Group of the Netherlands. The deal,
BY REGINALD TUCKER, which sailed through European
Union antitrust regulators, more
than doubles PPG’s sales in Europe,
Industry navigates through the rough patches where SigmaKalon is the second-
impacting local business conditions largest coatings company.
and the economy at large. January 15

A Federal Reserve report showed
industrial production in the U.S.
o say 2008 was a rough year course of the year, you would certain- grew by 0.3% in December—trump-
T would be putting it mildly. At

the start of the year—unbe-
knownst to many at the time—the
ly not get the sense that folks are
throwing in the towel. Quite the
opposite, actually.
ing initial forecasts calling for a
decline. That was due largely to
growth in exports and healthy con-
country was already on the cusp of a Did some operations shutter under sumer spending, which helped make
recession. An economic downturn the extreme economic duress? up for weakness in auto and hous-
that started with the housing market Absolutely. Have many finishing ing-related industries.
spread like a Southern California for- operations and the companies that Enthone, Inc., a business of
est fire to the financial markets, the supply them tightened their belts in Cookson Electronics, announces the
money markets, the credit markets 2008. Most certainly. Have growth continued expansion of the compa-
and—somewhere in between all that— and investment efforts been ham- ny’s operations throughout the East
to the major industrial markets. pered by limited access to credit and of Europe region with the opening of
The finishing industry—as well as financing? No doubt. But in the newly formed companies in Romania
its customers—observed what unfold- midst of all this, the industry (Enthone S.R.L.) and Slovakia
ed over the course of the year, and for focused on adjustment. On the man- (Enthone s.r.o.).
the most part it wasn’t pretty. ufacturing side, suppliers looked for Rohm and Haas Co. launches the
Financial market distress caused opportunities to partner with both initial operations of its new manu-
tighter credit conditions. Tighter stateside operations and global out- facturing plant in Sanshui,
credit conditions, in turn, negatively fits. At the finisher level, there was a Guangdong Province, China. The
impacted everything from the lay- much more intense focus on lean $10 million facility, which makes
man’s ability to purchase a new vehi- manufacturing practices and weed- products based on acrylic emulsion
cle to small businesses’ access to ing out inefficiencies in day-to-day technology, boasts more than 20,000
funds to invest in their companies or operations. A few calls even went in metric tons of capacity to produce
simply pay their workers. All this had favor of finishers on the environmen- water-based binders and emulsions
a trickle-down effect as consumers tal front via rulings designed to ease used to make consumer paints and
and businesses curtailed spending— the regulatory financial burden rela- coatings.
which, like a vicious cycle—caused tive to waste classifications, exposure
companies to layoff workers and preventive measures, and the like. January 21
postpone investment. The impend- I suppose the most sincere way you Emerging technology development
ing impact on the U.S.—and global— can sum up 2008 is that it was a year and application in the field of sur-
economy was palpable, as unemploy- of both highs and lows. Following face finishing for commercial and
ment spiked to 6.7% and more than a are some of the main events that military aircraft applications was the
half-million workers lost their jobs. made the headlines this past year:* main theme of the inaugural Surface
It would require an Olympic leap Engineering for Aerospace and
to put a bright spin on all that JANUARY Defense Conference, held at the
gloom. In fact, it is widely held by Coronado Springs Hotel in Walt
many economists and industry January 4 Disney World, Orlando, Fla. Scores
observers that we haven’t even seen The Sherwin-Williams Co. acquires of experts serving the aerospace and
the worst of times just yet—and that certain assets of Flex Recubrimientos, defense industries attended the two-
things will likely turn even more sour Acabados Automotrices and related day educational and networking
before sweeter times return. And yet, companies. Headquartered in event, which was co-sponsored by
when you look at all the activity the Monterrey, Mexico, the privately ASM International (The Materials
metal finishing industry has wit- owned companies manufacture and Information Society) and the
nessed and taken part in over the distribute automotive aftermarket National Association for Surface

2008
Year in commercial production units using
DuPont(TM) Echelon(TM) technol-
compliant products—which includes
waterborne basecoat—will be about
Review
Finishing (NASF).
ogy for low-PFOA content aqueous
fluoropolymer dispersions.
$198 million.
February 15
Akzo Nobel Powder Coatings February 7 The National Paint & Coatings
opens a facility in Dubai designed to The Occupational Safety and Health Association (NPCA) and the
strengthen the company’s presence Administration (OSHA) issues a new Federation of Societies for Coatings
in the important Middle East mar- compliance directive for occupational Technology (FSCT) sign a
ket. The factory represents the com- exposure to hexavalent chromium Memorandum of Agreement that
pany’s first manufacturing site in the [Cr(VI)]. The directive, OSHA essentially consolidates the gover-
United Arab Emirates. Located in Instruction CPL 02-02-074, Inspection nance, management and administra-
Jebel Ali, 35 kilometers southwest of Procedures for the Chromium (VI) tive functions of both groups under
Dubai, the new site offers a full range Standards, compelled compliance by NPCA, while preserving each organi-
of services and products, including requiring finishers—as well as other zation’s separate identities, opera-
color matching, rapid made-to-order affected industries—to install feasible tions, functions, and member servic-
products, and technical support. engineering controls. es. As part of the merger, FSCT and
The Canadian Paint & Coatings NPCA have agreed to combine the
FEBRUARY Association urges Environment International Coatings Expo (ICE)
Canada, the country’s governing reg- with the American Coatings Show
February 1 ulatory agency, to harmonize and Conference (ACS).
DuPont opens a fluoropolymer pro- Canada’s regulations with those of General Motors reports a loss of
duction plant in Changshu City, Europe and the U.S., particularly $38.7 billion for 2007, its biggest
China. The plant, which produces California. The parties negotiate a annual drop in the history of the
polytetrafluoroethylene (PTFE) fine- timeline for implementation by early company. GM principals cite a write-
powder and dispersion, is the fourth 2010. CPCA has estimates the costs down in tax credits in the third quar-
DuPont facility that has installed associated with the conversion to ter that were expected to expire

unused. As a result, the company applications laboratory houses mul- assets. The business will be inte-
announced plans to offer voluntary tiple, high-performance plating grated into Becker Specialty
buyouts to all 74,000 members of its lines for Enthone plating-on-plas- Corporation, a Chicago, Ill.-based
union-represented U.S. workforce. tics, copper/nickel/chrome, passiva- subsidiary of AB Wilh.
The Sherwin-Williams Co. signs a tion processes, surface preparation Rohm and Haas Company
definitive agreement to acquire the chemistry, zinc and zinc alloys, hard announces a worldwide price increase
Liquid Coatings Subsidiaries of chrome and electroless nickel have of up to 10% across its range of ion
Inchem Holdings of Inchem been installed. Additionally, lines exchange resins, adsorbents, and cat-
Holdings International Limited, for connector and leadframe pre- alysts. The increase will be effective
Singapore. Inchem specializes in cious and base metal plating, as well March 1, 2008,
waterborne, solvent-based, and as PWB fabrication final finishes,
ultraviolet (UV) curable coatings for oxide replacement alternatives and February 19
electronics, wood and plastic prod- metallization processes are fully The Metal Finishers Association of
ucts. Inchem, which will become operational. Southern California (MFASC)
part of Sherwin-Williams’ Chemical A newly released Federal Reserve Supplier Showcase and Surface
Coatings Division, has more than report showed industrial production Technology Association (STA)
400 employees across its four manu- in the U.S. rose 0.1% in January, Vendor Showcase drew hundreds of
facturing plants with sales of largely on the strength of output at visitor during “California Showcase
approximately $30 million. U.S. factories. Week,” in Montebello and San Jose.
The Sherwin-Williams Company The annual event provided educa-
February 20 acquires Becker Powder Coatings, tional, networking, and buying/sell-
Enthone, Inc., a business of Inc., in North America, a sub- ing opportunities.
Cookson Electronics, celebrates the sidiary of AB Wilh. Becker based in
grand opening of its advanced plat- Sweden. Simultaneously, AB Wilh. February 24
ing applications laboratory located Becker has acquired the North Roger Shukla, founder of Reliable
at the company’s West Haven, American coil coatings business Silver, passes. Shukla was regarded as
Conn., facility. The state-of-the-art of Sherwin-Williams and related a legend in the industry, a fair and

2008
Year in the first quarter reached a record
$245 million, a 20% increase over
industry, Greg Bocchi announces his
resignation from the position of
Review
astute businessperson, and also
sales in the same period a year ago.
Volume increased 15% with the
remainder coming from the favor-
executive director, effective April
30. Bocchi accepts the position of
president of The Vinyl Institute
someone who was truly proud of his able effects of currency translation. in Arlington, Va. The Vinyl Institute
work at Reliable and especially Operating profit for the quarter represents manufacturers of vinyl
appreciative of all the close relation- improved to a record $36 million, resin and vinyl systems additives.
ships inside and outside the compa- a 29% increase over the same period Global specialty chemicals manufac-
ny that came from that work. a year ago. All segments con- turer Sartomer Company announces
tributed solid revenue growth in the the opening of a new manufacturing
MARCH quarter over the previous year: plant in Nansha, in the Guangzhou
Revenue increased 41% in the province of China. The facility will
March 7 Advanced Technology segment, 13% manufacture specialty acrylate
Blair Vandivier, president of in the Adhesive Dispensing segment; monomers and oligomers used as raw
Benchmark Products and Seleco, 8% in the Industrial Coating and materials in products such as paints,
Inc. (Indianapolis, Ind.), and imme- Automotive segment. On a geo- inks, coatings, adhesives, circuit
diate-past chairman of the SUR/FIN graphic basis, first quarter sales boards, flooring, CDs, and DVDs.
Steering Committee, received the revenue increased 44% in Asia Pacific, Sartomer will sell materials manufac-
2007 Silvio C. Taormina Memorial 19% in Europe, 18% in Japan, 14% tured at the new plant to customers
Award at the National Association in the United States, and 8% in around the world, including Asia,
for Surface Finishing’s Annual the Americas. Europe, and the United States.
Management Conference in Cabo The Policy Group, the educational
San Lucas, Mexico. The honor is and advocacy arm of the National March 21
NASF’s most prestigious individ- Association for Surface Finishing Industrial production dropped 0.5%
ual award. (NASF), submits a proposal to the in February, according to a report
February auto sales dipped again EPA regarding the then-pending from the Federal Reserve. The falloff,
as General Motors, Ford Motor Co., USEPA “Plating and Polishing Rule.” the sharpest decline in four months,
Chrysler, and Toyota Corp. report- According to Christian Richter, one was attributed to diminished output
ed lower revenues. GM led the of the Policy Group’s principals, the at the nation’s mines, factories and
declines with 13%, while Ford EPA rule sought to impose new utilities—which ran at their slowest
Titan reported
2.qxp a 7% drop 11:05
12/18/2008 in sales.
AM Toyota
Page 1 requirements on non-chromium rate in more than two years.
Motors reported units sold were plating processes.
down 3% for the month in both the After more than 24 years of dedi- March 28
SUV and sedan categories. cated service to The Powder Coating Sirius Technology, Inc. and Taskem,
Nordson Corp. reported sales for Institute (PCI) and the coatings Inc., announce a merger. The deal,
which became effective April 1, 2008,
resulted in a new company,
When Quality Counts . . . Coventya, Inc. According to the par-
ties, the merger was designed to
Count on TITAN. bring about many valuable benefits
and opportunities to both customers
• Quality Experience • Quality Service • Quality Products
and employees. Customers will expe-
The Next Generation in Corrosion Resistant Equipment
rience a variety of new market oppor-
tunities via Coventya’s access to mul-
Anode Baskets • Dipping Baskets
Immersion Heating & Cooling Coils tiple Tier 1 suppliers and OEMs. In
Tanks & Tank Liners addition, product lines have been
Auxiliary Anodes broadened significantly, providing
Anode Hooks & Fasteners more choices and new technology for
Shell & Tube Heat Exchangers plating and surface finishing needs.
Custom Fabrications
Technical support will also expand
Titanium • Zirconium and improve further (both tank side
Niobium • Tantalum • Stainless Steel
and bench top), along with the abili-
ty to draw upon the global Coventya
TITAN technology group.
METAL FABRICATORS Columbia Chemicals, the
835 Flynn Rd., Camarillo, CA 93012-8702 • Ph: 805-487-5050 • Fax: 805-487-5047 • www.titanmf.com Brunswick, Ohio-based firm special-
izing in zinc plating additives and

processes, acquires a 25% stake in private equity group, Appaloosa by a 0.5% increase in production of
Metalite Chemicals, Foshan, China. Management, earlier that month nondurable consumer goods.
Metalite, a long-time Columbia backed out of a deal to invest $2.55 Major parts and materials suppli-
partner, specializes in environmen- billion in the troubled auto-parts ers to the automotive industry—as
tally friendly products for the maker. GM, which counts Delphi as well as a handful of platers and
Chinese market. its largest supplier, has already taken coaters—were on hand at the SAE
$7.5 billion in charges to support the Automotive World Congress in
APRIL parts company’s reorganization and Detroit, Mich. Finishers on hand—
would be clearly impacted by further several of which attended the show
April 4 disruptions at Delphi. GM had also for the first time—came to get a lead
First-quarter automotive sales con- already lowered prices for Delphi- on how Tier 1 and Tier 2 players are
tinued on their downward curve as made parts to help its finances. influencing finishing specifications
several of the industry’s largest man- Rohm and Haas Europe announces for their OEM partners and automo-
ufacturers reported a slump in sales. the acquisition of Savigneux, France- tive manufacturer customers.
General Motors Corp. and Chrysler based ACIL, its former exclusive dis- PPG Industries reports record sales
reported declines of nearly 13%, tributor for the French Powder for the first quarter of $3.7 billion,
while Ford Motor Co. posted a Coatings market. surpassing the prior year’s first quar-
decline of 7.7%. Sales at Toyota fell ter results by 41%. Performance
3.4%, representing the third consecu- April 18 Coatings segment sales in the first
tive month that it posted a year-over- A Federal Reserve report showed U.S. quarter increased $259 million, or 30
year falloff. industrial production rose 0.3% in %, as a result of the SigmaKalon and
March, despite projections forecast- Barloworld acquisitions, the positive
April 11 ing a decline. Output of U.S. facto- impact of stronger foreign currencies,
Delphi Corporation, the parts sup- ries, mines, and utilities all rose on increased selling prices and improved
plier once owned by General Motors, the heels of a 0.7% decline in output volumes. Industrial Coatings seg-
hits a stumbling block regarding its in February. The higher-than-expect- ment sales for the quarter increased
plans to emerge from bankruptcy. A ed industrial output number was led $189 million, or 22 %, as a result of
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2008
Year in field of metals, chemicals, materials,
and manufacturing.
General Motors announces plans
to layoff more than 3,500 workers at
Review
the SigmaKalon acquisition, stronger
April 24
The Association Connecting
assembly plants in Michigan,
Ontario (Canada), and Wisconsin.
According to GM, the cuts impact
foreign currencies and improved vol- Electronics Industries (IPC) urges its plants primarily responsible for the
umes in all businesses. California members to contact the manufacture of light trucks. The
Ian Sellars, the owner and manag- California Department of Toxic company plans to cut production of
ing director of Elcometer, and one of Substances (DTSC) regarding the full-size pickups by 88,000 units and
the founders of the modern coating state’s Green Chemistry Initiative. of large SUVs by 50,000 units this
inspection industry, passes. Under Through its “Green Chemistry calendar year. GM cited skyrocketing
his leadership, Sellars introduced to Initiative” the California Department fuel prices (nearing $4.25 per gallon),
the coatings industry a number of of Toxic Substances Control (DTSC) which steered consumers away from
firsts, the company said. plans to establish a new framework SUVs and pick-ups, and toward
for chemicals management, which smaller, more fuel-efficient vehicles.
April 22 would have major adverse implica- While GM’s automotive profit rose
Ensuring that “bad” science and tions for all types of industries to $392 million in the first quarter—
misinformation does not factor into including the electronics industry. largely on the strength of higher
legislators’ decision-making process- sales in every other global sales
es—especially when drafting laws or MAY region outside North America—the
rulings that stand to significantly company lost $3.25 billion, during
impact the metal finishing industry May 2 the previous quarter.
at large. That was the driving issue The Powder Coating Institute (PCI)
that dominated discussions at the names Steve Houston its new execu- May 9
2008 Washington Forum, held at tive director. Houston, who previ- Rohm and Haas Co., which makes
the L’Enfant Plaza Hotel in ously served as global marketing paint, coatings and salt, names
Washington, D.C. Organized by the director for DuPont’s Industrial Pierre R. Brondeau, president and
National Association for Surface Coatings business, replaces Greg chief operating officer, and created a
Finishing (NASF) in conjunction Bocchi, who resigned from PCI on chairman’s committee to oversee the
with The Policy Group—the associa- Feb. 20 to accept the executive direc- company’s direction. Brondeau
tion’s government relations arm— tor position with the Vinyl Institute. joined Rohm and Haas in May 1989
the 2008 Washington Forum hosted Houston, who started his career and most recently served as execu-
an impressive roster of regulatory with Nordson in 1981, has chaired tive vice president and business
and environmental authorities, as several associations, twice serving as group executive.
well as recognized experts in the PCI’s president. TrueLogic Company, LLC, makers
of TrueChem chemical and wet-
process management/control soft-
ware, announces the opening of its
Asia-Pacific regional office in
Singapore. TrueLogic Far East will be
responsible for business develop-
ment, sales and customer satisfac-
tion for TrueChem across the Asia-
Pacific region.
The move comes as many of
TrueLogic’s customers are asking for
the TrueChem software to be
installed in their Asian factories to
assist in SPC-based quality control
improvement and in helping to
ensure consistency in their produc-
tion and laboratory operations.
May 16
Henkel Corporation announces a 5-
6 Park Drive • P.O. Box 365 • Franklin, NJ 07416
Tel: 973-209-6210 • Fax: 973-209-6435 to-15% price increase on select items
across its product range. Tom Rapps,
Circle 005 on reader information card or go to Circle 031 on reader information card or go to vice president, marketing, adhesives
www.metalfinishing.com/advertisers www.metalfinishing.com/advertisers

