Ministry of Defence

Defence Standard

03-18/Issue 2 13 September 1997

CHROMATE CONVERSION COATINGS

(CHROMATE FILMING TREATMENTS)
GRADES: STANDARD AND BRUSHING FOR
ALUMINIUM AND ALUMINIUM ALLOYS

This Defence Standard supersedes

Def Stan 03-18/Issue 1
dated 28 December 1979
DEF STAN 03-18/2

AMENDMENTS ISSUED SINCE PUBLICATION

AMD NO DATE OF TEXT AFFECTED SIGNATURE &

ISSUE DATE

Revision Note

This Defence Standard has been updated in order to bring method and procedures into line
with up-to-date requirements.

Historical Record

Def Stan 03-18/Issue 1 dated 28 December 1979

 DEF STAN 03-18/2

CHROMATE CONVERSION COATINGS (CHROMATE FILMING TREATMENTS)

GRADES: STANDARD AND BRUSHING FOR ALUMINIUM AND ALUMINIUM
ALLOYS

PREFACE

This Defence Standard supersedes

Def Stan 03-18/Issue 1
dated 28 December 1979

i This Defence Standard specifies the requirements for Chromate Conversion Coatings
(Chromate Filming Treatments) for Aluminium and Aluminium Alloys.

ii This Standard has been produced on behalf of the Defence Engineering and
Equipment Standardization Committee (DEESC) by the Corrosion Prevention of Metals
Subcommittee (E3).

iii This Standard has been agreed by the authorities concerned with its use and is
intended to be used whenever relevant in all future designs, contracts, orders etc and
whenever practicable by amendment to those already in existence. If any difficulty arises
which prevents application of the Defence Standard, the Directorate of Standardization shall
be informed so that a remedy may be sought.

iv Any enquiries regarding this Standard in relation to an invitation to tender or a

contract in which it is incorporated are to be addressed to the responsible Technical or
Supervising Authority named in the invitation to tender or contract.

v This Standard has been devised for the use of the Crown and its contractors in the
execution of contracts for the Crown. The Crown hereby excludes all liability (other than
liability for death or personal injury) whatsoever and howsoever arising (including, but
without limitation, negligence on the part of the Crown its servants or agents) for any loss or
damage however caused where the Standard is used for any other purpose.

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CONTENTS PAGE

Preface 1

Section One: General

0 Introduction 3
1 Scope 3
2 WARNING 3
3 Related Documents 4
4 Definitions 5
5 Information to be Supplied to the Processor 5
6 Process Control 5

Section Two: Preparation,Coatings and Supplementary Treatments

7 Preparation of Surface 7
8 Chromate Conversion Coating Treatment 7
9 Retreatment 10

Section Three: Production Control and Inspection

10 Production Control 11
11 Inspection 11

Table A Colours and Uses of Chromate Films 8

Table B Minimum Sample Areas for Determining Weight per Unit Area A-1
Table C Reagents for Determining the Weight per Unit Area of Chromate A-2
Coatings on Aluminium
Table D Details of Paints B-1

Annex A Determination of the Weight per Unit Area of Chromate A-1

Conversion Coatings
Annex B Process Control Tests B-1
Annex C Spot Test for the Presence of Protective Films C-1
Annex D Approximate Conversion of Metric Units to Imperial D-1
Equivalents (Non-US)

2
 I

DEF STAN 03-18/2

CHROMATE CONVERSION COATINGS (CHROMATE FILMING TREATMENTS) FOR

ALUMINUM AND ALUMINIUM ALLOYS

GRADES: STANDARD AND BRUSHING

Section One: General

0 Introduction

0.1 Chromate conversion coatings give a measure of protection against corrosion, in

particular under humid conditions. They can be used as paint bases because they markedly
improve the adhesion and performance of paint schemes in Service environments. The
process may also be used where the coating is required to be electricly conductive or for local
repair of damaged anodic coatings where it may slightly degrade the abrasion resistance of
the surrounding anodic film.

0.2 The majority of chromate conversion coatings are applied by immersion or spraying
techniques with provision for limited swab or brush application to small areas. There is,
however, a requirement for a Brushing Grade of chromate conversion coating which can be
applied by brush or swab to large areas.

