ARTICLES COATED WITH ABRASION RESISTANT COATING

Abstract: A coating composition includes a cured base coat (12) of polyurethane-containing resin covered by a cured top coat (14) of a silicon-containing resin. The top coat resin is applied in an uncured state to the base coat, the two resins are thereafter heated to at least 140 F, and thereafter the top coat resin is cured to produce the coating composition. A clean metal surface (11) is coated with the coating composition by applying uncured base coat (12) resin to the metal surface (11), curing the base coat resin, and thereafter applying the top coat (14) as described above.

Description: ARTICLES COATED WITH ABRASION RESISTANT COATING ABRASION RESISTANT COATING COMPOSITIONS, METHODS FOR MAKING THEM. AND ARTICLES COATED WITH THEM CROSS-REFERENCE TO RELATED APPLICATIONS This application claims inventions disclosed in co-pending provisional Application No. 60/126.587 filed March 26. 1999 and co-pending provisional Application No. 60/147,328 filed August 5. 1999. BACKGROUND OF THE INVENTION This invention relates to abrasion-resistant coating compositions, methods for making them, and articles coated with them. More particularly, the invention provides an improved silicon-containing cured synthetic resin coating composition which forms a protective, abrasion resistant coating. Such coating compositions are sometimes referred to as silicone hard coat resins, or organo-polysiloxanes, such as the compounds produced by the condensation of hydroxy organosilicon compounds formed by the hydrolysis of organosilicon halides. The preferred silicon-containing coating compositions include products which combine colloidal silica with various acryloxy or glycidoxy functional compounds, such as acryloxy or glycidoxy functional silanes, or non-silyl acrylates. Transparent abrasion-resistant coatings made from silicon-containing synthetic resins have been used to coat transparent plastics which do not shatter or are more resistant to shattering than glass, but which are subject to scratching and marring due to everyday contact with abrasives such as dust, cleaning equipment, and ordinary weathering. However, the application of these prior art coating compositions to metal surfaces has met with little success because of inadequate adhesion between the metal and the cured resin. SUMMARY OF THE INVENTION This invention provides a silicon-containing cured synthetic resin coating composition which bonds firmly to metal surfaces to provide superior protection from abrasion and chemical attack. The coating composition of the invention includes a base coat layer of cured polyurethane-containing resin which bonds strongly to the metal surface to be protected. A top coat layer of uncured silicon-containing synthetic resin is deposited on the cured layer of polyurethane-containing resin, and heated to create a strong interlinking between the silicon-containing synthetic resin and the layer of polyurethane-containing resin. Thereafter, the silicon-containing synthetic resin is cured by heat, actinic radiation such as UV light, or particle radiation such as electron beam. The final silicon-containing cured synthetic resin coating composition can be clear or pigmented. For example, the polyurethane-containing resin can include pigment or metallic particles for decorative effect. Practically any kind of metal surface which has been adequately cleaned can be coated in accordance with this invention. The polyurethane-containing layer can be any of the well-known polyurethane coating compositions, or blends of polyurethane and acrylic resin. The layer of polyurethane or polyurethane/acrylic mixture is coated onto a clean metal surface by any of the suitable, well-known and commercially available processes, such as spraying or electrodeposition. DESCRIPTION OF THE DRAWINGS FIG. 1 shows an enlarged cross section a piece of metal coated with a coating composition of this invention; and FIG. 2 is a block diagram showing a method for cleaning and coating a metal work piece with a coating in accordance with the invention. DESCRIPTION OF THE INVENTION The Polvurethane-Containing Resin As used herein, the terms "polyurethane resin" and ''polyurethane-containing resin" include resins which are either all polyurethane, polyurethane which includes epoxy groups, or an acrylic-polyurethane copolymer as described below, or a mixture of those resins. My presently preferred process for electrodeposition of a base coat of a polyurethane-containing resin on metal surfaces is disclosed in ClearClad Coatings, Inc. " s Installation and Operation Manual (Release No. 2.0, Manual Series No: 1 192, Copyrighted 1997 by ClearClad Coatings, Inc.). A copy of the Manual is attached as Appendix 1. The electrodeposition process described in the Manual is referred to as electrophoretic coating. The process deposits a cross-linked organic polyurethane-containing lacquer coating to any metal with proper treatment as described in the Manual. The base coat of the polyurethane-containing resin can be clear or colored (with pigment), translucent or opaque, and has a substantially uniform thickness over the coated surface, usually in the range of 1-100 microns (.00004"-.0040"). For coating aluminum and magnesium surfaces, I prefer to use ClearClad LCX® polyurethane electrocoat enamel supplied by ClearClad Coatings, Inc., and which is described in the manual on page 48. That type of polyurethane electrocoat enamel is described in U.S. Patent Nos. 3,922.253, 3,947,338. and 4.241.200, which are incorporated herein by reference. The polyurethane electrocoating composition is produced by reacting an isocyanate-terminated prepolymer with a minor amount of peroxide to provide a polyurethane polymer blocked with pendant peroxide groups, and then co-reacting acrylic monomers with minor amounts of other ethylenically unsaturated monomers in the presence of the preformed polyurethane peroxide polymer to provide polyurethane copolymer with those monomers. The resulting polyurethane acrylic block copolymer can also contain carboxyl or amine groups for disbursing into a dilute aqueous solution and provide an anodic or a cathodic electrocoating composition. -?. As explained in U.S. Patent No. 4.241.200 (the "200 patent), an aqueous-dispersed electrocoating composition containing an aery lic-polyurethane copolymer is produced by reacting tertiary alkyl peroxide with a diisocyanate to provide a diperoxide blocked urethane prepolymer which functions as a free radical initiator in a subsequent polymerization of acrylic monomers. The polyurethane acrylic copolymer is suitable for use in either anodic or cathodic electrocoating composition. The most useful peroxide is a t-butyl hydroxymethyl peroxide although other hydroperoxides such as t-butyl hydroperoxide and cumene hydroperoxide can be used. Tertiary-butyl hydroxymethyl peroxides can be produced by reacting molar equivalents of formaldehyde with tertiary-butyl hydro peroxide as shown by Erdy, et al., in J. of Polymer Science. 8. A-I, 763-769 (1970). Referring to the isocyanate compound to be reacted and capped with a tertiary alkyl peroxide, the polyisocyanate can be a di- or triisocyanate structurally illustrated as: R-NCO R-NCO wherein R can be the same or different and R can be either aliphatic or aromatic group. Suitable polyisocyanates are preferably diisocyanates such as 2,4 or 2,6 toluene diisocyanate, phenvlene diisocyanate, hexamethylene or tetramethylene diisocyanate, 1 ,5 -naphthalene diisocyanate, ethylene or propylene diisocyanate as well as trimethylene or triphenyl triisocyanate, and similar di- or triisocyanate. The polyisocyanate can be generally selected from the group of aliphatic, cyclo-aliphatic and aromatic polyisocyanates such as, for example, hexamethylene 1 ,6-diisocyanate; isophorone diisocyanate. 1,4-dimethyl cyclohexane. diphenylmethane diisocyanate; polymethylene polyphenyl polyisocyanate; and mixtures thereof. The urethane diperoxide prepolymer is then copolymerized with acrylic ethylenically unsaturated monomers to provide a polyurethane-acrylic copolymer. The urethane diperoxide reacts through the peroxide linkage group wherein each peroxide becomes a free radical initiator which activates the ethylenic double bond whereby the urethane prepolymer free radical reacts with an ethylenic double bond to provide a urethane copolymer. Other activated ethylenic double bonds coreact with other monomer double bonds to provide copolymerized acrylic monomers. The urethane copolymer contains by weight at least about 10% urethane and preferably between 20% and 50% urethane with balance being copolymerized acrylic monomers with minor amounts of other ethylenically unsaturated monomers. The molecular weight of such polymers are preferably between about 3,000 and 50,000. Useful ethylenically unsaturated monomers include, for example, lower alkyl esters of acrylic or methacrylic acid such as methyl-, ethyl-propyl-, butyl-, acrylates or methacrylates, 2-methylhexyl aery late, n-octyl aery late, 2-ethylhexyl aery late, as well as similar methacrylates. Minor amounts of other ethylenic monomers include vinyl aromatic hydrocarbons such as styrene. alpha-methyl styrene, similar alkyl styrene. vinyl toluene, vinyl naphthalene, and divinyl benzene; aliphatic hydrocarbons such as 1.3 butadiene, methyl-2-butadiene. 1 ,3-peperylene. cyclopentadiene, dicyclopentadiene, 2,3-dimethyl butadiene, and similar conjugated polyolefins; vinyl halides such as vinyl chloride and vinylidene chloride; and vinyl esters such as vinyl acetate. Particularly preferred ethylenically unsaturated monomers include alkyl acrylates and methacrylates with minor amounts of styrene, alpha-methyl styrene, t-butyl styrene, 1,3 -butadiene, isoprene, and acrylonitrile. On a weight basis, the polyurethane-acrylic matrix copolymer contains between 10% and 90% polyurethane, between 10% and 70% acrylic monomer, and up to 50% other copolymerized ethy 1 enic monomers . The polyurethane-acrylic polymers can be rendered water soluble by introducing pendant amine groups on the polymer to provide an aqueous electrocoating solution suitable for electrocoating onto a cathode substrate. Amine groups can be attached to the polymer by reacting free carboxyl groups with an alkyleneimine or substituted alkyleneimine as suggested in U.S. Pat. Nos. 3,679,564 and 3,617,458. The amine group is reacted with at least 1% of an acid salt proton donor to render the polymer positive ionic for electrocoating onto a cathode substrate. Useful solubilizing salts include proton donating acids such as phosphoric, sulfuric, hydrochloric, acetic, formic, lactic, and similar organic or inorganic acids. In similar manner, polymers containing carboxyl groups can be solubilized in water by neutralizing with amine salts or bases such as KOH or NaOH and further provide an anodic electrocoating composition. Carboxyl groups can be introduced into the polymer by reacting polycarboxylic acids such as maleic, fumaric, acrylic, or methacrylic acid. Preferred carboxyhc acids are acrylic or methacrylic acid. The acid number of the polymer should be between about 20 and 200 and preferably, between 40 and 80. At least about 2% solubilizing salt such as KOH or NaOH is preferred. The polyurethane-acrylic matrix copolymer containing hydroxyls or carboxy Is are adapted to be cross-linked with aminoplast resins such as melamine-formaldehyde. Melamine resins can be selected from melamine or melamine derivatives such as methylol melamine or similar alkylated melamine-formaldehyde reactive resins commonly referred to as aminoplast resins. Melamine resins, for instance, can cross-link hydroxyl containing polyurethane-acrylic matrix copolymers when heat cured at temperatures of about 300 °F. to 400 °F for about 20 minutes. Ordinarily about 65-70 weight parts of polyurethane-acrylic matrix copolymer mixed with about 25 to 35 weight parts melamine cross-linker provide a resin mixture containing between about 20% to 40% by weight melamine. Other cross-linkers such as blocked isocyanates, phenolic resins, etc., can also be used. The polyurethane-acrylic matrix polymer mixed with aminoplast resin can be dispersed in water by adding polymer to a water bath containing the proper solubilizing salt such as proton donor salt for cathodic compositions and amines or bases for anodic compositions. The polymer solids content of the electrocoating bath can be generally between 5% and 25% by weight and preferably, between 5% and 15%. The electrocoating composition can be electrocoated onto a cathode or anode substrate by passing direct electric current between the anode and cathode to electrodeposit a coating onto an anode substrate. The current is reversed for deposition onto a cathode substrate. The substrates are electrically conductive metal such as iron, steel, aluminum, galvanized steel, zinc, chromium, tin, gold, silver, copper, lead, brass, bronze, and similar electroconductive materials. Electrocoating is carried out at a voltage above the threshold voltage of the electrocoating paint composition which is the voltage at which the polymer will electrocoat due to a direct electric current being passed through the electrocoating bath. The maximum tolerable voltage is slightly below the rupture voltage of the paint coating being applied to the substrate, where the rupture voltage is that voltage which causes the paint film already applied to rupture upon continued application of such voltage. The desirable voltage is between 20 and 500 volts and preferably between 50 and 300 volts. The temperature of the electrocoating bath is generally between 15°C and 50°C and preferably between 20°C and 35°C. Agitation is preferred to maintain uniformity of the dilute polymer solution. The electrocoating compositions of the "200 patent are further explained in the following examples. EXAMPLE 1 Tert-butyl hydroxymethyl peroxide is prepared as follows. About 60 grams (0.513 mole) of reft-butyl hydroperoxide is slowly dropped into a 55 gram of formaline solution (37%; 0.67 mole) at room temperature. After the addition is complete, the mixture is stirred overnight (16 hours) at room temperature. The resulting product was vacuum distilled at 8-9 mm of mercury. The boiling point of the product was about 51° C.-53 ° C. and the yield was about 28 grams. Isocyanate prepolymer blocked with peroxide is produced as follows. About 8 grams of the tert-butylhydroxymethyl peroxide and 50 grams of Spenkel (from Spencer Kellog Co.) P-49-60CX (an aromatic urethane Mn600, NCO sq. wt. 350) containing 0.07 mole isocyanate functionality plus 0.16 grams of dibutyl acetate are introduced into a reaction vessel. After 4 days of stirring at room temperature, there is still a minor amount of free isocyanate present. About 10 grams of methanol is added to react with the free isocyanate before proceeding further. The resulting product is a urethane diperoxide. A urethane copolymer is produced by the following: 38 grams of the urethane diperoxide is dissolved in 200 grams of benzene. A monomer mixture of 60 grams styrene.90 grams of ethyl aery late, and 30 grams methacrylic acid is dropwise added. The polymerization is conducted under nitrogen and a temperature of about 80 °C, and the resulting final copolymer contains approximately 17.4% by weight polyurethane. EXAMPLE 2 In a manner similar to Example 1 , about 400 grams 40% solids (DV-2222) isocyanate (an isocyanate prepolymer. Mn4000. NCO sq. wt. 1300. from Spencer Kellog Co.) is reacted with 20 grams of tert-butyl hydroxymethyl peroxide. 0.4 grams of dibutyl tin acetate, and 0.4 grams of triethylamine are stirred under nitrogen atmosphere in a reaction flask after 4 days. About 10 grams of methanol is added to react with the free isocyanate. The product is a peroxide terminated polyurethane which is then added to 400 grams of benzene. Monomers consisting of 160 grams styrene, 240 grams of ethyl acrylate. and 80 grams of methacrylic acid are added under nitrogen blanket at reaction temperature of about 84°C. The final copolymer contains 25% by weight polyurethane. An electrocoating bath is produced on a weight basis as follows: 208 parts copolymer 46.5 parts Cymel 303 (melamine) 24.5 parts Methylon resin 75108 ° 1.7 parts Surfynol non-ionic surfactant 10.7 parts butyl cellosolve 10.7 marts Mineral spirits 21.4 parts hexyl cellosolve JJ.J parts diisoproplanolamine (85% solution) 384 parts deionized water where n = 1-3 Upon electrocoating. a smooth coating with excellent flexibility is obtained. EXAMPLE 3 Similar to Example 1. a peroxide terminated urethane prepolymer is prepared from 40 grams Spenkel P-49-755 (a urethane prepolymer from Spencer Kellog), 100 grams xylene, 15 grams of t-butyl hydroxymethyl peroxide and 0.2 grams of di-butyl tin dilaurate. The mixture is heated at about 50° C. for about 3 hours. Fifty ml. of butyl cellosolve is added and the reaction mixture is then heated to about 90°C. Thereafter, a monomer mixture of 60 grams styrene, 90 grams ethyl acrylate. and 30 grams methacrylic acid is added to the reaction mixture. The polymer has an Acid No. of 52.3. Excess solvent is removed and sufficient butyl cellosolve is added to provide a solids content of 64.9% by weight. The number average molecular weight is determined to be about 20.000. This resin solution is used to prepare an electrocoating bath solution as follows: 57.8 grams resin 13.9 grams melamine 10,719-28 (from American Cyanamid) 4.5 grams dimethylethanolamine 90.8 grams deionized water 10 The resin and melamine are heated together at 150° F.-160 0 F. and mixed with preheated (160° F.) deionized water containing the dimethylethanolamine. The resulting mixture is diluted with 833 grams water to provide a 5% polymer solids electrocoating solution. Electrocoating is carried out at 130 volts at 80° F. for 15 seconds to provide an electrocoated film of about 0.21 ι to 0.26 mils. This primer coating is baked at 540° F. for 45 seconds. The resulting coating withstands 100 MEK rubs with only slight surface effect. The Silicon-containing Curable Synthetic Resin The silicon-containing curable synthetic resin can be any of many silane, silicone or 20 organopolysiloxane coating compositions, such as are disclosed in U.S. Pat. Nos. 3,451,838, 3,986,997, 4,027,073, 4,373.060, 4.624.870, 3,707,397, 4,207,357, 4,242.381. 4,284,685, 4,308.317, 4,353,959, 4,615,947, and 5,120.81 1. These 13 patents are incorporated herein by reference. I presently prefer to use a silicon-containing curable synthetic resin available from General 25 Electric Company as UVHC 8558™ silicone hard coat resin. Products of this type are disclosed in U.S. Patent Nos. 4,348,462. 5.242.719, 5,468,789. 5,607.729, and 5.712.325, which are incorporated herein by reference. U.S. Patent No. 4,348.462 (the "462 patent) discloses a silicon-containing coating composition which does not require heat to initiate curing of the product, which is made by the -, Q combination of colloidal silica with acryloxy functional silanes or water miscible hydroxy acrylates, or preferably both, with catalytic amounts of UV-sensitive photoinitiators. The radiation curable coating composition of the '462 patent comprises: (A) 100 parts by weight of colloidal silica (SiO,). For example, Nalco 1034 is a dispersion colloidal silica of 34% and 66% water by weight, o r The dispersion of colloidal silica is used in an amount sufficient to provide 100 parts of silica by weight. Colloidal silica is available in basic or acidic form. Either may be used. However, the acidic form (low sodium content) is preferred. To the 100 parts colloidal silica (about 294 parts by weight of the Nalco 1034 dispersion) is added (B) 5 to 500 parts, and preferably 50 to 200 parts, of an acryloxy functional silane or glycidoxy functional silane. These silanes assist to impart high abrasion resistance to the coating compounds but it has been found that without more, adhesion is poor. To improve adhesion, there is added in addition to these acryloxy and glycidoxy functional silanes. from 10 to 500 parts, and preferably 50 to 200 parts of (C) a non-silyl acrylate material. Especially preferred acrylates are water miscible hydroxy acrylates. Non-hydroxy acrylates could be utilized but are not preferred since they are less miscible in water. In these systems water is useful as a viscosity reducing agent. The above described ingredients are catalyzed with catalytic amounts of (D) ultraviolet light sensitive photoinitiators or blends of such initiators. Radical-type initiators can be used alone but it is preferred that a combination of radical and cationic-type photoinitiators be used for improved abrasion resistance. When acidic colloidal silica is used, it is required that there be such a combination of photoinitiators. The radical-type catalysts are used to cure the acryloxy functional portions of the composition. The cationic-type catalysts cure the siloxane portions. A combination of catalysts gives tighter cure properties and improved abrasion resistance. The catalytic amounts of these photoinitiators may vary, but ordinarily the cationic-type catalyst such as the hereinafter described onium salts are present in an amount of, approximately, 0.05 to 5.0% by weight based upon the amounts of ingredients A, B, and C. and preferably are present in an amount of from 0.1 to 1.5%. The radical type photoinitiators ordinarily are present in an amount of, approximately 0.5 to 5.0% by weight of ingredients A, B, and C, and preferably are present in an amount of, approximately. 