ASTM B 117 Screening of Nonchromate 

Conversion Coatings on Aluminum Alloys 

2024, 2219, 5083, and 7075 Using DOD Paint Systems 

by Brian E. Placzankis, Chris E. Miller, 

and Craig A. Matzdorf 

ARL-TR-2907 April 2003 

Approved for public release; distribution is unlimited. 
NOTICES 

Disclaimers 

The findings in this report are not to be construed as an official Department of the Army position unless 

so designated by other authorized documents. 

Citation of manufacturer’s or trade names does not constitute an official endorsement or approval of the 

use thereof. 

Destroy this report when it is no longer needed. Do not return it to the originator. 
Army Research Laboratory 

Aberdeen Proving Ground, MD 21005-5069 

ARL-TR-2907 April 2003 

ASTM B 117 Screening of Nonchromate 

Conversion Coatings on Aluminum Alloys 

2024, 2219, 5083, and 7075 Using DOD Paint Systems 

Brian E. Placzankis and Chris E. Miller 

Weapons and Materials Research Directorate, ARL 

Craig A. Matzdorf 

U.S. Naval Air Systems Command 

Approved for public release; distribution is unlimited.
i

Acknowledgments 

The authors would like to thank the following people who contributed to this study: 

Russel Kilbane of the University of Maryland Baltimore Campus and Gerard Chaney of Harford 

Community College for assistance in preparing hundreds of test panels for exposure, and 

Geoff Hoerauf and Mike Starks (Red River Army Depot) of the Bradley Fighting Vehicle 

Systems Environmental Management Team for providing additional U.S. Army background 

information and a Phase II demonstration validation site. Additional thanks go to Tom Landy 

and Carl Handsy of the U.S. Army Tank-Automotive Research, Development, and Engineering 

Center for supplying initial U.S. Army ground vehicle materials input for this study. The authors 

also thank Steve Carr of the U.S. Army Aviation and Missile Command for providing continuous 

input to the study concerning pretreatment issues on U.S. Army missile systems. Finally, we 

thank the U.S. Naval Air Systems Command’s Michael Kane, Environmental Security 

Technology Certification Program, and the Joint Group on Pollution Prevention for sponsoring 

this study. 
ii

Contents 

Acknowledgments i

List of Figures iii

List of Tables iv

1. Introduction 1

2. Experimental Procedure 1

3. Results 3

3.1 Al 2024..........................................................................................................................11 

3.2 Al 2219 ..........................................................................................................................12 

3.3 Al 5083 ..........................................................................................................................12 

3.4 Al 7075..........................................................................................................................17 

4. Discussion 23

5. Conclusions 24

6. References 24

Appendix. Complete 3000-hr ASTM B 117 Neutral Salt Fog ASTM D 1654 Creepback 

Ratings 27

Report Documentation Page 32
iii

List of Figures 

Figure 1. ASTM B 117 test panel matrix breakdown.....................................................................2 

Figure 2. Test chamber and panels used for ASTM B 117.............................................................3 

Figure 3. Color code shading patterned for detailed descriptions. ...............................................11 

Figure 4. Al 2024 with 85582nc/85285 at 3000-hr ASTM B 117................................................13 

Figure 5. Al 2024 with 53030/53022 at 3000-hr ASTM B 117. ..................................................14 

Figure 6. Al 2219 with 85582nc/85285 at 3000-hr ASTM B 117................................................15 

Figure 7. Al 2219 with 53030/53039 at 3000-hr ASTM B 117. ..................................................16 

Figure 8. Al 5083 with 53030/53039 at 3000-hr ASTM B 117. ..................................................18 

Figure 9. Al 5083 with 53022/53039 at 3000-hr ASTM B 117. ..................................................19 

Figure 10. Severe delamination of Brent Oxsilan Al-0500 pretreated Al 7075 with 

85582c1/85285 at 1 week ASTM B 117 exposure. .................................................................20 

Figure 11. Severe delamination of Brent Oxsilan Al-0500 pretreated Al 7075 panels with 

85582c1/85285 at 2 weeks ASTM B 117 exposure.................................................................20 

Figure 12. Al 7075 with 85582nc/85285 at 3000-hr ASTM B 117..............................................21 

Figure 13. Al 7075 with 53022/53039 at 3000-hr ASTM B 117. ................................................22 
iv

List of Tables 

Table 1. Evaluation of painted of coated specimens subjected to corrosive environments–

ASTM D 1654...........................................................................................................................4 

Table 2. ASTM D 1654 scribe creepback ratings for Al 2024 coated with 23377/85285. ............4 

Table 3. ASTM D 1654 scribe creepback ratings for Al 2024 coated with 85582c1/85285..........5 

Table 4. ASTM D 1654 scribe creepback ratings for Al 2024 coated with 85582nc/85285..........5 

Table 5. ASTM D 1654 scribe creepback ratings for Al 2024 coated with 53030/53039. ............5 

Table 6. ASTM D 1654 scribe creepback ratings for Al 2024 coated with 53022/53039. ............6 

Table 7. ASTM D 1654 scribe creepback ratings for Al 2219 coated with 23377/85285. ............6 

Table 8. ASTM D 1654 scribe creepback ratings for Al 2219 coated with 85582c1/85285..........6 

Table 9. ASTM D 1654 scribe creepback ratings for Al 2219 coated with 85582nc/85285..........7 

Table 10. ASTM D 1654 scribe creepback ratings for Al 2219 coated with 53030/53039. ..........7 

Table 11. ASTM D 1654 scribe creepback ratings for Al 2219 coated with 53022/53039. ..........7 

Table 12. ASTM D 1654 scribe creepback ratings for Al 5083 coated with 23377/85285. ..........8 

Table 13. ASTM D 1654 scribe creepback ratings for Al 5083 coated with 85582c1/85285........8 

Table 14. ASTM D 1654 scribe creepback ratings for Al 5083 coated with 85582nc/85285........8 

Table 15. ASTM D 1654 scribe creepback ratings for Al 5083 coated with 53030/53039. ..........9 

Table 16. ASTM D 1654 scribe creepback ratings for Al 5083 coated with 3022/53039. ............9 

Table 17. ASTM D 1654 scribe creepback ratings for Al 7075 coated with 23377/85285. ..........9 

Table 18. ASTM D 1654 scribe creepback ratings for Al 7075 coated with 85582c1/85285......10 

Table 19. ASTM D 1654 scribe creepback ratings for Al 7075 coated with 85582nc/85285......10 

Table 20. ASTM D 1654 scribe creepback ratings for Al 7075 coated with 53030/53039. ........10 

Table 21. ASTM D 1654 scribe creepback ratings for Al 7075 coated with 53022/53039. ........11 

Table A-1. Al 2024–T3 panel designation, coating system, and ratings. .....................................28 

Table A-2. Al 2024–T3 panel designation, coating system, and ratings. .....................................28 

Table A-3. Al 2219–T87 panel designation, coating system, and ratings. ...................................29 

Table A-4. Al 2219–T87 panel designation, coating system, and ratings. ...................................29 

Table A-5. Al 5083–H131 panel designation, coating system, and ratings..................................30 

Table A-6. Al 5083–H131 panel designation, coating system, and ratings..................................30 

Table A-7. Al 7075–T6 panel designation, coating system, and ratings. .....................................31 

Table A-8. Al 7075–T6 panel designation, coating system, and ratings. .....................................31 
1

1. Introduction 

Eight candidate hexavalent chromium (Cr+6) free conversion coatings for evaluation on 

aluminum alloys were selected based upon feedback from U.S. Navy, U.S. Air Force (USAF), 

U.S. Army, and National Aeronautics and Space Administration (NASA) representatives at an 

initial meeting with personnel representing the Environmental Security Technology 

Certification Program (ESTCP) and the Joint Group on Pollution Prevention (JG-PP). Most 

funding for this study was provided by these organizations. The overall nonchromate study 

consists of two phases: phase I laboratory validation of alternatives through extensive coupon 

tests to evaluate paint adhesion, corrosion resistance and other criteria, and phase II field testing 

and process validation of selected alternatives at various user facilities. 