1 Scope

1.1 This Standard specifies the properties of chromate conversion coatings on aluminium
and aluminium alloys. It gives inspection and testing requirements for chromate conversion
coatings.

1.2 Where there are differences in the requirements for the Brushing Grade from the
Standard Grade they are highlighted in this Standard.

2 WARNING

This Standard calls for the use of substances and/or procedures that may be injurious to
health if adequate precautions are not taken. It refers only to technical suitability and in no
way absolves either the designer, the producer, the supplier or the user from statutory and all
other legal obligations relating to health and safety at any stage of manufacture or use.

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3. Related Documents

3.1 The following documents and publications are referred to in the text of this Standard:

BS X 33 Specification for Two Component Epoxy Primer for Aerospace

Purposes
BS EN 2089 Aluminium Alloy AL-P2014A-TA or Sheet and Strip
0.4mm ≤ a ≤ 6mm
BS 3900: Part E6 Methods of Test for Paints. Part E6 Cross-cut Test
BS 3900: Part F12 Methods of Test for Paints. Part F12 Determination of Resistance to
Neutral Salt Spray
BS 7479 Method for Salt Spray Corrosion Tests in Artificial Atmospheres
Def Stan 03-2 Cleaning and Preparation of Metal Surfaces
Def Stan 80-161 Paint, Spraying, Epoxy, Two Pack. Types: Gloss, Semi-gloss,
Egg shell, Matt

3.2 Reference in this Standard to any related documents means in any invitation to
tender or contract the edition and all amendments current at the date of such tender or
contract unless a specific edition is indicated.

3.3 Related documents are obtainable from:

DOCUMENT SOURCE
British Standards (BS) British Standards Institution
Sales Department
389 Chiswick High Road
London W4 4AL
Tel: 0181 996 9000
Fax: 0181 996 7400
Defence Standards (Def Stan) Directorate of Standardization
Ministry of Defence
Kentigern House
65 Brown street
GLASGOW G2 8EX
Tel: 0141 224 2531
Fax: 0141 224 2503

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4 Definitions

For the purpose of this Standard the following definitions apply:

4.1 Grades

4.1.1 Standard Grade. This grade covers the normal immersion/spraying grade with
limited application to small areas by brush or swabbing.

4.1.2 Brushing Grade. This grade covers products which are designed to be applied by
brush or swab to large areas ie in excess of one square metre. The resultant chromate filmed
surface is normally painted.

4.2 Process Control Schedule. The document which specifies/defines:

(a) The sequence of manufacturing operations and processes.

(b) The control parameters and their tolerances for each individual process
within the total sequence.

4.3 Significant Surface. That area of the item, covered or to be covered by the coating
and for which the coating is essential for serviceability and/or appearance.

5 Information to be Supplied to the Processor

The following information shall be given on the drawing, contract or order:

(a) The number of this Defence Standard.

(b) The grade of treatment (eg. Standard Grade - see 4.1).
(c) The specification and metallurgical condition of the basis metal.
(d) The significant surface (see 4.3).
(e) The treatment method (see clause 8).
(f) If the items are to be painted (see 10.2).

6 Process Control

6.1 A Process Control Schedule suitable for achieving the requirements of this Standard
shall be prepared by the processing contractor(s) prior to the commencement of production.

6.2 Details of the coating process, including all preparatory treatments and after-
treatments, processing, significant surface, tests and all other processes and treatments shall
be included in the Process Control Schedule

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6.3 All stages in the complete Schedule shall follow each other without delay.

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Section Two. Preparation, Coating and Supplementary Treatments

7 Preparation of Surface

7.1 All surfaces shall be free from oil, grease and cleaning solution residue.

7.2 General cleaning. Items shall be cleaned and deoxidized in accordance with
Def Stan 03-2. Casting skin on certain alloys may interfere with the subsequent production of
satisfactory coatings. Casting skin may be removed by methods contained in Def Stan 03-2.

7.3 Cleaning prior to repair. Only the affected area shall be cleaned as a minimum.

8 Chromate Conversion Coating Treatments

8.1 General information (Standard and Brushing Grades)

8.1.1 Items which are to be chromate coated can be immersed in static or agitated baths,
sprayed, brushed or swab coated. Precise details of the working conditions will be found in
the operating instructions for the various chromate filming treatments.