1 to 3% by weight. The radiation curable coating compositions are made by mixing (A) an amount of colloidal silica sufficient to provide 100 parts by weight of silica with 5 to 500 parts of (B) acryloxy or glycidoxy functional silanes or mixtures thereof, and 10 to 500 parts by weight of (C) a non-sylyl acrylate. This mixture is catalyzed by combining it with effective amounts of ultraviolet light sensitive catalysts, which preferably are a blend of radical -type and cationic-type UV catalysts. The catalyzed compositions can then be coated by well known techniques onto selected substrates and cured by exposure to ultraviolet radiation. The ingredient B is the acid hydrolysis product of an acryloxy-functional silane or the acid hydrolysis product of a glycidoxy-functional silane or mixtures thereof. The acryloxy-functional silane has a general formula: R 6 wherein R 3 and R 4 are the same or different monovalent hydrocarbon radicals, including halogenated species of such radicals. Preferably, R 3 and R 4 will be lower alkyl radicals such as methyl, ethyl, propyl, etc., but may include other saturated and unsaturated species including vinyl, aryl, etc. R 3 is a divalent hydrocarbon radical having from 2 to 8 carbon atoms. R 6 is a hydrogen or a montvalent hydrocarbon radical. The letter b is an integer from 1 to 3, c is an integer from 0 to 2 and d is an integer equaling 4-b-c. In many of the embodiments of the present invention, be will ordinarily be 3, c will be 0 and d will equal 1. Specific examples of acryloxy-functional silanes include: 3-methacryloxypropyltrimethoxysilane 3-acryloxypropyltrimethoxysilane 2-methacryloxyethyltrimethoxysilane 2-acryloxyethyltrimethoxysilane 3-methacryloxypropyltriethoxysilane 3-acryloxypropyltriethoxysilane 2-methacryloxyethyltriethoxysilane 2-acryloxyethyltriethoxysilane Such acryloxy-functional silanes are commercially available. For example, 3 -methacryloxypropyltrime-thoxy silane can be obtained from Union Carbide or United Chemical Technologies, Inc. The ingredient B of the coating composition may also be a glycidoxy-functional silane instead of the acryloxy-functional silane just described, or it may be a combination or mixture of both types of silanes. A glycidoxy-functional silane has the general formula given by (R 7 0) e R —Si—R 9 —0—CH 2 —HC—CH 2a i \ / y O wherein R 7 and R s are the same or different montvalent hydrocarbon radicals as described above for R 3 and R 4, R 9 is a divalent hydrocarbon radical having from 2 to 8 carbon atom. The letter e is an integer from 1 to 3, f is an integer from 0 to 2 and g is an integer equaling 4 — e — f. Specific examples of useful glycidoxy-functional silanes are the following: 3-glycidoxypropyltrimethoxysilane 2-glycidoxyethyltrimethoxysilane 3-glycidoxypropyltriethoxysilane 2-glycidoxyethyltriethoxysilane These glycidoxy-functional silanes are also commercially available. One source, for example, is Petrarch Systems. Inc. Constituent C is an acrylate compound which increases the abrasion resistance of the cured product when used with the colloidal silica described above. These acrylate compositions are considered to be non-silyl functional to distinguish them from the acryloxy functional silanes described above. These acrylates are esters of acrylic acid, but especially preferred are the water miscible hydroxy acrylates. Among the acrylates which may be utilized in the present invention are: 2-Hydroxy ethyl acrylate 2-Hydroxy ethyl methacrylate 3-Hydroxy propyl acrylate 3-Hydroxy propyl methacrylate 2-Hydroxy-3-methacryloxy propyl acrylate 2-Hydroxy-3-acryloxy propyl acrylate 2-Hydroxy-3-methacryloxy propyl methacrylate Diethylcnc glycol diacrylate Triethylene glycol diacrylate Tetraethylene glycol diacrylate Trimethylol propane triacrylate Tetrahydro Furfuryl methacrylate 1 -6-Hexanediol diacrylate To this mixture is added a catalytic amount D. a photoinitiator. Effective photoinitiators are radiation sensitive aromatic halonium. sulfonium or phosphonium salts which have been described in the literature. Cationic photoinitiators have been described by Crivello in numerous U.S. patents and applications, such as the following, for example, which are hereby incorporated by reference: U.S. Pat. No. 4,136.102 issued Jan. 23. 1979 and U.S. Pat. No. 3.981,897 issued Sept. 21, 1976. Such cationic photoinitiators can have the general formula (R'°-C 6 H A )^< ^ MQ h - In this formula, X is a radical selected from I. P or S. M is a metal or metalloid and Q is a halogen radical selected from CI. F, Br. or I. R 10 is hydrogen or a mono-valent hydrocarbon radical having from 1 to 12 carbon atoms. The letter h is an integer having the value of 4 to 6 inclusive, and n is an integer having the value of 2 or 3. The expression MQj; applies to any number of ionic species but preferably will be selected from SbF^, AsF 6 . BF^ and PF 6 . Particular cationic catalysts include diphenyl iodonium salts of tetrafluoro borate, hexafluoro phosphate, hexafluoro arsenate, and hexafluoro antimonate: and triphenyl sulfonium salts of tetrafluoroborate. hexafluoro phosphate, hexafluoro phosphate, hexafluoro arsenate. and hexafluoro anfimonate. It is ordinarily preferable to utilize approximately 0.1 to 1.5 parts by weight of the cationic photoinitiator for every 100 parts by weight of the mixture of ingredients A, B and C as described above. However, depending upon individual desired process parameters such as rate of cure and ultimate abrasion-resistance, the amount of the photoinitiator can range from approximately 0.05 to 5 parts by weight per 100 parts of the mixture of ingredient A, B. and C. These cationic photoinitiators are particularly effective for initiating a cross-linking reaction upon exposure to ultraviolet radiation. Good hard coatings having excellent adhesion can thus be obtained when the coating composition is applied to a substrate and exposed to radiation such as that provided by UV lamps. Improved abrasion-resistance is obtained with the same hard coating compositions when in addition to the cationic photoinitiators described above, there is also utilized a radical-type initiator which is effective for cross-linking or self-condensing the acryloxy-functional portions of the silanes contained in the composition. Such radical photoinitiators include among others, benzoin ethers, alpha-acyloxime esters, acetophenone derivatives, benzil ketals and ketoneamine derivatives. Specific examples of these photoinitiators include ethyl benzion ether, isopropyl benzoin ether, dimethoxy-phenyl acetophenone. and diethoxy acetophenone. The mixed products of ingredients A. B, and C are effectively catalyzed to form satisfactory radiation curable hard coatings by combining 100 parts by weight of such products and mixtures with from, approximately, 0.5 to 5.0 parts by weight of a combination of photoinitiators. The photoinitiator combination is comprised of, approximately, 10 to 90% by weight of a cationic-type initiator such as diphenyliodoniumhexafluoroarsenate and the remaining portion is a radical-type initiator such as ethylbenzoin ether. Examples of silicon-containing synthetic resins made in accordance with the '462 patent are given below: EXAMPLE 4 Into a 500 cc-3-necked flask is placed 175 g of Nalco 1034A colloidal silica dispersion (about 59.5 g silica). 47 g of methacryloxypropyl trimethoxysiloxane (MPTMS) (Petrarch System Inc.) is then added drop-wise over a period of 20 minutes at 25 °C. After stirring for an additional 40 min.. the mixture of 68 g of 2-hydroxyethyl acrylate and 25 g of diethyleneglycoldiacrylate is added. The slightly hazy solution is then combined with 1 g of diphenyliodoniumhexafluoroarsenate and 2.5 g of ethylbenzoin ether as photoinitiators. This catalyzed mixture is flow-coated on Lexan ® and air-dried for 40 min. and cured under UV light in 6 seconds in a nitrogen atmosphere to give a clear hard coating with good adhesion. EXAMPLE 5 To 750 g of colloidal silica (Nalco 1034A) is added dropwise 118 g of 3-methacryloxypropyltrimethoxysilane (MPTMS) (A- 174, Union Carbide), at 25 ° C. After stirring for 15 min.. 240 g of 3-glycidoxypropyltrimethoxy silane (GPTMS) (Petrarch System) is added dropwise over the course of 30 min. while the temperature is kept below 30° C. The mixture is then stirred at 25° C. for one hour, and combined with 300 g of 2-hydroxyethylacrylate, 88 g of diethyleneglycoldiacry late. 88 g of tetrahydrofurfurylmethacrylate. 4.4 g of bistoluyliodoniumhexafluoroarsenate and 15 g of ethylbenzoin ether. This composition is flow-coated on Lexan and cured under UV-light in 3 seconds to provide a transparent coating having excellent abrasion resistance. EXAMPLE 6 A mixture of 45 g of MPTMS (A- 174) and 10 g of OPTMS (A- 187) is added to 150 g of Nalco 1034A during 30 min. at 25 ° C. After stirring for 4 hours an excess of water and intrinsic solvents are removed under reduced pressure. The thick residue is then combined with 100 g of 2-hydroxy-3-methacryloxypropylacrylate (HMPA). 40 g of diethyleneglycoldiacrylate, 1.2 g of triphenylsulfoniumhexafluoroarsenate and 4 g of diethoxyacetophenone (DEAP). This is coated on Lexan and cured under UV-light within 9 seconds under a nitrogen atmosphere. EXAMPLE 7 To 300 g of colloidal silica (Nalco 1034A) is added 90 g of 3-acryloxypropyltrirnethoxysilane followed by 20 g of 3-glycidoxypropyltriethoxysilane at 20° C. After stirring for an additional 30 min. an excess of water is removed under reduced pressure. The clear residue is combined with 40 g of 2-hydroxy-3-methacryloxypro-pyl acrylate (HMPA) and 40 g of diethyleneglycoldiacrylate (DEGDA). This is irradiated on Lexan in the presence of a catalytic amount of triphenylsulfonium-hexafluoroarsenate and diethoxyacetophenone and cures within 6 seconds under nitrogen. EXAMPLE 8 A mixture of 150 g of colloidal silica (Nalco 1034A) and 45 g of 3-methacryloxypropyltriethoxysilane is mixed at 25° C. for 2 hours 20 g of HMPA and 20 g of DEGDA are then added followed by 0.6 g of tri-phenylsulfoniumhexafluoroarsenate and I g of diethoxyacetophenone. It is then flow coated on Lexan and drained for 30 min. Upon exposure to UV-light for 10 seconds under nitrogen, a clear high abrasion resistant coating with good adhesion is obtained. EXAMPLE 9 Three hard coating compositions are obtained by mixing 30% colloidal silica (Nalco 1129).2-hydroxyethylmethacrylate (HEMA) and 3-glycidoxypropyltrimethoxy si lane (GPTMS) according to the parts by weight (pbw) given in the following table. To each of these mixtures is added a blend of photoinitiators consisting of 0.04 parts diphenyliodonium hexafluoroarsenate and 0.04 parts ethyl benzoin ether, wherein the parts are based upon the weight of the total mixture. The catalyzed compositions are flow coated onto Lexan sheets and air dried for 30 minutes. After the coated Lexan sheets had been air dried they are exposed to radiation in a UV processor for 3 seconds thereby producing a cured high abrasion resistant transparent film. The Δ% H 500 is also indicated in the following table. 30% Colloidal Sample Silica HEMA GPTMS Δ% H 500 A 30 pbw 5 pbw 5 pbw 1.7 B 30 9 9 5.4 C 30 5 9 2.6 EXAMPLE 10 Another high abrasion resistant coating composition is produced by mixing two parts by weight colloidal silica dispersion (Nalco 1034A) with one part of water. To this mixture is added, in a dropwise fashion, one part of 3-methacryloxypropyltrimethoxysilane at 25' C. After stirring for two hours, the resultant mixture is further combined with two parts 2-hydroxyethyl acrylate and 0.15 parts dephenyliodonium hexafluoroarsenate and 0.3 parts ethyl benzoin ether. The catalyzed mixture is flow coated onto Lexan and air dried for 30 minutes whereupon the coating was cured on a UV processor. Several samples all cured to high abrasion resistant coatings showing good adhesion. All samples cured in 6 to 9 seconds of UV exposure and had Δ% H 500 values of 4 to7. U.S. Patent No. 5,712,325(the '325 patent) discloses an alternate method for making a silicon-containing synthetic resin similar to UVHC 8558 resin available from the General Electric Co. As explained in the '325 Patent, a curable silicon-containing polyacrylate hardcoat composition is made by substantial removal ofvolatiles at a temperature of 25° C to 100 ° C. and 1 torr to 760 torr pressure from a silicon-containing polyacrylate mixture comprising by weight: (A) 100 parts of the product of reaction at a temperature of about 20° C. to about 100° C. of a mixture of (i) about 5% to about 20% by weight of alkoxysilylacrylate, and (ii) correspondingly about 80% to about 95% by weight of a colloidal silica alcoholic dispersion consisting essentially of colloidal silica in a C(3-5) branched aliphatic alcohol, or a mixture of - 1 J- a C(3-5) branched aliphatic alcohol and a C(I-5) straight chain alcohol, where the colloidal silica is present in the colloidal silica alcohol dispersion at from about 5% to about 70% by weight, (B) about 10 to about 400 parts of at least one polyfunctional reactive acrylic monomer and, (C) an effective amount of gelation inhibitor, where there is present in the colloidal silica alcohol dispersion sufficient water to effect the hydrolysis of the alkoxysilylacrylate. Some of the preferred C( 3 . 5 ) branched water miscible alcohols which can be used in the practice of the invention are isopropanol, isobutanol. tertbutanol, and neopentanol. The gelation inhibitors which can be used in the practice of the invention include aerobic and anaerobic gelation inhibitors. The preferred aerobic inhibitor is methylhydroquinone. Among the anaerobic gelation inhibitors which can be used are 2.2,6.6-telxamethylpipeaidinyloxy(TEMPO). 4-hydroxy-2, 2,6,6-tetramethylpiperidinyloxy (4--OH TEMPO), galvinoxyl, 2,2-d/phenyl-l-picryl-hydrazyl hydrate, Ban-field's radical. 1 ,3.5-triphenyl verdazyl. Koelsch's radical 1 -nitroso-2-naphthol and bis(2.2.6.6-tetramethyl-4-piperidinyloxy)sebacate. An effective amount of aerobic or anaerobic gelation inhibitor is 10 ppm to 10,000 ppm, based on the weight of reactive acrylic monomer used in the curable silicon containing polyacrylate hardcoat composition. Some of the alkoxysilylacrylates which can be used in the practice of the method of the invention are shown by the following formula: where R4 is a C(l-13) monovalent organic radical. R5 is a C(I-8) alkyl radical. R6 is selected from hydrogen, R4. radicals or mixtures thereof. R7 is a divalent C(l-8) alkylene radical, a is a whole number equal to 0-2 inclusive, b is an integer equal to 1-3 inclusive, and the sum of a+b is equal 1-3 inclusive. Included within the alkoxysilylacrylates are compounds having the formulas: CH 2 =CCH 3 C0 2 -CH 2 CH 2 -Si(OCH 2 CH 3 ) 3 , CH 2 =CHC0 2 -CH 2 CH 2 -Si(OCH 3 ) 3 , CH 2 =CCH 3 C0 2 -CH 2 CH 2 -Si(OCH 3 ) 3 , CH 2 =CHC0 2 -CH 2 CH 2 -Si(OCH 2 CH 3 ) 3 , CH 2 =CCH 3 C0 2 -CH 2 CH 2 CH 2 -Si(OCH 3 ) 3 , CH 2 =CHC0 2 -CH 2 CH 2 CH 2 -Si(OCH 3 ) 3 , CH 2 =CCH 3 C0 2 -CH 2 CH 2 -Si(OCH 2 CH 3 ) 3 , CH 2 =CHCO 2 -CH 2 CH 2 CH 2 -Si(OCH 2 CH 3 ) 3 , CH 2 =CCH 3 C0 2 -CH 2 CH 2 CH 2 CH,-Si(OCH 3 ) CH 2 =CHC0 2 -CH 2 CH 2 CH 2 CH 2 -Si(OCH 3 ) 3 , CH 2 =CCH 3 C0 2 -CH 2 CH 2 CH 2 CH 2 -Si(OCH 2 CH 3 ) 3 . CH 2 =CHCO 2 -CH 2 CH 2 CH 2 CH 2 -Si(OCH 2 CH ) 3 , etc. CH 2 =CHCO 2 -CH 2 CH 2 CH 2 CH 2 -Si(OCH 3 ) 2 .CH 3 , CH 2 =CHC0 2 -CH 2 CH 2 CH 2 CH 2 -Si(CH 3 ) 2 ,OCH 3 , CH 2 =CHCO 2 -CH 2 CH 2 CH 2 CH 2 -Si(OCH 3 ) 2 CH 3 , Among the polyfunctional reactive acrylic monomers which can be used in the practice of the method of the invention, are compounds shown by the formula: where R 6 is as previously defined. R 8 is a polyvalent organic radical and n is an integer having a value of 2 to 4. Some of the reactive acrylic monomers which can be used are for example: CH 3 CH 3 CH 2 =CCOO~CH 2 -OOCC=CH 2 CH 2 =CHOO-CH 2 -CH 2 -OOCCH-=CH 2 CH^CHOO-CH,-CHOHCH7-OOCCH-=CH 7 CH 3 CH 3 CH 2 =CCOO-(CH 2 ) 6 -OOCC=CH 2 OOCCH=CH 2 CH 2 =CHOO-CH 2 -CH 2 -CH-CH 3 Br CH 2 =CHCOO ( ( ) )— OOCCH=CH 2 , etc. Silicone ester acrylate oligomer (EBECRYL 350, UCB Radcure Inc.) aliphatic urethane diacrylates triacrylates of the formulas: OOCCH=CH, CH 2 =CHCOO-CH2-CH 2 -CHCH 2 -OOCCH=CH 2 CH1-CHCOO-CH9 CH 2 =CHCOO-CH 2 -C-CH 2 -CH 3 CH 2 CHCOO-CH 2 CH 2 -OOCCH=CH 2 OOCCH=CHτ Tetraacrvlate of the formulas: CH 2 =CHCOO-CH 2 CH,=CHCOO-CHo-CH-CH-,-OOCCH=CHo CH 3 CHCOOCH 2 and OH CH 2 =CHCOO-CH 2 CHCH-CH 2 CH-OOCCH=CH 2 CH-,=CHCOO-CH < , CH -OOCCH=CH Additional acrylates having at least 3 or more reactive groups are dipentaerythritol monohydroxypenta acrylate. hexafunctional polyurethane acrylate. and silicone aorylate oligomer (Ebecryl 1360, UCB Radcure Inc). The coating compositions made in accordance with the '325 patent can contain one or more of the polyfunctional reactive acrylic monomers. Preferably a mixture of two polyfunctional reactive acrylic monomers are used and in particular a diacrylate and a triacrylate. In addition, minor amounts of a monoacry 1 ate also can be used. The compositions are UV curable or electron beam curable. These compositions can contain nonacrylic UV curable unsaturated organic monomers in amounts up to 50% by weight of the UV curable hardcoat compositions. There are included, for example, such materials as N-vinyl pyrrolidone, styrene, etc. When the coating compositions of the '325 patent contain a mixture of aery lie monomers, it is preferred that the ratio, by weight, of the diacrylate to the polyfunctional, such as trifunctional acrylate be from about 10/90 to about 90/10. Some of the mixtures of diacrylate and triacrylates which can be used include mixtures of hexanediol diacrylate with pentaerythritol triacrylate, hexanediol diacrylate and trim-ethylolpropane triacrylate. dietheyleneglycol diacrylate with pentaerythritol triacrylate, and diethyleneglycol diacrylate with trimethylolpropane triacrylate. While coatings may likewise contain the ultraviolet light reaction product of a single polyfunctional acrylic monomer, coatings which contain the photoreaction product of two polyfunctional acrylic monomers, are preferably the product of a diacrylate and triacrylate. The photocurable coating compositions also can contain a photosensitizing amount of photoinitiator. i.e.. an amount effective to effect the photocure in air or an inert atmosphere, for example, nitrogen, of the coating composition. Generally, this amount is from about 0.01% to about 10% by weight, and preferably from about 0.1 % to about 5% by weight of the photocurable coating composition. Photoinitiators which preferably can be used in a nonoxidizing atmosphere, such as nitrogen, are those selected from the group consisting of: benzophenone and other acetophenones, benzil. benzaldehyde and O-chlorobenzaldehyde. xanthone. thioxanthone. 2-chlorothioxanthone, 9,10-phenanthrenenquinone, 9,10-anthraquinone, methylbenzoin ether, ethylbenzoin ether, isopropyl benzoin ether, 1-hydroxycyclohexyphenyl ketone. α . C - di e t ho xy ac e t o p he no ne . α . - d i me th o x y ac eto o p he no ne , l-phenyl-1.2-propanediol-2-o-benzoyl oxime, 2,4.6-trimethylbenzoyldiphenyl phosphine oxide, and. .α-dimethoxy-α-phenylacetopheone. The coating compositions made in accordance with the '325 patent may also optionally contain UV absorbers or stabilizers such as resorcinol monobenzoate, 2-methyl resorcinol dibenzoate. etc. In addition, other UV absorbers are benzophenones, benzotriazoles, cyanoacrylates and triazines. The stabilizers including hindered amine can be present in an amount, based upon the weight of the coating composition, exclusive of any additional solvent which may optionally be present, of from about 0.1 to 15 weight percent, and preferably from about 3 to about 15 weight percent. The coating compositions made by the method of the present invention may also optionally contain various flatting agents, surface active agents, mar resistant additives, thixotropic agents. UV light stabilizers and dyes. Various surface-active agents, also may be used in the coating compositions made by the method of the invention and include anionic, cationic and nonionic surface-active agents. The materials are described in Kirk-Othmer Encyclopedia of Chemical Technology, Vol. 19. Interscience Publishers. New York, 1969. pp. 507-593. and Encyclopedia of Polymer Science and Technology, Vol. 13, Interscience Publishers, New York. 1970, pp. 477-486. both of which are incorporated herein by reference. The following examples show how to make a curable silicon-containing curable synthetic resin in accordance with the '325 patent. All parts are by weight. EXAMPLE 1 1 A mixture is heated at 60° - 70° C. for 2 hours consisting of 99 g of a mixture of colloidal silica in isopropyl alcohol having a pH of 3-5 containing 30% Si0 2 13 g of methylacryloxypropyltrimethoxysilane. and 0.2 g of galvinoxyl. After heating, 36.2 g of hexanedioldiacrylatc is added and the mixture is stripped under vacuum (30 torr) with a nitrogen bleed. This produces 76 parts of a radiation curable purple oil having a viscosity of 56.5 cps. A blend of 10 g of the purple oil. 10 g of trimethylolpropanetriacrylate. 1.2 g of Vicure® 55. methylbenzoyl formate of Akzo Chemical Co.. and 30 g of isopropanol was flow coated onto a polycarbonate substrate and UV cured in air at 20 ft./min. The cured coating was found to be abrasion resistant as shown by the steel wool rub test and it had a yellowness index of 0.8. The above procedure was repeated except that 99 g of a colloidal silica methanol mixture having 30% by weight of Si0 2 . 13 g of methylacryloxypropyltrimethoxysilane. and 0.2 g of galvinoxyl were heated for 1 hour at 65 °C. There was then added 36.2 g of hexanedioldiacrylate and the solution was stripped. A yellow gel was obtained. The above procedure using the colloidal silica methanol mixture was repeated except that about 30% by weight of isopropanol was added to the mixture prior to stripping. There was obtained an radiation curable oil having a viscosity of 146 cps. EXAMPLE 12 A mixture was heated consisting of 520 g of IPAST of Nissan Chemicals (a low pH mixture of 156 g of Si0 2 in isopropanol having about 14.9 g of water). 