As in a previous study [1] of these Cr+6

 alternatives, the focus of this particular report is 

constrained to phase I laboratory data. This report specifically examines American Society for 

Testing and Materials (ASTM) B 117 [2] accelerated corrosion exposure of aluminum A1 

2024, 2219, 5083, and 7075 specimens treated with the candidate hexavalent chromium-free 

pretreatments as well as one hexavalent chromium-based pretreatment (Alodine 1200S) used as 

a control. In order to closely match conditions found in currently fielded equipment, five 

organic coating systems commonly used in fielded Department of Defense (DOD) systems 

were selected. 

2. Experimental Procedure 

Al panels (each nominally 7.62 H 12.7 cm) of alloys 2024-T3, 2219-T87, 5083-H131, and 

7075-T6 were obtained. Prior to pretreatment and testing, all coupons were clearly labeled 

using a mechanical scribe to permanently affix the experimental designation. Twenty-five 

panels with each pretreatment combination were prepared for each alloy for neutral salt fog 

exposure. Each set of 25 panels was further subdivided into 5 groups, one for each of the five 

selected DOD coatings. The five DOD coating systems applied were: 

• MIL-PRF-23377 [3] high solid epoxy primer with MIL-PRF-85285 [4] high solid 

polyurethane topcoat (USAF/U.S. Navy). 

• MIL-PRF-85582c1 [5] waterborne epoxy primer with MIL-PRF-85285 topcoat (U.S. 

Navy). 

• MIL-PRF-85582nc waterborne epoxy chromium-free formulation primer with 

MIL-PRF-85285 topcoat (Experimental/JG-PP/USAF/Navy/Boeing). 
2

• MIL-P-53030 [6] water-reducible epoxy primer with MIL-C-53039 [7] chemical agent 

resistant single component polyurethane topcoat (U.S. Army/U.S. Marine Corps 

[USMC]). 

• MIL-P-53022 [8] epoxy primer with MIL-C-53039 polyurethane topcoat (U.S. 

Army/USMC).

The first two coating systems, 23377/85285 and 85582c1/85285, each contained hexavalent 

chromium compounds in their primer formulations; therefore, elimination of Alodine 1200S 

pretreatment would only reduce the total hexavalent chromium present in these cases. The 

remaining three coating systems (85582nc/85285, 53030/53039, and 53022/53039) were 

chromium free. The two U.S. Army/USMC coating systems meet chemical agent resistant 

coating (CARC) specifications. 

Prior to painting, all of the panels were cleaned and pretreatments were applied per each of the 

pretreatment manufacturers specifications at the U.S. Naval Air Systems Command (NAVAIR) 

facilities. The coating system’s respective primer coats were applied within 24 hr after the 

pretreatment application to each group of five panels for each pretreatment for each alloy. The 

topcoats were applied after 24 hr primer cure. The full coating system was then cured at 

ambient conditions for 14 days. The panels were then delivered from NAVAIR to the U.S. 

Army Research Laboratory (ARL) test facilities. Figure 1 depicts a schematic detailing the 

ASTM B 117 neutral salt fog panel test matrix. 

Figure 1. ASTM B 117 test panel matrix breakdown. 

One large corrosion test chamber was used to evaluate all of the coated aluminum test panels 

(Figure 2). Immediately prior to exposure, the panels were all “X” scribed using a standard 

carbide-tipped hardened steel scribe. The scribed panels were placed into the chamber and 
3

Figure 2. Test chamber and panels used for ASTM B 117. 

exposed to ASTM B 117 neutral salt fog conditions consisting of 95 °F with saturated humidity 

and atomized fog of 5% NaCl solution. In order to chronicle the corrosion, specimens were 

numerically rated for damage at weekly intervals up to 3 weeks followed by subsequent 

inspections at 500-hr intervals up to 3000 hr or until specimen group failure using method 

ASTM D 1654 [9]. Specimen group failures were defined when three or more of the panels in 

a particular alloy/pretreatment/coating set were measured with a rating of “0” under method 

ASTM D 1654. In addition, the representative panels rated from each of the five test panels 

were digitally scanned at 600-dpi resolution and saved as high-quality graphics files. In order 

to facilitate easier viewing of the inevitable large quantities of data from this matrix, color 

codes were assigned based upon ranges of ASTM D 1654 ratings. Table 1 depicts the ASTM D 

1654 rating parameters and also defines the colors and their respective rating ranges. 

3. Results 

With the exception of the early failures previously defined under ASTM D 1654, the coated 

panels were all subjected to 3000 hr of ASTM B 117. The creepback ratings at the designated 

intervals for the representative panels are characterized in Tables 2–21. In addition, final 

3000-hr creepback ratings for all panels are listed and characterized in the Appendix. The 

prevalent failure mode for most of the panels was blistering along the scribe. In addition to the 

creepback severity color coding assigned in Table 1, additional corrosion characterization 
4

Table 1. Evaluation of painted of coated specimens subjected to corrosive environments–ASTM D 

1654. 

(mm) (in) 

Note: Solid colors depict normal scribe creepback from corrosion. 

Table 2. ASTM D 1654 scribe creepback ratings for Al 2024 coated with 23377/85285. 

Panel # Pretreatment 1 Week 2 Weeks3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

2-001 Alodine 1200S 10 9 9 9 9 9 9 9

2-101 TCP10 10 10 9 9 9 9 9 9

2-201 Alodine 5200 10 10 9 99999

2-302 Sanchem 7000 10 9 9 65332

2-401 X-IT PreKote 10 10 10 10 9 9 9 9

2-501 Oxsilan Al-0500 10 10 10 10 10 10 9 9

2-601 Chemidize 727ND 10 9 9 9 9 9 9 9

2-701 Bi-K Aklimate 10 10 10 10 9 9 9 9

2-801A Boegel 10 10 10 10 10 9 9 9

Note: Solid colors depict normal scribe creepback from corrosion. 

through application of textures to the color coded cells is provided in the tables. Figure 3 

details these additional characterizations and provides examples. In cases where blistering 

occurred away from the scribe, the table cells appear with diagonal crosshatching. In situations 

where coating creepback from the scribe resulted from adhesion loss, vertical crosshatching 

was used. In a few rare situations, mixed failure mode consisting of nonscribe blistering with 

adhesion loss at the scribe occurred. In these situations a finer textured crosshatching pattern 

was used. 
5

Table 3. ASTM D 1654 scribe creepback ratings for Al 2024 coated with 85582c1/85285. 

Panel # Pretreatment 1 Week 2 Weeks 3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

2-056 Alodine 1200S 9 9 9 9 9 9 9 9

2-106 TCP10 10 10 10 9 9 9 9 9

2-206 Alodine 5200 10 10 9 9 9 9 9 9

2-307 Sanchem 7000 10 9 9 7 7 7 7 7

2-407 X-IT PreKote 10 10 10 10 10 9 9 9

2-508 Oxsilan Al-0500 10 10 10 9 9 9 9 9

2-606 Chemidize 727ND 9 9 9 9 9 9 8 8

2-706 Bi-K Aklimate 9 9 9 9 9 9 8 8

2-806A Boegel 10 10 10 10 10 9 9 9

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure. 

Diagonal crosshatching denotes blistering away from immediate scribe regions. 

Table 4. ASTM D 1654 scribe creepback ratings for Al 2024 coated with 85582nc/85285. 

Panel # Pretreatment 1 Week 2 Weeks3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

2-011 Alodine 1200S 10 9 9 9 8 7 7 7

2-111 TCP10 9 9 9 6 5 5 5 4

2-211 Alodine 5200 9 9 9 6 5 5 5 5

2-311 Sanchem 7000 9 5 4 0 0

2-411 X-IT PreKote 10 9 9 5 3 0 0 5

2-511 Oxsilan Al-0500 9 9 9 8 7 7 7 7

2-611 Chemidize 727ND 9 9 8 5 4 3 3 3

2-711 Bi-K Aklimate 9 5 3 0 0 333

2-811A Boegel 9 9 9 7 6 6 5 5

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure. 

Diagonal crosshatching denotes blistering away from immediate scribe regions. 

Table 5. ASTM D 1654 scribe creepback ratings for Al 2024 coated with 53030/53039. 

Panel # Pretreatment 1 Week 2 Weeks3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

2-016 Alodine 1200S 9 9 9 8 8 8 8 7

2-116 TCP10 9 7 6 4 4 4 4 4

2-216 Alodine 5200 9 9 9 9 9 9 8 7

2-316 Sanchem 7000 7 3 2 0 3333

2-416 X-IT PreKote 9 7 4 2 0 0 0 5

2-519 Oxsilan Al-0500 4 3 2 0 4333

2-616 Chemidize 727ND 9 9 1 20000

2-716 Bi-K Aklimate 9 3 0 0 5555

2-817A Boegel 9 9 9 7 5 5 5 5

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure. 
6

Table 6. ASTM D 1654 scribe creepback ratings for Al 2024 coated with 53022/53039. 