8.1.2 Chromate solutions are usually acidic and contain hexavalent and/or trivalent
chromium salts, together with other components which may be varied to affect the
appearance and hardness of the film. Different metallic materials should not be treated
together in order to avoid galvanic corrosion.

8.1.3 Chromate conversion coatings harden with age by gradual dehydration and should
therefore be handled carefully for the first 24 hours. After treatment, yellow chromate
coatings become discoloured when treated in hot water, for this reason the temperature in the
final demineralized or deionized rinsing bath should not exceed 50°C with a maximum
conductivity of 10 mS/m (100 µS/cm).

8.1.4 The chromate film may be air-dried or dried in a warm air circulated oven at a
maximum temperature of 60°C. When heated to a temperature above 70°C, yellow chromate
coatings lose what remains of their water solubility. Associated with this is a reduction in the
corrosion resistance of the coating.

8.1.5 The film does not have the insulating properties of an anodic film and may be used
where electrical continuity is a design requirement, eg radio frequency (RF) screening
2
purposes. Typically, where contact is made over an area of 1 mm between two filmed
surfaces by an applied force exceeding 0.1 N, the contact resistance will be less than 500
ohms. Electrical conductivity is best achieved on colourless to iridescent light yellow
coatings.

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8.1.6 Depending on the chromate conversion coating conditions, the surface finish and the
type of alloy of the items being treated, the following colours can be obtained: colourless
(transparent), iridescent to light yellow, yellow to brown (see table A).

8.1.7 The colour of chromate films may fade with exposure to light over time with no
significant effect on the properties of the film.

Table A

Colours and Uses of Chromate Films

APPEARANCE COATING WEIGHT USES

2
PER UNIT AREA g/m

Yellow to brown 1.3 - 3 Maximum corrosion resistance;

generally used as final finish

Yellow to 0.2 - 1.3 Moderate corrosion resistance;

iridescent used as a paint base and for
bonding

Colourless 0.05 - 0.2 Decorative; slight corrosion

resistance; low insulation
resistance

8.1.8 Coating weight may be determined by the method given in annex C.

8.2 Immersion method (Standard Grade)

8.2.1 The solution shall be contained in a suitable tank resistant to attack by oxidizing
agents and acids.

8.2.2 The items shall be presented to the solution in a clean and wetted condition. Water of
conductivity not greater than 10 mS/m (100 µS/cm) shall be used to make up the chromate
bath. The solution composition, pH, time and temperature shall be maintained within the
manufacturer’s instructions.

NOTE: Temperature must not be allowed to rise above 34°C as deterioration of the
solution will occur.

8.1.3 The time of immersion and chemical composition of the bath are the controlling
factors governing the formation of the required type of film (see table A). The solution

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 DEF STAN 03-18/2

composition will slowly change with use, and chemical analysis shall be carried out at a
frequency to ensure that the limits of composition specified are maintained.

8.3 Brush or swab method (Standard Grade)

2
8.3.1 This method is used for surface areas up to 1 m where immersion or spraying
techniques are unsuitable.

8.3.2 This method is also used to repair mechanically damaged surfaces which have been
previously chromate filmed or anodized.

8.3.3 Preparation of the Significant Surface shall be as in clause 7.

8.3.4 The working solution shall be made up in accordance with the manufacturer’s
recommendations, using water of conductivity not greater than 10 mS/m (100 µS/cm), and
shall be applied to the cleaned area with brush or swab. Application to vertical surfaces shall
be started from the lowest edge, applying the solution as generally and evenly as possible.

8.4 Brush or swab method (Brushing Grade)

2
8.4.1 This method is used for surface areas exceeding 1 m where immersion or spraying
techniques are unsuitable.

8.4.2 Preparation of the Significant Surface shall be as in clause 7.

8.4.3 Not all chromate conversion coatings are suitable for this method of application;
hence, any material supplied must be certified by the manufacturer as being suitable for large-
scale brush or swab application.

8.4.4 Solution composition shall be to the manufacturer’s recommendations and shall be

applied to the clean area with brush or swab. Application to vertical surfaces shall be started
from the lowest edge, applying the solution as generally and evenly as possible.