68.3 g of methylacryloxypropyltrimethoxysilane. and 0.75 g of 4 -OH TEMPO. The mixture was heated to 83 ° C. for 3 hrs. and allowed to cool to room temperature. There was then added 183.1 g of hexanedioldiacrylate. While bubbling nitrogen through the mixture, the mixture was stripped at 30 torr for 1 hour at ambient temperatures. After one hour of stripping, the pot temperature rose to 63 °C. There was obtained 412.2 g of a radiation curable oil having a viscosity of 53 centipoise. Application of the Coating Composition of this Invention to a Metal Surface. An example of a finished product of this invention is shown in Fig. 1. A metallic substrate or work piece 11, such as aluminum, stainless steel, nickel, copper, gold, silver, chromium, tin, magnesium, zinc. lead, brass, bronze, or various other metals or metallic alloys, is covered by a base coat 12 of cured polyurethane. The base coat is covered by a top coat 14 of a cured silicon-containing synthetic resin, such as one of those described above. Fig. 2 shows a process for making the product shown in Fig. 1. Referring to Fig. 2. the metal substrate (work piece which can be any of many different types of metal objects, e.g., wheels, tools, hardware or plumbing fixtures, or the like) is subjected to an alkaline wash 16 in a conventional chemical polishing procedure. The alkaline wash can be any suitable aqueous composition, such as Soak 715™ supplied by Solin Products, Inc. of Anaheim, CA.. and described in Solin * s Product Bulletin No. 1 1034 (attached as Appendix 2) issued 01/01/93 for Soak 715™. The primary ingredient in Soak 715™ is borax, and the solution has a pH of about 10. The metal substrate is subjected to the alkaline wash by spraying, dipping, or agitation at a temperature between about 100°F to 210°F for 1 -10 minutes, depending on the contaminants which may be on the surface of the substrate to be coated. The metal substrate is then subjected to a first rinse stage 18 in regular water for at least 10 seconds, and then subjected to an acid wash 20 for at least 10 seconds at a temperature between about 100°F andabout200°F. The acid wash can be any suitable commercially available material. I use AC25™ supplied by Solin, and described in Solin ' s Material Safety Data Sheet (attached as Appendix 3) dated 4/90 for AC-25™, which is a mixture of phosphoric and sulfuric acids in water, and has a pH between 0.9 and about 2. The acid-washed work piece then passes through a second rinse stage 22 in regular water for at least 10 seconds. The rinsed substrate work piece then passes through a chemical polishing stage 23, such as that described in a Technical Information Bulletin (attached as Appendix 4) published by Albright & Wilson Americas (A&WA). That A&WA bulletin describes how to effect chemical polishing of aluminum in a manner well known to those skilled in the art. If other metals are used as a substrate, appropriate well known chemical polishing procedures are used for the specific metal or alloy employed. For chemical polishing of aluminum, I prefer to use Phosbrite 172™, which is a phosphoric acid-sulfuric acid-nitric acid solution developed by A&WA, and described on page 17 of the A&WA Bulletin. The chemically polished substrate then passes through a third rinse stage 24 in regular water for at least 10 seconds. The rinsed substrate then passes through a desmutting stage 26, which includes soaking in nitric acid (about 40% nitric acid by weight in water), or a suitable proprietary desmutting solution, such as Solin' s Desmut 51™ solution to remove smut. Desmut 51™ is a mixture of concentrated nitric and sulfuric acids, and is normally used at 5% to 12% by volume in water. The desmutted substrate passes through 4th, 5th and 6th rinse stages 28, 29, and 30, respectively. To prevent contamination of the cleaned surface, the 6th rinse stage 30 preferably uses deionized water. The substrate is then moved directly from the 6th rinse stage 30 to a chromate dip 31 , which can be any suitable commercially available chromate dip solution and process. For example, in treating aluminum surfaces, I prefer to use BENCHMATE 320P material, which is available from Benchmark Products at 5425 W. 84th Street, Indianapolis, Indiana 46268. To prepare the chromate dip solution. I dissolve 5 grams of the BENCHMATE 320P material per liter of deionized water. The solution has a pH of about 1.5. I immerse the work piece in the chromate dip solution at room temperature for about 10 seconds, and follow that with a seventh rinse 31 A in deionized water at about 200°F for about 60 seconds. Thus, the cleaned surface of the substrate is chromated, which provides added corrosion protection and serves as a good base for the subsequent application of the polyurethane base coat 12 (FIG. 1). The chromate treatment gives good corrosion creep protection if the final coating is compromised by a nick, scratch, cut. or the like. BENCHMATE 320 P is described in Benchmark Product ' s Technical Data Bulletin (attached as Appendix 5), Benchmark Product's Material Safety Data Sheet (attached as Appendix 6). After the seventh rinse 31 A. the chromated substrate is passed through an eighth rinse 31 B in deionized water at about room temperature. The substrate is then moved directly from the 8th rinse stage 3 IB to a ninth rinse stage 32 in deionized water. The transfer of the substrate from the eighth rinse 3 IB to the ninth rinse 32 is preferably effected without permitting the surface of the substrate to dry so that it is protected by a film of water at all times during the transfer between the eighth and ninth rinse stages. The clean chromated substrate work piece is now ready for application of the base coat 12 of polyurethane. which preferably is at least partially copolymerized with one or more acrylic monomers. The base coat is applied by any of the suitable, well-known and commercially available processes, such as dipping, spraying or electrodeposition. Some of the electrodeposition processes are described in U.S. Patent Nos. 5.756.221, 5,401,823, 5,350.636 (which includes pigments in the urethane coating). 4,973.392. 4,939,216, 4,869,796, 4.617,331, 4,612,049, 4,554.212, 4,547,409, 4.496,672.4.477.642.4.416.753, 4,058,444 and 3,869.366. These patents disclose conductive aqueous emulsions of polyurethane compounds suitable for electrodeposition on metallic surfaces. Each of the 15 foregoing patents is incorporated herein by reference. As indicated above, my presently preferred process for electrodeposition of polyurethane on metal surfaces is disclosed in ClearClad Coatings, Inc.'s Installation and Operation Manual (Appendix 1) (Release Number 2.0, Manual Serial Number: 1 192, copyrighted 1997 by ClearClad Coatings, Inc.). The electrodeposition process described in the Manual is referred to as electrophoretic coating. The process deposits a cross-linked organic polyurethane lacquer coating to any metal with proper treatment as described in the Manual. The coating can be clear or colored with pigment, translucent or opaque, and has uniform thickness over the coated surface, usually in the range of 1 - 100 microns (.00004"-.0040"). For coating aluminum and magnesium surfaces, I prefer to use ClearClad LCX® polyurethane/acrylic electrocoat enamel supplied by ClearClad Coatings, Inc., and which is described in the Manual on page 48. The ClearClad urethane/acrylic coating material is supplied as a concentrate, which is diluted with deionized water to form an emulsion coating bath in a coating tank 34 (FIG. 2). Electrodes (anodes), not shown, are placed in the coating bath and made anodic (+) in a direct current (DC) circuit (not shown). The work piece to be coated is placed in the bath and made cathodic (-). As current flows, the resinous polyurethane/acrylic material in the emulsion deposits on the substrate work piece 10. The deposited polyurethane/acrylic is an insulator, and as it coats the metallic substrate, current flow is reduced until the electrodeposition stops. Thus, the coating process gives a uniform thickness over the substrate. Typical time required to apply the polyurethane/acrylic base coat 12 is 30-200 seconds. The final coating thickness is proportional to the voltage applied to the DC source, which generally is in the 10-150 volt range. The higher the voltage, the longer the electrodeposition. and therefore the thicker the deposited polyurethane/acrylic film required to insulate the substrate and stop the coating process. The electrodeposition process continues until all conductive areas on the workpiece are insulated, giving a uniform thickness over the part being coated. The self-limiting characteristic of the coating process results in good "throwing power" into hard-to coat places. To start coating, the voltage is slowly "ramped up" either automatically or manually to the desired final voltage, which remains on for the time required to achieve a complete and uniform coat. Simple surfaces are completely coated in a relatively short time. Surfaces with complex configurations require longer coating time, which is easily determined by simple experimentation. I prefer to deposit a polyurethane/acrylic film which results in a final cured base coat with a thickness between about 2 and about 100 microns (.00004"-.0040"). The base coat can either be clear, or contain pigment, as described in the prior art cited above. After the substrate is coated with the base coat, it is removed from the coating tank 34 and passed through a tenth rinse stage 36 to remove excess coating material as described in the ClearClad Manual on pages 1-10. After the excess coating material is removed by rinsing in the tenth rinse stage 36. the work piece is passed through an eleventh rinse stage 38 in deionized water. Thereafter, the polyurethane/acrylic base coat is air dried at drying stage 40 for three to ten or more minutes, depending upon the complexity of the work piece, to allow water to evaporate. The base coat is then subjected to a curing stage 42 in an air-circulated oven (not shown) free of airborne particulate matter, and capable of maintaining the work piece at the desired temperature for up to 15 minutes. Usually, a complete cure is achieved in about 5 minutes, especially if the air-circulated oven uses heated air supplemented by infrared radiation. Ordinarily, the cure takes place at a temperature between about 200°F to about 375°F. The actual curing temperature depends on the particular coating composition used, and is easily determined by simple experimentation. The work piece coated with the cured base coat is passed through a cooling stage 44 in air for between 1 and 10 minutes to drop the temperature below about 120°F. It is optionally then passed into a solvent rinse stage 46 to start the process for applying the silicon-containing resin top coat 14 (FIG. 1). The solvent rinse can be any suitable polar organic liquid, such as isopropyl or isobutyl alcohol. If necessary, the work piece is coated at a primer station 48 with an appropriate primer for the silicon-containing top coat material. I have found that the solvent rinse 46 can be omitted, and that no primer need be used if the top coat is applied by using appropriate silicon-containing curable synthetic resin compositions, such as those described in the patents referred to above and incorporated by reference herein. I prefer to use silicon-containing resin compositions which include a substantial amount of colloidal silica particles to give the finished top coat superior hardness and resistance to abrasion. For example. UVHC 8558™ resin supplied by General Electric Company (and described in U.S. Patent No.5,712,325 referred to above) provides a thin, clear, mar-resistant film when applied to the base coat. The UVHC 8558™ resin does not require any solvent rinse or primer, and is applied in an application stage 50 (FIG. 2) by spraying, dipping, flowing, or spin coating. The UVHC 8558™ resin is preferably diluted with isobutyl alcohol to about 25% by weight for spraying, 50%-70% for spin coating, 40%-45% for dipping, .??_ and 10%-40% for flow coating. The concentration of the resin is adjusted so that, depending on the method of application, the final cured top coat has a thickness between about 1 micron and about 10 microns (.00004" to about .0004"). In general, the cured base coat should be between about 2 and about 15 times thicker than the cured top coat. I have obtained an excellent coating composition with a cured base coat thickness of about 15 microns, and a cured silicon-containing synthetic resin top coat thickness of about 5 microns, giving a total thickness of about 20 microns for the final coating composition. The work piece with the uncured top coat resin on the cured base coat resin is then passed through a solvent flash offstage 52 for at least 10 seconds to allow excess solvent in the top coat resin to evaporate. Thereafter, the top coat resin is cured in a curing stage 54 for about one second to about 60 minutes, depending on the composition of the resin, and the curing technique, which can be with ultraviolet light, hot air curing, particle bombardment, such as electron beam, or any combination of those techniques. For example, GE's SHC 5020 resin cures at 266°F in about 30 minutes. GE's SHC 6000 resin cures at that temperature in about 60 minutes. Curing time varies with the properties of the silicon-containing resin used and the curing method, all of which is easily established by simple experiments to achieve the desired result. In curing the silicon-containing resin by the application of heat alone, best results are obtained by using a relatively high temperature for a fairly short period of time to minimize the tendency of the cured silicone resin to crack, which can be induced by the difference between the coefficient of thermal expansion for the metallic substrate and the silicone resin. I presently prefer to use GE's UVHC 8558™ resin (which is cured by ultraviolet light, and therefore does not require the application of heat for curing) diluted with isobutyl alcohol as described above for applying the top coat to the work piece prepared as described above. Preferably, after the top coat resin has been applied and passed through the flash-off stage 52 for 20 to 300 seconds, the work piece is then passed into a hot air oven 53 at about 160°F to 195°F, and preferably at about 175°F for about 5 minutes. Preferably, the hot air oven includes air circulation so that heat transfer to the part is rapid. This heating step improves the bonding between the silicon-containing top coat resin and the underlying polyurethane/acrylic base coat. Alternatively, this heating in the hot air oven can be reduced in time by minimizing the cooling time for the work piece in cooling stage 44 after the polyurethane/acrylic is cured at about 350° F. Depending on the specific silicon-containing resin used, and the amount of diluent and other volatiles in the silicon-containing resin, the work piece with the cured base coat can be cooled to about 100°F, and the silicon-containing resin can be applied directly to the warm surface of the cured base coat. The heat will cause rapid solvent flash off. Thereafter the silicon-containing resin can be heated to between about 160°F and 195°F. and thereafter cured. In using this alternative procedure, which reduces the time required for heating in hot air oven 53, care must be taken that the volatile materials in the top coat are not flashed off so fast as to cause bubbles or haze in the final coat, if a clear top coat is desired. Lό- With either procedure, after the volatiles are flashed off and the interface between the top coat and base coat has been heated to above about 160°F to cause interlinking of the two coats, the work piece passed into the curing stage 54. which for the GE UVHC 8558 resin includes an ultraviolet light source for curing the resin to the final hard top coat. This heating step occurs after substantially all the volatiles have been removed from the uncured topcoat so there is substantially no evaporative cooling effect. This assures that the temperatures of the interface between the uncured top coat and the cured base coat reaches ambient temperatures. It should be pointed out that heating the UVHC 8558™ resin to 160°F. or more, is contrary to the supplier ' s recommendation that the material not be heated above about 130 °F. However, I obtain superior bonding between the silicon-containing resin and the cured base coat by heating the interface between them above about 160°F. and preferably to 175 °F or higher, and thereafter curing the silicon-containing resin with ultraviolet light. Preferably, the ultraviolet light should be at 250 to 360 nm with at least 75 mj/cπr of minimum energy, as recommended in the GE Product Description Sheet 4979 (12/94) for "UVHC 8558 ABRASION RESISTANT SILICONE HARD COAT FAST CURE" (attached as Appendix 7). Using one Fusion ultra violet Type H bulb at 300 watts per inch, which applies between about one-half to about joules/cm 2 to the surface of the work piece, the UVHC 8558 resin can be fully cured in about one second to about five minutes depending on the size and configuration of the work piece. The UVHC 8558 resin has 100% solids by weight, a viscosity of 20-80 cstk at 77°F, a density of 10 lbs/gal; an abrasion resistance of 10 Taber, d%H500, and a flash point of 81 <>C. GE's Material Safety Data Sheet (attached as Appendix 8) for UVHC 8558™ refers to three trade secret components, which are identified in the State of New Jersey as Trade Secret Registry Nos. 1147301 4-5005; 1 147301 45137; and 1 147301 4-5135. In another preferred embodiment, I substituted GE's UVHC's 3000 hard coat silicone resin, which contains a uv absorbent, for the UVHC 8558™ resin. The UVHC 3000 resin is cured by uv light as described above for the UVHC 8558 resin, and is described in GE's Material Safety Data Sheet for UVHC 3000 hard coat resin. In general and for best results, I prefer to use a silicon-containing synthetic curable resin for the top coat which includes a dispersion of colloidal silica, such as described in U.S. Patent No. 5,712,325 referred to above and incorporated herein by reference. As disclosed in that patent, the preferred resin composition includes between 80 to about 95% by weight of colloidal silica dispersed in alcohol where colloidal silica in the dispersion is between about 5% to about 70% by weight. The curable silicon resin is an alkoxysilylacrylate, preferably of the general formula given above. I also get good results using a simple mixture of an alkoxysilylacrylate, such as 3-methacryloxypropyltrimethoxysilane (available from United Chemical Technologies, Inc. as M8550-KG), and colloid silica dispersed in an alcohol having 2 to 5 carbon atoms, such as isopropyl alcohol. Nissan Chemical Co.'s IPA-ST is a dispersion of about 30% colloidal silica by weight in isopropyl alcohol. Thorough mixing of one volume of Nissan ' s IPA-ST colloidal silica dispersion with one to four volumes of the M8850-KG for about one minute provided a silicon-containing curable synthetic resin which made a good top coat when applied to a base coat of cured polyurethane or to a cured polyurethane/acrylic mixture. However, this top coat takes about twice as long to cure with uv light as the above examples which include photoinitiators. Moreover, the final appearance of the more simple top coat is not quite as clear as the other examples. Nevertheless, the more simple top coat forms with the base coat a superior coating composition that protects and adheres firmly to metal surfaces. The improved coating composition of this invention appears to depend on the heating of the interface between the uncured silicon-containing topcoat and the cured polyurethane-containing base coat. Without this heating step the top coat does bond firmly to the base coat. Moreover, the heating step appears to cause at least part of the silica to concentrate in a zone 60 (FIG. 2) within 1 or 2 microns of the exposed surface of the top coat. Examination of a section of the cured coating composition on a metal substrate with a scanning electron microscope indicated that most of the colloidal silica concentrated in a zone within 1 or 2 microns of the exposed surface of the top coat, and there was no discemable boundary in a region 62 of the cured coating composition where the uncured top coat resin initially contacted the cured base coat resin. The coating composition of this invention, applied to metal substrates as described above provides superior bonding, resistance to corrosion, abrasion, and the like. For example, common marking materials widely used by vandals to apply graffiti to exposed surfaces are easily removed by simply rubbing the surface of the article coated as described above with 000 steel wool. This removes the graffiti without marring the surface of the cured silicone resin top coat. APPENDIX 1 TM <3 wra irem INSTALLAΉON AND OPERAΉON MANUAL Release Number 2.0 CLEARCLAD ™ is an L.V.H. registered product name. gs, Inc. File HKIOM. VC bme 2/10/97 An Overview of Electrophoretic Coatings s Coating System Requirements and Coating Procedures Table of Contents An Overview of Electrophoretic Coatings (Section 1) 1 Coating System Requirements and Coating Procedures (Section 2) 3 Equipment Required and Preparation (Section 3) 7 Mixing of ClearClad ConcentratestAdditives and Bath Makeup (Section 4) 13 Bath Maintenance and Control (Section 5) 20 Ultrafϋtration, Design and Operation Considerations (Section 6) 26 Colored ClearClad Coatings (Section 7) 42 Analytical Control Methods (Section 8) 44 ClearClad Coating Products, Characteristics and 48 Operating Conditions (Section 9) Troubleshooting Guide (Section 10) 53 Coverage of ClearClad Coatings (Section 11) 61 Appendix A (Section 12) 63 An Overview of Electrophoretic Coating Electrophoretic Coating, sometimes referred to as E-Coat, is a general term describing the application of organic coatings (Lacquers) to metallic substrates through the use of electric currents. As one might imagine, there are a vast number of formulations and techniques within the whole field of electrophoretic coatings. Additionally, these coatings can be can be further categorized into two groups which make the item to be coated either anodic (+) or cathodic (-) in a direct current circuit. For our purposes here we will discuss primarily ClearClad cathodic coatings which employ state of the art techniques developed over many years of experience endeavoring to maximize the quality and properties of these films as well as ease of application. The ClearClad process deposits a cross linked organic polyurethane lacquer coating to any metal with proper pretreatment. The coating can be clear or colored, translucent or opaque, and has uniform thickness over the pan, typically in the 10-20 microns (.0004" - .0008") range. It is extremely durable resisting the affects of chemicals, tarnishing, abrasion and ultraviolet light. ClearClad is applied using, what is termed, an electrophoretic deposition process. This is a method to uniformly deposit the resinous material which makes up the lacquer coating before curing through electrodeposition techniques. The equipment to accomplish the coating looks remarkably like electroplating equipment but that is where any analogy stops in many ways, especially as regards environmental impact. The electrodeposition process for ClearClad can be described in a general way as fellows. ClearClad is supplied as a concentrate which is diluted with deionized water to form an emulsion in the coating tank that is stable over a specific pH range in the mild acid regioa Electrodes (anodes) are placed in the coating bath and made anodic (+) on a direct current (DC) power source. ' The article(s) to be coated are placed in the bath and made cathodic (-) on the same power source. As current flows electrolysis of the water takes place, oxygen and hydrogen are evolved at the respective electrodes, the anodes and the work, and, at the work to be coated (cathode), a thin layer of alkalinity forms at the interface with the solution. The resinous material in the solution becomes unstable at this alkaline interface and coagulates on the work. The resins, as deposited on the work, are an electrical insulator and as the coating adheres on the work the current is reduced until the electrolysis stops and deposition of resinous material is terminated. The coating process continues until all conductive areas on the work are insulated giving a uniform thickness over the part being coated and good "throwing power" into generally hard to coat places. Typical time required to apply the coat is 45-90 seconds. With this system, the coating thickness is proportional to the voltage applied from the DC source, generally in the 25-75 volt range. This is, for example, because a higher voltage can sustain 5 electrolysis longer and needs a heavier film to insulate the substrate and limit electrolysis and stop the coating process and vice versa. One can quickly see the why electrophoretic coating is not really analogous to electroplating. An electroplated layer of metal depends on the current (ionic conduction) through the solution where metal ions in the plating solution are reduced at the work (cathode) in the form of metal. The thickness of the plated metal layer at any point on the surface depends on the amount of current at that point and i o the length of time that it was exposed to this current flow. As a result plating tends to be non uniform in thickness since it is virtually impossible to maintain uniform current over the entire surface of a part. The differences between electroplating, that requires ionic conduction, and electrophoretic coating that requires it only to sustain a small amount of electrolysis of the water portion of the coating bath, bring out an important point that will be stressed throughout this manual. That is, cleanliness of the coating bath and the necessary steps, on a production basis, to maintain the required level of cleanliness. The best indicator of the cleanliness of the coating bath is it's electrical conductivity. If an electrophoretic coating bath becomes too conductive, leading to increased ionic conduction, there is more gas evolved at the electrodes. At the work, excessive gassing will cause major problems in the coagulated resinous material as deposited. The importance of bath cleanliness and proper control cannot be emphasized enough. On exiting the coating tank, the electrodeposited film of ClearClad need be only rinsed, air dried if one ^ υ chooses and oven cured after the coating operatioa Information on these subsequent steps will be covered in more detail later in this manual. 