2-Day
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March 2 & 3 - PLANET HOLLYWOOD - Las Vegas, NV
2-Day Technical Conference for Targeted Markets
2-Day Exhibition • Plus Evening Special Event
Special Emphasis for the Following Markets:
• Custom Coaters • Architectural • Military
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For complete conference Sponsored by:
descriptions, list of exhibitors
and registration information,
visit: www.thecoatingshow.com
Special Evening Event

Don’t Miss our 2nd Event in ‘09…
Monday, March 2:
COATING EAST 2009, Sept. 30 - Oct. 1,
Reception &
Gaylord Opryland, Nashville TN.
RAT PACK Concert!
2008
Year in June 13
utilities and consumer-goods mak-
ers. Capacity utilization, which meas-
Review
and sealants, cited dramatic increas-
The Environmental Protection
Agency (EPA) announces plans to
amend the list of hazardous wastes
ures the proportion of plants in use,
fell to 79.4, the lowest since
September 2005, when Hurricane
es in energy costs as well as raw mate- from non-specific sources (called F- Katrina disrupted manufacturing
rial prices dramatically. wastes) by modifying the scope of the and oil production along the U.S.
EPA Hazardous Waste No. F019. Gulf Coast.
May 23 Specifically, the agency stated its
A Federal Reserve report showed intent to exempt wastewater treat- June 27
industrial production in the United ment sludges from zinc phosphat- Rohm and Haas Company begins
States dropped 0.7% in April, more ing, when such phosphating is used operations at its new high-tech plant
than double the decline analysts pre- in the motor vehicle manufacturing in Querétaro, Mexico. According to
dicted. Manufacturing output fell by process—provided that the wastes are the company, the facility is the first
0.8%, with half of that weakness not placed outside on the land prior plant in Latin America to operate
coming from large cutbacks in auto to shipment to a landfill for disposal, under its “21st Century
production due to falling demand and the wastes are placed in landfill Manufacturing” principles guaran-
for new cars and problems related to units that are subject to or meet the teeing best standard levels of effi-
a strike at a parts supplier for specified landfill design criteria. ciency and productivity.
General Motors. Overall motor vehi-
cle and parts production plummeted June 16 JULY
8.2% following a 4.3% decline the SUR/FIN 2008 kicked off in
prior month, the report said. Autos Indianapolis, where hundreds of July 1
were assembled at an 8.3 million attendees came in search of new EPA published the final regulation
annual pace last month, the fewest products, equipment, and answers to for plating and polishing area
since a strike-depressed 8.2 million address their day-to-day finishing sources in the Federal Register (73
in July 1998. challenges. The event also boasted Fed. Reg. 37728). The final rule, 40
American Axle and Manufacturing quality technical educational pro- CFR Part 63, Subpart WWWWWW,
Holdings, Inc.—a key supplier to grams and business seminars; invalu- is effective immediately for new
General Motors (GM)—and the able networking opportunities and affected sources (i.e., those that
United Auto Workers reach a tenta- information sharing; and new prod- begin operations on or after July 1,
tive agreement to put the brakes uct demonstrations and member- 2008). Existing plating and polish-
on an 11-week strike. At the same ship activities on the exhibition show ing operations must comply with
time, Canadian Auto Workers floor. the new regulatory requirements by
union members at three General Winners of several prestigious July 1, 2010.
Motors of Canada locations vote awards and honors—including the
in favor of a new three-year labor August P. Munning Award and the July 3
agreement with the company. At the Silvio Taormina Award—were June revenues dipped 36% at
time, industry watchers thought the announced during a special presen- Chrysler; 28% at the Ford Motor
move would pave the way for GM to tation ceremony on the exhibition Company; 21% at Toyota; and 18%
give the green light to begin ramping floor at SUR/FIN 2008. Among at General Motors and Nissan. Auto
up production. them: manufacturers attribute the dimin-
John Kinne, Xtalic Corp., was ished sales to rising fuel prices and
JUNE named the recipient of the 2008 the subsequent negative impact on
August P. Munning Award; Frank light truck sales. At Toyota, truck
June 6 Altmayer (Presidential Award); Dr. sales plummeted 38.9%, while
General Motors announces plans to Eric Brooman (Scientific Chrysler’s truck sales dipped 30.1%.
cease production at four of its assem- Achievement Award); Blair Vandivier At GM, which earlier during the
bly plants dedicated to the produc- (Silvio C. Taormina Award); and year announced plans to shutter
tion of pick-up trucks and SUVs. The Robert Burger, James Kennedy, Rob four truck plants, light trucks were
shutdowns, set to be completed by Mason, Scott Maurer, and Clay down 16%.
2010, are in direct response to esca- Mueller—all of whom received the AkzoNobel Powder Coatings
lating fuel prices and the subsequent Award of Merit. announced splans to raise prices by
consumer pullback in purchases of as much as 15% for certain products.
gas-guzzling vehicles. The targeted June 20 According to the company, the hikes
facilities include: Janesville, Wis.; A Federal Reserve report showed U.S. are in response to escalating energy
Moraine, Ohio; Oshawa, Ontario; industrial production in May fell costs, transportation expenses, and
and Toluca, Mexico. 0.2% due to diminished output by certain raw material increases.

July 11 Chemetall announces price even more drastic cuts. Among the
Rohm and Haas Company enters increases between 5–20% and imple- initiatives: tighten inventory con-
into an agreement with The Dow ments specific surcharges due to the trols on engines and other parts;
Chemical Company that calls for requirements of its different global reduce payroll for salaried workers by
Dow to acquire all of the outstand- markets. Company executives cite 20%; eliminate health care coverage
ing shares of Rohm and Haas com- increased costs for energy, raw mate- for older white-collar retirees; sus-
mon stock for $78 per share in cash. rials, and transportation. pend annual stock dividend of $1 a
The agreement provides that Rohm share; delay $1.7 billion in payments
and Haas Company will retain its July 18 to a health care trust for retired
Philadelphia Headquarters location Industrial production unexpectedly hourly workers; eliminate executive
and continue to do business under rebounded in June by 0.5%, its bonuses and pay raises for salaried
the Rohm and Haas name. biggest jump in nearly a year, accord- workers; and curtail sales and mar-
The American Coatings Show & ing to a report from the Federal keting expenses by limiting capital
Conference, held June 2–5, 2008, at Reserve. The performance was based spending to $15 billion through
the Charlotte Convention Center in on the strength of utility and mining 2009. Overall, G.M.’s plan called for
Charlotte, N.C., scored top marks in output, as well as an uptick in manu- $10 billion in cost cuts, combined
T&S ad.qxd
all key8/23/2007 2:34 and
areas: domestic PM interna-
Page 1 facturing output, which rose 0.2% in with $5 billion in new financing
tional attendance, and the exhibition June after a 0.1% falloff in May and a from asset sales and debt offerings.
portion. The American Coatings 0.9% fall in April. Motor vehicle and
Show drew visitors from 48 countries parts production rose 5.4%, offset- July 25
worldwide, with 79% of the 5,600 visiting declines for machinery and fab- Core business sector performance,
tors hailing from the U.S.; 4% coming ricated metal products, while total timely acquisitions, and, yes, price
from Canada; and the remaining 17% industrial capacity rose in June to increases, led to a healthy second-
from other countries and regions, 79.9% from 79.6% in May. quarter sales for some of the indus-
including Mexico, Brazil, Japan, and General Motors (GM), on the heels try’s largest paint, coatings, and
India, as well as the European Union, of its recent announcement to scale chemicals suppliers. At PPG
the Middle East, and Australia. back truck production, announced Industries, Inc., second-quarter earn-
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areas for maintenance and product visibility. Our washers are designed with Stainless Steel Drain Sheets inside of the wash-
er, covering the majority of the solution tanks. Above any part of the open tank (even on non-heated tanks) we install eas-
ily removable panels. The removable panels make it easy to clean, while keeping fallen parts above the solution tank for
easy removal. The return open areas of the drain sheets are covered with a framework that is covered with expanded metal.
A slip resistant expanded metal is used on the drain boards and removable panels to reduce personnel slippage.
39126 Alston Aver • Zephyrhills, FL 33542 • (813) 779-8024 Fax: (813) 779-0732
www.taegerenterprises.com

2008
Year in PPG Industries celebrates the
opening of its new automotive coat-
Semiconductor Applications Center
represents a multi-million dollar
Review
ings edged higher as sales across its
ings plant in the city of Wuhi, China
(Anhui Province). The move is
designed to support Chery
investment that further enables
Enthone to deliver customer-driven
solutions to the dynamic wafer fab-
core coatings, specialty materials, Automotive, one of PPG’s biggest rication marketplace.
and optical products businesses grew customers in the region. To date PPG
25%, driven by an acquisition and has invested more than $10 million SEPTEMBER
growth in emerging markets. in the facility.
Meanwhile, September 5
Sherwin-Williams Company August 22 Enthone Inc., a business of Cookson
reported better-than-expected quar- The Environmental Protection Electronics, has announced the
terly profit and sales, and the paint Agency announces plans to launch acquisition of Ormecon GmbH,
maker’s shares rose more than 12%. an interim policy that offers incen- headquartered in Ammersbek,
Sales rose 1.4% to $2.23 billion, bet- tives to new owners who correct Germany. The acquisition further
ter than the $2.19 billion analysts environmental violations at recent- strengthens Enthone’s market lead-
had expected, aided by acquisitions ly-acquired regulated facilities.
and stronger international sales Under the interim policy, new own-
ers may receive lower penalties than
AUGUST long-time owners. Under the cur-
rent EPA Audit Policy, the Agency
August 1 offers reduced penalties to compa-
The Environmental Protection nies that self-audit their facilities;
Agency issues national emission promptly disclose and correct any
standards regarding the control of violations discovered; and take
hazardous air pollutants for nine steps to prevent future violations.
metal fabrication and finishing area Under the interim policy, an owner
source categories. This final rule who acquires a new facility may
establishes emission standards in the get additional penalty reductions
form of management practices and from disclosing an even greater
equipment standards for new and range of violations.
existing operations of dry abrasive Enthone, Inc., a business of
blasting, machining, dry grinding Cookson Electronics, announces the
and dry polishing with machines, opening of its state-of-the-
spray painting and other spray coat- art Semiconductor Applications
ing, as well as welding operations. Center in Taoyuan, Taiwan. The
KMI Engineered Design Solutions

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ing printed wiring board (PWB) sur- included a customer seminar on new OCTOBER
face finishes product portfolio, while trends and technologies for elec-
bolstering the company’s plan to trolytic corrosion protection, zinc October 10
offer a platform of new coatings flake coatings for automotive fasten- The Environmental Protection
technologies for a wide range of elec- ers, and Atotech’s involvement in Agency publishes a final rule that
tronics, functional and decorative sustainable development. essentially revises the definition of
metal applications. solid waste to exclude certain haz-
U.S. sales of automobiles declined September 23 ardous secondary materials from
by 15.5% in August, marking the Economic turmoil and uncertainty regulation under Subtitle C of the
fifth consecutive month of double- did not prevent paint and powder Resource Conservation and Recovery
digit declines. Sales fell 20%, 26% coaters from attending COATING Act (RCRA). The purpose of this
and 35% at General Motors, Ford, 2008, which kicked off at the final rule is to encourage safe, envi-
and Chrysler, respectively. Indianapolis Convention Center. ronmentally sound recycling and
Meanwhile, sales at Nissan Motor Most of those leads, exhibitors resource conservation and to
rose 14%, while revenues dropped reported, came from finishers seek- respond to several court decisions
less than 10% Toyota Motor and ing to either upgrade their paint and concerning the definition of solid
Honda—both of which have had coating operations or install entirely waste. The EPA’s action is expected
trouble meeting demand for some of new coating systems from the ground to result in regulatory and materials
their smaller cars. up. More than a few finishers report recovery cost savings of approxi-
that they have been contacted by mately $95 million per year for those
September 12 manufacturers and metal formers industries impacted.
Atotech celebrates the grand open-
ElectroSteam.qxd 1/25/2006 4:50 PM Page
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2008
Year in and reach, Jason Finishing Group
aims to position itself as a premier
first nine months of the year, GM
sold almost 400,000 fewer than mil-
Review
users worldwide—join forces under
provider of finishing solutions.
Executives say this change in struc-
ture will provide customers with con-
lion by Toyota. And last year, GM
narrowly edged out Toyota by just
7,000 units. Separately, a Commerce
the single corporate name: ALMCO densed field sales territories for bet- Department report showed sales of
KleenTec, Inc. ter customer coverage; more field new cars and trucks in the United
PPG Industries, Inc. announces application engineers to support States plummeted nearly 32% year
plans to close three coatings and technical needs of customers; and over year, as tightening credit mar-
glass plants as part of a restructuring new application laboratory at the ket put the pinch on loans and
plan that will eliminate several hun- Cleveland, Ohio, headquarters to financing options.
dred jobs and save $100 million provide testing and solutions across
annually. The company’s automotive the broad finishing spectrum. NOVEMBER
coatings plant in Springdale, Pa., will
remain open, but two plants in October 24 November 21
Canada and Netherlands will close, The EPA signs a ruling regarding a U.S. industrial production rose more
eliminating 260 jobs. One glass pro- new definition of solid waste that than forecast in October as refineries
duction line at an Illinois plant, removes regulatory barriers that and oil rigs restarted operations in
where 275 people work, will be idled, inhibited recycling of manufacturing the Gulf of Mexico following shut-
PPG said. Other reductions in the wastes, known also as secondary downs caused by Hurricanes Gustav
work force will result in an undis- materials. As a direct result of intense and Ike. The 1.3% increase in produc-
closed number of workers in North lobbying by the IPC, the definition tion at factories, mines and utilities
America and Europe losing their jobs, was revised to exclude secondary followed a revised 3.7% drop in
spokesman Jeremy Neuhart said. materials from the Resource September—the biggest since 1946,
Conservation and Recovery Act the Federal Reserve announced earli-
October 17 (RCRA) hazardous waste regulations er this week.
U.S. industrial production plunges if they’re recycled according to spe- The heads of Detroit’s Big Three
2.8% for the month of September, cific requirements. The ruling stands automakers and the United Auto
according to a Federal Reserve to help U.S. PCB manufacturers save Workers union testified before a
report. The falloff, the biggest drop millions of dollars as well as encour- Senate committee, warning represen-
since 1974, reflected weakened busi- age recycling. tatives that the domestic auto indus-
ness and manufacturing conditions DYMAX Corporation, a leading try could face collapse without an
exacerbated by a credit crunch, hurri- global manufacturer of advanced emergency infusion of federal funds.
canes, and an aircraft mechanics light-curing adhesives, coatings, and The leaders of General Motors, Ford
strike at Boeing Corp. curing equipment, acquires Danbury, Motor Co., and Chrysler requested
General Motors announces plans Conn.-based Tridak, a leading design- $25 billion in loans to keep operat-
to lay off 500 hourly workers at its er and manufacturer of standard and ing in the short term.
Detroit Hamtramck Assembly plant custom equipment for dispensing Rohm and Haas declares the
by December 23 due to reduced and filling virtually any material. opening of the initial phase of a new
demand for the Buick Lucerne and This acquisition expands DYMAX’s manufacturing facility in the
Cadillac DTS. At the same time, the capabilities to supply adhesives and Ramenskoye region of Moscow,
company announces plans to close other materials, the equipment to Russia—its largest investment in
its metal stamping plant near dispense them, and the systems to Russia to date. The new polymer
Grand Rapids, Mich., by the end of cure them. emulsions facility, which will focus
2009, costing about 1,340 hourly An IPC market report showed rigid on additives for paint and coatings
jobs. In addition, the automaker PCB shipments fell 3.8% in materials and adhesives, is planned
will cease sport utility vehicle pro- September, with bookings falling to have an eventual capacity of
duction at its Janesville, Wis., facto- by16.4%. Meanwhile year-to-date, 70,000 metric tons upon comple-
ry in December—earlier than previ- rigid PCB shipments are increased tion of the final stage.
ously announced. 4.2%, with bookings falling 0.8%.
Jason Incorporated, parent compa- General Motors third-quarter sales November 26
ny of JacksonLea, Osborn fall 11.4%. Units sold during the SFCHINA, held in the city of
International, and Lippert Unipol, period totalled 2.11 million com- Guangzhou, at the Guangzhou
announces the formation of the pared with 2.38 million in the same International Convention &
Jason Finishing Group. By combin- period last year. If current trends Exhibition Centre (Pazhou
ing the manufacturing and technical persist, analysts predict the compa- Complex). A total of 318 exhibitors
resources of the individual company could cede its market-leading from 16 countries/regions had par-
nies, while leveraging global presence position to Toyota. Through the ticipated, of which 69 are first-time