8.5 Washing and drying after treatment

8.5.1 After treatment, large structures shall be thoroughly washed in clean running water
(maximum temperature 50°C).

8.5.2 After treatment, other items shall be washed in clean running water (maximum
temperature 50°C) to prevent over-treatment which will occur where the solution is retained.
The normal time of washing is about one minute. It is recommended that items of irregular
contour be washed in jets of water. All items shall then be finally rinsed in water having a
conductivity not greater than 20 mS/m (200 µS/cm). A slight contamination by the
processing solution is acceptable.

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DEF STAN 03-18/2

8.5.3 After washing and rinsing, items shall be dried as soon as possible in clean air at a
temperature not exceeding 60°C.

8.5.4 The primer or first coat of the specified paint scheme shall be applied to the dry
chromate filmed surface within 16 hours.

9 Retreatment

Unsatisfactory coatings shall be completely removed either mechanically, in accordance with

Def Stan 03-2, or chemically with the solution referenced in annex A. Other chemical
treatments may be used, providing the properties of the subsequent conversion coatings and
the basis metal are not adversely affected. After removal of unsatisfactory coatings, items
shall be retreated in accordance with clauses 7 and 8.

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Section Three. Production Control and Inspection

10 Production Control

10.1 The process shall be carried out in accordance with the Process Control Schedule and
shall comply with the requirements of annex A.

10.2 For applications where chromate filmed surfaces are subsequently painted, tests for
paint adhesion shall be carried out in accordance with annex B, test 1.

10.3 For applications where chromate filmed surfaces are not subsequently painted, tests
for corrosion resistance shall be carried out in accordance with annex B, test 2.

10.4 Frequency of testing shall be such that the processor can demonstrate that the
chromate film produced by the process meets the requirements of the appropriate test at
annex B.

11 Inspection

11.1 The chromate films shall be free of flaws or defects and shall not be powdery when
examined with the unaided eye. The colour of films resulting from process may vary from
colourless to golden yellow brown depending on alloy composition and method of surface
preparation. Iridescence and variations in colour from one area to another will frequently be
observed and are acceptable. Failure to colour match within batch, batch to batch or where it
has been necessary to process in more than one operation shall not be cause for rejection.

NOTE 1: Chromate conversion coatings are not intended as a colour matching process.

NOTE 2: Chromate films produced by the large scale brushing method (see 8.3) will
result in greater variations in appearance than those obtained by the standard method. This is
particularly apparent on surfaces which have been previously painted and stripped prior to re-
chromate filming.

11.2 Dry films shall be adherent when tested 24 hours after processing with a white
paper. The test shall consist of two strokes of white paper such as a No 40 Whatman filter
paper under light finger pressure. No more than the faintest stain shall be shown on the paper
and the film shall not show signs of having been removed.

NOTE: Chromate films should not be handled with bare skin.

11.3 The presence of a corrosion resistant film may be verified by applying the spot test
described in annex C.

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 DEF STAN 03-18/2
ANNEX A

Determination of the Weight per Unit Area of Chromate Conversion Coatings

A.1 The minimum sample size is given in table B. The weight per unit area of the
2
chromate coating in g/m can be obtained from the equation:

X= (a)-(b) .10,000
A

where X is the weight per unit area

a is the initial weight of the sample
b is the final weight of the sample after stripping with a reagent from
table C, washing and drying
A is the area of coating to be sripped

Table B

Minimum Sample Areas for Determining Weight Per Unit Area

EXPECTED WEIGHT MINIMUM SAMPLE

PER UNIT OF THE AREA
CHROMATE COATINGS
2 2
g/m cm

<1 400

l to 5 200

A.2 Where nitric acid is used as the reagent, the sample shall be rinsed after stripping
by with demineralized water.

A.3 When the sodium nitrate/sodium hydroxide melt is used to dissolve the chromate
coating, the procedure is as follows:

A.3.1 Immediately after the coating has dissolved, the sample shall be rinsed for 10 to 15
seconds with running water to cool and clean it.

A.3.2 The sample shall then be immersed for 15 to 30 seconds in approximately 38% v/v
nitric acid to remove any of the salts still clinging to the surface.