25 ClearClad Coating System Requirements The following flow diagram shows the key step in the coating system. A discussion of each part of the system and their purpose follows. 1) Pretreatment 2) De-Ionized Water Rinse 3) Clearclad Coating Tank 4) Drag Out Rinse 5) Rinse Aid Rinse 6) Oven Curing Figure 1 1) Pretreatment - The pretreatment will vary with the type of metal to be coated as well as where it is coming from. For example, parts coming directly from a plating line still on plating racks may need minimal pretreatment. Freshly racked parts that may have soils, polishing compounds, oils, etc. may need extensive cleaning before coating. The basic requirement from the p retreatment. for good coating, is to have a clean water break free surface condition. One would want the parts to have been through an acid dip of some kind so as not to drag any alkaline material encountered in any prior steps into the coating bath thereby gradually raising the acid pH of 5 the bath. For example, if one were pretreating polished brass parts for coating a typical pretreatment cycle would be to ultrasonically clean the parts first in a mild alkaline solution to remove any remaining compounds and soils. Next, after rinsing, the parts would be electrocleaned in a strong alkaline cleaner to insure a water Break free surface. This would be followed by good Deionized (DI) water rinses. At this point the surface of the material, although DI rinsed, is of an alkaline nature since that was the last cleaning bath that they were in. It is best to follow the rinsing with a mild acid dip to gain an acid nature to the surface before moving on towards the coating tank. 10 This acid dip can be as simple as a dilute solution of sulfuric acid (5%), also other acids are used depending on the type and condition of base metal being coated. As a general rule it is best to avoid hydrochloric acid (HCL) since any chloride radical of the HCL dragged forward will increase the conductivity of the subsequent rinses and the coating bath. See the Typical Pretreatment Cycles section in Appendix A of this manual. 15 An example at the other end of the spectrum would be coating with ClearClad of gold plated parts as they exit a gold plating line. If the gold plating bath used is of an acid pH then, most probably, one could just perform good DI water rinsing and enter the coating bath directly. 2) De-Ionized Water Rinse - This rinse is most important and it's purpose is to protect the coating bath from any drag-in of contaminants the work was exposed to in the pretreatment cycle. The actual construction will depend on the workload and should require a minimum of two static rinses with ~ rinse aid (See Equipment Required and Preparation section next in* this manual). The important point is that the last rinse that the work sees before entering the coating tank be maintained below 50 microsiemen in conductivity. If this rinse rises above this conductivity level work should be stopped until the rinse conductivity is corrected by complete or partial change. 3) ClearClad Coating Tank - The pretreated and rinsed rack of work is then placed in the coating tank. It is generally placed on a cathode bar that supports the rack in the tank with all the work immersed in the coating solutioa The rack need not be agitated by cathode bar reciprocation as is 25 common in electroplating tanks, mild solution agitation of the ClearClad solution by the pumps is adequate agitatioa Once placed in the tank the rack is allowed to wet with coating solution without any application of voltage for 5-10 seconds and possibly as long as 45 seconds for more complex part configurations. It is important upon entering the tank to remove the work and reenter the tank at least one additional time to help this wetting process. The voltage from the rectifier is slowly "ramped up" either 30 automatically or manually to about 30 volts DC, The voltage remains on for approximately 60 seconds and at the end of this time the rack is removed. One must take care to assure that there is, ideally, an approximate 1:1 anode to cathode ratio is 35 maintained. That is, the area of anode material in the tank is about equal to the area of the cathode (the work on the Tack). For racks of work that ary in area of work to be coated it may be necessary to remove or install some anodes, generally just hung over an anode bar against the walls of the tank, to maintain this ratio. For racks with consistent work area the anode setup once established need not be changed. 4) Drag Out Rinse - On exiting the coating bath, the rack of work is the rinsed very thoroughly in a drag out πnse tank immediately following the coating tank. In the preferred setup this drag out rinse is "Closed loop" for maximum use of the ClearClad material (98%*+-) and to minimize 10 waste effluent. (See Equipment Required and Preparation next in this manual) This rinse takes off any excess ClearClad material and, in the closed loop setup, will return it to the coating tank. This rinsing is best achieved by repeated immersion and removal of the rack so that the work pieces break the surface of the rinse many times. The effectiveness of the rinsing may be judged visually by the absence of water break or runs on the surface of the parts and the removal of any excess material. j 5 5) Rinse Aid Rinse - The rinse aid rinse is a closed rinse that contains a small amount of Rinse Aid (approximately 1 ml/liter), a wetting agent, to help in shedding the water before oven curing. The rinsing action required here need be much less vigorous since most of the work removing excess material has been done in the Drag-Out Rinse. Upon removal from the rinse aid rinse, the rack should be shaken if possible to shed as much of the remaining water as possible. Use of clean compressed air blow off is possible for some types of parts. 7f s Special attention must be paid to such areas as blind holes or small cavities in the parts that may hold solution that will bleed out during the oven curings Any significant water remaining on the surface during the oven curing cycle may cause water marks in the cured coating or improperly cured coating. Generally speaking, a vigorous shaking of the rack after the rinse aid rinse and a room temperamre drying in a clean atmosphere before the oven curing cycle are adequate for excess water removal. It should be pointed out that the coating at this time is "tacky" to the touch and the handling and holding of the rack before it is placed in the oven for curing must be accomplished in a clean area free of 25 airborne particles that might stick to the tacky surface. 6) Oven Curing - An air circulated oven free of airborne paniculate and capable of maintaining the racked parts so that the base metal of the parts being coated will be exposed to the curing temperamre for a minimum of 15 minutes is required. This "metal temperature" may be distinct from the oven air temperamre. That is to cure parts for 15 30 minutes metal temperature at 160°C (320°F) it may be necessary to place them in the oven at 165°C (329°F) for 20 minutes. This would allow for heat up time of the base metal temperamre to the curing temperamre and also compensate for the fact that the metal temperamre of the parts may not quite reach the oven temperamre. 35 Also, as a practical matter, it is a good idea to check the actual temperamre of curing by an independent means from time to time. Often one finds that the theπnostatic control system on commercial ovens may be sensing the oven air at an area different from where the parts to be cured and you may not be getting the curing temperature you require. The curing temperatures of various ClearClad products are in the range of 120°C to 160°C (248°F to 320 C F). The actual curing temperature you will require will depend on the particular Clearclad product or combination of products you are using. For a quick test to ascertain proper curing see the Miscellaneous Tests section in Appendix A. Equipment Required and Preparation The diagram below (figure 2) shows a typical ClearClad coating tank and its associated drag out tank. Also shown are the ultra filter (UF), paniculate filter (F), strainer (S), and the ion trap (IT) and the plumbing of these items into the system. Workflow From Pretreatment To Rinse/Dry/Cure Figure 2 The items shown in figure 2 are the heart of the ClearClad coating system and the function of each will be discussed. In addition, and not shown, depending on the installation heaters and/or a cooling coil may be required to maintain the coating bath within it's operating temperature range. The coating and drag out tanks are generally of Polypropylene material and are configured with a dam/weir arrangement as shown. The pump and filter (F) is operated generally with a standard 10" filter cartridge (I micron retention typically) and is returned to the coating tank through a "sparger" tube that, across front to back dimension of the tank, creates a uniform solution flow in the direction as shown forcing overflow over the weir arrangement. The purpose of this pump/filter circuit is to continually filter the coating solution to remove any paniculate and create a gentle solution agitation to continually refresh the supply of material at the surface interface where the coagulation of resinous material takes place during coating. This pump/filter circuit can be accomplished with external components as shown. However, it can also be accomplished with an "over the side" filter/pump assembly in the weir as long as the output of the filter/pump is directed back into the coating tank through the sparger assembly to create the flow required. The ultra filtration unit (UF) is a means by which water and water soluble materials may be removed from the ClearClad bath while retaining the ClearClad resins and returning them to the coating bath. To understand the importance of ultra filtration one must consider what takes place as the coating proceeds. The -key items that take place are: a) The solids content of the coating bath is reduced as the coating is formed on the work and the acid content of the bath is increased. b) Despite all precautions to avoid it, some contamination may be dragged in to the coating bath that will contaminate the coating bath, since it is an electrolyte, raising it's conductivity. c) Solid materials from the coating bath will be dragged out on the coated work and will be rinsed off in the subsequent rinse. Unless efforts are made to recover these dragged out solids low utilization of the coating material will result. In the recommended closed loop installation shown in figure 2, the UF unit provides a unique capability to control these changes that are happening to the bath during coating. The UF unit, put simply, is a membrane filter that allows the large particles (resin solids) to be concentrated and returned to the coating tank while the small particles, water, electrolytes, acids and some solvent are "Permeated" through the membrane and returned to the closed drag out tank. The permeate loop is shown being valved to go either back to the drag out tank or to the effluent drain. In actual practice, greater than 90% of the permeate is returned to the drag out tank and something less than 10% may be removed from the system, from time to time, as solids are replenished to the coating bath. This will be covered in greater detail in the Bath Maintenance and Control section of this manual. The portion of this permeate stream returning to the drag out tank is passed through an Ion Trap (IT) to remove ionic contamination that would increase the conductivity of the coating tank. Also shown in figure 2 is a strainer (S) ahead of the input pump to the UF unit. The purpose of this strainer is simply to remove any large particles that may clog the internal input strainer of the UF unit and they are generally easier to maintain than disassembling the UF unit and clearing it's internal strainer. It may be a simple plumbing type strainer or it could be a filter housing with a coarse filter cartridge (e.g. 500 micron stainless steel). The type of device used would depend on the type of work that the system will be processing. Additionally, two 3-way valves are shown on the input and output of the UF unit. These valves allow diverting of drag out tank solution (Permeate) through the UF unit (dotted lines) to purge it periodically for good maintenance and before an extended shut down. This procedure is covered thoroughly in the Ultrafiltration section later in this manual. The diagram below (figure 3) shows the coating tank and it's associated drag out tank as well as the pre-dip Deionized Water Rinse tank(s) and the subsequent Rinse Aid Rinse (conditioning rinse). Rinse Aid Rinse Figure 3 Equipment General - Any material in contact with ClearClad should be inert and non-corrodible. Plastics such as polypropylene, PVC and nylon are suitable. For metal components stainless steel (grade 316) is preferred. Tanks - Normal acid resistant plating taaks in polypropylene or PVC with full width weir can be used. Techniques to adjust the height of the material in the weir may also be employed. It is important to limit the fall over the weir to the top of the solution in the weir compartment to 3 inches. Exposure of the ClearClad solution to falls greater than this may cause degradation of the ClearClad material in the coating tank. . Rectifier - Should provide 1.5 amperes per square foot of anticipated coating area with variable DC voltage range up to approximately 75 volts. A timer that controls the time duration of power is also recommended. Filter System - A filter system with a filter cartridge with I micron retention and a return via a sparger tube that creates gentle solution movement across the entire width of the weir is preferred. Filter cartridges should be "leached out" in hot DI water for 15 minutes prior to use. Anodes - Anodes should be of 316 Stainless steel and placed uniformly around the inside of the tank and secured firmly to buss bars. The total area of the anodes should approximate the area of work to be coated to maintain an approximate 1: 1 anode to cathode ratio. 0 Ultrafdtration - The UF filter should be of the recommended type. Your ClearClad distributor can provide these or recommend approved UF membranes. The unit should be sized to the coating tank volume to produce approximately 10% of the coating tank volume per hour in terms of Permeate. For more detailed information see TRAP System Design Criteria in the Ultrafiltration section (section 6) of this manual. • * Ion Trap - The IT cartridge is the same size as a standard 10" size filter cartridge and any suitable housing for such a cartridge will suffice. The actual Ion Trap cartridge should be purchased from ClearClad Coatings, Inc. or through your ClearClad distributor. This Ion Trap is not a simple mixed bed deionizine resin cartridge and use of non-approved cartridges here mav cause damage to the ClearClad coating bath. Curing Oven - The oven used for curing the ClearClad coating should be of the air 0 recirculation type with sufficient thermal capacity to quickly recover from loading losses. Accurate thermostatic control is essential and needs to be frequently checked. The oven must be capable of maintaining metal temperamre for 15-20 minutes and in some case for as long as 30 minutes. Metal temperature refers to the temperamre of the components as opposed to the air temperature of the oven itself as mentioned earlier in this manual. Pumps - Pumps with totally enclosed motors are preferred. The body of the pump (exposed 5 to solution) should be of suitable plastic (PVC or polypropylene) or stainless steel and only pumps having Viton or Teflon seals should be used. For more information on pump selection, see the Ultrafiltration in Section 6 of this manual. Piping - Wherever possible "hard piping" of schedule 80 PVC should be used. Do not use silicone based pipe joint compounds during assembly construction. Burrs should be removed from the inside of piping during assembly. All joints should be close fitting and all connections should be full 0 length in their sockets to avoid leakage. Valves - For on/off control plastic "Ball" valves should be used. Valves should be full port type with Viton seals and Teflon seats rated to a minimum of 125 psi. 5 Note: Teflon is a registered trademark o E.l. DuPont Corp. Preparation of Equipment The cleanliness of the coating tank and it's associated closed loop drag out tank are essential to the proper start up and maintenance of good quality coating of the system. Therefore, the following steps are very important and need to be followed closely. Important Note: If you are converting existing equipment from another type ofE-Coat material the 10 following procedure may not be adequate for preparation before start up. You should contact your ClearClad distributor for advice on a proper preparation procedure designed to remove traces of the specific E-Coat system formerly utilized that may effect the performance of the ClearClad bath being installed and in some instances could damage the new bath beyond repair. Prior to Bath make up the equipment to be used should be. cleaned as follows. 1) Thoroughly clean any dirt, soils, oils and other foreign materials from the from the inside * - 1 of tank surfaces, piping that is accessible, and filter housings. Pay particular attention to any greases or oils that may be present. Finally wipe these same surfaces with a clean white rag to insure all possible contaminants have been removed. 2) Leach out the filter cartridge(s) to be used in hot water for 30 minutes. Follow this with a soak in a warm 5% sulfuric acid solution for 30 minutes. Finally thoroughly rinse the cartridge(s) in deionized water before reinstalling them. 0 3) Fill the coating tank with the following solution. A quantity of glacial acetic acid (440A324) Emulsion Stabilizer may also be used) equivalent to 1% of the total system volume (the total system volume being the working volume of the coating tank and the drag out tank) and a quantity of (430A264) Solvent replenisher equivalent to 5% of the total system volume. The balance of the solution is water (tap water may be used at this point), fill both the coating and drag out the tanks to working levels and circulate this solution through the system for two hours 5 and then dump. Note: During each of these steps requiring circulation through the system, it is a good idea to operate all valves in the system to insure that all internal surfaces that will be exposed to the ClearClad bath are contacted during each of these cleaning steps. After completion of each of these steps, and the solution for that step is dumped, be sure that all pipes and filter housings are flushed. 