Panel # Pretreatment 1 Week 2 Weeks3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

2-025 Alodine 1200S 9 6 5 5 4 4 4 3

2-121 TCP10 9 9 7 6 5 4 3 3

2-221 Alodine 5200 9 9 9 7 6 5 5 5

2-324 Sanchem 7000 2 2 0 00000

2-425 X-IT PreKote 9 2 1 0 4333

2-523 Oxsilan Al-0500 2 1 0 65444

2-622 Chemidize 727ND 4 4 3 2 0 000

2-721 Bi-K Aklimate 0

2-821A Boegel 9 9 9 9 7 7 7 5

Note: Solid colors depict normal scribe creepback from corrosion. 

Table 7. ASTM D 1654 scribe creepback ratings for Al 2219 coated with 23377/85285. 

Panel # Pretreatment 1 Week 2 Weeks3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

9-001 Alodine 1200S 10 10 10 9 9 9 9 9

9-101 TCP10 10 10 10 10 10 5 5 4

9-201 Alodine 5200 10 10 10 9 9 9 9 8

9-301 Sanchem 7000 7 5 4 3 3 3 3 2

9-401 X-IT PreKote 9 9 9 9 9 9 9 7

9-501 Oxsilan Al-0500 10 9 9 8 8 8 7 7

9-602 Chemidize 727ND 7 7 6 5 4 4 4 3

9-701 Bi-K Aklimate 9 9 9 9 9 9 7 6

9-801A Boegel 10 10 7 4 3 3 3 3

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure.

Table 8. ASTM D 1654 scribe creepback ratings for Al 2219 coated with 85582c1/85285. 

Panel # Pretreatment 1 Week 2 Weeks3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

9-006 Alodine 1200S 10 10 9 9 9 9 9 9

9-106 TCP10 9 9 9 9 9 9 8 8

9-206 Alodine 5200 10 10 10 10 10 10 9 9

9-306 Sanchem 7000 6 6 6 5 5 5 5 5

9-406 X-IT PreKote 9 9 9 9 9 9 9 9

9-506 Oxsilan Al-0500 10 10 9 8 8 8 8 8

9-606 Chemidize 727ND 9 9 7 7 7 7 7 7

9-706 Bi-K Aklimate 9 9 9 9 9 9 6 6

9-806A Boegel 7 7 7 7 7 6 6 6

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure. 

Fine textured crosshatching denotes adhesion failure AND blistering away from scribe. 

Diagonal crosshatching denotes blistering away from immediate scribe regions.
7

Table 9. ASTM D 1654 scribe creepback ratings for Al 2219 coated with 85582nc/85285. 

Panel # Pretreatment 1 Week 2 Weeks3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

9-011 Alodine 1200S 9 9 8 8 8 8 7 7

9-114 TCP10 7 7 7 7 6 5 5 5

9-213 Alodine 5200 8 8 8 8 7 7 6 6

9-314 Sanchem 7000 5 5 4 2 1 0

9-411 X-IT PreKote 8 6 5 4 2 0 5 5

9-511 Oxsilan Al-0500 9 9 9 7 7 7 5 5

9-611 Chemidize 727ND 7 7 7 5 5 4 4 4

9-713 Bi-K Aklimate 5 5 3 3 2 0 0 3

9-811A Boegel 7 7 7 5 5 5 4 4

Notes: Solid colors depict normal scribe creepback from corrosion. 

Diagonal crosshatching denotes blistering away from immediate scribe regions. 

Table 10. ASTM D 1654 scribe creepback ratings for Al 2219 coated with 53030/53039. 

Panel # Pretreatment 1 Week 2 Weeks3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

9-017 Alodine 1200S 9 8 8 7 6 6 5 5

9-116 TCP10 7 7 7 6 5 5 5 5

9-219 Alodine 5200 8 7 6 5 5 5 4 4

9-318 Sanchem 7000 4 3 2 0 3333

9-416 X-IT PreKote 7 5 5 3 0 555

9-520 Oxsilan Al-0500 5 4 3 0 0 333

9-617 Chemidize 727ND 4 2 0 0

9-716 Bi-K Aklimate 3 2 0 0 5555

9-816A Boegel 6 5 4 4 3 3 2 2

Note: Solid colors depict normal scribe creepback from corrosion. 

Table 11. ASTM D 1654 scribe creepback ratings for Al 2219 coated with 53022/53039. 

Panel # Pretreatment 1 Week 2 Weeks3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

9-021 Alodine 1200S 5 3 3 1 0 0 0 0

9-121 TCP10 7 6 6 6 6 6 5 5

9-221 Alodine 5200 7 6 6 5 4 3 3 3

9-323 Sanchem 7000 2 1 1 0 0000

9-421 X-IT PreKote 3 1 0 0

9-523 Oxsilan Al-0500 3 3 1 0

9-621 Chemidize 727ND 3 3 3 3 3 1 1 1

9-721 Bi-K Aklimate 1 0 0 0

9-821A Boegel 7 7 5 4 4 4 3 3

Notes: Solid colors depict normal scribe creepback from corrosion. 

Diagonal crosshatching denotes blistering away from immediate scribe regions.
8

Table 12. ASTM D 1654 scribe creepback ratings for Al 5083 coated with 23377/85285. 

Panel # Pretreatment 1 Week 2 Weeks 3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

5-001 Alodine 1200S 10 9 9 9 9 9 9 9

5-101 TCP10 10 10 10 10 10 9 9 9

5-201 Alodine 5200 10 9 9 9 9 9 9 9

5-301 Sanchem 7000 10 9 9 9 9 9 9 9

5-401 X-IT PreKote 9 9 9 9 9 9 9 9

5-501 Oxsilan Al-0500 10 10 10 10 10 9 9 9

5-601 Chemidize 727ND 10 9 9 9 9 9 9 9

5-701 Bi-K Aklimate 10 9 9 9 9 9 9 9

5-801A Boegel 10 10 10 10 10 10 10 9

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure. 

Table 13. ASTM D 1654 scribe creepback ratings for Al 5083 coated with 85582c1/85285. 

Panel # Pretreatment 1 Week 2 Weeks 3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

5-006 Alodine 1200S 10 9 9 98888

5-106 TCP10 10 10 10 10 9 9 9 9

5-206 Alodine 5200 10 9 9 9 9 9 9 9

5-306 Sanchem 7000 9 10 9 99999

5-406 X-IT PreKote 9 9 9 9 9 9 9 9

5-506 Oxsilan Al-0500 9 9 9 99977

5-606 Chemidize 727ND 9 9 9 99999

5-706 Bi-K Aklimate 10 10 9 9 9 9 9 9

5-806A Boegel 10 10 10 10 10 10 10 9

Notes: Solid colors depict normal scribe creepback from corrosion. 

Diagonal crosshatching denotes blistering away from immediate scribe region. 

Vertical crosshatching denotes adhesion failure. 

Table 14. ASTM D 1654 scribe creepback ratings for Al 5083 coated with 85582nc/85285. 

Panel # Pretreatment 1 Week 2 Weeks3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

5-011 Alodine 1200S 10 9 9 9 9 9 9 9

5-111 TCP10 9 9 9 9 9 9 9 9

5-211 Alodine 5200 10 9 9 9 9 9 9 9

5-311 Sanchem 7000 7 5 4 3 2 1 1 1

5-411 X-IT PreKote 7 5 4 2 0 0 0 0

5-511 Oxsilan Al-0500 9 9 9 9 9 9 7 7

5-611 Chemidize 727ND 7 6 5 3 1 0 2 2

5-711 Bi-K Aklimate 7 5 4 2 0 333

5-811A Boegel 10 9 9 9 9 9 9 9

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure.
9

Table 15. ASTM D 1654 scribe creepback ratings for Al 5083 coated with 53030/53039. 