2008
Year in sales dropped 26.8 %.
The National Association for
facturers their re seeking lower taxes
on new cars, lower fuel prices and
Review
exhibitors. At the closing of the show,
Surface Finishing (NASF) announces
the names of the new officers and
board members for 2009. Among the
increased grants for research into
hybrid cars and new technology.
a total of 10,871 visitors had regis- appointments: Michael Siegmund, December 8

tered to attend. In spite of the world- MacDermid Inc., Waterbury, Conn., Nordson Corp., a leading manufac-
wide economic downsizing, the show who has been selected to serve as turer of spray equipment, systems,
managed to maintain a high level of the president of the trade associa- and supplies, inaugurates its new
attendance, according to Sinostar, tion for 2009. He succeeds Ray customer lab near Shanghai, China,
which organizes the event. Lucas, Valley with events and training for indus-
Chrome Plating, Inc., Clovis, Calif., try partners and customers. The
DECEMBER who has completed a two-year term. 86,000-square-foot office facility
China’s automobile manufactur- houses 190 employees and operates
December 5 ing industry presses Beijing for gov- as a Center of Excellence to demon-
U.S. Department of Commerce offi- ernment help as it copes with stalling strate Nordson’s capabilities to cus-
cially declares the economy is in a vehicle sales. This autumn, after six tomers in a variety of industries,
state of recession, which, economists years of 20% or more annual growth, including appliance, automotive,
say, began as early as December 2007. vehicle sales were flat or slightly neg- container, nonwovens, electronics,
Sales plummeted by more than ative. Citing the $25 billion in loans furniture and wood assembly, life
40% at three automakers: 47% at that Congress has already approved science, packaging, powder and liq-
Chrysler, 42% at Nissan and 41% at to help their American counterparts uid painting, product assembly,
General Motors. Toyota sold 33.9 % increase green research, Chinese and semiconductor.
fewer vehicles than in November executives inform the government in
2007, Honda’s sales declined 31.6 %, Beijing that they also need emer- *Denotes the date when the event was
and Ford’s fell 30.6 %. BMW said its gency measures. Specifically, manu- reported in Metal Finishing.

TECHNICALLY
speaking
MIKE BARNSTEAD & CHRISSY BIELER, MACDERMID, INC.,WATERBURY, CONN.
use in hexavalent chromium solu-
Trivalent Chromium tions. Despite the EPA’s exemption,
many state and local agencies are
for a New Generation restricting them. One notable exam-
ple is Minnesota, where stringent
H exavalent chromium plating

has been in use since the 1920’s,
and has been used extensively in
proposed to reduce the limit to 1, but
due to concerns over the technical
feasibility of reaching this limit set-
limits on the perfluorochemicals
(PFCs) PFOS, perfluorooctanic acid
(PFOA), and perfluorobutanoic acid
many different industries as a pro- tled on the current limit of 5 Ìg/m3. (PFBA) are in place
tective decorative coating. Aside There are still legal battles being (www.pca.state.mn.us/cleanup/pfc/i
from some refinement to the cata- waged over the PEL, and it is likely ndex.html). In addition, it is always
lyst system, the chemistry of the sys- that the 5 Ìg/m3 limit will be further possible that the EPA may change
tem has been basically the same for lowered. A hearing on the PEL issue their position. One simple way to see
many decades. Deposits from hexa- is scheduled before the 3rd Circuit the degree of activity on PFOS regu-
valent chromium systems are cur- Federal Appeals Court on November lation is to perform a simple web
rently industry standard in the 21, 2008. search for “PFOS regulations” and
majority of industries, and hexava- Since hexavalent chromium plat- see the tens of thousands of hits.
lent systems are frequently specified ing solutions have very low efficien- This could be the topic of a very
as the chrome plating bath of choice. cy, the majority of the electrical ener- lengthy paper in itself, but for this
The system is known, robust, and gy used during plating creates gas, article the take away is that PFOS
produces excellent results. So, why which carries minute amounts of the and other PFCs are getting a lot of
talk about alternatives? hexavalent chromium into the air. attention, and will likely be restricted
One of the most effective ways to or even banned for metal finishing
TWO MAJOR DRIVERS IMPACTING reduce the misting is the use of sur- operations.
HEXAVALENT CHROMIUM factants to lower the surface tension
The focus on the health and environ- of the process. In decorative hexava- TRIVALENT CHROMIUM:
mental impact of hexavalent chromi- lent chromium plating the surfac- A BRIEF HISTORY
um is increasing, and there are many tant of choice is usually a form of Trivalent chromium processes have
major drivers in play which point to perfluorooctane sulfonate (PFOS) or been commercially available since
a future where hexavalent chromium a closely related compound. The the 1970s. The first generation sys-
plating may become economically same attributes which make PFOS tems were mainly niche systems, pri-
and environmentally impractical, attractive for chromium plating are marily due to the darker deposit
due to increased regulatory impact what make them persistent in the color compared to hexavalent
on the hexavalent chromium environment. PFOS compounds are chromium. Also, the minimal thick-
process, as well as on components very stable, and are not significantly ness of the deposit (often less than
commonly used in chromium plat- consumed by chemical breakdown or 0.2 micron) and the deposit impuri-
ing. Two very significant drivers are electrolytic consumption in hexava- ties provided inferior corrosion pro-
touched on below, PEL and PFOS. lent chromium plating solutions. tection compared to hexavalent
In the US, in 1993 a national non- While that makes them ideal for use chromium, limiting the end uses for
profit public interest organization in the harsh conditions of hot the process.
called Public Citizen chromic acid solutions, their stabili- In the 1980s second generation sys-
(www.citizen.org/index.cfm) had ty is also the reason for their persist- tems evolved. The second generation
petitioned OSHA to lower the per- ence in the environment. Trivalent systems differed from the first gener-
missible exposure limit to airborne systems do not normally use PFOS ation systems primarily in improved
hexavalent chromium (PEL) of 52 based surfactants due to the compar- deposit color. The early 1990s also
Ìg/m3 (micrograms per cubic meter atively mild nature of the solutions. saw the first introduction of dark
of air) to 0.25 Ìg/m3, due to the car- In the US, the Environmental trivalent chromium systems, creat-
cinogenic nature of the hexavalent Protection Agency has granted a ing a wider variety of options for part
chromium and the resulting impact temporary exemption to plating use designers. These second generation
on worker health. In 2004 OSHA for PFOS compounds, allowing their systems are still in widespread use
www.metalfinishing.com January 2009 I metalfinishing 27

TECHNICALLY
speaking
sion standards, which earlier systems
could not consistently do. In addi-
tion, the color is improved due to the
lack of alloying elements such as iron
in the deposit.
SUMMARY OF AUTOMOTIVE TEST

DATA: HEXAVALENT V. TRIVALENT
CHROMIUM
Extensive studies have been complet-
ed which have evaluated hexavalent
chromium against the third genera-
tion of trivalent chromium. (Unless Figure 1. CIELAB color space comparison of hexavalent versus trivalent chromium deposits
otherwise stated, all data presented
in the remainder of this article was in addressing calcium chloride corro- chromium layer to dissolve:
generated using this most recent sion, or “Russian Mud”. On corrod-
trivalent process.) Comparative tested samples plated using hexavalent 2Cr + 6HCl +1.5O2 à 2CrCl3 + 3H2O
ing performed by automotive OEMs chromium processes, the chromium
has proven the functionality of triva- layer appears to have been attacked. Chromium deposited from sulfate-
lent and hexavalent chromium This is unusual for this finish since based trivalent electrolytes performs
deposits to be very similar. CASS test the chromium layer usually acts as significantly better than chromium
results show that there is no differ- the cathode in the corrosion cell. deposited from hexavalent elec-
ence between the two processes after The mechanism of corrosion has less trolytes (under these conditions of
50, 80, and 200 hours of exposure. to do with galvanic differences and is corrosion). The mechanism by which
After four cycles of thermal testing (- related to the dissolving of the this improvement is gained is cur-
30C x 60m, RT 15m, 70C x 60m, RT chromium layer rather than the rently under review.
x15m) there was no cracking underlying nickel. An oxidation
observed on either chromium reaction occurs and the chromium CASS PERFORMANCE
deposit. Abrasion testing shows no layer is chemically dissolved. The cal- To test the corrosion of the third
difference in the performance of cium chloride mud remains in con- generation trivalent system, a series
trivalent versus hexavalent chromi- tact with the chromium surface. of plated parts were subjected to 24,
um. In addition, an evaluation of the Over a period of time, the calcium 48, and 72 hours CASS per ASTM
color of trivalent chromium plated chloride absorbs carbon dioxide B368, in an ISO 17025 approved lab.
at 0.1, 0.2, 0.3, 0.5, and 0.8 Ìm causing a decrease in pH as shown by A set of parts were removed from the
showed no color difference over the the following equation. cabinet at 24 hours, another set at 48
range of thickness levels. hours, and the final set at 72 hours.
As mentioned, trivalent chromium CaCl2 + H2O + CO2 à CaCO3 + 2HCl The parts were rated per ASTM B537
chemistries have evolved over the This acidic environment combined - Standard Practice for Rating of
years and so have the colors of their with dissolved oxygen causes the Electroplated Panels Subject to
deposits. The first two genera-
tions of trivalent chromium had Table 2 - CASS Test Matrix
significant color differences in Cycle A Cycle B Cycle C Cycle D Cycle E
comparison to hexavalent Semi-Bright Nickel 20 – 25 µm 20 – 25 µm 20 – 25 µm 20 – 25 µm 20 – 25 µm
chromium. The third genera- High Sulfur Nickel 1 – 2 µm 1 – 2 µm
tion, however, has a color that is Bright Nickel 10 -12 µm 10 -12 µm 10 -12 µm 10 -12 µm 10 -12 µm
comparable to that of standard Microporous Nickel 1 – 2 µm 1 – 2 µm
hexavalent processes. Figure 1 Noble Nickel 1 – 2 µm 1 – 2 µm 1 – 2 µm
shows a CIELAB color space
Trivalent Chromium 0.3 - 0.4 µm 0.3 - 0.4 µm 0.3 - 0.4 µm
comparison of all four chromi-
Hexavalent Chromium 0.3 - 0.4 µm 0.3 - 0.4 µm
um deposits.
24 hr CASS Rating 9 8 8 10 10
CALCIUM CHLORIDE 48 hr CASS Rating 6 7 3 10 9
CORROSION 72 hr CASS Rating 6 7 3 9 9
Trivalent chromium deposits Average CASS Rating 7 7.3 4.7 9.7 9.3
have proven to be advantageous

TECHNICALLY
speaking Cycles D and E both use triple
nickel (semi-bright, bright, microp-
orous nickel), and differ only in the
both over a noble nickel as well as
over a microporous nickel layer.
Atmospheric Exposure. The parts chromium layer. Cycle D was plated DARK TRIVALENT CHROMIUM
were all processed in the same plat- in trivalent chromium, while cycle E PROCESSES
ing line, using the same equipment, was plated in hexavalent chromium. Dark trivalent chromium is gaining
pretreatment processes, and plating Comparing Cycle D to Cycle E, there large acceptance as a decorative fin-
process tanks to minimize variation. is no significant performance differ- ish. These processes are approved by
A summary of the test matrix is ence in trivalent chromium vs. hexa- automotive OEMs for interior appli-
shown below in Table 2. valent chromium in CASS testing. cations as well as some select exterior
Looking at the matrix, cycles A & Noble nickel was found to be infe- applications. In addition to their
B both use quad nickel (semi-bright, rior to microporous nickel when all attractive appearance these finishes
high sulfur, bright, and noble nickel other layers were identical, both from have other added benefits over bright
layers) and differ only in the chromi- a hexavalent sys-
um layer. Cycle A is plated from a tem and a triva- Table 3. Door Handles CASS Tested per ASTM B368
trivalent bath, while cycle B used a lent system. The 24hrs 48hrs 72hrs Failure Point
hexavalent chromium bath. lack of the active Bright Cr+3 10 10 10 > 132 hrs, < 154 hrs
Comparing the CASS results of cycle sites generated by Cr+6 10 10 10 > 132 hrs, < 154 hrs
A to cycle B, there is no significant using microp- Dark Cr+3 10 10 10 > 96 hrs, <120 Hrs
performance difference in trivalent orous nickel
chromium vs. hexavalent chromium resulted in a sig- Table 4. Effects of Metallic Impurities in Dark
in CASS testing. nificant degradation Trivalent Chromium Systems
Cycles C and D both utilized of the plated deposit Effect
triple layer nickel and a trivalent when subjected to Nickel Reduces plating rate
bath to apply the chromium, and CASS testing, for both Iron Reduces corrosion protection
differ only in the final Ni layer. trivalent and hexava- Zinc Reduces plating rate and throwing power
Cycle C used semi-bright, bright, lent deposits. This is Copper Reduces plating rate and darkens deposit
and noble Ni, while cycle D used due to the fact that the
semi-bright, bright, and microp- third generation
orous Ni. The noble nickel layer process deposits a chromium coating chromium processes. They exhibit
was applied using the same microp- more similar to hexavalent deposits, excellent coverage and throwing
orous nickel with no solids added. which are pore free coatings. power and display a consistent color
Comparing Cycle C to Cycle D, it is No significant difference was over all current density ranges. They
shown that using microporous detected when comparing the triva- operate at lower current densities in
nickel provides far better protection lent chromium layer and the hexava- comparison to hexavalent chromium
than noble nickel. lent chromium layer. This was true electrolytes and also contain less
PATTI ADHESION
TESTERS
TOLBER GOES GREEN

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Electroless Nickel, Anodizing, Bright Chrome, Hard Chrome, Chemical Milling, Gold, Silver, Zinc, and most acid and
alkaline cycles.The Tolber Division supplies a well-established line of plastisols, rack coatings, vinyl tapes, and waxes M.E. Taylor Engineering, Inc.
to serve most plating requirements.Tolber Division also supplies strippers/reducers for each of its masking products. Phone (301) 975-9798
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On the Web at
www.adhesiontesting.com
220 West 5th Street • Hope, Arkansas • 870-777-3251 • Fax: 870-777-8056
www.tolber.com • E-mail: tolbermail@sbcglobal.net
Circle 037 on reader service card or go to
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© EnviroTech International 2006