30 4) Refill the system with tap water again, circulate for 30 minutes and dump. 5) Refill the system with deionized water having conductivity of less than 15 microsiemens/cm (ms). Circulate for 30 minutes and dump. 35 6) Refill the system with deionized water having conductivity of less than 15 ms. Measure the conductivity when the tanks are filled and note the measurement. Circulate for 30 minutes. Remeasure the conductivity. If the conductivity rises less than 15 ms from the reading taken immediately after refilling the system then you may dump and proceed to make up the new bath. If the conductivity rises more than 15 ms from the reading taken after refilling the system you should repeat steps 3) - 6) above since there are still sources of contamination in the equipment. Mixing of ClearClad Concentrates/ Additives and New Bath Make Up ClearClad products are provided primarily as concentrates that must be diluted with a diluent, either de-ionized water or existing bath material (de-ionized water if making a new bath, bath material if making replenishments to an existing bath). In this section we will discuss the proper methods for dilution of ClearClad concentrates (often referred to as "letting down" the ClearClad concentrate) and addition of color agents, matting agents, solvents, etc. Due to the diversity of ClearClad product types and additives, a system of off-line pre-mixing is recommended for facilitating both new bath make-up and production bath replenishment. As the physical and chemical nature of different ClearClad products can vary greatly, the effectiveness of the mixing and diluting of these is important to the ultimate quality of the process and the final product. Certain products may be added directly to the bath without pre-mixing and this capability will be stated on the appropriate data sheet. However, it should be assumed that all products need pre-mixing unless otherwise stated. Off-line premixing involves the "charging" of paint concentrate into a suitable pre-mixing tank where mixing with additives (where appropriate) and D.I.water/bath material for pre-dilution is accomplished using mechanical stirring (see figure 4). When pre-dilution is complete, all or some of the charge is transferred directly into the process bath via the weir so that final incorporation is accomplished via the bath circulation system (In the case of a new bath make up the pre-diluted material would be introduced through a filter directly into the coating tank until the system was completely filled and circulation could be started). The pre-mixing tank and stirrer combination may range from a laboratory beaker & spatula for very small installations to specifically designed and built stainless steel tanks with permanent motorized mixers for larger operations. However, in all sizes of operation, a propeller-type motorized mixer is recommended as this will give the best emulsification through effective mixing. Any mixer should have sufficient torque to create a vortex at all stages of mixing and dilution. Electric-motor driven mixers are the most versatile. Suitable types range from small laboratory models (0.5 - 10 liters mixing capability) to industrial grades with several hundred liter mixing capability. Small installation pre-mixing may utilize cordless electric drills with a suitable propeller attachment - the more powerful 9.6v types are recommended capable of 1500 r.p.m. with higher torque. Air-motor driven mixers are available especially in medium to large industrial sizes. Important Note: In the case of medium to large scale mixes, if ambient temperatures in the mixing environment are around 90 "F or higher, then attention must be paid to the flash point of the ClearClad materials. In these circumstances, air-motor driven mixers are ideal. Fixed electric motors should be of the explosion proof type. In the case of small scale mixes using cordless drills or removable electric motors, there is a pre-blending method given below to cope with this situation. Pre-mixing Equipment. Materials of Construction The pre-mixing tank and stirrer should be constructed of sound material that is inert to all of the materials to which they will come into contact. For the pre-mixing tank, this includes glass (for very small installations), stainless steel (304 & 316 grades are suitable), PVC, polypropylene and high density polyethylene. Other mateπals should be referred to the ClearClad supplier to insure they are compatible for use with ClearClad products. The same considerations apply to ancillary piping, transfer pumps, etc. with which ClearClad materials may come into contact before, during or after pre-dilution. For the stirrer, stainless steel is the typically used material. Important Note: DO NOT USE mild steel, aluminum, copper, tin, zinc, or their alloys' Pre-m ring Equipment. Configurations and Dimensions The diagram in figure 4 shows the values for the key parameters of the recommended pre-mixing setup. D • Diameter of Mixing Tank Figure 4 It is strongly recommended that these guidelines are observed and adhered to. The dimensions and configurations are based on adaptations of well established procedures in mixing technology and, as such, will enable the most efficient and effective results. The preferred basic geometry for the pre-mixing tank is a cylinder, closed flat at the base, with the height being between 1 to 1.2 times the diameter. The volume of the final pre-dilution - having a solids content of no more than 15% - should occupy between 1/2 and 2/3 of the total mixing tank volume. This determines the initial concentrate charge volume to be approximately 20% or 1/5 of the total mixing tank volume. Conical bottomed tanks may be used in conjunction with fixed transfer pumps for larger or fully automated systems. Further elaborations may include the use of baffles and/or offset/angled stirrers. The engineering of these is outside the scope of this manual, however, the mixing and pre-dilution principles are the same. A propeller stirrer should have a spinning diameter of between 1/4 and 1/3 of the tank diameter. The simplest mounting configuration is vertical with the shaft aligned along the central axis of the mixing tank. The distance of the propeller from the floor of the mixing tank (flat bottomed type) should be 1/3 to 1/2 of the depth of the concentrate charge - i.e. approximately 1/10 of the tank diameter. The sizing of the pre-mix equipment, as a practical matter, will depend first upon whether you are doing a bath make up or replenishments to an existing bath. In the case of a new bath make up, depending on the size of the bath, you may wish to use a larger mixing setup to reduce the number of pre-mix lots. Since this problem is faced only on make up, you could use a temporary setup, but the same precautions must be taken with any temporary set up, cleanliness, proper mixing, etc. For Example, if you were making up a 400 liter (approximately 100 gallon) HDX bath 80 liters of HDX concentrate would be required to be added to the bath for make up. This concentrate would have to be diluted to approximately 264 liters (approximately 70 gallons). Using an 80 liter pre-mix tank it would take 5 pre-mix lots of approximately 53 liters each to dilute the concentrate required. On the other hand, if you expected to use only 5 liters/day of concentrate for replenishment based on the output of work from the coating tank, on a daily basis the total volume of pre-mix lot required would be 16.5 liters. In this case you would want to use a pre-mix tank of approximately 25 liters (6-7 gallons) for proper mixing. Therefore, since new bath make up is done infrequently, more important is the sizing the pre-mix equipment used in pre-diluting replenishment quantities that must added frequently. The equipment and setup to facilitate these frequent replenishments is very important. The sizing will be based on the rate (i.e. how much material per day) and frequency (i.e. how many times per day) of replenishment additions. These two parameters can be used to derive the optimum size of the pre-mixing tank. It is highly recommended that small frequent additions are made versus occasional large ones. This will both maintain better quality and consistency of the bath as well as simplifying the pre-mixing process and equipment. On the basis that any bath should be replenished at least twice daily, the following broad example illustrates a flexible approach. In the following table, under "pre-dilution batch transferred" (A) denotes that the whole of each pre- dilution is transfeσed to the bath in one shot. (B) denotes that the pre-dilution is made as a batch for the day, kept on stir and the indicated number of portions (no more than three are recommended) are transferred at regular intervals. Rate of Use Frequency of Adds Size of Pre- -mix Tank Pre-dilution Batch diters/dav) fnumber/dav Total Volume (liters ' ) Transferred niters ' ) 1 1 5 (A) 1 x 3.3 1 2 5 (B) 2 x 1.65 2 I 10 (A) 1 x 6.6 2 2 10 (B) 2 x 3.3 2 2 5 (A) 2 x 3.3 5 3 10 (A) 3 x 5.5 10 2 50 (B) 2 x 16.5 10 5 10 (A) 5 x 6.6 25 3 50 (A) 3 x 27.5 50 5 50 (A) 5 x 33 For example, referring to the above table, if your daily usage is two (2) liters there are several possibilities shown for handling this replenishment. They are: a) Make up a pre-dilution quantity using 2 liters of concentrate in a 10 liter mixing tank bringing the final pre-dilution volume to 6.6 liters. Add this entire quantity in one shot to the bath via the coating tank weir. b) Make up a pre-dilution quantity as in a) above but add it in two shots of 3.3 liters each staged over the operating shift. In this case the un-added portion of the pre-diluted lot would have to be kept mixing while waiting to be added to the tank. c) Make up a pre-dilution quantity using 1 liter of concentrate in a 5 liter mixing tank bringing the final pre-diluted volume to 3.3 liters. Add this quantity all to the tank at one time. Repeat this operation again at an interval during the operating shift to get the required 2 liters of concentrate into the coating tank. It is clear from this that intelligent management of replenishment frequency allows a wide range of replenishment rates to be accommodated by a limited range of pre-mix tank sizes. Consultation with your ClearClad Suppliers technical staff will enable the optimum size/configuration to be established based on estimated or established usage coupled with a "best-fit" daily add frequency. Important Note: After using the pre-mixing setup, it is important to follow the cleaning procedures outlined in the following sequence. A build up of un-dispersed solids on the inside surfaces of the mixing tank and on the stirrer will ultimately result in paniculate and micro-gel cratering problems - apart from it being a waste of material if it has to be "dug out" periodically. The extended mixing time before transfer and the flushing with permeate after transfer are designed to avoid this situation. Pre-mixing Procedure Terms used Concentrate: Any ClearClad resin/paint concentrate including resin based matting agents. Additives: Solvents, dyes, pigment dispersions, emulsion stabilizers, miscellaneous modifiers etc. that are intended to be pre-dispersed in concentrate (see specific data sheets). Diluent: D.I.water for new bath make up; coating bath material for routine replenishment of existing baths. Sequence 1. Ensure internal surfaces of mixing tank, stirrer and any transfer pumps or equipment are properly clean, (with dedicated equipment and previous adherence to this sequence this should not be necessary - but it is prudent to check all the same). 2. The standard cohcentrate charge (K) in this mixing tank configuration is 1/5 of the total volume of the tank. CHECK THE CONCENTRATE DATA SHEET! If the concentrate solids (as supplied) are outside the range of 45 - 55% and or the supply density (specific gravity) is outside the range 0.9 - 1.1 grams/cm 3 then recalculate as follows: K x 50 = Concentrate charge volume Density (grams cm 3 ) x Solids (%) Otherwise use K as standard (l/5th of pre-mix tank) 3. Add the charge of concentrate to mixing tank avoiding pour-runs or splashes on the tank walls. 4. Ensure stirrer propeller is immersed in concentrate and start stirrer. 5. Add any additives at this stage. If more than one is required, add one at a time ensuring homogeneity before the next add. Keep the pour stream directed into the stirrer vortex. 6. Add a shot of diluent, equal to K 4 and wait until homogeneity is reached. - ) 7. Repeat step 6 three times. 8. Add remainder of diluent (up to max 2/3 of total mixing tank volume) in 4 equal shots ensuring time to homogeneity between each shot. 9. Leave on stir for minimum 20 minutes. 10 10. Transfer all or part (as appropriate) of pre-dilution to coating bath. Slow addition through a filter medium via the weir is preferred. Pre-dilution batches under staged addition (type (B) above) regimes should be kept on stir until completely transferred, especially pigmented and/or matted types. 1 1. When mixing tank is empty, charge with permeate up to the 2/3 line and stir for 10 minutes to clean mixing surfaces. Similarly flush any transfer pumps and equipment. This permeate flushing solution can be added to the drag-out bath for reclaim. 15 12. At this point the mixing equipment should be substantially clean. Mopping up of "puddles" in the mixing tank with absorbent paper should be all that is required. Inspection and cleaning of the equipment at this stage will avoid any difficulties later. Important Note: If the ambient temperature in the area where the mixing is taking place is 20 unavoidably greater than 90 "F, and a non-explosion proof electric motor is used for the motorized mixer, substitute the following for steps 4 & 5. 4. Add diluent equal to 1/6 of charge volume and pre-mix to homogeneity by hand using clean flat bladed implement. This will increase the flash point to 120 - 140°F. Additives with flash points below 120°F should be similarly pre-mixed at this stage. CHECK DATA SHEETS. 25 5. Once all the low flash point materials have been added and thoroughly hand mixed, install the motorized stirrer in the mixing tank, ensure the propeller is immersed in concentrate and start the stirrer. Add higher flash point additives as appropriate ensuring homogeneity between multiple adds. New Bath Make Up For a new bath make up the first question that must be answered is the amount of ClearClad concentrate that will be required to make up the bath. That answer relates to the amount of solids content (%) that -' you wish to have in the completed bath and the size of the bath. The typical solids content for operating ClearClad baths is 10%. Consult the Data Sheet for the bath type you are installing to ascertain the nominal value of solids required for your installation. ClearClad 35 concentrate is typically supplied at 50% solids and is diluted one part concentrate to four parts total water to yield a solids content of the finished bath of 10%. The method used to dilute the concentrate has been thoroughly covered earlier in this section. With this information at hand, the steps to make a new bath make up would be as follows. 1) Calculate amount of ClearClad concentrate required to give desired solids content in the coating final bath. The following formula may be used to make this calculation. Solids Content Req'd (%) Tank size X = Amount of Concentrate required Solids Content (%) of Concentrate being used for makeup Example: For a 200 liter (approx. 53 gallons) tank size, at 9% solids content, 36 liters of concentrate will be required. This assumes a concentrate with 50% solids is used. 2) Knowing the amount of ClearClad concentrate required for the bath and the mixing tank volume(s) you have available, decide on the size and number of pre-mix lots that will be necessary to dilute the required concentrate. 3) Mix the concentrate with de-ionized water (15 microseimens maximum) following the mixing sequence described on page 17-18. If additives are required for the bath add them in proportionate increments to each pre-mix lot. e.g. If 25 ml/liter of yellow dye is required and you are using 100 liters of concentrate for the make up, a total of 2500 ml of yellow dye will be required. If you were going to use four pre-mix lots for diluting the concentrate, add 2500 mls/4 or 625 mis to each pre-mix lot. 4) Add each completed pre-mix lot through a filter media (5 micron filter bag recommended) into the coating tank. 6) Fill the coating tank and weir to final working volume with deionized water. 7) - The closed loop drag out tank should be prepared by adding a quantity equivalent to 3% of it's volume (the drag out tank and weir only) of 430A264 Solvent Replenisher. The balance should be made with deionized water to the working volume of the drag out tank. 8) - Once both tanks are filled the system solution should be allowed to circulate using both the paniculate pump/filter system and the ultrafilter for a period of 24 hours. The bath is then be ready to coat. Bath Maintenance and Control A working ClearClad solution consists of four principle parts. They are: a) Solids Content - Also known as the non-volatile content (NVC). This is the resinous portion of the solution which accounts for the final coating. b) Solvent Content - A number of solvents are present in the solution and a portion of these are incorporated into freshly deposited coating which give flow and leveling during the o curing of the deposited coating. -c) Acid Content" - The acid allows the solids to disperse in water. The acid separates from the solids during the coating process and most of it remains in the bath. d) Water - Deionized water must be added to the coating system from time to time to make up for losses due to evaporation and drag out. Some water is also entrained in the - deposited coating but this is evaporated quite readily. The control of the coating system depends mainly on the maintenance of these four principle parts of the coating bath. This assumes a cathodic bath, were it an anodic bath, i.e. ClearClad Anoclad, this would be alkali content 0 Maintenance of the Solids Content As the coating bath is worked the solid content is depleted by formation of the coating on the work. This depletion is monitored by analyzing the solids content of the bath, the specific procedure for determining solids content follows in the Analytical Control Methods section of this manual. The solids are replenished by periodic additions of ClearClad concentrate. Typically ClearClad concentrates contain approximately 50% solids, however, check the data sheet for the specific concentrate for the 5 bath you are using. For concentrate additions to the bath the following steps should be taken. 1) - The following formula may be used to calculate the amount of concentrate that must be added to return the coating bath to the desired nominal solids content. 0 B x (C - D) A = 5 Where.- A = ClearClad Concentrate required to replenish the bath (liters) B = Volume of the coating bath in liters (liters) C = Required nominal solids content (%) D = Current solids content (%) E = Solids content of ClearClad concentrate For example, in the 200 liter bath we used an example in the Bath Make Up section, after use, if we determined that the solids content had dropped to 6.0% and we wanted to return it to the nominal 9.0% that we made it up at, how much concentrate would we need to add? (Remember, we assumed a concentrate with 50% solids was used) 200 x (9.0 - 6.0) ClearClad concentrate required (Liters) = 50 ClearClad concentrate required (Liters) = 12 2) Pre-mix the required ClearClad concentrate with existing bath material and any additives (dyes, pigments, matting agents) as described in section 4. 3) Pour the pre-mixed lot material into the coating tank weir through a filter media (5 micron filter bag recommended) and allow it to circulate through the system for at least 15 minutes before using the bath. Ideally, additions of ClearClad concentrates should be made as frequently as practical in order to minimize fluctuations in the other bath parameters. In this way an equilibrium is maintained and the other parameters of the bath will not be significantly affected. For a regularly used bath with consistent bath loading (number of racks, work area, etc.) a correct replenishment procedure can be easily established and implemented. As to the frequency of replenishments, if the above 12 liter depletion took place over a three day period, it would be better to replenish 4 liters of concentrate each day (two 2 liter additions staged over the operating period) so the bath does not go to far out of specifications. If the solids content is maintained and periodically monitored, such procedures will allow the overall bath maintenance to be carried out with reasonable accuracy. Maintenance of Solvent Content Under normal circumstances, the correct solvent levels will be maintained through the normal replenishment of solids as outlined above. This is because the concentrate contains the correct amount of solvent relative to the solids content of the concentrate. However, if the solids content of the bath is allowed to stay consistently lower than 8% or higher than 12% or if significant quantities of ultrafiltrate permeate are being discarded, it may become necessary to balance the solvents independently of the solids content. The analysis for the solvent content is done normally by gas chromatography and analysis service of bath samples for solvent content is provided by ClearClad Coatings, Inc. through your ClearClad Distributor. Once solvent levels are determined, corrections can be made to the bath with specific ClearClad products for this purpose on advice from your ClearClad Distributor or ClearClad Coatings, Inc. 10 Two principle types of solvents are present in ClearClad coating baths. They are: a) Disperse Phase (DP) solvent which is contained principally in the solids and acts directly on the coating. It is replenished with Solvent Replenisher 430A250. b) Continuous Phase (CP) solvent which, in fact, are found in both phases and have a less direct effect on the coating. It is replenished with Solvent Replenisher 430A264. 15 Important Note: Solvent Replenisher 430A250 is not water soluble and must be mixed with concentrate before adding it to the bath. Never pour ClearClad Solvent Replenisher 4S0A250 directlv into the coating or drag out tanks! ,. . « - ' 6 6 iX l fl i SJ SΛ For additions of Solvent Replenisher 430A250 use the following procedure £ -£•**••• } ^< rv t J " t -^ tΛΛ " J ~ 20 1) Measure the required amount of the Solvent Replenisher 430A2. 2) Add this one part solvent replenisher to two parts of concentrate in Mix well with a motorized mixer or manually with a flat bladed pac section 4 until a uniform mixture is obtained. 3) To one part of this mixture add two pans of dilute bath material and mix for at least five r. , minutes until a smooth opalescent like mixture is obtained. Add a further one part of dilute bath material and mix. 4) Pour solution into the coating tank weir and allow to circulate through the system for at least 15 minutes before using the bath (longer circulation, even overnight would be preferable). For additions of Solvent Replenisher 430A264 use the following procedure. This is the CP solvent 30 replenisher and it is fully miscible with water. 1) Measure the required amount of the Solvent Replenisher 430A264 into a clean container. 35 2) Slowly add the solution into the ClearClad tank weir and allow it to circulate through the system for at least 15 minutes. Maintenance of Acid Content" During the coating process, the acid content of the bath that allows the solids to disperse in water, separates from the solids and most of it remains in the bath. Therefore, the acid content of the coating 0 bath grows as the system is worked. Through the use of ultrafiltration, the acid content can be completely controlled (see following section on ultrafiltration). Simple put, by removal of small quantities ultrafiltrate permeate being returned to the drag out tank the acid level of the system is reduced. Discarding of ultrafiltrate permeate will reduce the acid content of a normal bath by about 15%-20% for every bath volume equivalent of permeate discarded. The measure of the acid content is termed the MEQ and it is determined by a titration method (see the c Analytic Control Methods section of this manual). The analytical procedure gives a "MEQ/100 grams" of bath material that is used to calculate an "MEQ corrected" value related to the bath solids which is the key MEQ value that should be controlled. If the MEQ corrected value is specified to be at a nominal value of 35 for a given bath and by analysis it is found to be 45, you would reduce the MEQ corrected value by discarding permeate from the ultrafiltration loop going back to the drag out tank (see figure 2). If, in discarding permeate, too much is discarded resulting in a MEQ corrected value that is to low, it may be adjusted upward through the 0 use of Cathodic MEQ Adjuster (440A945) additions directly to the bath. As an example, suppose we discarded too much permeate and we arrived at a value of 28 instead of the nominal value of 35 we desired. You would then add MEQ adjuster to bring the MEQ back up. You would calculate the amount of MEQ adjuster needed as follows. The rule for Cathodic MEQ Adjuster (440A945) is: Addition of . one ml/liter of coating bath, raises the MEQ corrected value one MEQ unit. 5 Example: Bath volume = 200 liter Bath Solids = 8.0% 0 Present MEQ/100 grams = 22.4 This assumes a cathodic bath, were it an anodic bath, i.e. ClearClad Anoclad, this would be alkali content 5 Present MEQ corrected value = 28 (i.e. 22.4 X 10.0/8.0) Desired MEQ corrected value = 35 MEQ corrected rise required = 7.0 MEQ corrected rise required = 5.6 (i.e. 7.0 X 8.0/10.0) MEQ cathodic adjuster required = 5.6 x 200 ml or 1 120 ml required This volume is added directly to the coating bath and allowed to react for one hour before any further analysis. Summary of Bath Control A routine analysis of a ClearClad coating bath will report the following parameters. 