A-1
DEF STAN 03-18/2
ANNEX A (Concluded)

A.3.3 A second rinse of cold running tap water and brief rinse with demineralized water
prior to drying shall complete the stripping process. The sample shall be dried by blowing
with clean compressed air or by immersion in acetone and air drying.

A.4 Both the reagents in table C attack the basis material to a slight degree. The loss of
2
mass per unit area after 10 minutes pickling is in the order of 0.1 g/m . If necessary, this
loss must be determined separately and be taken into account in determining the weight per
unit area.

Table C

Reagents for Determining the Weight Per Unit Area of

Chromate Coatings on Aluminium

REAGENTS SUITABLE FOR TIME TEMPERATURE

min °C

Nitric acid Freshly produced chromate 5

(S.G. 1.42) coatings dried at temperatures to 25
below 70°C 15

Melt, consisting of 98% Freshly produced chromate 2 385

sodium nitrate and 2% coatings dried at temperatures to to
sodium hydroxide above 70°C and aged chromate 5 415
coatings

NOTE: Facial protection and protective gloves should be worn when liquifying the salts
and when working with the molten material. Molten materials that have hardened should
never be heated from below, but are to be liquified from above and from the side to prevent
any non-molten block of salt from being thrown out.

A-2
 DEF STAN 03-18/2
ANNEX B

Process Control Tests

B.1 Test 1 - Paint Adhesion

B.1.1 Adhesion of approved paint schemes to conversion coatings shall be verified by

use of the cross-cut test described in BS 3900: Part E6. Two panels (measuring at least 50
mm x 100 mm) of aluminium alloy to BS EN 2089, an equivalent specification or the alloy to
be coated shall be treated with the chromate filming product under test, applied in accordance
with the same procedure to be used in production.

B.1.2 A coat of epoxy primer complying with BS X 33 Type 1, shall be applied to the
chromated panels within 2 to 4 hours of the chromate filming process. This shall be followed
by a coat of glossy epoxy finish to Def Stan 80-161 (see table D for details of paints). All
paints to be applied and allowed to dry at a temperature of (23 ± 2)°C and a relative humidity
of (50 ± 5)%.

Table D

Details of Paints

COATING DRY FILM WEIGHT DRYING TIME

2
BS X 33 Type 1 30 ± 5 g/m 4 hours minimum
(Epoxy Primer) 16 hours maximum

2
Def Stan 80-161 30 ± 5 g/m 7 days
(Glossy Epoxy Primer)

B.1.3 Each panel shall then be scribed according to BS 3900: Part E6 using a 2 mm
spacing to form two grids each containing 25 squares. Tape shall be applied to, and removed
from, one of each pair of grids as described in Part E6. Both the grids on each panel shall
meet classification 0, ie no squares detached.

B.1.4 The panels shall then be exposed for 720 hours to hot salt-fog as described in BS
3900: Part F12, and then be rinsed in running tap water and allowed to dry for 24 hours at
room temperature.

B.1.5 Tape shall then be applied and removed as described in BS 3900: Part E6, to the
grid on each panel not previously tested with tape. The result shall not rise above
classification 2 after the adhesion test, ie up to 15% of the cross-cut area of paint may be lost
by failure at the conversion coating.

B-1
DEF STAN 03-18/2
ANNEX B (Concluded)

B.2 Test 2 - Corrosion Resistance of Conversion Coating Exposed to a Salt-Fog

Environment Test

B.2.1 The test shall be carried out in triplicate and in accordance with BS 7479. It shall
be performed on test panels of aluminium alloy to BS EN2089, an equivalent specification or
the alloy to be coated, with the panels measuring at least 25 mm x 100 mm. The test shall
commence 12 to 36 hours after chromate filming. After exposure to the salt-fog for a
minimum of 96 hours, the test panels shall be removed from the test cabinet and visually
inspected for the presence of corrosion product.

B.2.2 No corrosion product shall be visible on the chromate filmed test panels after
exposure.

B-2
 DEF STAN 03-18/2
ANNEX C

Spot Test for the Presence of Protective Films

C.1 Outline of test. A drop of chemical solution that when in contact with the basis
metal results in a change in colour when compared with a drop on a cleaned but untreated
surface.

C.2 Method.