TECHNICALLY
speaking Copper ................................15 microns
Semi-bright Nickel ..........24 microns
High Sulfur Nickel ............2 microns
New systems now exist which meet
all the requirements which older
generations could not consistently
metal than standard bright chromi- Bright Nickel ....................14 microns do. Current applications include
um processes. Microporous Nickel ........1.0 micron automotive, plumbing, hardware,
Chromium ........................0.3 microns house wares, and many other indus-
TEST DATA FOR DARK TRIVALENT tries where appearance and perform-
CHROMIUM All samples were tested in an ISO ance are critical.
Humidity and CASS testing have 17025 laboratory. The samples were
been performed for dark trivalent tested per ASTM B368 and were eval- BIO
chromium processes using hexava- uated and rated per ASTM B537. Mike Barnstead is the Manager for
lent chromium as a comparison. For The results from this testing (see Decorative Coatings for MacDermid’s
both sets of testing panels were plat- Table 3) illustrate that there is no dif- Advanced Surface Finishing business in the
ed in the following: ference in corrosion performance Americas. He is responsible for
between the three coatings. “Failure MacDermid’s Decorative and Plating on
Semi-bright Nickel........17.5 microns point” denotes a visible change in the Plastic product lines. Barnstead attended
Bright Nickel ....................7.5 microns coating appearance. Michigan State University in East Lansing,
Microporous Nickel ........1.0 micron Mich., and North Carolina State
Chromium ........................0.3 microns METALLIC IMPURITIES University in Raleigh, N.C. Barnstead has
Metallic impurities can have a nega- been involved in the metal finishing busi-
After five weeks in a humidity cab- tive effect on a dark trivalent chromi- ness since 1989, the last 12 with
inet at room temperature and 100% um plating bath. These effects can MacDermid. He is active in the NASF and
relative humidity there was no color be seen in Table 4. While these risks is currently co-chairman of the Technology
difference observed on either the exist, metallic impurities can easily Committee.
hexavalent or dark trivalent chromi- be removed from the system.
um panels. The dark trivalent Chrissy Bieler is the Marketing Manager
chromium finish was able to with- CONCLUSION of Decorative Coatings, Americas, and
stand 72 hours CASS with a rating of With the increasing pressures put on works out of MacDermid’s Waterbury,
10 per ASTM B368. hexavalent chromium plating, and Conn., office. She holds a Bachelors
Additional testing was performed the anticipated increase in restric- Degree in Chemistry from Bucknell
on plastic door handles to compare tions, it is possible that hexavalent University in Lewisburg, Pa., and a
the CASS performance of hexavalent, chromium plating may become Masters Degree in Chemistry from
bright trivalent and dark trivalent impractical in the near future. Southern Connecticut State University in
chromium deposits. The door han- Trivalent systems are a logical sub- New Haven, Conn. Bieler has worked in
dles were plated in the following: stitute, but until recently the per- the metal finishing industry since 2000 at
formance of these systems was inad- MacDermid, Inc., and is an active mem-
equate to meet market demands. ber of the NASF.
New Book
Chromium Plating
By G.A. Lausmann. 1st edition 2007
with 360 pages. € 97,– plus postage.
ISBN 3-87480-228-0
Table of contents:
1 History
2 The electrolytic deposition of chromium
3 Decorative chromium plating
4 The hard chromium plating
5 Stripping of chromium deposits
6 Troubleshooting
7 Equipment and auxiliary items
8 Waste water treatment and recycling
9 Analytical control
10 Tables
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TECHNICALLY
speaking
BY QIUYUAN FENG,a TINGJU LI,a HAITAO TENG,a XIAOLI ZHANG,a YU ZHANG, a EXPERIMENTAL PROCEDURES
CHANGSHENG LIU,b JUNZE JINa Fabrication of Ni–Al2O3 compositecoatings
a
STATE KEY LABORATORY OF MATERIALS MODIFICATION & SCHOOL OF The Ni–Al2O3 composite coatings
MATERIALS SCIENCE & ENGINEERING, DALIAN UNIVERSITY OF TECHNOLOGY, were prepared by SCD and CEP
DALIAN, LIAONING, CHINA; AND bCOLLEGE OF MATERIALS & METALLURGY, techniques from a typical Watt’s
NORTHEASTERN UNIVERSITY, SHENYANG, LIAONING, CHINA bath. The bath composition and
plating conditions are listed in
Investigation on the Corrosion and Table 1. Analytical reagents and de-
ionized water were used to prepare
Oxidation Resistance of Ni–Al2O3 the plating solution. The nano-
Al2O3 particles with a mean diame-
Nano-composite Coatings Prepared ter of 100 nm (Luming Nanometer
Material Co., Ltd., Dalian, China)
by Sediment Co-deposition were chosen to co-deposit with nick-
el in these experiments, which were
(Editor’s note: This article originally conventional electroplating (CEP) estimated by transmission electron
appeared in Surface & Coatings technique. microscope (TEM, Tecnai G220 S-
Technology, published by Elsevier B.V. In 1972, a new technique called Twin) detailed elsewhere.43 Prior to
Feng et al. 2008;202[17]:4137–44.) sediment co-deposition (SCD) was the co-deposition, the alumina par-
gaining importance in producing ticles were ultrasonically dispersed
I t is well known that the properties

of the composite coatings are heav-
ily dependent upon the degree of
better quality metal matrix compos-
ite coatings.31 The salient features of
this technique are higher incorpora-
in the bath for 40 min. The bath was
stirred intermittently (off/on time:
10/60 s) by a magnetic stirrer and
particle incorporation in the tion of the reinforcements, for lower heated to 50°C by an automatic
deposit. Higher incorporation per- bath concentrations and higher controller. The thickness of the
centages and more uniform distri- degree of uniformity of the distribu- coatings was fixed to 25 µm. Each
bution of inert particles in the metal tion of reinforcing particles in the experiment was carried out with a
matrix lead to the improvement of metal matrix. Over the past decades, fresh solution.
the mechanical, tribological, anti- successful co-deposition of micro- Mild steel disc of Φ22 mm ˘ 4
corrosion, and anti-oxidation prop- sized particles with metal such as mm was used as the cathode; the
erties of the coatings. There are graphite,32 Al,33 Si3N4,34 SiC,35,36 TiO2,37 anode was a pure Ni plate. Before
many methods to improve the con- MoS2, WS2,38–40 PTFE,41 and dia- the co-deposition, the mild steel
tent of particles in the composite mond42 have been reported by using discs were mechanically polished to
coatings, such as the addition of this modified SCD technique. Their 1,000-grit finish, and ultrasonically
metal cationic accelerants1,2 and corresponding structures and prop- degreased with acetone. Then, a
organic surfactants3,4 in an elec- erties were investigated by many sequence of cleanings were per-
trolytic bath, ultrasonic irradiation,5 researchers. Unfortunately, there is formed to remove contamination
and the type of applied current.6,7 seldom research concerning the SCD on the substrate surface, the steel
Among these methods, the surfac- method on the nano-sized particles substrates were activated for 20 s in
tants including anion, cation, and with metal matrix. a mixed acidic bath. Cathodes were
nonionic surfactants are used exten- The present work is aimed at utiliz- positioned in the horizontal plane
sively to obtain more incorporation ing SCD technique to prepare nano- with the anodes kept above them,
of particles in composites. However, structured Ni–Al2O3 composite coat- maintaining an inter-electrode dis-
excessive surfactants will reduce the ings from Watt’s type bath contain- tance of 30 mm. The experimental
cathode area and increase deposit ing nano-Al2O3 particles. The corro- apparatus is shown in Feng et al.44
brittleness.8 In the last three decades, sion resistance and oxidation resist- After electrocodeposition, the spec-
micro and nano-sized inorganic ance after heat treatment of resulting imens were cleaned by ultrasound
inert particles with metal or alloy composites were investigated. For for 5 min, rinsed with water, ace-
such as SiC,9–13 ZrO2,14,15 Al2O3,3,6,16–25 comparison, the pure Ni coating and tone and then dried. For the sam-
Si3N4,26 TiO2,27 CeO2,28 nano-dia- Ni–Al2O3 composite coatings were ples of corrosion resistance test, the
mond,29 carbon nanotubes (CNTs),30 also fabricated by conventional elec- electrodeposition was carried out
etc. have been reported by adopting troplating (CEP) technique. on one side of mild steel substrates;

TECHNICALLY speaking
(3)
where icorr is the corrosion current density, Rp is the polar-

ization resistance, and βa and βc are the anodic and
cathodic Tafel slopes.
The polarization resistance is calculated on the basis of
the other side of substrates was sealed with PVC insu- the following equation:
lating type. For the samples of oxidation resistance test,
the electrodeposition was carried out on both sides (4)
of substrates.
The corrosion potential (Ecorr) and corrosion current
Characterization of composite coatings density (icorr) were calculated from the intersection of the
The surface morphologies of Ni–Al2O3 nano-composite cathodic and anodic Tafel curves using the Tafel extrapo-
coatings after corrosion tests and high-temperature oxi- lation method.
dation tests were observed using optical (MEF4A) and
scanning electron microscopy (SEM, JSM-5600 LV), High-temperature oxidation tests
respectively. Grain size and texture of deposits were Thermal oxidation was investigated in a muffle furnace
determined by X-ray diffraction (XRD, XRD-6000). (SX2-12-10). The temperature of the furnace was main-
The crystallite size was calculated using Scherrer tained at a set value by an automatic controller (precision
equation45: ±2°C). The experiment was carried out at 773 K, 873 K,
973 K, 1,073 K and 1,173 K for 1 h respectively and at
(1) 1,073 K for different exposure time. After oxidation, the
samples were withdrawn from furnace, cooled in air with-
out air flow for weighing using an electronic balance
where d is the averaged dimension of crystallites, K is (AL204, 0.01 mg). The weight gain was calculated using
the Scherrer constant, somewhat arbitrary value that the following equation:
falls in the range 0.87–1.0 (it is usually assumed to be 1),
λ is the incident radiation wavelength, β is the integral (5)
breadth of the structurally broadened profile, and θ is
the angular position. Texture of the electrodeposits was where ∆M is the weight gain, Mh is the weight after heat-
represented by a preferential orientation index, T, ing (in grams) and Mi is the initial weight of sample,
respectively, S is the overall area of sample (in cm2).
(2) RESULTS AND DISCUSSION

Crystallite size and orientation index
In our previous study,44 we investigated the microstruc-
defined as follows46: ture and surface morphology of Ni–Al2O3 composite
where I(hkl) and I0(hkl) are the X-ray diffraction intensities coatings, and it was shown that the Al2O3 particles dis-
of (hkl) plane in an experimental specimen and a standard tributed homogeneously in Ni matrix. Average crystallite
powder sample, respectively; n is the number of the size is calculated using Scherrer equation by means of the
planes. The larger the value of T is, the greater the degree (111) and (200) peaks broadening with the values in
of preferential orientation becomes. nanometer range as shown in Figure 1. It was shown that
the crystallite size of coating decreases remarkably with
Corrosion tests increasing of Al2O3 concentration in plating solution.
The electrochemical measurements were carried out in a That is to say, the incorporation of nanometer Al2O3 par-
three electrode cell. A mild steel plate coated with ticulates could restrain the growth of Ni crystals, and
deposits was used as a working electrode. A platinum result in grain refining. The codeposited particles appear
plate and saturated calomel electrode (SCE) were used as to have an effect on the growth of deposited Ni crystal-
the counter and reference electrode, respectively. lites, which may have resulted from: (i) increased numbers
Measurements were performed in 3.5 wt.% NaCl solu- of nucleation of electrodeposits, (ii) retarded growth of
tions at a temperature of 20°C, using a PAR2273 poten- the Ni grains, or (iii) change in the preferred growth ori-
tiostat/galvanostat system. Potentiodynamic anodic entations for grains. From Figure 1, it can be also seen
polarization curves were established. The corrosion rate that the crystallite size of Ni–Al2O3 composite coatings
of the deposits was determined using the Stern–Geary fabricated via the SCD technique is smaller than that of
equation from the polarization measurement47: the CEP technique. It means that the nano-Al2O3 con-

Fig. 1: Crystallite size of coating vs. Al2O3 concentration in plating Fig. 2: Polarization curves obtained for pure Ni coating and Ni–Al 6O3 nano-
solution. composite coatings fabricated using CEP and SCD techniques in 3.5 wt.%
NaCl solution at room temperature. Al2O3 concentration in plating solution:
(a) 0 g/l; (b, c) 5 g/l; and (d, e) 10 g/l.
tents in composite coating using SCD are higher than and the electrodeposited Ni coating were also tested.
that of CEP under the identical nano-Al2O3 concentration The corrosion potential (Ecorr) and corrosion current
in plating solution. density (icorr) calculated from the intersection of the
The preferential orientation index of Ni–Al2O3 nano- cathodic and anodic Tafel curves using the Tafel extrapo-
composite coatings using different electroplating tech- lation method are summarized in Table 3. The data clear-
nique are listed in Table 2. From this table, it can be seen ly reveals the enhancement of corrosion protection by
that the (111) plane enhances and the (200) plane declines Al2O3 reinforcement. Among these composites, the Ni-
with an increase of Al2O3 content in deposits for both 7.58 wt.% Al2O3 composite coating shows the highest cor-
SCD and CEP technique, while the orientation index of rosion resistance.
(111) plane is higher and the (200) plane is lower for SCD By utilizing the information in Figure 2 and Table 3, it
in comparison with CEP under the same nano-Al2O3 con- can be observed that in 3.5 wt.% NaCl solution the corro-
centration in plating solution, which can be attributed to sion potential increased with increasing of the nano-
the incorporation of nano-Al2O3 particles in nickel matrix Al2O3 contents in Ni-Al2O3 composite coating, while the
and has modified the texture from the soft (100) mode to corrosion current density of composite coating
the preferred (211) mode.13 It is very important to the decreased. Under the identical nano-Al2O3 concentration
wear, corrosion, and oxidation resistance of Ni–Al2O3 in plating solution, the Ni-Al2O3 composite coatings pre-
composite coatings. pared using SCD technique have higher corrosion poten-
tial and lower corrosion current density compared to that
Corrosion performance of CEP technique. This reveals that the Ni-Al2O3 com-
Typical anodic potentiodynamic polarization curves of posite coatings produced via SCD technique possess the
Ni–Al2O3 nano-composite coating obtained via SCD tech- better corrosion resistance. The lower corrosion rate of
nique in 3.5 wt.% NaCl solution are presented in Figure 2. Ni-Al2O3 composite coating produced via SCD technique
For comparison, nano-composite coatings T the Ni-Al2O3 when compared with pure Ni coating and composite
nano-composite coatings produced using CEP technique coatings fabricated via CEP technique may be attributed,

on the one hand, to the Ni matrix and the higher con- plating solution: (a) 0 g/l, (b, c) 5 g/l, and (d, e) 10 g/l
tents of nano-Al2O3 particles in the deposits, which coatings were improved.48
intrinsically presents a higher corrosion resistance; on Figure 3 gives the corrosion surface morphology of
the other hand, to the reduction of the grain size and the Ni-Al2O3 composite coatings in 3.5 wt.% NaCl solution.
structural modification of Ni crystallites expressed From Figure 3, it can be seen that some corrosion pits
through the alteration of the preferred orientation with occur on the surface of lower nano-Al2O3 content in
the incorporation of these particles (see Fig. 1 and Table composite coating. While on the surface of higher nano-
2). Moreover, in nano-composite deposits, nano-Al2O3 Al2O3 content in composite coating, there is only slight
particles embedded at the borders of Ni crystallites, as corrosion, which indicates that the higher nano-Al2O3
well as inside the Ni crystals,13 can help to prevent the content in deposits, the better corrosion resistance of
corrosive pits from growing up, and the incorporation of composite coatings will be. It is interesting to note that
nano-Al2O3 particles contributes to accelerate the passi- the corrosion resistance of Ni-Al2O3 composite coatings
vation process of the metal matrix as well. Subsequently, produced using SCD technique is superior to that of
the corrosion resistance of the Ni-Al2O3 nano-composite CEP technique.
(a) Ni-4.14 wt.% Al2O3 nano-composite coating, CEP (b) Ni-4.42 wt.% Al2O3 nano-composite coating, SCD
(c) Ni-5.76 wt.% Al2O3 nano-composite coating, CEP (d) Ni-7.58 wt.% Al2O3 nano-composite coating, SCD
Fig. 3: Corrosion surface morphology of Ni-Al2O3 composite coatings in 3.5 wt.% NaCl solution. Al2O3 concentration in plating solution: (a,b) 5 g/l and
(c,d) 10 g/l.

From Figures 2 and 3 and Table 3, it can be concluded

that the addition of nano-Al2O3 particles in the deposi-
tion process of nickel on the surface of mild steel signif-
icantly increased the resistance to corrosion. Obviously,
the nano-Al2O3 particles played a major role for improv-
ing the corrosion protection in three mechanisms.
Firstly, these nano-Al2O3 particles act as inert physical
Fig. 4: Weight gain of coatings at different temperatures. Al2O3
concentration in plating solution: (a) 0 g/l, (b, c) 5 g/l, and (d, e) 10 g/l. barriers to the initiation and development of defect cor-
rosion, modifying the microstructure of the nickel layer
and hence improving the corrosion resistance of the
coating. Secondly, dispersion of nano-Al2O3 particle in
the nickel layer results in formation of many corrosion
micro cells in which the nano-Al2O3 particle acts as cath-
ode and nickel metal acts as anode because the standard
potential of Al2O3 is more positive than nickel. Such cor-
rosion micro cells facilitated the anode polarization.
Therefore, in the presence of nano-Al2O3 particles, local-
ized corrosion is inhibited, and mainly homogeneous cor-
rosion occurs.49 Thirdly, because the crystallite size of
coatings is in the range of a nanometer (see Fig. 1), cor-
rosion must proceed along a circuitous path to reach the
substrate, which retards the corrosion process, thus
improving the corrosion resistance.
High-temperature oxidation performance

The weight gain of coating at different temperatures is
Fig. 5: Weight gain of coatings as a function of exposure time. Al2O3 shown in Figure 4. From this figure, it can be seen that
concentration in plating solution: (a) 0 g/l, (b, c) 5 g/l, and (d, e) 10 g/l. with increasing of temperature, the weight gain increases
for both pure Ni and Ni-Al2O3 composite coatings. When
temperature is lower than 973 K, all type of coatings show
Fig. 6: The log (time) vs. log (weight gain) plot for pure Ni coating and Ni-Al2O3
nano-composite coating. Al2O3 concentration in plating solution: (a) 0 g/l, (b, c) Fig. 7: XRD pattern of coating after high-temperature oxidation. Al2O3
5 g/l, and (d, e) 10 g/l. concentration in plating solution: (a) 0 g/l, (b, c) 5 g/l, and (d, e) 10 g/l.