1 ) Solids content (%) 2) pH 3) Conductivity in microseimens (ms) 4) MEQ/100 grams bath material 5) MEQ corrected to 10% solids 6) Solvent content, DP & CP <%) 1) Solids - This has been covered quite thoroughly beginning on page 16, remember, maintaining the solids content with in. close limits reduces the possibility of other detrimental effects on other bath parameters. 2) pH - This value should be interpreted in relation to other bath parameters such as MEQ, it is not very important in and of itself. 3) Conductivity - This value is probably the best indicator of bath "health". If the solids and MEQ corrected values are kept within reasonable limits any significant change in the conductivity is a good indicator of other problems. Typically, a good bath will be in the 400- 500 ms range (slightly higher for higher solids content). Higher conductivity readings generally point to contamination of some type that should be investigated and corrected immediately. 4) MEQ/100 grams - This is a measure of the acid content based on the titration of 100 grams of bath material. 5) MEQ Corrected - This value is calculated from the MEQ/100 grams result normalizing it to 10% solids. (MEQ/100 grams) x 10 MEQ Corrected = Bath actual solids (%) Regarding MEQ, consider the following example. The MEQ of a bath is specified to be 30 at 10% solids and the bath is analyzed weekly with the following results: Week MEO/100 grams Solids (%) MEO Corrected 1 30.00 10.00 30.00 2 24.00 8.00 30.00 3 24.00 7.10 33.80 4 40.00 10.00 40.00 The results show that an increase in the acid content took place between weeks 2 and 3. If the MEQ/100 grams results were examined alone without reference to the solids, this change would not be so apparent. 6) Solvent Content - This has been thoroughly covered beginning on page 18. Remember, a properly maintained bath, held within reasonable limits, will need minimal adjustment of it's solvents. Important Note: Records of the bath conditions as measured at any given time must be keep. The importance of good record keeping cannot be emphasized enough. A suggested Bath Log format is shown on the following page and an extra copy is in the back of Appendix A which can be used to make copies. A log of this type should be kept on each bath installed with daily notations of all actions taken with the bath. This bath history can be invaluable in troubleshooting the bath and adjusting additions for trouble free operation of the bath(s). o o CLEARCLAD BATH LOG ClearClad Coatings, Inc. Workflow From Pretreatment <&~ To Rinse/Dry/Cure Permeate to drain Particulate Filter Circuit Primary U/F Pump Circuit F a Pirtleulate Filter Permeate (Flux) Output Circuit U/F a Ultrafilter Membrane U ' •*■ * : < . ■ - * , ■■ j C'f. n * Crossfeed Circuit S s Strainer De-Ionized Water Feed IT a Ion Trap F igure 2 Ultrafiltration Design and Operation Considerations In order to understand the need for and advantages of ultrafiltration, the following processes which occur during the ClearClad coating operation should be reviewed. 1 ) As the solids content is reduced in the bath by formation of the coating on the work, the acid content of the coating bath is increased. 2) Ionic Contamination of the coating bath, an electrolyte, will most probably take place due to "carrying in" of contaminates from processes up stream. 3) Drag out of coating resinous solids material will take place as racks of work leave the coating tank and will end up in the first rinse after the coating tank. Items 1) and 2) above will have a direct influence on the coating quality and the stability of the coating bath. Item 3), if there is no subsequent recovery of materials dragged out of the coating bath, will result in poor utilization of the coating material and environmental problems due to a significant solids content in the effluent going to the drain. A properly installed and utilized closed loop ultrafiltration process will allow good control over the acid content of the coating bath and enable nearly 100% usage of the coating bath materials without creation of effluent solids that must be dealt with for proper pollution control. Ultrafilter Tubular Membrane Concentrated Resin Solids returned to Coating Tank ClearClad Solution from - Coating Tank d to Figure 5 Figure 5 shows how a typical ultrafilter membrane functions. The stream from the coating tank weir (see figure 2) contains not only large resin particles of resin solids but small particles, water, electrolytes, acid, solvents, etc. (the solvents are basically CP solvent although, in practice there is a small amount of DP solvent due to the coupling effect of the CP solvent). This latter group is "permeated" through the membrane while the large particles, the resin solids, are concentrated and returned to the coating tank. The unique ability of the ultrafilter membrane to separate the resinous solid materials from the other materials, some of which are contaminants, yields an ability to assemble and operate a most efficient coating system. To gain a better understanding of the reasons for this we should review the possible systems that could be assembled with a UF unit. The key point in each of the systems is how the o permeate is utilized, there are three possible ways. 1) Simple bath purification ("Kidney unit") - Operating in this mode, unlike the system shown in figure 2, most or all of the permeate produced is dumped to waste in order to eliminate water soluble contaminants. This system has major disadvantages in that: 5 a) There is a continual significant volume loss from the coating system, equivalent to the amount of permeate dumped, which has to be made up with deionized water. b) The non-contaminant constituents of the permeate (solvents, emulsion stabilizer, etc.) will be depleted from the coating bath faster than they can be replaced by the normal introduction of replenishing feed. This will necessitate overly frequent bath analysis in order to monitor losses, and make the required additions of replenishers. 0 2) Closed-loop reclaim - In this mode, a minor portion of the permeate is dumped to effect purification, but the majority is recycled back to the coating bath via the drag out tank. This drag out tank, which is being continually fed with permeate, rinses off the dragged out bath material from the coated components and, being counter flowed back into the coating bath, facilitates reclamation of the dragged out solids. Permeate sprays can be used over either or both the coating and drag out tanks in order to improve rinsing. 5 Advantages: a) Almost 100% utilization of coating material is possible. b) Permeate is a very effective rinsing medium. 0 Disadvantages: a) Greater permeate production is required than the "Kidney unit" system in order to provide sufficient volumes for both purification and reclamation. 5 b) Recycling of a major portion of the contaminants is unavoidable due to the "closed loop" nature of this mode of operation. c) There is still some volume change in the system due to the quantity of permeate dumped. 3) TRAP System - This concept - Total Reclaim And Purification - addresses the problems of the two previous systems by the introduction of ion exchange technology into the "closed loop". This is the recommended mode of operation and is the one diagramed in figure 2 of this manual. The Ion Trap introduced in the permeate return path to the drag out tank 0 provides ion exchange resins which selectively remove contaminants from the permeate, leaving the non-contaminating bath constituents present. Advantages: a) Only minimal quantities of permeate need be dumped. 5 b) There is minimal volume loss from the system. c) There is minimal, and easily controllable, loss of solvents, stabilizers, etc. from the system. d) Recycling of harmful contaminants through the closed loop system is avoided. In this mode of operation, with only a small percentage of permeate waste, TRAP enables the o purification effect of 100% permeate dumping, as in system 1) above, by selective contaminant removal. Accordingly, the greatest proportion of permeate can be utilized for rinsing and reclaiming. With the TRAP system, the amount of permeate dumping required will vary with the particular coating application. In order to control VOC, there may be a minimum volume of dumped permeate per unit of replenisher concentrate added. This is normally sufficient to account for any traces of contaminants "missed" by the TRAP. However, in applications where 5 contamination rates are unusually high, special attention may be required. The system as diagramed in figure 2 is a TRAP system and given the above comparisons one can see why it is the recommended installation. Regardless of which of the above systems is used, when permeate is removed from the system to reduce the acid content, deionized water is put back in the drag out tank to make up for this lost volume of solution in the system. Make un water is never added directly to the coatine bath. 0 In certain applications, using this "closed loop" concept in operations requiring large amounts of permeate to be discarded, where possible, some permeate should be returned to the drag out tank. This can prevent a dangerous situation caused by excessive depletion of acid in the bath. If this occurs, the 5 emulsion becomes unstable and this allows an even greater amount of acid to be removed. Further de- stabilization can then occur and this effect becomes self supporting. This can result in large decreases in conductivity and the process becomes difficult to operate. Also, if the MEQ is allowed to go too high, the converse can occur. The ClearClad emulsion can become so densely packed that ultrafiltration becomes difficult making further acid removal difficult. Proper use of ultrafiltration allows a means where the acid and any contaminants may be removed from the coating system independently of the solids. It is recommended that ultrafiltration systems for ClearClad installations be operated on a continuous basis (24 hours/day). If the ultrafiltration system on an installation is to be shut down for an extended period (plant vacation shut downs, etc.) the following procedure should be followed. a) After work through the coating system has ceased, operate the ultrafiltration system until the drag out tank is clear (all solids have been returned to the coating tank). b) Direct solution from the drag out tank to the input of the ultrafilter. c) Allow this "cleared" drag out solution to circulate through the ultrafiltration system for 20-30 minutes. d) Shut down the ultrafiltration system. Following this procedure will clean out any residue of resinous material remaining in the ultrafilter membrane that might coagulate and cause clogging of portions of the filter membrane. To facilitate this shut down procedure, if the system is plumbed as shown in figure 2, all one need do is operate the 3 way valves (C & D in fig. 2) at the input and output of the UF unit. This will redirect the flow from the drag out weir to the UF unit and from the output of the UF unit back to the drag out tank over the paths shown in dotted lines in figure 2. A typical analysis of ultrafiltrate permeate and the corresponding ClearClad bath analysis is given below. Item Permeate ClearClad Bath Solids (%) 9.00 pH 4.2 4.5 Conductivity (ms) 400 500 MMEEQO//110000 g grarammss 77..0000 27.00 MEQ corrected - 30.00 Solvent DP (%) 0.40 2.70 " CP (%) 4.00 4.00 TRAP System Design Criteria General The key to running a productive and efficient E-Coating system lies in the use of an ultrafiltration system based on the TRAP principle described on page 24, earlier in this manual. Although operation with other systems described in this same section of this manual is possible, we strongly recommend use of a TRAP system for the reasons discussed earlier. What we will do in this section will be to discuss the criteria for design and implementation of a TRAP System. This design is based on the adherence to certain basic rules for this system. They are: a) The basic coating system should consist of two tanks of approximately the same size and configuration (see figure 2 of this manual under Equipment Required and Preparation). Each tank should have a weir which is approximately 10% of it's volume. b) The output of solids from the U F tube, returned to the coating tank, must provide for an certain number of turnovers of the coating tank per hour: i.e. the number of times the coating tank volume is completely changed each hour. The turnover rates that should be observed depends on the type of bath you are installing. For clear baths the rate should be in the 3-5 turnovers per hour while pigmented or baths with matting agents should have turnovers in the 8-10 range. c) The output of permeate from the U/F tube should be approximately 10% of the drag out tank volume per hour (this assumes that the coating tank and drag out tanks are of similar volume). In other words, this permeate output, piped to the drag out tank, should completely change the drag out approximately 10 hours. Since the drag out tank is cross feed into the coating tank, the coating tank will also receive an input of permeate equivalent to it's volume every 10 hours which is our objective. Given these basic design rules, we will take on a specific system design to use as an example. For our example, we will assume that we are designing a coating tank that will be 100 gallons (approx. 380 liters) and that we will be running a clear ClearClad coating bath without any pigments or matting agents. We will have a drag out tank of the same approximate volume. Both tanks will have weirs of approximately 10 gallons (38 liters). Of the rules b) and c) above, the overriding one in designing this system is c) which calls for a specific amount permeate production to turnover the drag out tank approximately every ten hours. The turnover of the coating tank is nonetheless important, however, that is easily accomplished and will be explained in more detail later. We first must choose an ultrafiltration Tube (U/F) that will produce the required permeate output. In our example that is 10 gallons per hour (GPH) or 38 liters/hour (LPH) of permeate. The two figures following will help in our selection of the proper U/F membrane tube. First, figure 5 shows a graphical presentation of the relationship of coating tank size, required permeate Ultrafilter System Design Criteria Unilt = Colont (US) 1500 . Figure 6 production and primary pump rate through the U/F tube which creates the permeate needed (two graphs are shown, gallons and liters). It should be pointed out that the relationship of the primary flow through the U/F tube to production of permeate for these U/F tubes is reasonably constant for all of these U/F tubes as long as the maximum flows indicated are not exceeded. Referring to figure 6, by locating our 100 gallon coating tank capacity in our example on the right vertical axis and looking to the left axis, we need approximately 10 GPH of permeate (the 10% of rule c) above). By locating the point at which 100 gallon capacity line crosses the curve and projecting down to the bottom horizontal axis we can see that the primary U/F flow that will be required to produce the permeate we need (10 GPH) for our system is approximately 17 GPM flow in this circuit. We know that this primary flow will be returned from the output of the U/F be to the coating tank. Generally, all this flow would be returned directly to the coating tank through a sparger mbe in the bottom of the coating tank as previously discussed (see page 8 of this manual). However, to observe rule b) we must consider the turnover rate of the coating tank if we return all of this flow to the coating tank. We know our coating tank volume is 100 gallons. If we were to return all of the U/F output to the coating tank, we would be sending to the coating tank: 17 gallons/minute X 60 minutes/hour = 1020 gallons/hour Since our coating tank is 100 gallons, this flow of 1020 GPH would create a turnover rate of 10.2 times per hour. This would be acceptable if we were using a pigmented bath or one with matting agents in it. In our example however, we said we were using a clear bath that requires only 3-5 turnovers/hour. You will note in the system diagram in figure 2 of this manual, that there are shown two valves (A & B) on the output stream from the U/F tube. One returning to the coating tank sparger and the other to the tank weir. To bring the flow into the coating tank sparger down into line with the turnovers we require, we would shunt a portion of this flow away from the Coating tank directly into the tank weir through the use of these two valves. In our case we would want to shunt a little more than half the flow into the weir to get the turnovers down into the 3-5 turnovers/hour range. In this way we can use a pump large enough to produce the permeate we need and control the turnovers of the coating tank depending on which kind of coating bath we are using. Ultrafiltration Tube Selection Knowing the above information about the U/F system we will use in our example, we can turn to the selection of the actual U/F membrane unit we will use. To recap our example figures, we need approximately 17 GPM of primary pump flow through the U/F tube to produce approximately 10 GPH of permeate. Figure 7 shows a selection of various sized U/F membrane mbes from two recommended manufacturers. By looking at the Maximum Design U/F Primary Flow information we can quickly rule out the units designated A, B and F, we need a unit that will allow a primary flow rate of 17 GPM and these are below that number. Ultrafilter Membrane Data Koch Membrane. Inc. A G Technology. Inc. Unit Designation A B C D E F G H Size Diameter r 2" 3" 3" 5" 1.25" 3" 3" Length 25" 25" 25" 43" 43" 12" 26" 44" Membrane Area (Sq. Ft) 1.0 5 15 26.5 66 1.5 23 40 Nominal Flow, Primary Pump Circuit (GPM) 1.1 6 17 30 76 2 26 46 (LPM) 4.3 22 65 1 15 286 7 100 174 Permeate Produced at Nominal Flow* (GPH) 0.7 3 10 18 46 . 1 16 28 (LPH) 2.6 13 40 70 174 4 61 106 Maximum Design U F Primary Flow (GPM) 1.4 7 21 38 95 2 33 57 (LPM) 5.4 27 81 144 358 8 125 217 Nomenclature Designation A - Koch HF1 0-45CXM #0720050 B - Koch HF5-45CXM #0720150 C - Koch HF15-45CXM #0720090 D - Koch HF26.5-45CXM #0720125 E - Koch HF66-45CXM #0720172 F - AGT #UFP100E5A G - AGT #UFP100E55 H - AGT #UFP100E75 * Note: These permeate flow rates are "Decayed Rates", see text for further explanation. Figure 7 Any of the remaining units shown would suffice in our example application as long as the Primary Pump Flow rate, determined by the pump selection, was sized to give 17 GPM. However, to make efficient use of the U/F unit, you would probably choose the unit designated C since it's permeate production is 10 GPH at nominal flow rating for this U/F tube. The unit G would probably be the next logical choice but it would be running at only about 60% of it's capacity. It should be pointed out that this data for the permeate produced at nominal flow rates is the "decayed "rate of production for these units. By decayed rate we mean the following: when a new U/F unit is put into service on an installation of this type, permeate production will be greater initially. Were we to install a C unit on our example coating tank, it's permeate production at nominal flow (decayed) is 10 GPH. Initially we would probably see permeate production in the area of 14-15 GPH. However, after a few days operation it would arrive at a steady state rate of production of 10 GPH, ] o what we choose to call the decayed rate. Important note: Run 24 hours/day, as they should be on any TRAP installation, U/F tubes should be flushed with permeate on a regular basis. Typically, each week when routine maintenance of the 'system is being done. This is easily accomplished when the system is plumbed as shown in figure 2. You will note in that diagram that there are lines (shown dotted) that connect the output of the U/F tube, through a 3-way valve (C), to the drag out tank and a return path, also through a 3-way valve ι ,- (D), from the drag out weir to the input of the U/F unit. By flushing permeate through the U/F tube using this circuit for only about 20-30 minutes each week, the efficiency of the U/F unit can be maintained. Failure to do this on a timely basis will cause permanent damage to the U/F tube. When not maintained in this way, the permeate production of the U/F tube will fall 20-30% below the decayed rate and it will never return to it's optimum performance even when flushing is done. 0 Pump Selection In selecting a suitable pump for any TRAP application, there are two key operating specifications that this pump must meet. First, that it supply the primary flow rate required by the U/F circuit. Second, it must provide this output flow rate at an output pressure of approximately 35 pounds per square inch (psi) (or approximately 80 Feet of head, a pressure measurement frequently encountered in pump sizing, the conversion is; Feet of head X .433 = psi). Also, bear in mind in selecting a pump that, the 25 ClearClad solution in the coating tank, that will be pumped, has a specific gravity and viscosity close to that of water. With this in mind, considering again our example tank, we know we need a pump that will provide 17 GPM of flow, the output pressure of the pump must be 35 psi (approximately 80 ft. of head) and the specific gravity and viscosity of the ClearClad solution being pumped are near enough to water for purposes of selecting a pump. Through the courtesies of a pump supplier we recommend, Goulds 30 Pumps, Inc. who manufacture and distribute G & L Goulds pumps, we have reproduced portions of a pump Performance Curve to use as an example (see figure 8). These are for their pump series NPE IST (3500 RPM) which are stainless steel body pumps having Viton seals (an important consideration for long life). 