DESCRIPTION OF THE TECHNOLOGY efficiency; replaces the conventional Cr +6plating process;
With support from the Environmental Protection Agency’s (EPA) Small Business Innovation Research (SBIR) Program, Faraday Technology, Inc., has developed a cost- competitive functional trivalent chromium (Cr +3 ) plating process to replace hexavalent chromium (Cr +6 ). The pilot-scale technology is validating Faraday’s electrically mediated Cr +3 plating process (the FaradaicTM Process) as a “drop-in” replacement for the use of Cr +6 plating. This manufacturing process validation is being executed withMoyno Industrial Products, a large manufacturer of industrial pumps, and the Naval Air Depot (NADEP) at Cherry Point, NC.
The process uses modulated reverse-current electrolysis in conjunction with a Cr +3 plating chemistry and results in a performance-based, functional Cr +3 plating process to replace conventional Cr +6 chromium plating. The process incorporates Faraday’s E-CHANGETM In-Process RecyclingSystem (also developed under EPA SBIR Program funding) for effluent waste management. A controlled Alpha test of the FaradaicTM Process was completed in a pilot-scale manufacturing cell designed and built by Faraday. This testwas conducted using strut rods provided by a Tier 1 automotive supplier.
Faraday’s functional Cr +3 plating process demonstrates equivalent or superior plating rate, hardness, and current and results in a more environmentally friendly and workersafe plating pr ocess. The FaradaicTM Process demonstrates a thickness of 10 mils (250 m) and a plating rate of 1.44- 2.25 μm/min; whereas, conventional Cr +6 plating processes demonstrate a thickness of 6-10 mils (150-250 m) and a plating rate of 0.76-1.27 μm/min.

SIGNIFICANCE OF THE TECHNOLOGY

EPA has identified Cr +6as 1 of 17 “high-priority” toxic chemicals. These chemicals were selected based on theirknown health and environmental effects, production volume, and potential for exposure. Hexavalent plating baths operate at elevated temperatures and produce a mist of chromic acid. The Clean Air Act, as well as local constraints, regulate the emission of chromium to the air and water. Because Cr +6 plating produces hazardous air emissions, all of the Cr +6 platers must control and monitor the bath surface tension and report the results to EPA. In contrast, Cr +3 platers are not required to monitor bath surface tension. Use of Cr +3 in industrial and commercial processes is preferred over Cr +6 on the basis of the comparison of the toxicities. EPA has classified Cr +6 as a group A, known human carcinogen, and considers Cr +3 as being much less toxic and an essential element in the human diet. Cr +3 is classified by EPA as a Group D carcinogen, not classifiable as to carcinogenicity in humans.

Ø Faraday Technology, Inc., developed a cost-competitive Cr +3 plating process to replace Cr +6 plating.

Ø The process uses a modulated reverse-current electrolysis in conjunction with a reduced-cost Cr +3 plating chemistry.

Ø Faraday’s functional Cr +3 plating process demonstrates equivalent or superior plating rate, hardness, and current efficiency.

Ø To date, $219,723 in commercial revenue has been secured to support Faraday’s pilot-scale activity.

### A pilot-scale plating Cr +3 

### line (left) is being operated at the Faraday facility in Clayton, OH. This plating line is a small-scale version of a shop-floor full-scale line. This line is being used to validate the FaradaicTM Process on shock rods and pump rotors (right).

The FaradaicTM Process is being widely implemented for:

Ø F aradaicTM Industrial Coatings, such as functional chromium from a trivalent chromium bath.

Ø F aradaicTM Edge and Surface finishing of advanced engineering alloys, such as stainless steel, aluminum, nickel, titanium, and the like without toxic, exotic electrolytes.

Ø FaradaicTM Leveling—metalization without levelerbrightener additives for advanced electronics applications.

Ø FaradaicTM Environmental Countermeasures—electrically mediated systems for in-process recycling of rinse waters and plating bath chemistry.

The functional Cr +3 plating process supports the FaradaicTM Process technologies listed above, by providing environmentally conscientious reclamation and reuse of process solutions.

COMMERCIALIZATION SUCCESS
To date, Faraday has secured $219,723 in commercial revenue to support this pilot-scale activity. Additionally, Faraday is preparing samples for external evaluation by Concurrent Technologies Corporation and NADEP Cherry Point. Faraday has a successful track record of technology commercialization, with six strategic technology alliances currently under contract and 60 percent of its annual sales coming fr om commercial sources. Faraday has filed patent application #08/871,599 titled, “Electroplating of MetalsUsing Pulse Reverse Current for Control of Hydrogen Evolution” based on this SBIR-funded project.

AWARDS AND COMPANY HISTORY

Faraday Technology, Inc., is an electrochemical process technology development company focused on enhancing and commercializing theFaradaicTM Process, its platform electrochemical manufacturing technology. Founded in 1991, F araday has established itself as a

note worthy applied research and development company with approximately 80 publications and more than 30 patents/ patents pending. The company has been recognized with a number of awards, including: the U.S. Small Business Ad ministration-sponsored Small Business/Enterprise Spirit Awar ds, the State of Ohio Governor’s Thomas Edison Emerging Technology Award, the Affiliate’s Society Coun cil of Dayton Outstanding Technology Leadership Award, the Abner Brenner Silver Medal Award for a paper published in Plating & Surface Finishing, and the Ernst & Young Entrepreneur of the Year Award (High Technology Finalist for 2001).