Panel # Pretreatment 1 Week 2 Weeks 3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

5-016 Alodine 1200S 10 9 9 5 5555

5-116 TCP10 10 10 9 9 9 7 7 6

5-216 Alodine 5200 10 7 7 6 6 6 6 6

5-316 Sanchem 7000 7 7 3 2 2 2 2 2

5-416 X-IT PreKote 9 9 7 4 4 4 4 4

5-516 Oxsilan Al-0500 5 5 4 1 0 0 3 3

5-616 Chemidize 727ND 5 4 3 0 0 000

5-718 Bi-K Aklimate 4 4 2 0 0 0 0 0

5-816A Boegel 9 9 9 4 3320

Note: Solid colors depict normal scribe creepback from corrosion. 

Table 16. ASTM D 1654 scribe creepback ratings for Al 5083 coated with 3022/53039. 

Panel # Pretreatment 1 Week 2 Weeks 3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

5-021 Alodine 1200S 10 9 9 9 9 9 9 9

5-121 TCP10 10 10 10 10 10 9 9 9

5-221 Alodine 5200 10 9 9 9 9 9 9 9

5-321 Sanchem 7000 3 3 2 0 0000

5-421 X-IT PreKote 5 3 3 2 2 0 0 3

5-521 Oxsilan Al-0500 9 4 3 0 0 0 4 4

5-621 Chemidize 727ND 5 2 2 0 0 000

5-722 Bi-K Aklimate 331 0 9777

5-821A Boegel 9 7 7 5 4 2 2 2

Note: Solid colors depict normal scribe creepback from corrosion.

Table 17. ASTM D 1654 scribe creepback ratings for Al 7075 coated with 23377/85285. 

Panel # Pretreatment 1 Week 2 Weeks 3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

7-001 Alodine 1200S 10 10 10 9 9 9 9 9

7-101 TCP10 9 9 9 9 9 9 9 9

7-201 Alodine 5200 10 9 9 9 9 9 9 9

7-301 Sanchem 7000 10 10 9 9 9 9 9 9

7-402 X-IT PreKote 10 9 9 9 9 9 9 9

7-501 Oxsilan Al-0500 9 9 9 9 9 9 9 9

7-601 Chemidize 727ND 9 9 9 9 9 9 9 9

7-701 Bi-K Aklimate 9 9 9 9 9 9 9 9

7-801A Boegel 9 9 9 9 9 9 9 9

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure. 
10

Table 18. ASTM D 1654 scribe creepback ratings for Al 7075 coated with 85582c1/85285. 

Panel # Pretreatment 1 Week 2 Weeks 3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

7-006 Alodine 1200S 10 9 9 9 9 9 9 9

7-106 TCP10 9 9 9 9 9 9 9 9

7-206 Alodine 5200 9 9 9 9 9 9 9 9

7-306 Sanchem 7000 7 3 2 2 2 2 2 0

7-408 X-IT PreKote 9 9 9 9 9 9 9 9

7-506 Oxsilan Al-0500 0

7-606 Chemidize 727ND 99 5 5 5 5 5 5

7-706 Bi-K Aklimate 9 7 7 7 7 7 7 7

7-806A Boegel 10 9 9 9 9 9 9 9

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure. 

Fine textured crosshatching denotes adhesion failure AND blistering away from scribe.

Table 19. ASTM D 1654 scribe creepback ratings for Al 7075 coated with 85582nc/85285. 

Panel # Pretreatment 1 Week 2 Weeks 3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

7-011 Alodine 1200S 9 9 9 9 9 9 9 9

7-114 TCP10 10 9 9 9 9 9 9 8

7-211 Alodine 5200 10 9 9 9 9 9 9 9

7-311 Sanchem 7000 9 7 7 7 6 5 3 1

7-413 X-IT PreKote 7 6 5 3 3 2 1 0

7-511 Oxsilan Al-0500 9 9 9 9 9 9 9 8

7-611 Chemidize 727ND 5 5 2 0 2222

7-711 Bi-K Aklimate 8 7 4 0 0 333

7-811A Boegel 9 9 9 9 9 9 8 8

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure. 

Table 20. ASTM D 1654 scribe creepback ratings for Al 7075 coated with 53030/53039. 

Panel # Pretreatment 1 Week 2 Weeks 3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

7-016 Alodine 1200S 9 9 9 9 9 9 7 7

7-116 TCP10 8 8 8 8 8 8 7 7

7-219 Alodine 5200 7 7 7 7 7 7 7 7

7-317 Sanchem 7000 3 3 2 0 3333

7-417 X-IT PreKote 2 2 2 1 0 0 0 0

7-516 Oxsilan Al-0500 5 2 1 1 1 1 1 0

7-616 Chemidize 727ND 1 0 0 0 0000

7-720 Bi-K Aklimate 3 2 0 0 5555

7-816A Boegel 9 7 6 5 4 4 4 3

Note: Solid colors depict normal scribe creepback from corrosion. 
11

Table 21. ASTM D 1654 scribe creepback ratings for Al 7075 coated with 53022/53039. 

Panel # Pretreatment 1 Week 2 Weeks 3 Weeks 1000 hr 1500 hr 2000 hr 2500 hr 3000 hr

7-021 Alodine 1200S 9 9 9 99987

7-121 TCP10 9 8 8 8 8 8 8 8

7-222 Alodine 5200 8 8 8 88876

7-322 Sanchem 7000 8 7 7 7 7 7 6 6

7-423 X-IT PreKote 4 2 2 0 4333

7-521 Oxsilan Al-0500 3 3 3 33333

7-624 Chemidize 727ND 2 0 0 0 0000

7-724 Bi-K Aklimate 3 1 0 0 0 777

7-821A Boegel 9 7 6 64444

Note: Solid colors depict normal scribe creepback from corrosion.

Figure 3. Color code shading patterned for detailed descriptions. 

3.1 Al 2024 

For Al 2024, the top performing pretreatments were clearly visible. For this particular alloy, it was 

the Cr+6

 free coating systems that most aided in revealing the better performers. With the exception 

of the Sanchem process, all of the pretreatments for the hexavalent chromium bearing 23377/85285 

coating system performed well and completed 3000 hr with the highest ratings among the coating 

systems (Table 2). 

The 85582c1/85285 coating system also contains hexavalent chromium; overall it performed similar 

when compared vs. the 23377/85285 system for the same pretreatments. As with 23377/85285, 

Sanchem showed degradation, though not as severe. In addition to problems on Sanchem-treated 

panels, the Bi-K pretreatment had blistering away from the scribed areas past 2500 hr (Table 3). 
12

The remaining three Cr+6 free coating systems: 85582nc/85285, 53030/53039, and 53022/53039 

provided a much greater challenge for the pretreatments. At the conclusion of 3000 hr, all of the 

pretreatments including hexavalent Alodine 1200S showed significant corrosion damage. Many of 

the pretreatments were unable to sustain acceptable performance levels and were terminated prior to 

the end of 3000 hr. The most consistent performance among the three chromate-free coating systems 

was provided by the Boegel, Alodine 5200, NAVAIR TCP, and Alodine 1200S pretreatments 

(Tables 4–6, Figure 4). In the specific case of the 53022/53039 CARC system, Boegel and Alodine 

5200 pretreatments even exceeded the performance for Alodine 1200S (Figure 5). The Brent 

Oxsilan pretreatment rendered respectable performance at or near the leaders for the 85582nc/85285 

system but performed poorly on the U.S. Army’s 53030/53039 and 53022/53039 CARC-based 

coating systems. 

3.2 Al 2219 

Of all of the Al alloys examined in this study, Al 2219 with its high copper (Cu) content is by far the 

most corrosion prone and provides a difficult situation for even hexavalent-based Alodine 1200S. 

For the chromate-based 23377/85285 coating system (although all pretreatments lasted the full 3000-

hr duration) significant corrosion damage occurred on most of the pretreatments. 

The best performers for this coating system were Alodines 1200S and 5200, the Brent Oxsilan 

pretreatment, and Bi-K. It should be noted that NAVAIR TCP had mixed results; two panel 

replicates rated “4” and “5” with the remaining three panels all rated at “9.” For the chromate 

containing 85582c1/85285 system, the best performers were Alodines 1200S and 5200, NAVAIR 

TCP, X-IT PreKote, and Brent Oxsilan. The remaining pretreatments performed in the intermediate 

range with ratings ranging from 4 to 7. 