C.2.1 Surfaces required. An untreated surface from which the surface oxide has been
removed by acid or alkali and a thoroughly dryed treated surface.

C.2.2 A drop of test solution shall be applied via an eye dropper to both the treated and
untreated surfaces. The solution will turn blue-green very quickly on an untreated surface,
while the time to turn blue-green on the treated surface will vary with the thickness of the
chromate film.

NOTE: Aged coatings dried at elevated temperatures (that is, dehydrated coatings) develop
a coloured spot more quickly than fresher ones.

C.3 Solution Make-up. The test solution shall be formed from equal volumes of the
following solutions.

C.3.1 Solution A

Reagent grade
Iron nitrate Fe(N0 3) 3. 9 H2O 2g
Reagent grade
Hydrochloric acid-HCl (S.G. 1.16 - 1.18) 20 ml
Distilled or deionized water 473 ml

C.3.2 Solution B

Reagent grade
Potassium ferricyanide K 3Fe(CN)6 2g
Distilled or deionized water 473 ml

NOTE 1: When stored separately, the solutions are stable. When mixed, storage life is
limited to a maximum of 1 week.

NOTE 2: The mixed test solution should not be exposed to direct sunlight.

C-1
DEF STAN 03-18/2
ANNEX C (Concluded)

COLLATION PAGE

C-2
 DEF STAN 03-18/2
ANNEX D

Approximate Conversion of Metric Units to Imperial Equivalents (Non-US)

SI IMPERIAL IMPERIAL SI Context Used

2 2
1 MPa 145 lbf/in 1 lbf/in 0.006895 MPa Tensile Strength

2
1 MPa 20886 1 lbf/ft 0.000048 MPa Tensile Strength
2
lb f/ft

2 2 2 2
1 kgf/m 0.205 lbf/ft 1 lbf/ft 4.88 kgf/m Tensile Strength

3 3
1 g/ml 62.43 lb/ft 1 lb/in 0.016017 g/ml Density

1 g/l 0.161 oz/gal 1 oz/gal 6.225 g/l Concentration

1 µm 0.000039 in 1 thou 25.4 µm Thickness

(mil in US)

2 2 z 2
1 A/m 0.0929 A/ft 1 A/ft 10.76 A/m Current Density

2 2 2 2
1 A/dm 9.29 A/ft 1 A/ft 0.1076 A/dm Current Density

1g 0.0353 oz 1 oz 28.349 g Weight

1 kg 2.205 lb 1 lb 0.454 kg Weight

1 ml 0.035 fl oz 1fl oz 28.41 ml Volume

ll 0.220 gal 1 gal 4.546l Volume

D-1
DEF STAN 03-18/2
ANNEX D

COLLATION PAGE

D-2
COLLATION PAGE
DEF STAN 03-18/2

This Standard may be fully reproduced

© Crown Copyright 1997 except for sale purposes. The following
conditions must be observed:
Published by and obtainable from: 1 The Royal Coat of Arms and the
Ministry of Defence publishing imprint are to be omitted.
Directorate of Standardization 2 The following statement is to be inserted
Kentigern House on the cover:
65 Brown Street ’Crown Copyright. Reprinted by
GLASGOW G2 8EX (name of organization) with the
permission of Her Majesty’s
Tel: 0141-224 2531 Stationery Office.’
Fax: 0141-224 2503 Requests for commercial reproduction should be
addressed to MOD Stan 1, Kentigern House,
65 Brown Street, Glasgow G2 8EX

The following Defence Standard file reference relates to the work on this Standard -
D/D Stan/313/11/3.

Contract Requirements

When Defence Standards are incorporated into contracts users are responsible for their correct
application and for complying with contract requirements.

Revision of Defence Standards

Defence Standards are revised when necessary by the issue either of amendments or of revised
editions. It is important that users of Defence Standards should ascertain that they are in
possession of the latest amendments or editions. Information on all Defence Standards is
contained in Def Stan 00-00 (Part 3) Section 4, Index of Standards for Defence Procurement -
Index of Defence Standards and Specifications published annually and supplemented periodically
by Standards in Defence News. Any person who, when making use of a Defence Standard
encounters an inaccuracy or ambiguity is requested to notify the Directorate of Standardization
without delay in order that the matter may be investigated and appropriate action taken.

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