Fig. 8: Surface morphology of coatings after high-temperature at 800°C for 120 min. Al2O3 concentration in plating solution: (a) 0 g/l, (b, c) 5 g/l, and
(d, e) 10 g/l.
almost the same and slow weight gain. While temperature nano-Al2O3 contents in composite coating significantly
is higher than 973 K, the weight gain changes rapidly and decline when compared with that of the pure Ni coating
reaches a higher value. However, the weight gains of Ni- and lower nano-Al2O3 content in deposits in the long
Al2O3 composite coatings are lower than that of pure Ni term. It can also be seen that the Ni-Al2O3 composite coat-
coating. Meanwhile, the weight gains of composite coatings produced via SCD technique have lower oxidation
ing produced via SCD technique decrease in comparison rate as compared to Ni-Al2O3 composite coatings pro-
with that of CEP technique under the same nano-Al2O3 duced via CEP technique under the identical nano-Al2O3.
concentration in plating solution. The kinetics of oxidation process can be described by
Figure 5 shows the plot of the mass change of coatings examining the growth time constant or n value, which is
as a function of exposure time during oxidation at 1,073 K. found as the exponent in the following rate equation50:
In general, weight gain of samples increases with increas- where Dm is the change in mass, A is the sample surface
ing time as expected. However, the weight gains of higher area, k is the oxidation rate constant, t is the exposure

time, and C is a constant. Taking logarithms of both sides Al2O3 particles that originally existed in the Ni-Al2O3
of Equation (6) gives: composite coatings.51
(6)
CONCLUSIONS
The slope of a log-log plot gives the n value, which indi- After preparing the Ni-Al2O3 nano-composite coatings
cates the oxidation mechanism. The log (weight gain per from Watt’s electrolyte containing nanometer sized Al2O3
area) vs. log (time) plots for high temperature oxidation of particles by using SCD and CEP technique, the corrosion
the pure Ni coating and Ni-Al2O3 composite coating are resistance and high temperature oxidation resistance of
presented in Figure 6. resulting composite coatings were investigated. The fol-
lowing conclusions are derived from the present study.
(7) (1) The embedded nano-Al2O3 particles in Ni matrix
refine the Ni grain and change the preferential orienta-
From Figure 6, we have calculated the growth-rate time tion of composite coatings. Hence, the composite coat-
constant of the log-log plots, which is listed in Table 4. From ing presents enhanced electrochemical corrosion resist-
these data, it can be seen that the growth-rate time con- ance, and improved oxidation resistance behavior.
stants of composite coating prepared via SCD technique are (2) The corrosion resistance of Ni-Al2O3 composite
smaller than that of CEP technique under the same nanocoatings produced using SCD technique is superior
concentration in plating solution. It indicates that the Ni- to that of CEP technique. It can be attributed to the
Al2O3 composite coatings produced using SCD technique nature of inert nano-Al2O3 particles, the finer grain
present the improved oxidation resistance behavior. structure and nano-Al2O3 particles embedded in Ni
The comparative result of XRD pattern on the pure Ni matrix retard the corrosion process to improve the
and Ni-Al2O3 composite coatings fabricated by SCD and corrosion resistance.
CEP technique after high-temperature oxidation are (3) The incorporation of nano-Al2O3 particles
shown in Figure 7, respectively. The XRD characterization enhances the oxidation resistance of the composite
(see Fig. 7) demonstrates that the scale on pure Ni coating coatings for both SCD and CEP techniques. No scale
consists of NiO and Fe2O3, while the scale on composite cracks formed and significantly fine oxide grains
coatings constitutes NiO, Fe2O3 and NiAl2O4.The occur- appeared on the SCD Ni-Al2O3 composite coatings as
rence of NiAl2O4 phase indicates that nano-Al2O3 parti- compared to pure Ni coating and CEP composite
cles incorporated with Ni matrix in deposits. coatings. It is considered that the rate-controlling dif-
Figure 8 shows the surface morphologies of the oxide fusion along short-circuit paths is blocked by second-
scale on the three coatings. For pure Ni coating, the Ni phase nano-Al2O3 particles and also by segregated alu-
crystals grew larger and some cracks occurred (Fig. 8a). minum ions from the dissolution of nano-Al2O3 parti-
For the oxidation of the Ni-Al2O3 composite coating, the cles that originally existed in the composite coatings.
grains became smaller for lower nano-Al2O3 content in
composite coatings in comparison with pure Ni coating ACKNOWLEDGEMENTS
(Figs. 8b and 8c). But for higher nano-Al2O3 content in This research work was financially supported by the
deposits after heat treatment, significantly fine oxide National Natural Science Foundation of China (Grant
grains appeared on the surface of the Ni-Al2O3 compos- Nos. 50234020 and 50474055) and the doctor visiting
ite coating (Figs. 8d and 8e). This can be attributed to scholar of Northeastern University. The authors are also
the incorporated higher nano-Al2O3 content in deposits thankful to Prof. M.K. Lei for corrosion tests.
that improve the oxidation resistance of composite coat-
ings by decreasing the growth rate of the oxide and NOTES
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31. M. Viswanathan, K.S.G. Doss, Met. Finish. 70 (1972) 83.
32. M. Viswanathan, M. Ghouse, Met. Finish. 77 (1979) 67.
33. H. Liu, W. Chen, Surf. Coat. Technol. 191 (2005) 341.
34. C.S. Ramesh, S.K. Seshadri, Wear 255 (2003) 893.
35. M. Viswanathan, Met. Finish. 71 (1973) 38.
36. M. Ghouse, M. Viswanathan, E.G. Ramachandran,
Met. Finish. 78 (1980) 31.
37. M. Pushpavanam, G. Varadarajan, S. Krishnamoorthy,
R. Thangappan, B.A. Shenoi, H.V.K. Udupa, Met.
Finish. 72 (1974) 46.
38. M. Ghouse, M. Viswanathan, E.G. Ramachandran, Circle 003 on reader information card or go to www.metalfinishing.com/advertisers

casestudy
BY TERRY KEIZER, NATIONWIDE INSTALLATION CORP., GRAND RAPIDS, MICH.
Saving Big Bucks With

Remanufactured Equipment
Midwest U.S. Firm. helps UAE-based company
bring phosphating in-house to conserve money and time.
B ig Red Tubular Industries L.L.C.

is a United Arab Emirates-based
company, established for the pur-
2. Hot soap clean
3. Hot water rinse
4. Dip in zinc phosphate chemical
pose of manufacturing unitized drill solution, with PH and tempera-
pipe for the oil & gas drilling indus- ture permanent control
try. The company is located in the 5. Cold water rinse
Industrial City of Abu Dhabi (ICAD
ll) and occupies a total 18,300 Among the phosphate line require-
square meter plot with 3,300 square ments:
meters of manufacturing facilities 1. One-man operation, fully
within its boundaries. automatic
The Big Red Tubulars facility is ide- 2. Full traceability of the application
ally located in the heart of the most treatment (recording of the
active region for oil and gas produc- temperature, PH and time
tion and is in close proximity to inde- parameters)
pendent internal plastic coating facil- 3. Environmentally friendly
ities associated with the internal coat- and compliant with UAE
Nationwide Installation Corp. thoroughly
ing of drill pipe. This position offers environment laws cleaned and painted refurbished equipment for
advantages to the region’s customers 4. Capacity of 8 baskets per hour, a client, Big Red Tubulars, to make the equip-
in terms of reduced freight cost, deliv- or 12,000 pounds per hour, at ment “like new.”
ery and transit time. full production 1,500 lbs capacity
The Big Red Tubulars state-of-the- per basket conserve exhaust requirements. New
art manufacturing technology allows tank heaters, level, pH controls were
the company to offer the drilling In order to meet these require- also provided and installed. (For ease
industry drill pipe in all API and ments, Big Red Tubulars contacted of shipping and installation, the
selected service-grade pipe in diame- Nationwide Installation Corp., based tanks were skidded and modularized
ters ranging from 2 3/8 inches to 6 in Grand Rapids, Mich., to supply an in sections, including the piping and
5/8 inches as well as all known speci- automated line for chemical surface wiring of the line.)
fications. All Big Red Tubulars stan- treatment. Nationwide Installation Other aspects of the system includ-
dard manufacturing complies with Corp. offered a used phosphate line to ed new Allen Bradley PLC for the
API Q1, API 7 and API 5 specifica- be remanufactured in a “like-new” control hoist, tank covers, level con-
tions. Plus, the company’s tool joint condition per Big Red Tubulars’ spec- trol and tank heating. In addition,
threading facility has the capability ifications at approximately 55% of the new automatic load and unload
to machine both API and premium cost of a new system ($950,000). The shuttles were engineered and provid-
connections such as the Big Red phosphate line was modified to fit Big ed with a tilt mechanism to assist in
Tubulars double-shouldered or low- Red Tubulars process layout, and all loading the heavy tool joints. Big Red
stress connections. After machining, tanks, hoists and structures were Tubulars also provided program-
all tool joints are subject to a chemi- thoroughly cleaned and painted. Big ming and complete testing of the
cal surface treatment (phosphating) Red Tubulars inspected and replaced line prior to shipment of the line.
to prevent galling in the threads dur- all mechanical and electrical devices Operator training was also provided.
ing the use of drill pipes. (gear boxes, motors, brakes, etc.) as For more information, contact
The chemical surface treatment required. In addition, a new PVC ven- Terry Keizer, Nationwide Installation
process consists of the following: tilation system was provided, includ- Corp., at (616) 575-9300 or e-mail
1. Cold water rinse ing pneumatic operated covers to tlkeizer@aol.com.

ORGANIC ing what type of equipment you will
need to meet your requirements. At
finishing
BY KEVIN COURSIN, PRESIDENT, KMI SYSTEMS,
INC., KRYSTAL LAKE, ILL.
this point it may be necessary to
bring in some chemical suppliers to
discuss what will be required to clean
the parts and what type (if any) phos-
phate or other pretreatment coating
will be required to meet the corro-
sion-resistance requirements. In
Steps to Prepare for Specifying addition, you should talk with paint
suppliers about your coating require-
a New Paint Finishing System ments. It may be necessary to have a
primer coat, or several coats, to meet
o it’s time to replace that old • The production volume of each the desired coating requirement, i.e.,
S paint finishing system, or you

are interested in purchasing
that first system. There are several
part (pcs/hr or pcs/year). Or if you
have a variety of parts, what is the
average volume per specific hanging
such as corrosion resistance, UV pro-
tection, gloss or other qualities.
Some of the items you should dis-
steps that you, as the buyer, must dimensions. This will ultimately cuss and review with them are:
consider and think about to allow determine the line speed at which • Cleaning Requirements
the equipment suppliers to provide the conveyor will be traveling and, q How is the part to be used?
an accurate quotation. By taking thus, the length of equipments, q Does it require a certain salt
these preliminary steps prior to such as the pretreatment washer, spray resistance?
going out for a request for quote, you ovens and cooling area. q Zinc or Iron Phosphate or
will have identified your real require- Nano-Technology?

ments. You also will have collected STEP #2 – GENERAL DATA. q Does it require laser smut
the necessary information that the In addition to the product data, removal?
equipment suppliers will need in there is some general data that will q Are the parts very dirty or oily?
order to prepare a quotation for you define how the equipment is con- q Does it require a primer coat
that will meet your needs. structed and how the layout of the and top coat?
Remember, the system you specify system fits. These include: • What type of coating is to be used?
will be used for 25 years or more, so • Plant geographic location q Powder
take the time to think what your cur- • New or existing building n What type?
rent needs are and also what any • Building column centers & q Liquid
potential needs will be in the future. location and height to the n Solvent based?
bottom chord of the building n Waterborne?
STEP #1 – PRODUCT DATA. truss and roof. q E-Coat
There are several items that must be • If a specific area is available to n Anodic
collected or determined by the buyer accommodate the system(s) n Cathodic
that will determine the size of the • Access into the building—i.e., q UV
system. These items must be defined external door sizes, location to

for the parts you wish to have coated: area, access through the plant or STEP #4 – PROCESS FLOW.
• Dimensional size and geometric any other building or existing Once you have determined the type of
shape of the parts equipment constraints process requirements that will be
• Weight of the parts as well as • Any time schedule desired for needed to achieve the desired finish,
their thickness (i.e. sheet metal, installation of the system you must think about how this trans-
structural weldments, etc.) • Natural gas pressure and Btu lates into what equipment will be
• Substrate material construction, content per cu.ft. required. If you need help in deter-
such as steel, aluminum, plastic, • Plant power available, i.e., 480 mining what it will take to do this,
etc. Volts - 3 Phase- 60 Hz consult a turn-key equipment system
• Surface area of the parts or spe- • Water analysis supplier. The main objective is to
cific location on the parts that • Environmental Requirements for determine either a written process
need to be coated. This includes this location, such as EPA air per- description and/or a process flow dia-
defining whether the parts are mitting or local wastewater dis- gram. The process flow should take
coated the same on all sides, charge limitations into consideration the following:
whether a dust coating is needed • Pretreatment
on the back side, or if there are STEP #3 – PROCESS q Qty of stages to meet process
specific areas that must be REQUIREMENTS. requirement and solution

masked. This next step is crucial in determin- for each

ORGANIC
finishing Line Speed
Calculation
Part Name
Given: 2,000 Hrs./Yr.
Production
Hanger Line
coated are racked or hung from the or No. Qty/Yr. Qty/Hanger Qty/Hr. Spacing (ft.) Speed (FPM)
conveyor. You must consider how XXX-XXX 100,000 2 25 4’-0” 1.66
water will drain from the parts dur- YYY-YYY 200,000 1 100 4’-0” 6.67
ing the pretreatment process and ZZZ-ZZZ 500,000 5 50 2’-0” 1.67
how the parts will be presented dur-
10.0
ing the coating process. This may
require different racks or hangers for Figure 1. Line speed calculation.
different parts. If a wide variety of necessary line speed calculation can lows. This same type set up can be
parts are being coated, a load bar be determined. The basic line speed used for determining product square
with multiple hanging points may formula is: feet per hour being processed.
have to be considered. The ergonom-
ic constraints of the loading and Line speed (fpm) = SUMMARY
unloading operators
Parts Loading Calculation
must also be considered
Part Name Qty/ Part Weight Hanger Load (lbs.) Line Speed Lbs of
especially if you have a
or No. Hanger (lbs.) Spacing (ft.) per ft. of Conv. (FPM) parts/hour
tall product or heavy
product. This may XXX-XXX 2 35 4’-0” 17.5 10.0 10,500
require adjusting the YYY-YYY 1 100 4’-0” 25.0 10.0 15,000
conveyor height, adding ZZZ-ZZZ 5 25 2’-0” 62.5 10.0 37,500
work platforms and/or
Figure 2. Parts loading calculation.
installing hoists or other
lifting devices. Some of the items to Qty pieces or racks per hour X By taking time to prepare a summary
think about are: Spacing of parts/racks on the of the technical issues you need to
• How can parts be hung or racked Conveyor (ft/pc) ÷ 60 min/hr have included in your system, it will
to present surface for coating save a great deal of time in the equip-
• Does the hanger need to rotate? This formula can be used easily if ment suppliers getting a proposal to
• Does the part require two or the quantity of parts or racks per you. Since the system parameters are
more hangers? hour are known along with the spac- determined, it will keep you from
• Can a load bar be used or a rack? ing of them. If there is a wide variety having to answer a lot of questions
• Considerations of parts in size and quantity it will be that would be needed to design and
q Do the parts hang straight or necessary to prepare a chart that will layout the system you require. It also
does the center of balance determine the line speed by a weight- will allow you to have a better chance
rotate them? ed average. The chart can easily be set of having an apple to apple compari-
q Do the parts swing – Clearance up in a Microsoft Excel spreadsheet son of different systems.
between parts to assist in the math calculation. (See
q Do the parts need
Parts Surface Area Calculation
to be hung in a cer-
tain fashion to Part Name Qty/ Part Surface Hanger Surface Area Line Speed Sq.ft. of
or No. Hanger Area (sq.ft.) Spacing (ft.) per ft. of Conv. (FPM) parts/hour
allow drainage?
q Are there holes or XXX-XXX 2 10 4’-0” 5.0 10.0 3,000
lips to hang the YYY-YYY 1 40 4’-0” 10.0 10.0 6,000
parts ZZZ-ZZZ 5 5 2’-0” 12.5 10.0 7,500
q Will the hanger
Figure 3. Parts surface area calculation.
mask the part from
being coated? Figure 3.)
• Once hanging arrangement is Depending upon the type of parts
determined, a mask opening can being processed, it may be necessary
be determined. Must have to determine if the parts will be
approximately 6” clearance batched by type, metal thickness or BIO
around largest color? In order to balance out the Kevin Coursin is the president of KMI
system and determine the product Systems, Inc, Crystal Lake, Ill. He has been
STEP #6 – LINE SPEED. heat load being processed (very in the paint finishing industry since 1981,
Once you have the quantity of parts important for the burner sizing of serving as both an end user as well as a sup-
needed to be painted and how they the washer and ovens), a simple cal- plier of finishing systems. He may be
will be hung on the conveyor, the culation table can be set up as fol- reached at coursink@kmisystemsinc.com.

