ANODIZING BASICS

Anodizing of aluminum can achieve a very durable surface that is unaffected by weather for many years and many chemicals if done properly. The anodized surface can be dyed into many different colors using organic dyes. These colors can also be mixed to provide a full spectrum of other colors. The dyed surfaces can be subsequently sealed in a hot seal solution to protect away from corrosion in the surrounding environment. . MECHANICAL & CHEMICAL SURFACE TREATMENTS Aluminum can not be anodized and dyed without preparation. The mechanical and chemical preparatory treatments determine the final appearance of the metal surface since its optical properties are not modified by the transparent anodic coating or by dyeing. The mechanical treatment may include buffing, grinding, sandblasting and etc. The chemical treatment is to clean the metal surface free from oils, occluded impurities, soap residues and the natural oxide film. ANODIZING A porous anodic coating is formed during the anodizing process. The porous film can adsorb dyes to produce a full spectrum of colors. The natural oxide film is very thin and has to be replaced by a thicker artificial formed film. The most popular method of anodizing is to use a direct current (D.C.) sulfuric acid process. The following table is the one most used in the industry. Sulfuric acid (free) : Aluminum content : Current density Voltage Current Temperature Time : : : : : 165 g/l 225 g/ 5 15g/l 1.2 1.8 A/ dm2 12 V 20 V D.C. 18 22C 25 40 minutes 8 12 um

Coating thickness :

The following table gives a guide line to the effect of the D.C. sulfuric acid process parameters on the dyeing properties of anodic coating :-

Parameters H2SO4 Conc.

Deviation Higher

Dyeing Intensity Deeper

Mechanical Strength Lower

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Lower Aluminum ions Higher Lower Current Density Higher Lower Temperature Higher Lower Time Longer Shorter Coating Thickness Thicker Thinner

Paler

Higher

Modified Coating Modified Coating Structure Structure Paler Paler Deeper Deeper Paler Deeper Paler Deeper Paler Higher Higher Lower Lower Higher Higher Lower Higher Lower

Remarks Sulfuric acid concentration An increase in the sulfuric acid concentration intensifies its dissolving action on the metal, producing pores of more markedly comical shape and of greater average diameter. As the increased porosity provides a greater inner surface area, the adsorptive capacity is enhanced allowing dyeing of greater intensity to be produced. During the service life of the anodizing solution more and more free sulfuric acid is expended in dissolving, and as the concentration declines so does the absorptiveness of the coating. In order to ensure that successive dyeings are of equal intensity, it is most important to maintain the free sulfuric acid concentration within a narrow limit of 160 225 g/l. Aluminum content The dye adsorptive capacity decreases sharply below 5g/l AL, but then remains nearly constant at higher concentration. At over 15 g/l the solution does not work efficiently and there are likely to be irregularities in the anodic coating. So in order to achieve color uniformity, it is advisable to keep the content between 5 g/l to 15 g/l. Current density At high current density and constant coating thickness the dye adsorptive capacity is lower since the metal is exposed for a shorter time to the

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dissolving action of the sulfuric acid. In joint anodizing of alloys which differ in composition, fluctuations in current density may occur between one part and another which are reflected in color differences when the parts are dyed. For this reason, only one alloy should be anodized in a given batch : this is particularly important if the parts are to be dyed. Temperature A rise in temperature intensifies the dissolving action of the sulfuric acid resulting in softer, more porous coatings with higher capacity of dye adsorption. As the temperature has a very marked effect, close control is imperative. The tolerance limits are +/- 2C. In this connection it should be noted that if the heat convection is inadequate, local temperature variations occur which later will result in uneven dyeings. To safe guard against the occurrence of local overheating there should be provision for thorough agitation and cooling of the anodizing solution. Anodizing time and coating thickness The thickness of the anodic coating is almost exactly proportional to the product of the current density and the time. At constant current density (which is only approximately reached in plant production), the coating thickness and consequently the adsorptive capacity for dyes are linearly proportional to the anodizing time. It follows that fairly thick coatings are necessary if deep dyeings are to be produced. A thickness of 12 um anodic coating is usually enough for general application. However, when high color durability is demanded the coating should be allowed to grow more than 12 um in thickness. For building parts, a coating thickness of 25 um is necessary. COLORING The following dyeing parameters have a pronounced effect on the dyeings Dyeing temperature The rate of dyeing increases with increasing temperature. If the temperature is too high, buildup of the dye is halted before the full intensity is reached. Dyeings produced at high temperature do not bleed so freely in sealing solutions or rinsing waters and also are more difficult to strip. In some dyes, dyeing at room temperature is possible and easier to control the desired shade. In most other dyes, the adsorption is very slow causing the dyeing times over-long. In general, the temperature region of 50- 60C represents the optimum compromise between attainable depth and acceptable dyeing time. Dyeing time

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The normal dyeing time ranges between 3 to 15 minutes. Very short dye times of a few seconds may cause many of the dyes to bleed heavily in the sealing solution. Dyeing for longer than 30 minutes brings no advantages. If the required color intensity is not achieved after this time, the problems may be the anodic coating being too thin, the dye concentration being too low or the bath are contaminated by foreign impurities. pH value The optimum dyeing pH normally comes within the region of 5 to 6. Too high in pH retards the dye adsorption resulting in pale shade. Too low in pH may cause the aluminum to dissolve into the dye solution causing the dye solution to break down or forms precipitation. Dye concentration Generally, a dye concentration of 3 5 g/l is enough to achieve a deep shade of al colors other than black. 1 3 g/l maybe used for achieve a pale shade. For the black colors, 8 10 g/l must be used to achieve a jet-black tone. SEALING The hot sealing process The hot sealing closes the pores of the anodic coating and fixes the dyes deposited in the pores. This process is also referred to hydro-thermal sealing. The hot sealing process is affected by the time and temperature factors and by the composition and the pH of the sealing solution. The minimum sealing time is 2.5 minutes per um. The temperature should be as close to the boil as possible. The seal solution should be set at pH 5.5 to 6.0. The pH adjustment is obtained with dilute acetic acid or sodium hydroxide. The cold sealing process The cold sealing process is only suitable for closing the pores of natural color anodic coating. This type of process is referred to as impregnation sealing. The process depends upon the reaction of an anodic coating with nickel and fluoride ions at room temperature. The minimum sealing time is about 1.0 minutes per um. The temperature should be as close to 25C as possible. The seal solution should be set at about pH 6.0.The control of nickel to fluoride ratio is an important factor in respect of seal quality of the final product.

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