For the three chromate-free coating systems: 85582nc/85285, 53030/53039, and 53022/53039, there 

was significant corrosion damage with many of the pretreatments unable to endure 3000 hr without 

failure. The most consistent performers for these systems were NAVAIR TCP, and Alodines 1200S 

and 5200. The Brent Oxsilan and Boegel pretreatments produced somewhat modest ratings vs. the 

leaders for the 85582nc/85285 coating system but performed much more poorly on the CARC-based 

systems (Tables 7–11, Figures 6 and 7). 

3.3 Al 5083 

Al 5083, well known for its stable protective oxide layer, does not usually significantly corrode, even 

under uncoated accelerated conditions. Due to its widespread use in ground systems, accelerated 

corrosion methods such as ASTM B 117 are still necessary for this alloy to detect potential adhesion 

and quality control issues. In contrast to a previous cyclic accelerated corrosion exposure studies 

under General Motors (GM) 9540P [1, 10, 11], surprisingly significant amounts of creepback 

corrosion via blistering were measured on the chromate-free coating systems. As with other alloys, 

the 23377/85285 coating system proved superior, and there was no significant creepback resulting 

from corrosion or coating system delamination (Table 12). For 85582c1/85285, blistering away 
13

 (a) Alodine 1200S (b) TCP 

 (c) Alodine 5200 (d) Oxsilan AL-0500 

Figure 4. Al 2024 with 85582nc/85285 at 3000-hr ASTM B 117. 
14

 (a) Alodine 1200S (b) TCP 

 (c) Alodine 5200 (d) Boegel 

Figure 5. Al 2024 with 53030/53022 at 3000-hr ASTM B 117. 
 15

 (a) Alodine 1200S (b) TCP 

 (c) Alodine 5200 (d) Boegel 

Figure 6. Al 2219 with 85582nc/85285 at 3000-hr ASTM B 117.
 16

 (a) Alodine 1200S (b) TCP 

 (c) Alodine 5200 (d) Boegel 

Figure 7. Al 2219 with 53030/53039 at 3000-hr ASTM B 117.
 17

from the scribe appeared at 1000 hr for Sanchem 7000. The Chemidize and Bi-K pretreatments also 

showed blistering away from the scribe appearing at 1500 and 2000 hr, respectively. Corrosion was 

most severe for the Brent Oxsilan pretreatment which rated a “7” beginning at 2500 hr. Although 

Table 13 shows almost all pretreatments rating “8” or “9” at 3000 hr, the best performers were 

NAVAIR TCP, Alodines 1200S and 5200, and Boegel, which achieved these ratings free of any 

other defects such as coating delamination. 

For the nonchromate-based formulations, the extent of corrosion measured on some of the 

pretreatments was surprisingly high for Al 5083 (Tables 14–16, Figures 8 and 9). However, this 

unexpected corrosion was useful in differentiating the effectiveness of the various pretreatments. For 

the 85582nc/85285 and 53022/53039 systems, the superiority of Alodines 1200S and 5200 and 

NAVAIR TCP pretreatments was obvious. For the 53030/53039 system, the ratings were 

significantly lower; however, Alodines 1200S and 5200 and NAVAIR TCP still performed better 

than the other pretreatments. 

3.4 Al 7075

For the coating system 23377/85285 as in the other alloys, most all of the pretreatments 

performed well with little or no damage to the scribed region. All of the pretreatments rated “9” 

at the conclusion of 3000 hr (Table 17). One item of note was a slight lifting or delamination 

along the length of the entire scribe of the NAVAIR TCP. This delamination, first measured at 

week 1, was very slight and never progressed or ever degraded the rating below a “9.” 

For the 85582c1/85285 system, the top performers with little or no damage were Alodines 1200S 

and 5200, TCP, X-IT PreKote, and Boegel (Table 18). As with the 23377/85285 system, 

NAVAIR TCP displayed the same minor delamination issue. The other pretreatments for this 

system were disqualified either by lower ratings due to corrosion, delamination, or both. Brent 

Oxsilan Al-0500 pretreatment catastrophically failed prior to 2 weeks across the majority of its 

five panels. The massive delamination of this particular pretreatment was unique across the 

entire test matrix (Figures 10 and 11). 

For the chromate-free systems, the most consistent performers were Alodines 1200S and 5200, 

and NAVAIR TCP (Tables 20 and 21). Unlike the chromate-containing coating systems, 

NAVAIR TCP pretreatment showed none of the minor coating delamination issues (Figures 12 

and 13). Two notable but inconsistent performers were Oxsilan Al-0500 and Boegel, which 

performed extremely well on 85582nc/85285 yet performed poorly on the CARC systems.
 18

 (a) Alodine 1200S (b) TCP 

 (c) Alodine 5200 (d) X-IT PreKote

Figure 8. Al 5083 with 53030/53039 at 3000-hr ASTM B 117. 
 19

Figure 9. Al 5083 with 53022/53039 at 3000-hr ASTM B 117. 

(a) Alodine 1200S (b) TCP 

 (c) Alodine 5200 (d) Boegel 
 20

Figure 10. Severe delamination of Brent Oxsilan Al-0500 pretreated Al 7075 with 

85582c1/85285 at 1 week ASTM B 117 exposure. 

Figure 11. Severe delamination of Brent Oxsilan Al-0500 pretreated Al 7075 

panels with 85582c1/85285 at 2 weeks ASTM B 117 exposure. 
 21

 (a) Alodine 1200S (b) TCP 

 (c) Alodine 5200 (d) Oxsilan AL-0500 

Figure 12. Al 7075 with 85582nc/85285 at 3000-hr ASTM B 117. 
 22

 (a) Alodine 1200S (b) TCP 

 (c) Alodine 5200 (d) Boegel 

Figure 13. Al 7075 with 53022/53039 at 3000-hr ASTM B 117. 
23

4. Discussion 

The purpose of this study was to provide ASTM B 117 accelerated corrosion performance data 

for alternatives to Cr+6

 -based Alodine 1200S. It should be stressed that good performance in 

accelerated corrosion testing alone does not guarantee a good conversion coating. Other 

conditions such as corrosion performance under thermal and humidity cycling, coating system 

adhesion, visible color changes to the substrate surface (for quality control) upon pretreatment 

application, toxicity issues other than Cr+6

, as well as the logistics and costs of processapplication steps, all play significant roles in determination of a viable pretreatment alternative. 

In order to obtain the most information possible, this overall ESTCP/JG-PP effort included 

additional laboratory procedures such as GM 9540P, SO2 salt fog, and adhesion methods, all 

conducted on the same alloy/pretreatment/coating combinations investigated in this portion of 

the study. Variations in application procedures such as surface preparations, bath conditions for 

dip processes, and spray applications were also included. These additional results may be 

accessed in other ESTCP reports. Information on these documents is available via 

ESTCP/JG-PP contacts <http://www.estcp.org/>. Ultimately, data from this study as well as 

data from all of the other evaluations will be offered to help end users identify potential 

alternatives to chromate conversion coatings currently in use by original equipment 

manufacturers (OEMs) and depots. 

It is likely that more than one pretreatment may be a reasonable replacement for Alodine 1200S. 

As seen from data in this study as well as previous studies [1, 11], pretreatments that often work 

well on one aluminum alloy, may not always work well for another. However, this does not 

necessarily mean that a unique pretreatment is needed for every unique situation. For simplicity 

as well as economies of scale, the best possible benefit for replacing Alodine 1200S would be 

gained by minimizing the number of finalists to as few as possible. A pretreatment that has wellrounded performance across many aluminum alloys would be the most desirable. In this 

particular study, two pretreatments (Alodine 5200 and NAVAIR TCP) were the best all-around 

non-Cr+6

 performers in ASTM B 117 salt fog exposure. Although NAVAIR TCP pretreatment is 

Cr+3

 based, toxicity studies on trivalent chromium exposure indicate no carcinogenic or other 

hazards similar to those found in Cr+6

 pretreatments such as Alodine 1200S [12, 13]. 

Nevertheless, environmental regulatory bodies such as those found in California and the 

European Union have implemented or indicated future stricter guidelines concerning the use of 

chromium-containing pretreatments. 

A previous study [1] of cyclic corrosion resistance under GM 9540P indicated a slight 

performance advantage for TCP over Alodine 5200. However, if trivalent chromium-based 

pretreatments such as TCP are not acceptable or allowed for implementation due to their total 

chromium content, Alodine 5200 should perform quite satisfactorily. Additional laboratory and 
24

automotive proving ground [14] studies involving Alodine 5200 have also shown good 

performance on a variety of Al alloys using 53022/53039-based CARC systems [11, 15–17]. 