35 We were able to ascertain that the series NPE/IST (3500 RPM) would do our job by using the pump Performance Coverage chart in their literature (not reproduced here) which shows the working ranges of the pumps within this NPE series. It is a simple graphic presentation on which you can locate your pump parameters (pressure [head], and flow required) and it will show you the type of pump within this series that will meet your requirements, in our case 1ST, 3500 RPM. Referring to figure 8, the pump Performance Curve for type 1ST (3500 RPM), and locating our points on this graph, we find the operating point for our. pump. Figure 8 Data: Courtesy of Goulds Pumps, Inc. You will note, there are several curves marked with different sizes, these are the performance of this pump with various sized impellers. You will also see several inverted curves marked with "hp" ratings, these indicate the work in horsepower that the pump will be doing. By locating our requirements on the graph, 17 GPM and 80 ft. of head (35 psi) we find our operating point. Since our operating point is just below the 4 3/4" diameter impeller curve, we would choose that size impeller and our output pressure will be just above 80 ft of head. Were we to choose the 4 7/16" impeller the output pressure would be too low, a little less than 70 ft of head. Conversely, were we to choose the 5 3/16" impeller, the output pressure would be too high, about 100 ft. of head. You will also note that the operating point is just slightly below the 3/4 hp curve, this tells us that the pu p will be doing about 3/4 hp of work moving our solution. Therefore, we would specify a pump with at least a motor capable of doing 3/4 hp of work on a continuous basis. To summarize our pump selection, we will use a 1ST (3500 RPM) pump with a 4 3/4" impeller and at least a 3/4 hp motor. Some further considerations about pump selection, depending on location of the TRAP system, if it is a reasonably clean and dry area, you can probably use a motor with NEMA standard ODP (open and drip-proof) construction. However, if it is located close to wet process tanks and susceptible to being splashed, a totally enclosed (TEFC) construction motor is recommended. As previously mentioned pump seals of Viton are also recommended to enhance pump life. As to further considerations about pump selection, single phase, 3 phase, operating voltage, etc., these can be left to your option as long as the specifications we have discussed here are maintained. Should you need any further assistance regarding pump selection or manufacturers you may contact 10 your ClearClad distributor or ClearClad Coatings, Inc. directly. Other TRAP System Design and Start Up Considerations Automatic De-ionized Water Additions - A very important point that must be dealt with is protection against the possibility of the U/F system running dry. As recommended, these systems should be run , , continuously, 7 days/week, 24 hours/day and therefore are often running unattended. If the bath is maintained and used daily, generally there is no problem since operators will be making adds, removing permeate and adding make-up deionized water. However, experience has shown that at some installations, after runs are completed the system may not be used for a period of time and it can be, literally, ignored. Without routine maintenance, difficult but avoidable problems may take place. The TRAP system will continue to circulate, there will be solution losses due to evaporation and other causes. Should the 0 solution level in the drag out tank fall too low, overflow into the drag out tank weir will stop. Soon the level in the coating tank will fall also because of no cross feed from the drag out tank and it will stop overflowing into it's weir also. At this point the coating tank weir will run dry. The U/F pump will begin to suck air and inject that air into the system. This will cause severe damage to the solution itself and the U/F membrane tube as well. A simple solution for this problem should be put in place at installation. You will note in the system 25 diagram (Figure 2) that a solenoid valve is shown controlling the feed of deionized water into the drag out tank. Turning the solenoid valve on and off to replenish the level in the drag out tank is easily accomplished through the use of a micro-float switch in the drag out tank adjusted to the control level desired. This precaution is highly recommended! Plumbing Considerations - As pointed out in Section 3 of this manual, wherever possible hard piping of schedule 80 PVC or equivalent should be used. Additionally, in the piping of the TRAP system, care 3 should be taken to minimize pressure drops in the piping of the system. What is meant by minimizing pressure drop is basically to avoid sharp bends and elbows wherever possible (use of the newer "sweep" bends is recommended). Also, use piping large enough for the flows that will be encountered (in our example tank, for the 17 GPM flow needed, 1 " i.d. PVC should be used). 35 Important Note: You will note in the system diagram (figure #2) that there is a valve (F) installed between the output of the primary pump supplying solution to the U/F unit and the input to the U/F unit. The purpose of this valve is as follows. At system start up the valve should be closed and gradually opened as the system starts to avoid "shocking" the U/F unit with a sudden application of pressure. This could damage the U/F membranes. Additionally, it should be closed when shutting down the system to avoid complete drainage of the U/F membrane during the shut down period. Complete drainage could cause drying out of the membrane and possible clogging. Also, in setting up the system, either the drag out tank itself or just the drag out tank weir needs to be marginally higher than the coating tank. Something like 1/2"- 1 " higher is adequate. The purpose is to always have a positive pressure from the drag out tank to the coating tank so that solution will flow from the " drag out tank to the coating tank through the cross feed connection. In the attachment of the cross feed connection to the drag out tank weir it is a good idea, on the inside of the tank weir wall, to put a 90° elbow turned up vertically. A pipe nipple of suitable length can be attached to this elbow and serve as a method to adjust the drag out tank weir height. Also, this will preclude any significant back flow from the coating tank should the level in the drag out tank drop for any reason. Cleaning of New U/F Membranes Tubes - When setting up a new system U/F membrane tube (or replacing an existing one) we recommend the following cleaning procedure before installing it in the system. Generally, these membrane tubes are shipped with a glycerin type preservative on the membrane fibers. In a suitable container having a volume of at least 6-10 times the volume of the membrane mbe make up the following solution. a) Fill the container 3/4 full with de-ionized water. b) Add Emulsion Stabilizer (440A324)" to bring the pH down to approximately 4.0 c) To this volume of solution add approximately 5-10% (by volume) of Solvent replenisher (430A264) This assumes you are cleaning the membrane tube for use on a cathodic system, were you going to use it on an anodic system Anodic DIPA Solution (440A057) would be used. If a pump is available, connect it from this reservoir of solution to the U/F membrane and back into the reservoir (it may be necessary to cap the permeate output port). Circulate this solution through the U/F membrane for about 10 minutes. Should a pump not be available to circulate the solution it may be done manually but care must be taken to see that the circulation is vigorous enough through the U/F unit, it should be at a rate of at least 10 GPM. When this is accomplished, the unit is ready for installation into the TRAP system. Testing Before Start up - With the TRAP system piped and completely installed to the tanks to be used, a "wet test" using only deionized water and approximately 2% Solvent Replenisher (430A264) is appropriate (Do not use straight de-ionized water, some membranes can be damaged if de-ionized water only is used ) . Certainly, you want to check for leaks and general system integrity, however, you also want to see what kind of flow you are getting in the coating tank. Once the ClearClad solution is installed ascertaining flow is difficult due to the opaque nature of the ClearClad solution. You want to be sure that there is uniform flow of solution over the parts to be coated when they are in the coating tank. If the flow is too fast it can "wash" the solution away before it has a chance to adhere to the item being coated. Should it be too slow, there may not be enough solution available to coat the item properly. By fashioning a simple flag on the end of a stick and moving it about in the coating tank when it is circulating just water you can easily see the action in the tank and watch for "dead" spots or areas of high flow or turbulence. Should these be encountered, adjustment of the sparger tube in the coating tank would be the first course of action. Filtration - As shown on the system diagram, two types of filtering devices can be used. One, marked "S" on the diagram is intended to be a coarse filter in front of the input to the U F mbe. This is very important to protect the U/F tube and must not be omitted. Also shown is a secondary filtering loop, marked "F" in the diagram, drawing from and returning to the coating tank. The purpose of this filter loop is to remove any fine paniculate through the use of a fine size filter cartridge, typically in the 5-10 micron range. It should be pointed out that we are aware that these two filtering devices could be consolidated into one filter, the one marked "S" in the diagram. In some installations, instead of using a strainer or coarse filter users have made use of filter bags, typically 5 microns, which will filter out both fine paniculate as well as gross particles. However, we do not recommend doing this. We recommend using separate a paniculate filter and separate strainer. The reason for this is that should foreign particles get into the coating bath that are too heavy to be' sent up and over the tank weir, they will never be removed from the bath. An example could be rust panicles. Having the separate paniculate filter loop insures their removal. Heating and Cooling - For efficient and consistent operation of ClearClad baths you must be sure that the coating bath is maintained in the operating temperamre range for the specific bath being used. Typically this is 23°C - 29°C (73°F - 84°F) and keeping the bath in this operating range is very important. We bring it up again in this section because often overlooked in these installations are the heating effects upon the solution as well as cooling to offset these effects. The work being done by the pump in our example bath (100 gallons) in moving the solution at a rate of 17 GPM is 3/4 of a horsepower (HP). A rule of thumb for typical pumps is that for each HP of work being done by the pump (not the size of the pump, the work being done) 1 150 BTU/hour of heat —*- Pump Work/HP • El«c. Power/ KW-HR Temperature Rise vs. System Capacity Units = Liters - Oegrββs C 10 u 9 ϊ 3 ? 1 S 6 - 5 200 400 600 800 1000 System Capacity (Lilβr j) ■ Pimp Work/HP • Dec. Power/ KW-HR Figure 9 energy are released into the bath (BTU is an abbreviation for British Thermal Unit which is defined as the heat required to raise 1# of water 1°F). Figure 9 shows the relationship of temperature rise/hour for various sized tanks per HP of pump work (Two curves are shown, gallons and liters). You will note that our example tank of 100 gallons will have a temperature rise of about 1.4°F per hour if it were doing 1 HP of work. Since it is doing 3/4 HP of work with our pump the temperature rise/hour will only be about 3/4 of 1.4°F or 1.05°F hour. In and of itself, this heat is not generally a problem since it will be dissipated to radiational cooling in normal work room ambients. However, you must also remember that additional heat is being added to the bath through the work being coated in the bath. For example, were we to run 20 racks of work per hour and the average current for one minute periods was 3 amperes at a voltage of 40 volts we would be introducing into the bath each hour: 10 3 amps X 40 volts X 20 racks = 2400 watts Since we would only be doing this 20 minutes in each hour (20 racks at 1 minute each in our example), the electrical power dissipated in the bath would be: 2400 watts X 20 minutes/60 minutes/hour = 800 watt-hours or 0.8 kilowatt-hours 15 Figure 8 also shows a curve for the temperamre rise due to electrical power dissipated in the bath per kilowatt-hour (KW-HR). In our example above, we can see that we will raise the bath temperature during operation of this kind by 4 °F/hour if we were dissipating 1 KW=HR, since we are only dissipating 0.8 KW-HR, the temperature rise would only be 3.2 °F/hour. All in, with our example 100 gallon tank, doing this amount of work, we will have a heat energy input that can cause a rise of 1.05°F/hour do to the pump and 3.2°F/hour due to electrical energy dissipated 20 for a total of 4.25"F/hour. This is what the temperature rise would be if this heat is not dissipated elsewhere. As a practical matter, this input of heat energy to the bath is not all going to just stay in the bath and raise it's temperamre. A great deal of it will be lost to radiational cooling to the surrounding environment where the bath is located. This, however, is difficult to quantify since it depends on the ambient room temperamre, surface areas of the tanks, size of the tanks and many other variables. 25 The point of this discussion is two fold. First, you must realize that the bath left with the TRAP circulating, as it should be, will experience some input of heat energy due to the pumping action alone. The amount of temperamre rise depends directly on the work the pump is doing. Second, the bath will also gain heat energy as it is worked due to electrical power dissipated from the coating process itself. To keep the bath in it's operating range for good coating and to avoid "cooking" the bath, i.e. letting it's temperature rise to a point where it becomes damaged, good design dictates a provision for cooling 30 of the bath must be made. These provisions can be as simple as having a heat exchanger (this could be stainless steel coils or Teflon tube heat exchangers) in the bath through which city water, colder than the bath temperamre, is circulated. More suitable, is a closed loop chiller that will provide chilled water •35 to the cooling coil. Either method just needs to be controlled by a simple temperature controller sensing the coating bath temperamre. Having discussed cooling of the coating bath, we should not neglect the fact that it may need to be heated at times to get it up into the operating range. The most frequent situation is the necessity to heat the bath after an overnight cool down. Often, the heating system will be turned on early in the morning automatically to have the bath ready to go at the start of a shift. The recommended heating system is by indirect means. That is, through the use of heat exchanger coils 1 o not unlike those used for cooling of the bath mentioned above. In fact, on a bath requiring cooling it may be possible to switch the coil over to circulating hot water or low pressure steam to heat the bath. The above heat exchangers would be considered internal heat exchangers, that is, they are in the coating tank. Should you wish to conserve tank space the use of an external heat exchanger is possible. These are devices that have an internal flow through jacketed cavity that is put in the TRAP primary pump circuit. About this internal cavity, they have an external jacket that surrounds it where hot water or steam can be introduced for heating of the solution or chilled water can be introduced for cooling. 15 The use of direct heaters like electrical immersion heaters, although convenient, is not generally recommended except for very small baths (50 gallons or less). Even in that case we do not recommend use of metal sheath heaters, but would advise only use of quartz heaters having an internal element with a quartz outer sheath and a protective guard of teflon. When using direct heaters of this kind extreme care must be taken to insure uniform flow in the tank and around the heater to guard against hot spots and temperature stratification in the coating tank. ' 20 In summary, regarding heating and cooling, for good coating the bath must be kept in it's operating temperamre range, typically 23°C - 29°C (73°F - 84°F). All too often, we are careful to heat the bath to operating temperature but, once there, forget to watch over temperamre when cooling needs to be applied. ■ 25 30 35 Quick Reference Ultafiltration TRAP System Design Guide This is a quick method to determine the Ultrafilter (U/F) size and Primary Pump Circuit flow rate for any given TRAP Ultrafiltration system. 1) The drag out (DO) tank volume is normally a similar capacity to that of the coating tank. If that is the case, what is the volume of the DO tank in the system in question? ExamDie: 150 gallons 2) With this information you know immediately what the permeate production required will be, it is 10% of the DO tank volume or 15 gallon per hour (GPH) for our 150 gallon example tank. 3) Turn to page 33 of the I/O Manual and from the chart select a U/F tube which has a "Permeate Produced at Nominal Flow" of at least 15 GPH. This could be either Koch unit "D" or AGT unit "G" for the example 150 gallon tank. 4) Determine the Primary Pump Circuit Flow Rate required by the following formula: Permeate Req'd (GPH) Flow Rate (GPM) 0.61 In example tank (150 gals): 15 GPH Flow Rate (GPM) = = 24 6 or approximately 25 GPM 0 61 You need a pump capable of delivering 25 gallons per minute (GPM) at 80 feet of head (35 p s i.) for this tank size and U/F tube for the Primary Pump Circuit. Note: If you are doing your calculations in Liters instead of gallons the same formulas apply. That is you may substitute a flow rate in liters per minute (LPM) and a permeate required in Liters per hour (LPH) in the above formula and the result will be in LPM. Colored ClearClad Coatings ClearClad coatings may be modified with dyes or pigments to give attractive finishes over many metals. Two type of colored finishes can be achieved. Tney are: 1) "Opaque" or "hard" - A coating of this type is where the substrate is not visible, all light is reflected from the surface of the coating itself. 2) "Transparent" - This is where the substrate is visible, but modified in color and appearance by the coating. The opaque or hard coating, 1) above, is essentially a paint and effectively opaque. The transparent coating, 2) above, is more complicated and requires additional explanation. To achieve any particular effect with transparent coatings of various colors, it is necessary to understand the mechanism of color filtration and reflection. Any light reflective surface has three main attributes. They are: a) Luminosity - That is, how much light is reflected. b) Color - That is, the spectral response of the light reflected. c) Gloss - That is, the specular coherence of the light reflected. In the cases of most metals encountered for coating, the substrates generally have medium to high luminosity, they are white or yellow in color and often have high gloss. The transparent colored ClearClad coatings will become a filter over such substrates and modify the color. This modification will only take place within the following limits.. First, the luminosity of the substrates cannot be increased. For example, it is not really possible to modify the conventional bright nickel to exactly simulate gold and brass. This is because the bright nickel is intrinsically darker (that is, it has lower luminosity than both gold and brass). Second, color absorbed by the substrate cannot be added. For example, it is nearly impossible to make a brass appear blue by coating it with a blue transparent ClearClad. This is because, the base brass metal already absorbs the blue component of white light thereby giving the characteristic brass color. Succinctly, the effect gained by use of transparent colors over base metals depends heavily on the luminosity, color and gloss of the base metal. A typical gold colored transparent ClearClad bath applied over bright silver plate yields a color that is close to Swiss gold color standard 2N 18 (i.e. 18 kt gold). The same bath applied to bright nickel plated parts yields a gold color but towards a very greenish gold. When applied directly to zinc die cast parts the color, although unique, becomes a very green color with only a slight tinge of gold. An endless variety of colors, transparent or opaque are possible with ClearClad coatings. Your ClearClad distributor can provide you with formulas for many colors. For special opaque colors, if you provide ClearClad Coatings, Inc., through your distributor, a color sample of the color desired, almost any color can be matched. If you are looking for a special effect with a transparent color you should provide a sample of the substrate you wish to coat as well a final color sample so that a proper determination of feasibility for that color on that particular substrate can be made. Analytic Control Methods Solids Content ( NVO - The following analytical method for determination of Solids content of a ClearClad bath is a gravimetric method. Apparatus required: a) Analytical balance, accuracy +/- 1 milligram. b) Oven, air circulated, thermostatically controlled, capable of maintaining 160°C. c) Dishes, flat bottomed, most convenient are of disposable aluminum approximately 3-5 cm diameter by 0.5-1.0 cm deep. Note: The oven should be set at a minimum of 100"C. Higher temperatures may be used up to 150"C, but it is most important to maintain a standard temperature and time for any series of solids determinations. It is normal in the organic coatings industry to adopt 100"C for 90-180 minutes for solids determinations. However, practical experience has demonstrated using 60 minutes at 120"C yields good accuracy with ClearClad products. Method: 1) Record the weight of a dish (A) 2) Add appVoximately 1 gram of bath sample to the dish and record the weight (B) (B=the weight of the dish + the sample) 3) Place the dish in the oven for the standard time and at the standard temperamre. 4) After the standard time has elapsed, remove the* dish and allow it to cool to room temperamre. 5) Weigh the dish with it's dry residue (C) Calculation of Results: (C - A) x 100 Solids Content (%) = (B - A) Note: It is advisable to carry out this determination in triplicate in order to insure reasonable accuracy. It is normal to take the arithmetic mean of three determinations having an agreement of within 0.1%. PH of the Solution - The pH of the ClearClad solution should be taken as follows. Apparams required: A pH meter calibrated with buffer at 7.0 Method: 1) Buffer the pH meter to 4.0. 2) Wash pH meter electrodes in distilled water. 