SurTec 650 Tri-Chrome Passivation of Aluminum

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1 SurTec International GmbH - July 2011 SurTec International GmbH

2 Content 1 Best Available Technologies 2 ONE Process Market Specific Parameter 3 Process Control/ Maintenance 4 Resource Load 5 Total Process Costs TCP of Alu_0711_TK 2 SurTec International

3 Best Available Technologies for Aluminum Pre-treatment Yellow Chrome Green Chrome TCP Cr(III) Chrome-free Bath contains Cr(VI) Bath contains Cr(VI) Bath free from Cr(VI) Bath free from any Cr Coating contains Cr(VI) Coating free from Cr(VI) Coating free from Cr(VI) Coating free from any Cr Gold/ yellow color of coat Green/ Clear color of coat No color of coat No color of coat SurTec 655 SurTec 657 SurTec 650 SurTec 641 Labelling as toxic Labelling as toxic No labelling Labelling as irritating Effluent: Cr-reduction Effluent: Cr-reduction Effluent: Neutralisation Effluent: Neutralisation Disposal as special waste Disposal as special waste Disposal as normal waste Disposal as normal waste TCP of Alu_0711_TK 3 SurTec International

4 Best Available Technology for Aluminum Pre-treatment Completely free of Cr(VI), other heavy metals and COD Product is a REACH compliant, registered substance Coating is WEEE, RoHS and ELV compliant Only labeling free chromating alternative Storage and transport w/o limitations Shelf life of min. 12 months Product categorized in WGK 1 Effluent treatment via simple neutralisation Waste disposal as standard waste One product for numerous markets, management via process parameter TCP of Alu_0711_TK 4 SurTec International

5 ONE Process Market Demand Driven Operation Parameter 1 Alcaline Degrease/ Etch Rinse (Cascade) Acid Deox/ Etch/ Desmut Rinse (Cascade) Passivation SurTec 650 Rinse DI-Rinse Switch from Chromating is possible without major line modifications By improving the rinse quality prior to the active baths the drag-in of contaminations (= driver for life time and quality) can be minimized < 400 µs/ cm prior to passivation Process sequence can be used for different final applications; parameter of the active baths might have to be adapted to final application 8 Dry TCP of Alu_0711_TK 5 SurTec International

6 SurTec 650 Tri-chrome passivation of Aluminum Example 1: Architectural Industry - Market Specific Process Using only acid etch prior to passivation is also possible Min. etch rate 2 g/m² for all steps prior to passivation recommended Optimum process parameter: ph = 3,0; conc. = 4,0 %, T = ambient, t = 1-2 min. Optimum coating weight mg/ dm² Major contaminants: Fe < 50 ppm; Al < 500 ppm Specifications/ Demands Performance Substrates: Mainly 6000 series, e.g. 6060, 6063 Paint adhesion (wet cross hatch): Gt 0 Mainly paint Adhesion to Epoxy/ PE powder paints SS Resistance (3000 h):< 1 mm creepage Painted Corrosion Resistance in SS, AASS and FFC AASS Resistance (3000 h): < 3 mm creepage Spray, dip, basket, vertical and shower application FFC/ Filiform (1000 h): F < 0,4 (l < 2 mm; H < 1/ 10 mm) Compatibility to small amounts of Fe, & Zn substrates Approval by GSB, Qualicoat & Schueco TCP of Alu_0711_TK 6 SurTec International

7 Example 1: Architectural Industry - Broad Operation Window Temperature CW ph CW max. max. min. min. T ph Operation at room temperature possible Operation at ph 2,5 to 3,5 is possible Concentration CW Time CW max. max. min. min. conc t Operation at conc. 3-5% are possible Treatment times from 1 5 are possible Coating weight as determining criteria, as destinct correlation between coating weight and corrosion resistance (e.g. filiform corrosion) could be proven TCP of Alu_0711_TK 7 SurTec International

8 Example 2: Aerospace Industry - Market Specific Process Best results achieved with sequence degreasing/ alcaline etch/ acid etch/ passivation Correct etch parameter are crucial Optimum passivation process parameter: ph = 3,75 4,0; conc. = 20 %, T = 30 C, t = 5 min. Optimum coating weight > 400 mg/ dm² To achieve SS resistance of 336 h it is neccessary to use a final seal Specifications/ Demands Performance Substrates: mainly 2000, 5000, 6000 and 7000 series e. g. 2024, 6063, 7075 Wet adhesion to Aerospace (Hex Cr) Primer system Wet adhesion test (wet cross hatch): Gt 1 Bare metal corrosion resistance in NSS: 168 h Bare metal corrosion resistance in NSS FFC/ Filiform (1000 h): F < 0,4 (l < 2 mm; H < 1/ 10 mm) FFC filiform - ASTM D 2803 QPL listing Repair or batch in spray, brush, basket, pen or immersion application TCP of Alu_0711_TK 8 SurTec International