Many currently fielded weapon systems in use by the services continue to use hexavalent 

chromate-containing coating systems such as 23377/85285 and 85582c1/85285. This additional 

Cr+6

 enables many prospective Cr+6 free pretreatments to “coast” though with their actual overall 

contribution to the total system obscured. Thus, in order to truly determine the degree of 

enhanced corrosion resistance gained from a hexavalent chromium-free pretreatment, a 

hexavalent chromium-free organic coating system must also be used when performing 

corrosiontest procedures. Current and future acquisition systems such as the Advanced 

Amphibious Assault Vehicle and the Brigade Combat Team Stryker are already mandating Cr+6

free organic coating systems. This trend is likely to continue and potentially may even be 

applied to some fielded DOD vehicles and weapons systems during overhauls. In order to 

clearly delineate the best possible Cr+6

 free pretreatment(s), additional experimental results from 

a wide range of methods, in addition to field tests on actual systems from NAVAIR and other 

participating DOD activities will be critical. 

5. Conclusions 

• Pretreatment performance varies among varying alloys. 

• DOD coating systems formulated with Cr+6 additives provided significantly enhanced 

corrosion resistance versus coatings without Cr+6

. 

• Alodine 5200 and NAVAIR TCP Cr+3

 performed best overall in ASTM B 117 salt fog 

among non-Cr+6

 based pretreatments with performance at or near Cr+6 based Alodine 

1200S across all alloys and coating systems examined. 

• Commercially available Alodine 5200, in conjunction with the chromium-free organic 

coatings tested in this study, provides a completely chrome-free coating system with good 

corrosion resistance. 

6. References 

1. Placzankis, B., C. Miller, and C. Matzdorf. “Analysis of Nonchromate Conversion Coatings 

on Aluminum Alloys 2024, 5083, and 7075 With DOD Coatings Using GM 9540P Cyclic 

Accelerated Corrosion Exposure.” Proceedings from the Triservice Conference on 

Corrosion, San Antonio, TX, January 2002.
25

2. American Society for Testing and Materials. Standard Method of Salt Spray (Fog) Testing. 

ASTM B117-90, West Conshohocken, PA, 1990. 

3. U.S. Department of Defense. Primer Coatings, Epoxy, High Solid. MIL-PRF-23377G, 

Washington, DC, September 1994. 

4. U.S. Department of Defense. Coating, Polyurethane, High Solids. MIL-PRF-85285, 

Washington, DC, April 1997. 

5. U.S. Department of Defense. Primer Coatings, Epoxy, Waterborne. MIL-PRF-85582, 

Washington, DC, September 1997. 

6. U.S. Department of Defense. Primer, Epoxy Coating, Water Reducible, Lead and Chromate 

Free. MIL-P-53030A, Revision A, Amendment 2, Washington, DC, 1992. 

7. U.S. Department of Defense. Coating, Aliphatic Polyurethane, Single Component, Chemical 

Agent Resistant. MIL-C-53039A, Washington, DC, May 1993. 

8. U.S. Department of Defense. Primer, Epoxy Coating, Corrosion Inhibiting, Lead and 

Chromate Free. MIL-P-53022-10, Washington, DC, February 1992. 

9. American Society for Testing and Materials. Standard Method for Evaluation of Painted or 

Coated Specimens Subjected to Corrosive Environments. ASTM D 1654-79A, 

West Conshohocken, PA, 1984 

10. General Motors Engineering Standards. Accelerated Corrosion Test; GM 9540P. 

GM 9540P, Detroit, MI, 1997. 

11. Placzankis, B., C. Miller, and B. Mullis. “Examination of Nonchromate Conversion 

Coatings for Aluminum Armor From Three Final Candidates Using Accelerated Corrosion 

and Adhesion Test Methods.” ARL-TR-2601, U.S. Army Research Laboratory, Aberdeen 

Proving Ground, MD, September 2001. 

12. M.B. Research Laboratories. “Appendix-Toxicology Report.” MB Project #98-7031, 

Spinnerstown, PA, December 1998. 

13. Gibb, H., P. Lees, P. Pinsky, and B. Rooney. “Lung Cancer Among Workers in Chromium 

Chemical Production.” American Journal of Industrial Medicine, vol. 38, no. 2, 

pp. 115–126, published online: 7 July 2000. 

14. King, S. “U.S. Army Aberdeen Test Center Accelerated Corrosion Test Facility.” U.S. 

Army Research, Development, and Acquisition, pp. 41–43, Aberdeen Proving Ground, MD, 

January/February 1999.
26

15. Placzankis, B., C. Miller, and B. Mullis. “Examination of Nonchromate Conversion 

Coatings for Aluminum Armor From Three Final Candidates Using Accelerated Corrosion 

and Adhesion Test Methods.” ARL-TR-2601, U.S. Army Research Laboratory, Aberdeen 

Proving Ground, MD, September 2001. 

16. Placzankis, B., C. Miller, and J. Beatty. “Accelerated Corrosion Analysis of Nonchromate 

Conversion Coatings on Aluminum Alloys 5083, 7039, and 6061 for DOD Applications.” 

Proceedings from the Triservice Conference on Corrosion, Myrtle Beach, SC, November 

1999. 

17. Placzankis, B., C. Miller, and J. Beatty. “Accelerated Corrosion Analysis of Aluminum 

Armor Alloy 2519 With Nonchromate Conversion Coatings for DOD Applications.” 

Proceedings from the U.S. Navy and Industry Corrosion Technology Information Exchange, 

Louisville, KY, July 1999. 
27

Appendix. Complete 3000-hr ASTM B 117 Neutral Salt Fog ASTM D 1654 

Creepback Ratings 
28

Table A-1. Al 2024–T3 panel designation, coating system, and ratings. 

Pretreatment 23377/85285 85582c1/85285 85582nc/8

Alodine 1200S 2-01 2-02 2-03 2-04 2-05 2-06 2-07 2-08 2-09 2-10 2-11 2-12 2-13 

Rating 9 6 9 9 7 9 9 9 9 10 7 6 6 

TCP10 (NAVAIR) 2-101 2-102 2-103 2-104 2-105 2-106 2-107 2-108 2-109 2-110 2-111 2-112 2-113 

Rating 9 9 8 9 9 9 9 8 9 9 4 4 4 

Alodine 5200 2-201 2-202 2-203 2-204 2-205 2-206 2-207 2-208 2-209 2-210 2-211 2-212 2-213 

Rating 9 9 9 9 9 9 9 9 9 9 5 7 7 

Sanchem 7000 2-301 2-302 2-303 2-304 2-305 2-306 2-307 2-308 2-309 2-310 2-311 2-312 2-313 

Rating 1 2 3 9 1 8 7 8L 8L 6

X-IT PreKote 2-401 2-402 2-403 2-404 2-405 2-406 2-407 2-408 2-409 2-410 2-411 2-412 2-413 

Rating 9 9 8 8 9 9 9 9 9 8

Oxsilan Al-0500 2-501 2-502 2-503 2-504 2-505 2-506 2-507 2-508 2-509 2-510 2-511 2-512 2-513 

Rating 9 9 10 10 9 9 10 9 9 9 7 5 7 

Chemidize 727ND 2-601 2-602 2-603 2-604 2-605 2-606 2-607 2-608 2-609 2-610 2-611 2-612 2-613 

Rating 9 6 9 8 6 8 9 9 7 9 3 3 1 

BI-K Aklimate 2-701 2-702 2-703 2-704 2-705 2-706 2-707 2-708 2-709 2-710 2-711 2-712 2-713 

Rating 9 9 8 7 6 8 8 8 8 8

Boegel 2-801A 2-802A 2-803A 2-804A 2-805A 2-806A 2-807A 2-808A 2-809A 2-810A 2-811A 2-812A 2-813

Rating 9 9 9 9 9 9 9 9 9 9 5 7 7 

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure. Diagonal blistering away from immediate scribe regions. 

Table A-2. Al 2024–T3 panel designation, coating system, and ratings. 

