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1、SurTec International GmbH SurTec 650 Tri-Chrome Passivation of Aluminum SurTec International GmbH - July 2011 TCP of Alu_0711_TK 2SurTec International Best Available Technologies Resource Load Total Process Costs Process Control/ Maintenance ONE Process Market Specific Parameter SurTec 650 Tri-Chrom
2、e Passivation of Aluminum Content 1 2 3 4 5 TCP of Alu_0711_TK 3SurTec International SurTec 650 Tri-Chrome Passivation of Aluminum Best Available Technologies for Aluminum Pre-treatment Yellow Chrome ?Bath contains Cr(VI) ?Coating contains Cr(VI) ?Gold/ yellow color of coat ?Labelling as toxic ?Effl
3、uent: Cr-reduction ?Disposal as special waste SurTec 655 Green Chrome ?Bath contains Cr(VI) ?Coating free from Cr(VI) ?Green/ Clear color of coat ?Labelling as toxic ?Effluent: Cr-reduction ?Disposal as special waste SurTec 657 TCP Cr(III) ?Bath free from Cr(VI) ?Coating free from Cr(VI) ?No color o
4、f coat ?No labelling ?Effluent: Neutralisation ?Disposal as normal waste SurTec 650 Chrome-free ?Bath free from any Cr ?Coating free from any Cr ?No color of coat ?Labelling as irritating ?Effluent: Neutralisation ?Disposal as normal waste SurTec 641 TCP of Alu_0711_TK 4SurTec International Complete
5、ly 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 si
6、mple neutralisation Waste disposal as standard waste One product for numerous markets, management via process parameter SurTec 650 Tri-Chrome Passivation of Aluminum Best Available Technology for Aluminum Pre-treatment TCP of Alu_0711_TK 5SurTec International Switch from Chromating is possible witho
7、ut 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 Process sequence can be used for different final applications; parameter of the active baths might have to be adapted to final appl
8、ication SurTec 650 Tri-Chrome Passivation of Aluminum ONE Process Market Demand Driven Operation Parameter Alcaline Degrease/ Etch 1 Rinse (Cascade) 2 Acid Deox/ Etch/ Desmut 3 Rinse (Cascade) 4 Passivation SurTec 650 5 Rinse 6 DI-Rinse 7 Dry 8 400 S/ cm prior to passivation TCP of Alu_0711_TK 6SurT
9、ec International Specifications/ Demands Using only acid etch prior to passivation is also possible Min. etch rate 2 g/m 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 50 -120 mg/ dm Major contaminan
10、ts: Fe 50 ppm; Al 500 ppm Performance SurTec 650 Tri-chrome passivation of Aluminum Example 1: Architectural Industry - Market Specific Process Painted Corrosion Resistance in SS, AASS and FFC Substrates: Mainly 6000 series, e.g. 6060, 6063 Mainly paint Adhesion to Epoxy/ PE powder paints Spray, dip
11、, basket, vertical and shower application Compatibility to small amounts of Fe, H 400 mg/ dm To achieve SS resistance of 336 h it is neccessary to use a final seal FFC/ Filiform (1000 h): F 0,4 (l 2 mm; H 1/ 10 mm) Wet adhesion test (wet cross hatch): Gt 1 Bare metal corrosion resistance in NSS: 168
12、 h QPL listing TCP of Alu_0711_TK 9SurTec International Specifications/ DemandsPerformance SurTec 650 Tri-Chrome Passivation of Aluminum Example 3: Electronic/ 3C - Industry - Market Specific Process Bare metal corrosion resistance in NSS Substrates: Mainly 6000 , series e.g. 6060 Corrosion resistan
13、ce with PE- powder paints Surface resistance prior and after NSS (MIL-DTL-81706 B) EMI Shielding (ASTM D-4935) Spray or immersion application Surface resistance prior NSS 500 / inch Surface resistance after 168 h NSS 1000 / inch Painted SS resisatnce 3000 h 1 mm Bare metal corrosion resistance in NS
14、S up to 168 h Shielding Effectiveness: up to 100 dB at 100 Mhz Optimum passivation process parameter: pH = 3,75 4,0; conc. = 20 %, T = 30C, t = 2 min. Optimum coating weight : ca. 100 - 250 mg/ dm; depending on application of final paint Process sequence is a compromise between bare metal corrsosion
15、 resistance driven e. g. Cu-content 1%: NSS = 240 h Optimum passivation process parameter: pH = 3,75 4,0; conc. = 20 %, T = 35C, t = 3 min. Optimum coating weight cannot be measured due to high roughness of the casted surface Spray or immersion application TCP of Alu_0711_TK 11SurTec International S
16、urTec 650 Tri-Chrome Passivation of Aluminum Model for Chemical Reaction Aluminum TCP Coating SEM TCP of Alu_0711_TK 12SurTec International Bath AnalysisLayer Control Replenishment Photometric method to check Zr concentration Direct calculation of product concentration out of Zr-concentration High a
17、ccuracy in conc. range from 0.5 10% 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 Quantitatively: XRF handgun to measure Zr and Cr on
18、-line Correlation between XRF and RFA proven for SurTec 650 Correlation betwen XRF measurement and coating weight could also be proven 1stIndication: Too thick layer leads to irrisicdence on Al-substrates SurTec 650 Tri-Chrome Passivation of Aluminum Simple Operation Process Maintenance TCP of Alu_0
19、711_TK 13SurTec International WaterEnergyEffluentWaste 50% Reduction of ionic load compared to traditional chromates; more cascades possible Reduction in rinse water consumption Due to the broad operation window SurTec 650 operates w/o heating or cooling Reduction in energy consumption No Chrome(VI)
20、 reduction required, simple neutralisation sufficient Reduction in chemicals and technology for effluent treatment Lower amount and less hazardous sludge compared to traditional chromates Significant reduction in waste and related disposal costs Traditional Cr(VI) Process SurTec 650 Process Ecologic
21、al Footprint Resource Load SurTec 650 Tri-Chrome Passivation of Aluminum Minimum Resource Load TCP of Alu_0711_TK 14SurTec International SurTec 650 Tri-Chrome Passivation of Aluminum Minimized Total Process Cost Standardized Costs Cost savings vs. Cr-free pre-treatments Cost neutral vs. Cr(VI) pre-t
22、reatment TCP of Alu_0711_TK 15SurTec International Approved by major OEMs in Aerospace, Architectural and Electronics/ 3C-industry Used by top global automotive supplier Approved by leading associations SurTec 650 Tri-Chrome Passivation of Aluminum Most wanted by the Industry TCP of Alu_0711_TK 16Su
23、rTec International No labelling of the product Optimized total process costs ONE Product for various industries Very broad operation window Easy and exact process control SurTec 650 Tri-Chrome Passivation of Aluminum Summary SurTec International GmbH SurTec 650 Tri-Chome Passivation of Aluminum SurTec International GmbH - July 2011