9 Example 3: Electronic/ 3C - Industry - Market Specific Process Optimum passivation process parameter: ph = 3,75 4,0; conc. = 20 %, T = 30 C, t = 2 min. Optimum coating weight : ca mg/ dm²; depending on application of final paint Process sequence is a compromise between bare metal corrsosion resistance driven & painted driven sequence Specifications/ Demands Performance Substrates: Mainly 6000, series e.g Painted SS resisatnce 3000 h 1 mm Corrosion resistance with PE- powder paints Bare metal corrosion resistance in NSS Surface resistance prior and after NSS (MIL-DTL B) Bare metal corrosion resistance in NSS up to 168 h Surface resistance prior NSS < 500 µω / inch Surface resistance after 168 h NSS < 1000 µω/ inch Shielding Effectiveness: up to 100 db at 100 Mhz EMI Shielding (ASTM D-4935) OEM approvals, eg Ericsson Spray or immersion application ELV, WEEE and RoHS compliant TCP of Alu_0711_TK 9 SurTec International

10 Example 4: Automotive Industry - Market Specific Process Optimum passivation process parameter: ph = 3,75 4,0; conc. = 20 %, T = 35 C, t = 3 min. Optimum coating weight cannot be measured due to high roughness of the casted surface Specifications/ Demands Performance Substrates: Mainly cast Aluminum, e.g. 226, 230, 231 Paint adhesion to E-coat & Epoxy/ PE paint Painted corrosion resistance in OEM specific test, eg. Cyclic corrosion test Cross hatch Gt 1 for all paint systems Bare metal corrosion resistance up to 240 h depending on substrate; e. g. Cu-content 1%: NSS = 240 h E-coat painted corrosion resistance: NSS 400 h < 1mm creepage Bare metal corrosion resistance in NSS Spray or immersion application TCP of Alu_0711_TK 10 SurTec International

11 Model for Chemical Reaction Aluminum TCP Coating SEM TCP of Alu_0711_TK 11 SurTec International

12 Simple Operation Process Maintenance 1 st Indication: Too thick layer leads to irrisicdence on Al-substrates Quantitatively: XRF handgun to measure Zr and Cr on-line Correlation between XRF and RFA proven for SurTec 650 Correlation betwen XRF measurement and coating weight could also be proven Layer Control Replenishment Bath Analysis Photometric method to check Zr concentration Direct calculation of product concentration out of Zr-concentration High accuracy in conc. range from % Time demand for one analysis max. 5 min. Pre-masking of Fe necessary No cross sensitivity towards Al, Mg, Zn or Cr SurTec 650 = 1K product Replenishment based on the measurement of the Zr and/ or Cr concentration TCP of Alu_0711_TK 12 SurTec International

13 Minimum Resource Load Water Energy Effluent Waste 50% Reduction of ionic load compared to traditional chromates; more cascades possible Due to the broad operation window SurTec 650 operates w/o heating or cooling No Chrome(VI) reduction required, simple neutralisation sufficient Lower amount and less hazardous sludge compared to traditional chromates Reduction in rinse water consumption Reduction in energy consumption Reduction in chemicals and technology for effluent treatment Significant reduction in waste and related disposal costs Ecological Footprint SurTec 650 Process Traditional Cr(VI) Process Resource Load TCP of Alu_0711_TK 13 SurTec International

14 Minimized Total Process Cost Standardized Costs Cost savings vs. Cr-free pre-treatments Cost neutral vs. Cr(VI) pre-treatment TCP of Alu_0711_TK 14 SurTec International

15 Most wanted by the Industry Approved by major OEMs in Aerospace, Architectural and Electronics/ 3C-industry Used by top global automotive supplier Approved by leading associations TCP of Alu_0711_TK 15 SurTec International

16 Summary No labelling of the product Easy and exact process control Very broad operation window Optimized total process costs ONE Product for various industries TCP of Alu_0711_TK 16 SurTec International

17 SurTec 650 Tri-Chome Passivation of Aluminum SurTec International GmbH - July 2011 SurTec International GmbH