Pretreatment 53030/53039 53022/53039

Alodine 1200S 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 2-24 2-25

Rating 7 7 8 8 7 4 4 3 5 3

TCP10 (NAVAIR) 2-116 2-117 2-118 2-119 2-120 2-121 2-122 2-123 2-124 2-125

Rating 4 5 5 5 5 3 4 5 5 4

Alodine 5200 2-216 2-217 2-218 2-219 2-220 2-221 2-222 2-223 2-224 2-225

Rating 7 8 8 8 8 5 7 6 7 7

Sanchem 7000 2-316 2-317 2-318 2-319 2-320 2-321 2-322 2-323 2-324 2-325

Rating

X-IT PreKote 2-416 2-417 2-418 2-419 2-420 2-421 2-422 2-423 2-424 2-425

Rating

Oxsilan Al-0500 2-516 2-517 2-518 2-519 2-520 2-521 2-522 2-523 2-524 2-525

Rating

Chemidize 727ND 2-616 2-617 2-618 2-619 2-620 2-621 2-622 2-623 2-624 2-625

Rating

BI-K Aklimate 2-716 2-717 2-718 2-719 2-720 2-721 2-722 2-723 2-724 2-725

Rating

Boegel 2-816A 2-817A 2-818A 2-819A 2-820A 2-821A 2-822A 2-823A 2-824A 2-825A

Rating 4 5 4 4 5 5 7 8 7 6

Notes: Solid colors depict normal scribe creepback from corrosion. 
29

Table A-3. Al 2219–T87 panel designation, coating system, and ratings. 

Pretreatment 23377/85285 85582c1/85285 85582nc/85285

Alodine 1200S 9-01 9-02 9-03 9-04 9-05 9-06 9-07 9-08 9-09 9-10 9-11 9-12 9-13 9-14 9

Rating 9 10 9 9 9 9 9 9 9 9 7 4 7 5 

TCP10 (NAVAIR) 9-101 9-102 9-103 9-104 9-105 9-106 9-107 9-108 9-109 9-110 9-111 9-112 9-113 9-114 9-

Rating 4 9 9 9 5 8 8 8 9 9 4 4 4 5 

Alodine 5200 9-201 9-202 9-203 9-204 9-205 9-206 9-207 9-208 9-209 9-210 9-211 9-212 9-213 9-214 9-

Rating 8 9 9 9 9 9 9 9 9 9 6 6 6 6 

Sanchem 7000 9-301 9-302 9-303 9-304 9-305 9-306 9-307 9-308 9-309 9-310 9-311 9-312 9-313 9-314 9-

Rating 2 4 4 3 3 5 7 6 7 6

X-IT PreKote 9-401 9-402 9-403 9-404 9-405 9-406 9-407 9-408 9-409 9-410 9-411 9-412 9-413 9-414 9-

Rating 7 7 7 8 7 9 9 9 9 9

Oxsilan Al-0500 9-501 9-502 9-503 9-504 9-505 9-506 9-507 9-508 9-509 9-510 9-511 9-512 9-513 9-514 9-

Rating 7 9 9 9 9 8 8 9 9 9 5 7 5 5 

Chemidize 727ND 9-601 9-602 9-603 9-604 9-605 9-606 9-607 9-608 9-609 9-610 9-611 9-612 9-613 9-614 9-

Rating 4 3 4 6 7 7 3 2 3 3 4 1 1 1 

BI-K Aklimate 9-701 9-702 9-703 9-704 9-705 9-706 9-707 9-708 9-709 9-710 9-711 9-712 9-713 9-714 9-

Rating 6 9 9 9 9 6 7 7 7 6

Boegel 9-801A 9-802A 9-803A 9-804A 9-805A 9-806A 9-807A 9-808A 9-809A 9-810A 9-811A 9-812A 9-813A 9-814A 9-8

Rating 3 5 4 4 5 6 6 5 5 6 4 4 4 4 

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure. Diagonal blistering away from immediate scribe regions. Fine textured crosshatching denotes adhesion failure AND blistering away from scribe. 

Table A-4. Al 2219–T87 panel designation, coating system, and ratings. 

Pretreatment 53030/53039 53022/53039

Alodine 1200S 9-16 9-17 9-18 9-19 9-20 9-21 9-22 9-23 9-24 9-25

Rating 6 5 7 7 5 0 2 3 0 0

TCP10 (NAVAIR) 9-116 9-117 9-118 9-119 9-120 9-121 9-122 9-123 9-124 9-125

Rating 5 5 4 5 6 5 5 5 3 5

Alodine 5200 9-216 9-217 9-218 9-219 9-220 9-221 9-222 9-223 9-224 9-225

Rating 5 4 5 4 5 3 3 4 2 4

Sanchem 7000 9-316 9-317 9-318 9-319 9-320 9-321 9-322 9-323 9-324 9-325

Rating

X-IT PreKote 9-416 9-417 9-418 9-419 9-420 9-421 9-422 9-423 9-424 9-425

Rating

Oxsilan Al-0500 9-516 9-517 9-518 9-519 9-520 9-521 9-522 9-523 9-524 9-525

Rating

Chemidize 727ND 9-616 9-617 9-618 9-619 9-620 9-621 9-622 9-623 9-624 9-625

Rating 1 2 3 3 3

BI-K Aklimate 9-716 9-717 9-718 9-719 9-720 9-721 9-722 9-723 9-724 9-725

Rating

Boegel 9-816A 9-817A 9-818A 9-819A 9-820A 9-821A 9-822A 9-823A 9-824A 9-825A

Rating 2 2 1 1 1 3 0 0 0 0

Notes: Solid colors depict normal scribe creepback from corrosion. 

Diagonal crosshatching denotes blistering away from immediate scribe regions. 
30

Table A-5. Al 5083–H131 panel designation, coating system, and ratings. 

Pretreatment 23377/85285 85582c1/85285 85582nc/85285

Alodine 1200S 5-01 5-02 5-03 5-04 5-05 5-06 5-07 5-08 5-09 5-10 5-11 5-12 5-13 5-14 5

Rating 9 9 9 10 10 8 9 9 9 9 9 9 9 9 

TCP10 (NAVAIR) 5-101 5-102 5-103 5-104 5-105 5-106 5-107 5-108 5-109 5-110 5-111 5-112 5-113 5-114 5-

Rating 9 8 9 8 8 9 10 8 9 9 9 9 9 9 

Alodine 5200 5-201 5-202 5-203 5-204 5-205 5-206 5-207 5-208 5-209 5-210 5-211 5-212 5-213 5-214 5-

Rating 9 10 9 9 9 9 9 9 9 9 9 9 8 9 

Sanchem 7000 5-301 5-302 5-303 5-304 5-305 5-306 5-307 5-308 5-309 5-310 5-311 5-312 5-313 5-314 5-

Rating 9 9 9L 9 9 9 9 9 9 9 0 1 0 1 

X-IT PreKote 5-401 5-402 5-403 5-404 5-405 5-406 5-407 5-408 5-409 5-410 5-411 5-412 5-413 5-414 5-

Rating 9 4 8 5 4 8 8 9 9 6 1 0 0 4 

Oxsilan AL-0500 5-501 5-502 5-503 5-504 5-505 5-506 5-507 5-508 5-509 5-510 5-511 5-512 5-513 5-514 5-

Rating 9 9 9 9 9 7 9 9 9 9 7 8 9 9 

Chemidize 727ND 5-601 5-602 5-603 5-604 5-605 5-606 5-607 5-608 5-609 5-610 5-611 5-612 5-613 5-614 5-

Rating 9 9 9 9 9 9 8 6 9 9

BI-K Aklimate 5-701 5-702 5-703 5-704 5-705 5-706 5-707 5-708 5-709 5-710 5-711 5-712 5-713 5-714 5-

Rating 9 9 9 9 9 9 9 9 9 9

Boegel 5-801A 5-802A 5-803A 5-804A 5-805A 5-806A 5-807A 5-808A 5-809A 5-810A 5-811A 5-812A 5-813A 5-814A 5-8

Rating 9 10 9 9 9 9 10 9 10 10 9 8 7 9 

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure. Diagonal crosshatching denotes blistering away from immediate scribe regions. 

Table A-6. Al 5083–H131 panel designation, coating system, and ratings. 