Big things come in the
SUR/FIN Package
Bold ideas. Best practices. New product innovations. Networking To reserve your booth or register,
and educational opportunities. These are just some of the big things contact
you can expect from SUR/FIN 2009, North America’s premier surface Cheryl Clark, NASF
finishing event. Whether it’s SUR/FIN’s first-class technical conference or 1155 15th Street, NW, Suite 500
its highly acclaimed automotive, aerospace and management sessions, Washington, DC 20005
you’ll be empowered with knowledge that you can immediately apply Phone: 202-457-8404
back in the office or on the shop floor. What’s more, this year’s host city Fax: 202-530-0659
is Louisville, recently named by Manufacturers’ News magazine as the e-mail: cclark@nasf.org
“Southeast’s leader in manufacturing.” And it’s all within an easy drive www.sur-fin.net
or direct flight to the automotive heartland--strategically located near
some of the world’s largest OEMs and applicators. So come to Louisville June 16-17
and be a part of something big. Kentucky International
Convention Center
SUR/FIN 2009. Think big. Win big. Louisville, KY.
Call for Papers. Abstracts now being accepted.

Submissions due January 15, 2009.

paintingproblem
solver
Ensuring Proper Grounding When Working
with an Electrostatic Spray Gun
SELECTING HIGH-QUALITY PAINT one can purchase conductive gloves that are suit-
Q :Which is a better quality exterior paint, Vista or Dunn

Edwards? My Home Owners Association asked me to
use Dunn Edwards but the painter gave
able for electrostatic paint application. Additionally,
leather-soled shoes are better than rubber soles. I have
also heard of painters wearing a grounded waist band,
me a cost estimate for Vista paint. I now need to decide where the band or belt is in direct contact with the
whether to keep to our original specification or accept the painter’s skin.
painter’s bid. I suggest that you go to the ITW-Ransburg website,
which may offer additional literature on this topic.
A : I do not keep up with the quality of individual

paints and, therefore, cannot give you an opinion. REPAINTING GARAGE DOORS
However, here are some general hints that might be use-
ful: In this competitive paint market, you usually get
what you pay for. Therefore, as a rule of thumb, one
Q :I bought a new steel garage door with two coats of baked-
on polyester. Due to our condominium rules, I need to
repaint the door. Do I need to prepare the door in some way in
can say that the higher the price, the better the quality. order to change the paint color? I tried painting with satin latex
This axiom is not always true, but if one paint costs $10 outdoor paint, but it doesn’t seem to adhere very well.
per gallon, and another $35 per gallon, it seems reason-
able to expect that the higher priced product will per-
form better. Why the higher price? More durable resins,
pigments, UV inhibitors, mildewcides and other ingre-
A :Your best bet is to scuff-sand the door to a dull
finish using 280 grit abrasive paper. Thoroughly
wash off the dust and other dirt deposits and then use a
dients are used in the better quality paints. Also, higher 100% acrylic primer and top coat. High-quality 100%
volume solids products are more expensive since they acrylic latex paints are designed to stand up to sunlight
give you greater coverage. for long periods.
Finally, Consumer Reports frequently publishes a com- Please experiment before you redo the entire
parison of paints made by different manufacturers. I door and test adhesion after a few days of exposure
suggest that you go to their website and search for their to sunlight.
latest paint report.
PERMITTING A NEW SPRAY BOOTH
GROUNDING OPERATOR WHEN USING
ELECTROSTATIC SPRAY GUN Q :I’m moving into a building and want to install and per-
mit a new paint booth. I need know to whom I should
Q :What options are available for grounding the operator

in a hand-held electrostatic spray gun system?
first go and what steps I need to take.
A :The handle of all electrostatic hand-held spray

guns should be grounded. Therefore, if your
A :Your local fire marshall will tell you exactly what
he requires before issuing a permit. In addition,
you might need to go to your local or state air pollution
painter is experiencing electrostatic shocks, your first control agency. The agency might have permit regula-
approach should be to test that the gun handle is tions to which you must comply. If an environmental
grounded. The best option for a painter is to hold the permit is required, VOC, Hazardous Air Pollutant (HAP)
handle firmly in the palm of his bare, sweaty hand and and paint particulate emission limits might be imposed.
make good contact with the handle. By wearing gloves
the painter isolates himself from the ground and will BIO
tend to build up an electrostatic charge. If he does wear Ron Joseph is a paint and coating consultant with Exponent, Inc.,
a glove, he should cut a hole in the palm, so that he can of Menlo Park, Calif. You may e-mail your questions directly to
have physical contact with the handle. Alternatively, him at rjoseph@exponent.com.

askJoe particle size diameter of 35 to 40
microns will suffice.
powder It’s also very important to consider

the distribution not only the median
particle size. It’s critical to avoid
a high concentration of fines or
small particles. Fines are defined as
Powder Coating Laser-Cut Surfaces, the particles less than 10 microns
in diameter. In general it is best
Plus Particle Size Distribution to have a less than 7% concentration
of fines.
Q: We noticed that the cured pow-

der does not stick readily to edges
that have been cut by a laser. What are
Keep in mind that these extra steps
can be cost-prohibitive.
Fines cause a number of problems.
They make it difficult to fluidize the
powder, which interferes with trans-
the causes of this and what can be done
to overcome the adhesion issues? Q: We are looking for epoxy that is
resistant to D.O.T 3 break
fluid. We are a manufacturer of stain-
port performance through system
hoses. Fines also have a tendency to
“overcharge.” They attain a high
A: Cutting steel with a laser

offers many advantages,
including precision, speed, less
less steel filters, and a customer of ours
uses D.O.T 3 break fluid with our fil-
ters, which we use an epoxy resin in our
charge to mass ratio, which makes
film build difficult, especially in
tight inside corners (Faraday cages).
rejects and low labor costs. However, assembly of the filter. Fines also have a tendency to clump
one of the problems inherent to and absorb moisture due to their
laser cutting is the blue oxide
edge it leaves on carbon steel.
Powder coatings don’t like to
A: D.O.T. 3 brake fluid is a tough
one. Most hydraulic fluids act
as a paint remover when exposed to
high surface area. Are you convinced
that fines are bad news in powder?
Large particles (>80 microns) can
adhere to this oxidized surface. an organic finish. Brake fluid will also cause problems. These boul-
Conventional iron or zinc phos- seriously attack conventional poly- ders have trouble making it to
phate doesn’t adequately penetrate ester and hybrid powder coatings. the substrate because of their high
the oxide to provide adhesion of the Standard epoxies fare better but only mass. Gravity pulls them to the
cured powder. This results in a loss a high-performance epoxy will ade- bottom of your booth, reducing
of adhesion and the potential for quately withstand regular exposure your transfer efficiency. The ones
serious corrosion problems. to the D.O.T. 3 material. Epoxies for- that make it to your part will cause
There are a few paths to compen- mulated for decorative purposes increased texture.
sate for this shortcoming. One is don’t have the chemical resistance Speaking of texture, if you are
to employ a more aggressive pre- needed to thwart the aggressive sol- applying a textured powder, you will
treatment process. Using a strong vating ability of the fluids used for want a much coarser particle size.
acid etch prior to the phosphate hydraulic systems. Therefore, I sug- Depending on the texture desired,
stage can attack the oxide layer gest you specifically ask your powder the median particle size may be as
enough to allow the phosphate to supplier for a brake fluid-resistant high as 70 to 80 microns. A powder
do its thing. Another option is to epoxy. These have been commercially with such a large median size won’t
avoid creating the oxidation by available for years, so you shouldn’t have many fines. You have to pay
using nitrogen in the laser cutting have a problem getting the right attention to the large particle size
process. It’s more expensive than material for the job. fraction, however. Really big parti-
using oxygen, but it minimizes oxi- cles (>200 microns) may cause undue
dation from the laser and, there-
fore, allows a conventional iron or
zinc phosphate process to provide a
Q: Just wondering what would be
the best particle size distribution
for any powder. Also, how powder charg-
and uneven texture.
ABOUT JOE POWDER

surface more amenable to adhesion ing is related to the powder volume. “Joe Powder” is a 30-
of a cured powder. year veteran of the pow-
A third option is physically abrad-
ing the edges automatically (blasting
or wheel abrading) or manually. If
A: Particle size distribution is
critical to successful applica-
tion of a powder coating. The “best”
der coating industry. He
has served as technical
editor of a trade maga-
you opt for a blasting process, it is particle size depends on what you zine, and has written
imperative to keep your media clean; are coating and how thick you several books. In addition, he has worked
otherwise, you can contaminate the intend to coat the item. For exam- with the Powder Coating Institute on var-
surface you are attempting to clean. ple, if you are trying to coat a rela- ious projects and initiatives. Feel free to
ScotchBrite® pads or wheels work tively simple object, around 50 submit your questions to him via e-mail at
well but require additional labor. microns (2.0 mils), then a median askjoepowder@yahoo.com.

Achieving Better Pretreatment
Performance from Manual Spray
Wand Systems
Speaker: Don LaFlamme, Coral
Chemical Co.
ARCHITECTURAL
Powder Coatings to Meet
AAMA Specs
Speaker: Tabitha McLeish, Rohm &
Haas
COATING WEST Conference & Exhibit Approved Applicator Certification
Process: Aluminum Extrusions
Set for Las Vegas, March 2 & 3, 2009 & Fabrications
COATING WEST 2009, the innovative Speaker: Tom Grady,
regional conference & trade show to Sherwin-Williams
be held on March 2 & 3 in Las Vegas,
has announced programming details. The Trip from
The event—the first of two regional Liquid to Powder
conference & shows to be held in 2009 Coating—A Case
for the users of industrial coatings— Study: AR Iron
will target specific market segments as Speakers: John Cole
well as general finishing. Held at and Doug Smilor,
Planet Hollywood in the heart of the Parker Ionics
Las Vegas strip, COATING WEST 2009
will focus on Architectural, ACE (agri- Environmental
culture & construction equipment), Footprint – Liquid
Aerospace and Military, Custom vs. Anodize vs.
Coaters and General Finishing mar- 8:30 PM and is included in the regis- Powder
kets. Additionally, an exhibition will tration for all end users of industrial Speaker: Dave Heflin, Akzo Nobel
showcase the latest in products and coatings. For complete details, and to
services for the users of industrial register, please visit the show website Chromium-Free Aluminum
coatings. The Chemical Coaters at www.thecoatingshow.com. Pretreatments: New Technologies
Association International (CCAI) and Increase Your Options
the Powder Coating Institute (PCI) are CONFERENCE PROGRAMMING Speaker: James Reneshaw –
co-sponsors of the events, and The BY MARKET SEGMENT Chemetall
Electrocoat Association, Porcelain ACE
Enamel Institute and the IRED Div of Coating Options for Agricultural AEROSPACE/MILITARY
the Industrial Heating Equipment & Construction Equipment Aerospace and Defense OEM
Association are sponsors as well. Speaker: Rodger Talbert, R. Talbert & MRO Cleaning Challenges
COATING WEST will also feature a Consulting Speaker: Jim Malloy, Kolene Corp.
virtual spray painting competition on
the show floor, an evening special BOMAG: From Batch to Automatic FPL Etch Vs. Phosphoric Acid as an
event featuring a famous Rat Pack Speakers: Bruce Bryan, Wagner Adhesive Surface
Tribute, and a plant tour of AR Iron’s Systems, Inc. and John Sudges, Speaker: Anne Deacon Juhl –
new powder coating installation fol- Midwest Finishing AluConsult
lowing the closing of the show floor
on Tuesday. The complete COATING Powder Coated Agricultural They ARE Different: Aircraft Paint
WEST 2009 schedule can be found on Machinery: A Case Study on Horsch Booths
www.thecoatingshow.com along Maschinenbau GmbH Speaker: Rich Thelen – Global
with conference abstracts and times. Speaker: Curtis Widerholdt, ITW Finishing Systems
Conference sessions are planned for Gema
the mornings of March 2 & 3 while Non-Hexavalent Chromium Seals
the exhibition will be open during the Trailer Expert Coats the Professional for Anodic Coatings
afternoons. The special event featur- Way: A Case Study on Krone Speaker: Greg Semas, Metalast
ing the Rat Pack Tribute will take Fahrzeugwerk GmbH
place on Monday evening from 6:30 – Speaker : Jeff Hale, ITW Gema Recent Developments in Trends in

Coating Technologies DuBois Chemicals Pneu-Mech Systems Mfg. LLC
Speakers: Paul Mills, Pi Star DuPont CoatingSolutions Pollution Control Products
Coatings; Craig Dietz; and Trena Echo Engineering & Production Porcelain Enamel Institute, Inc.
Benson and Jack McKeague, Supplies, Inc. Powder Coated Tough Magazine
DuPont CoatingSolutions Elcometer, Inc. Powder Coating
Electro-Steam Generator Corp. (The) Powder Coating Institute
Powder Coating Booths (The) Electrocoat Association Powder-X Coating Systems, Inc.
Speaker: JB Graves, Wagner Systems, Epcon Industrial Systems Precision Quincy Corp.
Inc. EPSI Pretreatment Equipment
Exel North America Manufacturers, Inc.
Advanced Powder Coating: You Fostoria Industries, Inc. Process Thermal Dynamics, Inc.
Want Answers? We’ve GOT Answers General Fabrications Corp. Products Finishing Magazine
Speakers: Ron Cudzilo, George Global Finishing Solutions LLC Rapid Engineering
Koch Sons; Terry Giles, Henkel; Henkel Richards-Wilcox, Inc.
Jerry Trostle, Wagner; and Steve (The) Hilliard Corp. Rohm & Haas Powder Coating
Houston, The Powder Coating Houghton Metal Finishing Shercon
Institute International Pump Mfg., Inc. Siemens Building Technologies
IRED Div. of Industrial Heating StockCap
Basic Processing of Porcelain Equipment Association System Technologies, Inc.
Enamel Coatings, Physical ITW Gema Trimac Industrial Systems, LLC
Properties and Major Products KMI Systems, Inc. Uni-Spray Systems Inc.
Speaker: Cullen L. Hackler, Koch Sons, LLC, George Uniontape
Porcelain Enamel Institute, Inc. Magic Rack/Production Plus Corp. Wagner Industrial Solutions
Metal Finishing Magazine Webb Co., Jervis B.
The Ins and Outs of IR & IR Midwesco/TDC Filter
Applications Midwest Finishing Systems, Inc.
Speakers: Mark Gentry, Advanced Mighty Hook, Inc. For more information, call Goyer
Energy; Tom Bannos, Red-Ray Nordson Corp. Management at (513) 624-9988 or
Manufacturing; Gary Metzger, ITW Parker Ionics visit www.thecoatingshow.com.
BGK; and John Podach, Fostoria
Industries
EXHIBITORS (as of Nov. 20, 2008;

visit our website for regular updates:
www.thecoatingshow.com)
ACE Equipment Co.