Pretreatment 53030/53039 53022/53039

Alodine 1200S 5-16 5-17 5-18 5-19 5-20 5-21 5-22 5-23 5-24 5-25

Rating 5 5 8 5 6 9 2 2 2 3

TCP10 (NAVAIR) 5-116 5-117 5-118 5-119 5-120 5-121 5-122 5-123 5-124 5-125

Rating 6 8 9 6 8 9 7 6 6 6

Alodine 5200 5-216 5-217 5-218 5-219 5-220 5-221 5-222 5-223 5-224 5-225

Rating 6 9 9 7 8 9 8 4 2 4

Sanchem 7000 5-316 5-317 5-318 5-319 5-320 5-321 5-322 5-323 5-324 5-325

Rating 4 4 5 4 4

X-IT PreKote 5-416 5-417 5-418 5-419 5-420 5-421 5-422 5-423 5-424 5-425

Rating 2 2 4 2 2

Oxsilan Al-0500 5-516 5-517 5-518 5-519 5-520 5-521 5-522 5-523 5-524 5-525

Rating

Chemidize 727ND 5-616 5-617 5-618 5-619 5-620 5-621 5-622 5-623 5-624 5-625

Rating

BI-K Aklimate 5-716 5-717 5-718 5-719 5-720 5-721 5-722 5-723 5-724 5-725

Rating 4 3 0 1 2

Boegel 5-816A 5-817A 5-818A 5-819A 5-820A 5-821A 5-822A 5-823A 5-824A 5-825A

Rating 0 9 9 9 5 2 1 2 2 9

Notes: Solid colors depict normal scribe creepback from corrosion. 
31

Table A-7. Al 7075–T6 panel designation, coating system, and ratings. 

Pretreatment 23377/85285 85582c1/85285 85582nc/85

Alodine 1200S 7-01 7-02 7-03 7-04 7-05 7-06 7-07 7-08 7-09 7-10 7-11 7-12 7-13 

Rating 9 9 9 9 9 9 9 9 9 9 9 9 9 

TCP10 (NAVAIR) 7-101 7-102 7-103 7-104 7-105 7-106 7-107 7-108 7-109 7-110 7-111 7-112 7-113 

Rating 9 8 8 8 9 9 9 9 9 9 8 9 6 

Alodine 5200 7-201 7-202 7-203 7-204 7-205 7-206 7-207 7-208 7-209 7-210 7-211 7-212 7-213 

Rating 9 9 9 9 9 9 9 9 9 9 9 9 9 

Sanchem 7000 7-301 7-302 7-303 7-304 7-305 7-306 7-307 7-308 7-309 7-310 7-311 7-312 7-313 

Rating 9 9 9 9 9 0 4 1 2 0 1 0 6 

X-IT PreKote 7-401 7-402 7-403 7-404 7-405 7-406 7-407 7-408 7-409 7-410 7-411 7-412 7-413 

Rating 9 9 8 9 9 9 9 9 7 9 4 2 0 

Oxsilan Al-0500 7-501 7-502 7-503 7-504 7-505 7-506 7-507 7-508 7-509 7-510 7-511 7-512 7-513 

Rating 9 9 9 9 9 8 9 9 

Chemidize 727ND 7-601 7-602 7-603 7-604 7-605 7-606 7-607 7-608 7-609 7-610 7-611 7-612 7-613 

Rating 9 9 9 8 9 5 4 0 0 1

BI-K Aklimate 7-701 7-702 7-703 7-704 7-705 7-706 7-707 7-708 7-709 7-710 7-711 7-712 7-713 

Rating 9 9 9 9 9 7 4 5 8 5

Boegel 7-801A 7-802A 7-803A 7-804A 7-805A 7-806A 7-807A 7-808A 7-809A 7-810A 7-811A 7-812A 7-813A 

Rating 9 9 9 9 9 9 9 9 9 9 8 7 9 

Notes: Solid colors depict normal scribe creepback from corrosion. 

Vertical crosshatching denotes adhesion failure. Fine textured crosshatching denotes adhesion failure AND blistering away from scribe. 

Table A-8. Al 7075–T6 panel designation, coating system, and ratings. 

Pretreatment 53030/53039 53022/53039

Alodine 1200S 7-16 7-17 7-18 7-19 7-20 7-21 7-22 7-23 7-24 7-25

Rating 7 8 8 9 7 7 5 9 6 6

TCP10 (NAVAIR) 7-116 7-117 7-118 7-119 7-120 7-121 7-122 7-123 7-124 7-125

Rating 7 7 5 7 6 8 8 9 9 9

Alodine 5200 7-216 7-217 7-218 7-219 7-220 7-221 7-222 7-223 7-224 7-225

Rating 6 5 7 7 5 8 6 6 5 7

Sanchem 7000 7-316 7-317 7-318 7-319 7-320 7-321 7-322 7-323 7-324 7-325

Rating 0 6 6 5 4

X-IT PreKote 7-416 7-417 7-418 7-419 7-420 7-421 7-422 7-423 7-424 7-425

Rating 3 0 2 0 1

Oxsilan Al-0500 7-516 7-517 7-518 7-519 7-520 7-521 7-522 7-523 7-524 7-525

Rating 0 2 No Panel 2032272

Chemidize 727ND 7-616 7-617 7-618 7-619 7-620 7-621 7-622 7-623 7-624 7-625

Rating

BI-K Aklimate 7-716 7-717 7-718 7-719 7-720 7-721 7-722 7-723 7-724 7-725

Rating

Boegel 7-816A 7-817A 7-818A 7-819A 7-820A 7-821A 7-822A 7-823A 7-824A 7-825A

Rating 3 3 3 2 3 4 4 5 5 5

Notes: Solid colors depict normal scribe creepback from corrosion.
32

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PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS.

1. REPORT DATE (DD-MM-YYYY)

April 2003 

2. REPORT TYPE 

Final 

3. DATES COVERED (From - To) 

FY01–FY02 

5a. CONTRACT NUMBER 

5b. GRANT NUMBER 

4. TITLE AND SUBTITLE 

ASTM B 117 Screening of Nonchromate Conversion Coatings on Aluminum 

Alloys 2024, 2219, 5083, and 7075 Using DOD Paint Systems 

5c. PROGRAM ELEMENT NUMBER 

5d. PROJECT NUMBER 

285B31 

5e. TASK NUMBER 

6. AUTHOR(S) 

Brian E. Placzankis, Chris E. Miller, and Craig A. Matzdorf * 

5f. WORK UNIT NUMBER 

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) 

U.S. Army Research Laboratory 

ATTN: AMSRL-WM-MC 

Aberdeen Proving Ground, MD 21005-5069 

8. PERFORMING ORGANIZATION 

 REPORT NUMBER 

ARL-TR-2907 

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) 10. SPONSOR/MONITOR'S ACRONYM(S) 

U.S. Naval Air Systems Command 

Code 4.3.4.1 

Bldg 2188 Unit S 

48066 Shaw Rd. 

Patuxent River, MD 20670-1908 

11. SPONSOR/MONITOR'S REPORT 

 NUMBER(S) 

12. DISTRIBUTION/AVAILABILITY STATEMENT 

Approved for public release; distribution is unlimited. 

13. SUPPLEMENTARY NOTES 

* U.S. Naval Air Systems Command, Code 4.3.4.1, Bldg 2188, Unit 5, 48066 Shaw Rd., Patuxent River, MD 20670-

1908. 

14. ABSTRACT 

This study examines corrosion resistance of eight nonchromate conversion coatings vs. hexavalent chromium based Alodine 

1200S controls on scribed coated test panels of aluminum alloys 2024, 2219, 5083, and 7075. Five representative Department 

of Defense primer/topcoat organic coating systems were evaluated for each of the conversion coating/alloy combinations. 

Scribed panels were exposed using ASTM B 117 (neutral salt fog) for 3000 hr and were photographed and measured at 1, 2, and 

3 weeks. Subsequent measurements were taken every 500 hr until “3000 hr” was reached or until failures from scribe creepback 

and/or via blistering occurred using method ASTM D 1654. Differences in pretreatment performance based upon variation in 

coating type as well as alloy were noted. Relationships between data from this study and data collected from previous cyclic 

acceleration corrosion exposure and how they may relate with respect to implementation of nonchromate pretreatments for 

various military applications are discussed. 

15. SUBJECT TERMS

corrosion, saltfog, ASTM B 117, GM 9540P, cyclic accelerated corrosion, aluminum, hexavalent chromium, 

nonchromate, chromate, conversion coating 

16. SECURITY CLASSIFICATION OF: 

19a. NAME OF RESPONSIBLE PERSON

Brian E. Placzankis 

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UNCLASSIFIED 

b. ABSTRACT 

UNCLASSIFIED

c. THIS PAGE 

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UL 

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40 

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(410) 306-0841 

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