ACT Test Panel Technologies
AkzoNobel
Argon Masking Corp.
Arizona Instrument LLC
Arkema, Inc.
AutoQuip, Inc.
Bulk Chemicals, Inc.
Calvary Industries, Inc.
Canadian Finishing & Coatings
Mfg.
Cardinal Industrial Finishes
Carpenter Chemicals, LC
Catalytic Industrial Systems
Chemical Coaters Assoc. Intl.
Clean Air Filters
Col-Met Spray Booths, Inc. 800-962-9900 or 800-576-8905
Coral Chemical Co. Fax: 626-653-3804
Custom Fabricating & Supplies Web: www.TMCSupplies.com
Datapaq, Inc. 812 1/2 N. Grand Ave., Covina, CA 91724
DeFelsko Corporation Circle 016 on reader service card or go to Circle 034 on reader service card or go to
Diamond Vogel Paints www.metalfinishing/advertisers www.metalfinishing/advertisers

cleaningtimes
Fished Out!
T his column is about managing
change, specifically in metal fin-
ishing. The-one sentence summary
That would be an excellent strate-
gy if environments were linear and
not multidimensional. But all that
of this column is this: maybe Dr. thrashing about liberates “sleeping”
DANIOS
Deming was wrong. particles, fibers, and micro-organ-
isms. This is dirt that was not caus-
FISHKEEPING ing quality problems and was locat- long. They were the stars of my
Recently, I was watching my wife ed outside critical work areas. tanks, and I loved them!
clean and restock our/her aquarium. Environments are non-linear and But I killed them as well by intro-
That led me to remember some of multidimensional—one change producing change. Their diet was small
my own experiences in raising and duces another, and another. live fish. Once, to save money, I sub-
killing tropical fish. Actually, I love I think lessons from managing
tropical fish. But I have made every aquariums can show why the oppo- AROWANA
mistake that can be made in trying to site strategy is a better one. Here are
meet their needs. In fact, some fish some examples of why I feel an equi-
have actually formed a union to col- librium strategy is best for both
lectively bargain not to be sold to me. aquariums and cleaning opera-
Seriously, isn’t an aquarium tions—even if the total level of
another kind of cleaning operation? I housed dirt is more in the equilibri-
started to wonder if some of what I um case.
have learned about raising tropical stituted minnows for zebra danios.
fish would be lessons of value in THE OVER-MANAGER The minnows were raised in the
management of cleaning operations. I always wanted to keep discus fish. wild, and were unknowingly dis-
Aquariums and cleaning operations The books all said the secret was pH. eased. Within three days, all crea-
are both managed environments. Keep it rock steady at 6.8. So I was tures big and small were dead.
And that’s the subject of this col- always sampling, testing for pH, I killed these fish because I made a
umn: learning about managing change I didn’t have to make. I intro-
one environment from manag- DISCUS duced a new variable. I destroyed the
ing another. equilibrium.
Both cleaning operations
and aquariums function best THE WRONG VARIABLES
when they are at equilibrium. Cichlids like cold clear acidic water.
Failure to grasp that realiza- I had a tank of lovely blue and yel-
tion cost the lives of too many low Rams (Ramirez fish). Always
fish, and made too much off- chasing each other, they were happy
spec product. and healthy (if you don’t’ count
split tails). My under-gravel filter
ABOUT MANAGERS adding base or acid, and sweeping was old and full of dirt. So I
Some feel that the best managed up the dead discus fish @ $50 each. removed the fish to a hospital tank,
cleaning operations one which is I was the above manager of clean- and cleaned their home.
always under change. That is, they ing operations, thrashing about. I On return to their fresh cold clear
are always striving to get the last par- killed the fish because I never let acidic water, they all got sick. Why? A
ticle, droplet, fiber, and micro- them get comfortable at equilibrium. microbiologist friend taught me that
organism identified, located, and I had liberated a strain of bacteria
discarded. These managers are WATCH THE WHOLE AQUARIUM that was under control by the organ-
always changing the system in order I have raised knife fish to two feet isms in the dirty filter. I was chasing
to improve it. and arowana to nearly three feet the wrong variable. It wasn’t “dirt.” It

was that strain of bacteria that was once under control.
TECHNICALLYspeaking
Our world is composed of detergent concentrations, they have not mentioned sweep, pulse, very-high-frequency
fluid flows and distributions, temperatures, and possi- ultrasonics, designer wave forms, multiple frequencies in a
bly cusum plots of significant variables. We look single tank, or sequential tanks with different frequencies
around and feel secure. Who wouldn’t, in the presence in each tank.” All true, but we have elected to start with the
of all that data? basics. Newer ultrasonic systems are complex and require a
Once, I managed my fish tanks that way. But I have great deal of thought and choice. In our opinion, some
seen my fish get ill (that strain of bacteria) and quality manufacturers select complex systems without really tak-
in my cleaning operation decline (a cause that mysteri- ing advantage of the capabilities of a basic system. Perhaps
ously went away) without perceptible changes in either in a future article, we will discuss specific ultrasonic fea-
environment. Some unknown variable caused both destroyed
tures in greatermy detail.
discus, ruined my rams? Isn’t periodic
problems. change in the
For now, we suggest cleaningthatbath what produces
you observe your currentperiodicsys-
change in cleaning quality? Yes, they are,
tem. Evaluate whether or not you are getting cavitation. and it is.
CONSISTENCY, OR NOT Determine and record the brand, model, serial number,
Nearly every customer I have ever encountered man- LOOSE
and CHANGE frequency. Check the settings. Then—
the ultrasonic
ages their cleaning operation the same way they wait But that
not during routine doesn’t mean all change should be test
production—pragmatically avoidedthe
until something unfortunate or embraced. Change should be
variables you have in your current system to see if you embraced whenare
happens (poor cleaning quali- improvement
functioning in isan wanted.
optimal Changesituation.should be generally
Of course, if you
ty, formation of an oil slick, a avoided
change anywhen equilibrium
settings, put them is wanted.
back to the way they were,
change of color or aroma, That’s a manager’s
and make sure you have the real job—to decide to
go-ahead if the
changecurrentthe
etc.), and discard the contents process. Then document the changes, the new routine,fish
equilibrium position is satisfactory (is the discus and
RAM of the cleaning bath and refill alive;
how caneffect
they we continue to afford
ultrasonic process to conditions.
feed the arowana? Is the
it with fresh. under-gravel filter contributing to some negative effect?
Then they ask me why their quality isn’t want they Are theTHE
ABOUT partsAUTHORS
being consistently cleaned? etc. Or, can the
want it to be—consistently OK. risk of change can be accepted
Barbara and Ed Kanegsberg, to achieve
BFK Solutions LLC, some gain?
are independent
The answer is in the figure above—periodic purge of My advice to readers, and clients, is seek a
consultants who help manufacturers improve cleaning and build-favorable equi-
soil via discarding the entire bath contents. This is over- librium position (fish alive and cleaning quality
ing processes. They can be reached at (310) 459-3614 or via e-mail consistent-
managing in action. atlyinfo@bfksolutions.com.
acceptable), and maintain that position until there is a
Consistency of cleaning quality comes when the significant incentive to find a better equilibrium position.
removal of soil material, and whatever else is unwanted NOTES Dr. Deming is right to an extent: improvement is only
in the cleaning bath, is done continuously, as in the achieved
1. Suslick K, through acceptance
Flannigan D. Plasma of the risk of change.
formation and tem-But
graph below. inperature
fishkeeping and in cleaning work, a
measurement during single-bubble cavita-satisfactory equi-
Here, as in fishkeeping, the best strategy is to manage to librium should be coveted,
tion. Nature 2005;434 (March 3):52–5. attained, and maintained.
produce an equilibrium—at the desired parameter values. 2.Here
Harmonimprovement
J, BransonisUltrasonics
not wanted—consistency is!
Corporation, personal
communication.
WHAT ABOUT DR. DEMING? 3.John Durkee is B,
Kanegsberg theKanegsberg
author of the book Management
E. Parameters of Industrial
in ultrasonic
In the last several decades we have all learned to value Cleaning Technology and Processes,
cleaning for implants and other critical devices.published by Elsevier
and practice “continuous improvement.” That manage- (ISBN 0-0804-48887). He is an independent
Journal of ASTM Int’l 2006 (Apr.);3(4). Available at: consultant special-
ment strategy is to always seek improvement through izing in metal and critical cleaning. You can
http://journalsip.astm.org/JOURNALS/JAI/jai_toclist. contact him at PO
change, and not accept the status quo. Box 847,
html. Hunt, TX 78024 or 122 Ridge Road West, Hunt, TX
Dr. Edwards Deming is credited with this manage- 78024; 830-238-7610; Fax 612-677-3170; or e-mail him at
ment philosophy. He means simply that improvement jdurkee@precisioncleaning.com.
won’t come without change.
You have no doubt noted the conflict between the rea-
soning and experience above, vs. Dr. Deming’s philoso-
phy. But isn’t change that assassinated my arowana,

July/August 2008 I metalfinishing I 44 January 2009 I metalfinishing I 53
sherwood
onmanagement
How to Speak Effectively 7. Specify action(s) to be taken.
Of utmost importance is noting
and Conduct Productive Meetings what action is to be taken, by
whom, and a completion date.
P resident-elect Barack Obama

knows better than most that effec-
tive and motivational speaking capa-
to speak in front of a large group,
and the fear increases incrementally
toward an insurmountable problem.
8. Close the meeting as specified.
Open-ended meetings prevent
planning. Individual questions
bilities can be powerful attributes. The mindset is one of “I just can’t do and detailed discussion for indi-
You won’t get elected president by it, and I won’t try.” viduals should be held by those
being a good speaker, but it can have a Many managers, CEOs, and execu- interested after the meeting.
profound and positive effect on your tives of small organizations do not
profits as an owner or your career as a communicate with their subordi- PUBLIC SPEAKING
manager or key executive. Conversely, nates unless it occurs in a negative Very few people are capable of deliv-
I have personal experience with indi- context, as in the case of substandard ering good presentations before
viduals who have suffered as a result performance. This is unfortunate large audiences. With practice and
of not being competent public speak- because positive communication effort, many people can provide
ers or meeting leaders. from manager to subordinate is con- passable performances. Public
For example, one of my client structive for both parties. In larger speaking for your company and
owner/managers had an unusual companies, most top bosses have lit- yourself can be beneficial for your
problem. She was a brilliant product tle eyeball-to-eyeball contact with career and increase profits for your
formulator, a terrific high-level sales- subordinates and, consequently, they company. In rare cases, the amateur
person, and had a controlled benevo- lose an important management tool. speaker can be paid an honorarium.
lent instinct toward her two hundred As a member of a trade association,
employees. In small around-the-table SMALL MEETINGS you may face the task of speaking at
groups, her presentations and dis- Around-the-table meetings are easy a regional meeting or a national con-
cussions were forceful, articulate, for most, but they still require vention. If you do a good job, it may
and well organized. The unusual advance preparation and competent be good for your ego. If you fumble,
problem stemmed from her inability delivery to be effective. Following stumble, and put the audience to
to speak to a large group, such as an these procedures noted below can sleep, you may never forget the
employee meeting with roughly help ensure success: resulting catastrophe. The following
more than 25 attendees. Standing in 1. Prepare a written outline of the guidelines can help you be a success-
front of this type of audience, she subject matter in advance. ful public speaker:
could not produce a reasonably good 2. Start on time. Don’t repeat 1. Preparation for your speech is
speech. Consequently, she would del- prior talks for the latecomers. a top priority. “Preparation” is
egate the responsibility to subordi- 3. Arrange the seating and require not writing out your speech care-
nates and lose the effectiveness of a that people be up close to you if fully and then reading the text to
“top gun” who cared enough to you are the principal speaker or an audience. Writing it is an
speak directly to employees. chairperson. Specifically, do not acceptable method, but only to
I did not attempt to help her over- allow anyone to sit alone at the get the facts down after research-
come this inability to speak in large end of the table. ing the subject. Preparing for a
groups, but it was likely that she fell 4. Review prior meeting minutes. speech involves a bit more work.
into the typical “fear of failing” syn- Request reports on actions items 2. Make an outline on cards in
drome that usually occurs before a from previous meetings. large print so you can glance at
large audience. Fear is a factor for 5. Control the discussion and them during your talk.
every speaker, including profession- questions. Stay on the subject. . 3. Practice your speech using the
als, but each time they perform they 6. Have minutes taken. This is outline as a guide. A video
overcome the apprehension. Non- essential if the meeting is to be a recording would be best, but try-
professionals and the inexperienced worthwhile expenditure of the par- ing it out on an audio recording
reinforce this fear each time they fail ticipants’ time. Continued on page 57

PRODUCT SHOWCASE:
CONVEYOR EQUIPMENT & SUPPLIES
OVERHEAD CONVEYOR one of the numerous conveyors it
For a more economical and time-sav- manufactures. This custom PV series
ing finishing system conveyor instal- is excellent for small items, easy to
lation, Lauyans & Company, Inc., clean, sanitary, and can be made to
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Conveyor with bolted construction. the Pocketveyor to your needs, plus
At the factory, each conveyor compo- many other specialties. For more
nent is equipment with flanges on information, call (847) 336-5033 or e-
the track ends for bolt-together mail dans@roll-away.com.
installation.
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Richards-Wilcox, Inc., offers a
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conveyor systems for many types of The Wheelabrator Roll Conveyor
finishing processes. Our conveyors Shotblast system has been specifical-
can increase your throughput and ly developed to provide surface
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floor space. tion industry. A continuous con-
The Richards-Wilcox conveyor trolled feed of steel into the blast
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together in the field eliminates much shapes and sizes. These Autoblast
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positioning and alignment much eas- have helped customers reduce their
ier. For more information, contact labor and energy costs. With 100%
Paul McDonald at (502) 774-2200, via efficient blast coverage, the con-
e-mail at pmcdonald@lauyans.com, trolled cycle of the system results in
or visit www.lauyans.com. more units cleaned in a shorter
amount of time, increasing overall
POCKETVEYOR tical pendants offering clean opera- productivity.
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Illinois, has been in the busi- can design and engineer a system to specifically designed to descale and
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tion, call (888) 852-1020, e-mail Modern automated processes have
mail@richardswilcox.com (include decreased the need to prepare, bevel,
the words “Powder Coating” in or grind steel prior to welding,
the subject line), or visit resulting in higher-quality welds.
www.rwconveyor.com. The system utilizes four EZEFIT
wheels that blast with steel shot
abrasive at a velocity of 265' per
second. The operation is available
in three different model sizes
equipped to suit plate widths of up
to 8' and structural steel up to 36"
high. For more information, e-mail
info@wheelabratorgroup.com or
visit www.wheelabratorgroup.com.

NEW ed for cleaning up welds and discol-
oration, light grinding, and paint
products and rust removal is available from

Rex-Cut Products, Inc., of Fall
River, Mass. Rex-Cut Sigma Screen
depressed center Type 27 wheels are
ideally suited for cleaning up weld
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Derived from renewable resources, to painting. Corcoat LTZ is stable wheels can be stacked onto a grinder
Dehydran SE 1 allows manufacturers and dependable, with cost-effective for use on metals, composites, and
to make use of the trend toward sus- quality results. wood. For more information, visit
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mulate with a defoamer that match- using this new technology will pro-
es various environmental require- vide today’s metal finisher with real, NEW “MEMORY” BUFFS
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global trend to eliminate fossil LTZ will give manufacturers and fin- Company, based in Chicago, has
ishers the ability to announced the development of its
compete in today’s “new-age” dip treat for sisal buffs,
difficult and competi- cloth buffs, and cloth and sisal com-
tive environment. For bination buffs. The new-age treat-
more information, ment allows for buffs to have a
visit www.coral.com. “memory,” coming back into shape
while being flexible for mush buff-
MESH ABRASIVE ing. The treatment is available in
WHEEL lite, medium, and hard densities.
A highly flexible abra- For more information, call (773)
sive wheel that runs 924-1515 or visit the company’s
cool and is well-suit- website, www.matchlessmetals.com.

sherwoodonmanagement this talent. The best jokes or car-
toons are those that relate to the
subject. (I know what you are all
Continued from page 54 heard clearly. Furthermore, deter- thinking: “Yes, Bert, how about a
for timing is also acceptable. mine if the projections or other joke relating to hydrogen embrittle-
(You don’t want to run out of display aides can be seen clearly. ment or cathode polarization?”)
time before a group of 400 or so.) 7. Q and A is great for the audi- President-elect Obama’s cam-
And listening to yourself can be ence and the speaker. To prevent paign was profoundly successful
enlightening, both good and bad. a lull when you have finished due, in part, to his speaking ability.
After practicing the speech a few your prepared talk and you ask The Los Angeles Times expressed the
times, you may know your sub- for questions, plant a few ques- opinion that Obama has shown
ject well enough to omit all but tions with buddies in the audi- leadership capabilities via his ability
occasional card referrals. ence to get the dialogue started. to communicate. I may not necessar-
4. While speaking, keep eye con- And, if available, have a portable ily agree with this exaggeration, or
tact with individuals around the microphone in the audience so its accuracy, but there is no doubt
room. Do not stare at the ceiling that the questions are heard. If that being a good speaker and hav-
or the floor. they cannot be heard, repeat the ing the ability to conduct productive
5. Graphic aids are valuable if question to the audience. meetings will be an asset to you and
used correctly. I’m old fashioned Depending on your reaction to these your company. I hope this article
and prefer overhead projectors. substances, do not drink excessive will help you reach that goal.
But feel free to use PowerPoint coffee (a stimulant) or alcohol (a
presentations is you’re more depressant) before speaking unless BIO
F
comfortable with them. Just you are familiar with their effects on Bert J. Sherwood is president of Sherwood
don’t rely on them too heavily. P body and personality. One shot
your Business Management Corp., a consulting
6. Check everything before you of booze can relax you, but three firm providing business and technical
speak. Have somebody stand at may intoxicate and ruin both your advice to surface finishing and manufac-
the back of the room to deter- speech and career. turing companies. He can be reached at
mine if the audio system can be Don’t tell jokes unless you possess sherwoodbj@aol.com.
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UV SHOWCASE:
CURING EQUIPMENT & SUPPLIES
UV-CURING RESIN cooler operation via proprietary
Sartomer Company offers CN820, a dichroic-coated glass reflectors that
UV/EB curing resin. CN820 is a free absorb heat-generating IR energy.
radical-curable acrylic The fully variable CoolWave 2 con-
oligomer designed to troller features adjustable UV power The robust
promote adhesion on output, a cooling pressure readout CoolWave
2–610 Curing
metals such as steel and remote parent machine inter- UV System by Nordson
and aluminum, glass, face offering multiple methods of
and polymer sub- connection for seamless integra-
strates. The oligomer tion. Visit www.nordson.com for and consistent exposure times.
can be used in energy more information. Additionally, the SideCure conveyor
curable applications Circle 162 on reader service card can be outfitted with up to four
that include screen 5000-EC lamps on top and up to
and offset inks, lami- CURING CONVEYOR SYSTEM four 5000-EC lamps on the sides.
nating adhesives and DYMAX offers its UVCS SideCure When 5000-EC lamps are configured
coatings. Please visit conveyor system for 180° curing. in series, the conveyor belt speeds can
www.sartomer.com or Designed for UV curing of DYMAX often be doubled. The SideCure con-
call (800) SAR- adhesives and coatings from the left, veyor system from DYMAX is ideal
TOMER for more right, and/or top, the innovative for bonding, masking, and coating
information. SideCure conveyor can be outfitted applications for high-tech sectors,
Circle 160 on reader service card with up to eight DYMAX 5000-EC such as the medical, electronic,
UV curing flood lamps. The convey- industrial, and aerospace industries
UV ROBOTICS or’s 12"-wide belt and 7.5" vertical where 180° UV curing is required.
Cleveland-based UV Robotics, LLC clearance, with 5"-high side-curing For more information on the UVCS
has been selected by Southern capability, allows for the curing of SideCure line, or other curing sys-
Company, one of the largest produc- large parts and makes the SideCure a tems from DYMAX, please, visit
ers of electric power in the U.S., to very versatile UV curing solution. In www.dymax.com.
modernize its Technical Applications addition, the relatively small convey- Circle 163 on reader service card
Center in Birmingham, Ala. The cen- or size (51" x 30" x 21.5") minimizes
ter, which serves as a technical R&D the footprint required for UV curing.
resource for the four-state region The use of the DYMAX SideCure
(Alabama, Georgia, Mississippi, conveyor system can often eliminate
Florida) will include a robotic UV potential “shadowed areas” around
curing system. This installation will components that are detrimental to
help Southern Company work with a light curing process. Furthermore,
the largest manufacturers in their the high-intensity DYMAX 5000-EC
service area to develop cost-efficient lamps used with the UVCS SideCure
UV curing processes. For more infor- conveyor provide 225 mW/cm2 of
mation about UV Robotics, visit intensity for fast UV curing, as well as
www.uvrobotics.com or contact Paul complete shielding from UV light UV SPOT LIGHT SOURCES
Mills at (440)570-5228. Hamamatsu’s Lightningcure
Circle 161 on reader service card LC8 series (L9566 and L9588)
features a 200-W mercury–
UV CURING SYSTEM The xenon lamp with high light
robust CoolWave 2–610 output (4,500 mW/cm2 at 365
Curing UV System by Nordson nm) and 3,000-hour life, cover-
provides greater application ing 300–700 nm. (Connectable
flexibility and system durabili- to a PC via the built-in RS232
ty at a lower cost of ownership. port.) Use the LC8 for UV cur-
The CoolWave 2 lamp head fea- ing, fluorescence excitation,
tures no internal gasketing; and precision bonding of elec-
eliminates maintenance-inten- tronics. For more information,
sive internal gasketing in the visit www.hamamatsu.com.
microwave cavity; provides Circle 164 on reader service card

EQUIPMENT
spotlight Dynatronix’ new 1200W LT Series
DC Power Supply.
New Technology in remote RS485 serial control and also

offers a LabVIEW driver for easy inte-
Electroplating Power Supplies gration into your control program. An
optional analog interface control
Built for long life, reliability and simplicity of operation board for PLC control is also available.
Ampere time and real time control.
C ombining proven design with the

latest technology. Dynatronix
started with 316 stainless construc-
know if the fan is not working prop-
erly. Fan is removable for easy clean-
ing and replacement.
Available through the front panel
or host control program.
Operating in crossover regulation
tion, which stands up to corrosive Standard 1⁄2 rack wide, 2U high pack- mode, the LT Series features both con-
electroplating environments. All inter- age Universal AC input. Units will stant current and constant voltage
nal components are sealed against operate on 100–264 VAC at 47–63Hz. control at the same time. Low ripple
corrosive environments. Models are available from 10–100 (<10 mV RMS) helps ensure consis-
On-demand cooling fan. Adjusts amps at 6–48 volts. Active power fac- tent operation and very high accuracy.
RPM levels based on internal heat- tor correction is built in.
sink temperature. A sensor alerts you Microprocessor control interface. Two Please visit the website at www.
at over-temperature threshold and digital encoders offer complete local dynatronix.com or contact Dave Osero at
shuts off the unit when temperatures control of the LT Series. Dynatronix (715) 268-5340, (800) 826-7172 or send
run 10 degrees higher than thresh- has written a simple host control pro- him an e-mail at dosero@dynatronix.com,
old. Locked rotor detection lets you gram called “Front Panel Plus” for for more information.
Surface finishing
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Anz_90x130_4c_USA.indd 1 22.09.2007 10:46:45 Uhr January 2009 I metalfinishing I 59
polishing&buffing
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Ph: 315-797-0470 Fax: (585) 247-1883 copper/brass Rosler polishing pastes and
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Fax: (315) 797-0058 E-mail: greg@gpbdistributing.com produce a high-gloss, smooth finish on a
www.divinebrothers.com wide variety of parts ranging from tur-
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BUFFS buffing, you'll find it at GPB ments.
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Section. The Categories for the
www.divinebrothers.com today!
www.gpbdistributing.com Next Few Available Issues Are:
February: Blasting
Equipment &Media
ELECTRO ABRASIVES CORP. March: Power Supplies

701Willet Rd.
Buffalo, NY 14218 JASON FINISHING GROUP
Ph: (716) 822-2500 • (800) 284-4748 April: Ovens
1715 Hamilton Ave
Fax: (716) 822-2858 Cleveland, OH 44114
E-mail: info@electroabrasives.com Phone: 1-800-720-3358 May: Filters & Pumps
Electro Abrasives Corp. manufactures sili- Jason Finishing Group, which includes
con carbide and boron carbide for lapping Osborn International and JacksonLea, is
and polishing. Boron carbide has a four- the premier provider of finishing prod-
July/August: Thickness
point flexural strength of 50,000 to 70,000 ucts and solutions. We offer the widest Testing
psi and a compressive strength of 414,000 array of products, manufactured across
psi, depending on density. It also has a low the broadest global footprint.
thermal conductivity (29-67 W/mK) and • Focused field sales territories For more details, contact our sales
has electrical resistivity ranging from 0.1 to • Strong Field Application Engineering managers:
10 ohm-cm. With its strength-to-weight team Larry Post: l.post@elsevier.com;
ratio and low thermal conductivity, it is • Extensive application solutions laboratory
Let us provide you with the solutions (212) 633-3191
ideal for a wide variety of polishing and
you need to be competitive! Bill Dey: w.dey@elsevier.com;
buffing applications, the company said.
(732) 758-6003
www.electroabrasives.com www.jasonfinishing.com
January 2009 I metalfinishing I 60 www.metalfinishing.com

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GROW YOUR COMPANY NOW
2009 MEDIA KIT COMPANIES ARE AVAILABLE
Metal Finishing's 2009 Media Kit Has Arrived!
for
This must-have media guide is packed with
pertinent information designed to help you plan your advertis- *MERGER OR PUCHASE*
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Metal Finishing's print magazine, digital edition, magazine ___________________________
extras, guide books & directories, Web site,
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to provide you with all the information you need. Also included IMPROVE PROFITS WITH
in this easy-to-read, full-color, 8-page kit is a detailed editorial
calendar listing the most frequently requested topics. OUR PUBLICATIONS:
To obtain a copy, visit www.metalfinishing.com and • Supervisory Training
click on the "2009 Media Kit" banner ad, or
contact our advertising sales managers "Do It Yourself" Workbookwith 3.5" disk and
today for a hard copy.
10 lessons:
Bill Dey: (732) 758-6003
e-mail: w.dey@elsevier.com Leadership, Production, Quality
Larry Post: (212) 633-3191 Control,Creativity,Time Mgt., Responsibilities,
e-mail: l.post@elsevier.com
Discipline,Training, Problem Solving
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• Activity-Based Costing &
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P&L Spreadsheet With Formulas & 3.5" Disk.
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To Order: Mail Check to:
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For Information:
e mail: sherwoodbj@aol.com
Janaury 2009 I metalfinishing I 62 www.metalfinishing.com

UPCOMING
events
FEBRUARY
Feb. 5–7 Indian Surface Finishing 2009 (ISF),
Mumbai, India. For more information, visit www.mfai.org.
Feb. 6–8 India International Coatings Show, Chennai,

India. For more information, visit www.coatingsindia.com.
Feb. 8–12 NASF Management Conference, Palm Beach,

Aruba. For more information, visit www.nasf.org.
Feb. 15–18 PACE 2009, New Orleans, La. For more

information, visit www.PACE2009.com.
Feb. 17–18 RadTech UV/EB West, Los Angeles, Calif.

For more information, visit www.radtech.org.
Feb. 18–20 The Waterborne Symposium: Advances in

Sustainable Coating Technologies, New Orleans, La. For
more information, visit www.psrc.usm.edu/waterborne.
Feb. 24–26 California Showcase Week, Montebello

and San Jose, Calif. Visit www.mfasc.org for details.
MARCH
March 2–3 COATING West, Las Vegas, Nev. For more
information, visit www.thecoatingshow.com.
March 19 Minnesota Paint & Powder Coating Expo,

White Bear Lake, Minn. For more information, visit
www.mntap.umn.edu.
March 22–26 CORROSION 2009 Conference & Expo,

Atlanta, Ga. For more information, visit
www.nace.org/c2009.
March 30–April 2 WESTEC 2009 Expo, Los Angeles, Calif.

For more information, visit www.sme.org.
March 31–April 2 IPC Printed Circuits Expo, Las Vegas,

Nev. For more information, visit www.goipcshows.org.
APRIL
Apr. 20–23 2009 SAE World Congress, Detroit, Mich.
For more information, visit www.sae.org.
Apr. 28–30 NASF Washington Forum, Washington, DC.

For more information, visit www.nasf.org.
MAY
May 7–9 EBRATS 2009, São Paulo, Brazil. For more
information, visit www.ebrats.org.br.
May 9–14 52nd Annual SVC Technical Conference,

Santa, Clara, Calif. For more information, visit www.svc.org.

ADVERTISERS’
index January 2009
a k
ABTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 KMI SYSTEMS, INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
AMERICAN PLATING POWER LLC . . . . . . . . . . . . . . . . . . . . . . . . .8
ATOTECH DEUTSCHLAND GMBH . . . . . . . . . . . . . . . . . . . . . . .IFC l
LANCO CORP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
b
BARON-BLAKESLEE, DIVISION OF ENVIRO TECH INT'L. . . . . . . . .15 m
MATCHLESS METAL POLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
c
CHEMETALL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 n
CLEVELAND PROCESS CORP. . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 NAPCO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
COATING WEST 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 NATIONWIDE INSTALLATION CORP. . . . . . . . . . . . . . . . . . . . . . . . .8
COLUMBIA CHEMICAL CORP. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
CORNERSTONE SYSTEMS, INC. . . . . . . . . . . . . . . . . . . . . . . . . . .18 p
CREST ULTRASONICS CORP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 PAUL N. GARDNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
PAVCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BC
d POLLUTION CONTROL PRODUCTS CO. . . . . . . . . . . . . . . . . . . . . .9
DIVINE BROTHERS CO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 PROCESS ELECTRONICS CORP. . . . . . . . . . . . . . . . . . . . . . . . . . .57
e r
ELECTRO ABRASIVES CORP. . . . . . . . . . . . . . . . . . . . . . . . . .14, 60 ROSLER METAL FINISHING USA . . . . . . . . . . . . . . . . . . . . .59, 60
ELECTRO-STEAM GENERATOR CORP. . . . . . . . . . . . . . . . . . . . . .23
ENVIRO TECH INT'L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 s
ESMA, INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 SEMICRO DIVISION ME TAYLOR ENGINEERING . . . . . . . . . . . . . .30
EUGEN G. LEUZE VERLAG KG . . . . . . . . . . . . . . . . . . . . . . . . . .33 SERFILCO LTD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
SINGLETON CORP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
SOCIETY OF VACUUM COATERS . . . . . . . . . . . . . . . . . . . . . . . . .IBC
f STEELMAN INDUSTRIES, INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
FANTA EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 SUR/FIN 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11, 46
FISCHER TECHNOLOGY, INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
FLEXI-LINER CORP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 t
TECHNIC, INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
g TECHTON AMERICAN, INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
GPB DISTRIBUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 THERMO-COTE, INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
TITAN INTERNATIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
h TITAN METAL FABRICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
HARDWOOD LINE MANUFACTURING . . . . . . . . . . . . . . . . . . . . .53 TMC PLATING SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
HAWK CREEK LABORATORY, INC. . . . . . . . . . . . . . . . . . . . . . . . .10 TOLBER DIVISION PYRAMID PLASTICS, INC. . . . . . . . . . . . . . . . . .30
T & S ENTERPRISES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
i
IPC PRINTED CIRCUITS EXPO . . . . . . . . . . . . . . . . . . . . . . . . . . .25 u
UDYLITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
j
J & T TECHNOLOGIES, INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 w
JASON FINISHING GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 WMV, INC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44


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January 2009 Vol. 107 No. 1: The Plating and Coating Industries' Technology Magazine

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January 2009

The Plating and Coating Industries’ Technology Magazine

Electroplating environmental challenges.

Deposits plated from TriChrome® have

From bright to dark:

TriChrome® is a tried and trusted technology

34 Investigation into the Corrosion Resistance

55 Product Showcase: Conveyors & Equipment

Description: IN ASSOCIATION WITH

Increasing regulatory pressures are forcing metal finishers

This Webinar will:

January 2009 I metalfinishing I 4 www.metalfinishing.com

www.metalfinishing.com January 2009 I metalfinishing I 5

We take lean manufacturing to the next level

ï Cost Effective Processing & Solutions

Technicís SBE is a new

Technic (SFTís) MP300 offers fully

(401) 728-7081 ï equipment@technic.com ï www.technic.com

Circle 029 on reader service card or go to www.metalfinishing/advertisers

6 I metalfinishing I January 2009 www.metalfinishing.com

Call the Experts! October 2008 jumped up to 1.00.

NOVEMBER U.S. AUTO SALES

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Pollution Control Burn-Off Ovens safely

Circle 023 on reader service card or go to www.metalfinishing/advertisers

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2. Wisconsin Finishers Awarded

4. Detroit’s Big Three

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Call for Papers. Abstracts now being accepted.

Circle 047 on reader information card or go to www.metalfinishing.com/advertisers

A s past SUR/FIN exhibitors will

12 I metalfinishing I January 2009 www.metalfinishing.com

and the economy at large. January 15

T would be putting it mildly. At

www.metalfinishing.com January 2009 I metalfinishing I 13

Circle 008 on reader information card or go to www.metalfinishing.com/advertisers

14 I metalfinishing I January 2009 www.metalfinishing.com

Circle 002 on reader information card or go to www.metalfinishing.com/advertisers

www.metalfinishing.com January 2009 I metalfinishing I 15

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Since 1957, Steelman has been leading the way in

Call today for our literature packet and informational video!

STEELMAN INDUSTRIES, INC PHONE: 1-888-735-8831

Circle 028 on reader information card or go to www.metalfinishing.com/advertisers

www.metalfinishing.com January 2009 I metalfinishing I 17

18 I metalfinishing I January 2009 www.metalfinishing.com

Special Evening Event

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THE "CLEAR" CHOICE SYSTEMS

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KMI Engineered Design Solutions

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Electro-Steam Generator Corp.

www.metalfinishing.com January 2009 I metalfinishing I 23

24 I metalfinishing I January 2009 www.metalfinishing.com

a total of 10,871 visitors had regis- appointments: Michael Siegmund, December 8

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H exavalent chromium plating

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SUMMARY OF AUTOMOTIVE TEST

www.metalfinishing.com January 2009 I metalfinishing I 29

TOLBER GOES GREEN