3) Immerse the electrodes in a coating bath sample and record the reading. 4) Wash the electrodes in distilled water. Note: pH control is not normally necessary. Due to the nature of the emulsion there tends to be a lot of drift. Nonetheless, pH measurements are useful. The pH of a typical solution is 4.2 once it has settled down after make up for a couple of days . Before this the pH will be high due to acid still locked up in the disperse phase. Conductivity - The conductivity of a coating bath sample should be taken as follows. Apparams required: Standard conductivity meter Method: The typical conductivity of a new solution (at 10% solids) is between 400-500 ms/cm. The conductivity increases with increasing solids content and vice versa. Generally speaking, conductivities of up to 700-800 ms are acceptable but it depends greatly on what material is causing the increase in conductivity. In most cases conductivity increases with a rise in acid content of the bath (MEQ). This situation is easily remedied through the use of ultrafiltration. In some cases conductivity rises due to drag in from processes up stream from the coating bath (metal salts from plating processes, poor quality rinses before the coating bath, etc.). Conductivity is also a helpful tool to measure the cleanliness of subsequent deionized water rinses. The conductivity of these rinses should not normally exceed 50 ms. Acid Content ( MEQ ) - The following analytical method for determination of the acid content of a ClearClad bath is a volumetric method. Apparatus required: a) Burette, 50 ml or 100 ml, accuracy 0.1 ml b) pH meter 0 c) Beaker, glass or plastic, 150-200 ml capacity d) Stirrer, motorized magnetic type preferred but a glass rod is adequate. Reagents required: a) NaOH or KOH, 0.1 molar, alcoholic (ethanolic or methanolic) b) 2 - Butoxy ethanol Method: 1) 50 grams of bath material is weighed into the beaker. This is then diluted with approximately 50 grams of 2 -butoxy ethanol. This is to prevent excessive precipitation when the titrant is added. 0 2) The pH probe is immersed in this sample (do not take this reading as the pH of the bath because the solvent interferes with the pH reading). 3) Add titrant to the sample while stirring until pH 9.0 is reached (pH 10.5 is the theoretical end point but experience has shown that excessive precipitation of the solids at this pH can block the pH probes giving erroneous results). 5 4) Record the quantity (ml) of titrant used (T) Calculation of Results: 1) MEQ/100 grams = 2 x T Q (MEQ/100 grams) x 10 2) MEQ corrected = Actual bath solids (%) 5 Notes: - When using a glass rod for stirring the sample, it is best to stir only while the titrant is being added and then stop to monitor the pH. This is because the movement in the sample affects the pH reading. The use of a magnetic stirrer insures that the degree of agitation is always constant so that any offset in the reading is constant and can be ignored. - If a pH meter is not available, it is possible to use phenolphthalein as an end point indicator. However, this is only possible with non colored ClearClad coating baths. - The above procedure assumes you are determining the MEQ of a cathodic bath which is indicative of the acid content of the bath. If you are determining the MEQ of an anodic bath, indicative of the alkali content of the bath, the following changes should be made to this procedure: 1) Reagent a) above is replaced with 0.1M Hydrochloric acid. 2) In step 3) of the method add titrant while stirring until pH 5.0 is reached. The typical normal MEQ corrected for an anodic bath is 60-70, however, CHECK THE DATA SHEET for the product you are analyzing. Solvent Content - This analysis is normally carried out by Gas Chromatography methods. General Conditions - The following are typical but many different conditions may be adopted at the discretion of the chrόmatographer. 1) Stationary Phase Carbowax (polyethylene glycol) 20M 15% on Chromosorb (diatomaceous earth) W NAW 80-100 mesh 2) Mobile Phase Nitrogen 30 ml/minute 3) Column 2 meter glass, inside diameter 3 mm 4) Detector Flame ionization 5) Temperatures Injection and detector - 200°C Column - 160°C Quantitation is in weight/weight and is determined by the internal standard method using 2-butoxy ethanol as the internal standard, approximately 10% is added to the sample. PRODUCT INFORMATION ClearClad LCX ® Polyurethane Electrocoat GENERAL DESCRIPTION ClearClad LCX Polyurethane Electrocoat Enamel, frequently referred to as E-Coat, offers excellent resistance to abrasion and marring for interior exposures. Additionally, ClearClad LCX Polyurethane yields cured films with excellent mechanical properties and solvent / chemical resistance, even at thinner film builds. This permits opaque and transparent coatings for products requiring cosmetic enhancement, corrosion protection or both. Typical uses for ClearClad LCX Polyurethane Electrocoat Enamel include vending equipment, tools and construction equipment, decorative metalwork, exercise equipment, housewares, lighting products and automotive under hood products. TYPICAL PHYSICAL PROPERTIES Application Method: Cathodic Electrophoretic Deposition Typical Cure Schedule: 15 minutes @ 325 * F Recommended Film Thickness: 0.2 to 1.2 mils available Color: Clear, Dyed Transparent and Opaque Gloss: Flat to Full Gloss Surface: Very Smooth and Uniform Crosshatch: 100% Adhesion (ASTM D3359) Pencil Hardness: 4H-5H (ASTM D3363) Mandrel Bend: To 1/4 inch (ASTM D522) Impact Resistance: To 100 in ibs.(ASTM D2794) Flexibility: Pass IT Bend Salt Spray Resistance: To 300 Hours (ASTM B117) QUV Resistance: Excellent Solvent Resistance: Very Good Acid/Alkali Resistance: Very Good Storage: 6 months @ 80F All test, unless otherwise noted are performed on 24 gauge (B1000) lab panels electrophoretically applied at 0.8 to 1.2 mils cured in an electric convection oven. PRODUCT INFORMATION ClearClad LCB ® Polyurethane Electrocoat GENERAL DESCRIPTION ClearClad LCB Polyurethane Electrocoat Enamel, frequently referred to as E-Coat, offers excellent resistance to prolonged weathering and ultraviolet exposures for copper bearing surfaces (i.e., brass and bronze). Additionally, ClearClad LCB Polyurethane yields cured films with excellent mechanical properties and solvent / chemical resistance, even at thinner film builds. This permits opaque and transparent coatings for products requiring cosmetic enhancement, corrosion protection or both. Typical uses for ClearClad LCB Polyurethane Electrocoat Enamel include plumbing fixtures, architectural metalwork/hardware, recreational equipment and brass marine equipment. TYPICAL PHYSICAL PROPERTIES Application Method: Cathodic Electrophoretic Deposition Typical Cure Schedule: 15 minutes @ 325 * F Recommended Film Thickness: 0.2 to 1.2 mils available Color: Clear, Dyed Transparent and Opaque Gloss: Flat to Full Gloss Surface: Very Smooth and Uniform Crosshatch: 100% Adhesion (ASTM D3359) Pencil Hardness: 4H-5H (ASTM D3363) Mandrel Bend: To 1/8 inch (ASTM D522) Impact Resistance: To 160 in lbs.(ASTM D2794) Flexibility: Pass 0T Bend Salt Spray Resistance: To 600 Hours (ASTM B117) QUV Resistance: Excellent Solvent Resistance: Excellent Acid/Alkali Resistance: Excellent Storage: 6 months @ 80F All test, unless otherwise noted are performed on 24 gauge (B1000) lab panels electrophoretically applied at 0.8 to 1.2 mils cured in an electric convection oven. PRODUCT INFORMATION ClearClad HDX ® Polyurethane Electrocoat GENERAL DESCRIPTION ClearClad HDX Polyurethane Electrocoat Enamel, frequently referred to as E-Coat, offers excellent resistance to prolonged weathering and ultraviolet exposures. Additionally, ClearClad HDX Polyurethane yields cured films with excellent mechanical properties and solvent / chemical resistance, even at thinner film builds. This permits opaque and transparent coatings for products requiring cosmetic enhancement, corrosion protection or both. Typical uses for ClearClad HDX Polyurethane Electrocoat Enamel include electrical equipment, chemical processing equipment, architectural metalwork, recreational equipment and lawn/garden equipment. TYPICAL PHYSICAL PROPERTIES Application Method: Cathodic Electrophoretic Deposition Typical Cure Schedule: 15 minutes @ 325'F Recommended Film Thickness: 0.2 to 1.2 mils available Color: Clear, Dyed Transparent and Opaque Gloss: Flat to Full Gloss Surface: Very Smooth and Uniform Crosshatch: 100% Adhesion (ASTM D3359) Pencil Hardness: 4H-5H (ASTM D3363) Mandrel Bend: To 1/8 inch (ASTM D522) Impact Resistance: To 160 in lbs.(ASTM D2794) Flexibility: Pass 0T Bend Salt Spray Resistance: To 600 Hours (ASTM B117) QUV Resistance: Excellent Solvent Resistance: Excellent Acid/Alkali Resistance: Excellent Storage: 6 months @ 80F All test, unless otherwise noted are performed on 24 gauge (B1000) lab panels electrophoretically applied at 0.8 to 1.2 mils cured in an electric convection oven. PRODUCT INFORMATION ClearClad HSR ® Polyurethane Electrocoat GENERAL DESCRIPTION ClearClad HSR Polyurethane Electrocoat Enamel, frequently referred to as E-Coat, offers excellent resistance to corrosion and tarnish resistance, particularly to perspiration, for interior exposures Additionally, ClearClad HSR Polyurethane yields cured films with excellent mechanical properties and an outstanding combination of UV, Solvent, chemical and wear resistance, even at thinner film builds. This permits opaque and transparent coatings for products requiring cosmetic enhancement, corrosion protection or both. Typical uses for ClearClad HSR Polyurethane Electrocoat Enamel include jewelry, watches, door hardware and tableware. TYPICAL PHYSICAL PROPERTIES Application Method: Cathodic Electrophoretic Deposition Typical Cure Schedule: 25 - 30 minutes @ 325 * F - 356 β F Recommended Film Thickness: 0.2 to 1.2 mils available Color: Clear, Dyed Transparent and Opaque Gloss: Flat to Full Gloss Surface: Very Smooth and Uniform Crosshatch: 100% Adhesion (ASTM D3359) Pencil Hardness: 4H minimum (ASTM D3363) Perspiration Test: 6 Cycles (ANSI/BHMA 18-1897) Mandrel Bend: To 1/8 inch (ASTM D522) Impact Resistance: To 120 in lbs.(ASTM D2794) Flexibility: Pass 0T Bend Salt Spray Resistance: To 300 Hours (ASTM B117) QUV Resistance: Excellent Acetone Resistance: In Excess of 1000 Double Rubs Acid/Alkali Resistance- Very Good Storage: 6 months @ 80F All test, unless otherwise noted are performed on 24 gauge (B1000) lab panels electrophoretically applied at 0.8 to 1.2 mils cured in an electric convection oven. PRODUCT INFORMATION ClearClad Anodic ® Polyurethane Electrocoat GENERAL DESCRIPTION ClearClad Anodic Polyurethane Electrocoat Enamel, frequently referred to as E-Coat, offers excellent resistance to prolonged weathering and ultraviolet exposures for aluminum and magnesium surfaces Additionally, ClearClad Anodic Polyurethane yields cured films with excellent mechanical properties and solvent / chemical resistance, even at thinner film builds. This permits opaque and transparent coatings for products requiring cosmetic enhancement, corrosion protection or both. Typical uses for ClearClad Anodic Polyurethane Electrocoat Enamel include electrical equipment, chemical processing equipment, architectural metalwork, recreational equipment, lawn/garden equipment and automotive wheels. TYPICAL PHYSICAL PROPERTIES Application Method: Anodic Electrophoretic Deposition Typical Cure Schedule: 15 minutes @ 325T Recommended Film Thickness: 0.2 to 1.2 mils available Color: Clear, Dyed Transparent and Opaque Gloss: Flat to Full Gloss Surface: Very Smooth and Uniform Crosshatch: 100% Adhesion (ASTM D3359) Pencil Hardness: 4H-5H (ASTM D3363) Mandrel Bend: To 1/8 inch (ASTM D522) Impact Resistance: To 160 in lbs.(ASTM D2794) Flexibility: Pass 0T Bend Salt Spray Resistance: To 600 Hours (ASTM BU7) QUV Resistance: Excellent Solvent Resistance: Excellent Acid/ lkali Resistance: Excellent Storage: 6 months @ 80F All test, unless otherwise noted are performed on 24 gauge (B1000) lab panels electrophoretically applied at 0.8 to 1.2 mils cured in an electric convection oven. Troubleshooting Guide Defect: Pittlne/Pinholes Shows up as small holes in coating as if made by the point of a pin. Description & Cause Action Required 1 ) May be present on the substrate before Examine substrate before coating. If defect is coating, especially on plated metals (or base present, correct at appropriate stage. metals) in the form of porosity. 2) Inadequate or badly contaminated pre- Improve rinsing and/or renew with clean ClearClad rinse(s) (Carry over of rinse(s). contaminants has increased the conductivity of the coating bath and is causing excess electrolysis). See General Note # 1. 3) Low solvent level Check solvent levels and replenish as necessary. 4) High conductivity of the coating bath due Determine the MEQ corrected (@10% solids), to contamination and/or high MEQ. if within specifications look for various types of contamination. Investigate the sources of contamination and eliminate (see 2) above and General Note #1). High MEQ and contamination-may reduced by discarding ultrafiltrate permeate. If ultrafiltration is not installed, replace part or all of coating bath as necessary. 5) Low solids content (NVC) Increase solids content (NVC) to specification. 6) Excessively rapid heat up in curing oven (a Difficult if the oven is efficient. Leaving tendency with parts of low mass). doors open between loads can slow temperamre recovery time. Defect: Pittinε/Pinholes (Cont..) Description & Cause Action Required 1) Air flow in curing oven is too great. This In the curing oven, turn off the air circulation causes rapid evaporation of the flow solvents for a short time after the work enters the oven. in the coating before they have an opportunity to effect flow. This leads to high viscosity in the coating and "solvent boil" effects (see General Note #2) Defect: Craterine or Cissins This looks like a small, local, surface tension or solvency effect which results in a small disc shaped depression in the coating. It may appear to be a "blister' do to an optical "illusion" when, in fact it is an indentation or "crater" like depressioa- Description & Cause Action Required 1) Polishing compound residues on polished. Degrease, ideally utrasonically and use cathodic surfaces. electrocleaner. For brass base metals, use an organic acid dip at the end of pretreatment. 2) Oil or grease residues on substrate before Degrease as necessary coating, 3) Contamination on the surface of the bath Stop bath circulation and examine bath surface. with water insolubles such as oil or other If foreign liquid materials are on the surface, water immiscible liquids. remove by dragging clean tissue or muslin on surface of the bath. Alternatively, a special filter may be fitted to the bath paniculate filtration system. 4) Paniculate contamination Increase the filtration rate or use a smaller pore size filter cartridge. Defect: Craterim or Cissine (Cont..) Description & Cause Action Required 5) Contamination of post ClearClad rinses. Clean or replace rinses. Consider using rinses Dirt on the surface of the rinses is deposited on with weirs, ideally, with a filtered feedback the coating. loop. 6) Contamination of coating bath with silicone This situation can be confirmed by certain materials (domestic polishes, special lubricants, laboratory tests. If these tests prove positive, certain hand and barrier creams, high the remedy may be a special additive. In temperamre greases, etc.). extreme cases a new bath may be necessary. Seek the advice of your ClearClad Coatings, Inc. distributor. 7) Airborne contamination Usually identifiable by the consistency and pattern of occurrence. Identify source and eliminate. Defect: Iridescence/" Rainbowins " Generally caused by low film thickness (less than 3 microns). The thin film causes interference colors through refractive effects. Description & Cause Action Required 1) Bad or intermittent electrical contacts. Clean and check contacts. Remedy faults as necessary. 2) a) Bath temperamre Low Item d), low conductivity is normally only b) Bath solids content Low or High encountered in a very new bath, compensate c) Bath solvent Low with higher coating voltage. d) Bath conductivity Low or High e) Bath MEQ High All other items, determine and correct as f) Coating voltage Low necessary. g) Coating time Low h) Drag out MEQ High (causes "wash off") Defect: "Oranεe Peel" Manifests itself as a surface condition, most apparent when the part is held at an angle to a light source, which resembles the irregular surface of an orange. Description & Cause Action Required 1) Too high a coating temperature due to: a) Bath Temperamre high a) Reduce bath temperamre b) Anodes too close to the work or too b) Rearrange anodes or reduce anode area. high in surface area. c) Low bath MEQ c) Increase MEQ 2) Low solvent level Determine solvent levels and replenish as necessary. 3) Rapid heat up in oven See "Pitting/Pinholes" Items #6 & #7 above. Defect: General loss of reflectivity Description & Cause Action Required 1) Low solvent level Check solvent levels and replenish as necessary. 2) Excess bath and/or rinse contamination with Check filtration and quality of rinses. paniculate. 3) Contaminated air in curing oven (e.g fumes Investigate oven and nearby processes and from a nearby process entering oven). correct as required. 4) Insufficient air changes in oven Increase curing oven ventilatioa Defect: Local loss of reflectivity (Cont..) Description & Cause Action Required 1) Local patches of high film thickness a) Due to contamination of bath or work Refer to "Pitting/Pinholes" Items #1 & #2 pieces. above. b) Patches of higher film thickness Refer to "Orange peel" 2) Localized "rupture" due to adherent water on a) Increase MEQ to 40 metal surfaces (from pre-ClearClad rinses) causing drastic reduction in solids at the metal b) Avoid "live entry", i.e. allow some time after surface/solution interface. Normally it will immersion of the work in the bath before appear as random, irregular "islands" of rough applying current. appearance, or with colored ClearClad baths , darker more intense color. This defect can c) Adopt repeated immersion & withdrawal of easily occur with new baths as used ones, and work in the coating bath to rinse away excess is easily confused with a similar defect due to water (e.g. three times in and out before contamination. Sometimes, these two defects coating) can occur simultaneously and care is required in the diagnosis. If one assumes that the defect is d) Use a closed pre-ClearClad rinse containing due to contamination only, then remedy by 0.1 - 1.0 ml/liter of rinse aid. This reduces the discarding ultrafiltrate permeate may be only amount of water adhering to the metal surface partially successful. by making it physically easier to remove due to surface tension reduction. All the above courses of action are reasonably effective, and in combination, usually eliminate the defect. Defect: Discoloration Description & Cause Action Required 1) a) Yellowing and or cloudiness over Carbon treat silver plating solution. This may silver plating due to breakdown of be required frequently if stainless steel anodes organic brighteners in curing oven. are used or if high brighteners levels are used. Defect: Discoloration (Cont..) Description &. Cause Action Required 2) Darkening of copper or brass (solid or plated) a) Oven temperamre to high Check oven temperamre and adjust as necessary. b) Coating not sufficiently free of water Insure coating has cleared before entering oven. before entering oven (oxidation due to dissolved air in water) c) Oxidation before coating (usually Use an acid dip before pre-ClearClad deionized during cleaning in hot alkaline soaks or rinses (5 - 10% sulfuric is preferred except in electrocleaners) the case of highly polished surfaces in which case an organic acid such as sulfamic would be preferred). Defect: Rinsine related problems (Post ClearClad) Description & Cause Action Required 1) Rinse or water marking all over work pieces, Adjust (usually increase) rinse aid concentration in conditioning rinse. 2) Rinse marks only at the drain point )lowest point) on parts (may appear as light patches with tinted coatings). a) Concentration of rinse aid excessive Reduce Rinse Aid concentration or discard rinse and make up at correct concentration. b) Excess solvent (film too soft) Proceed- as in a) above then reduce the solids content (NVC) of the bath (this reduces both the effect of the solvent and the amount of drag out). Defect: Rinsing related problems (Post ClearClad) (Co ..) Description & Cause Action Required 3) Water marking even with correct rinse aid concentration in conditioning rinse. a) Time between coating and rinsing too Reduce time interval between coating and long rinsing b) Insufficient movement in Increase agitation in rinse tank conditioning rinse 4) Scum or powdery "tide marks" after oven curing a) Excessively high hardness of rinse Use Deionized water for rinses. waters b) High drag out solids in rinse (usually Discard old rinses and make up new. the case with old, well used rinses). Defects: Miscellaneous Description & Cause Action Required 1) Coating soft after oven cure (lack of cure) a) Oven temperamre too low Check oven. Often, built in thermostatic controls are misleading. If in doubt use a mercury thermometer or a calibrated oven temperamre recorder (place sensing bulb close to parts in oven). b) Heavy parts not reaching curing Check thermal profile with temperamre temperamre within oven curing time. recorder (place sensing bulb close to parts). Defects: Miscellaneous (Cont..) Description & Cause Action Required c) Insufficient oven curing Determine correct oven curing schedule and time for temperamre set. coordinate oven temperamre and curing time. 2) Poor adhesion of coating to substrate Almost certainly due to poor cleaning before coating, investigate and correct as necessary. Defects: General Notes 1) Carry over of electrolytes into the coating bath over a period of time causes a deteriorating cycle of problems. The contamination in the coating bath sensitizes the system to the surface contamination on the incoming work. These two factors, added together, cause local or general excess gassing which leads to pitting and other surface disruption. 2) Pitting/Pinholes, items #6 & #7, These are unusual causes of defects in production ovens, but very efficient laboratory ovens with high air velocities and rapid temperature recovery rates often are a source of problems. 3) Inconsistent discoloration with untinted coatings suggests causes other than coating defects. It is wise, in all cases of discoloration to remove part of the coating in the effected area and examine the substrate. The discoloration may be only in the coating, only on the substrate, or present in both. Coverage of ClearClad Coatings The coverage of ClearClad materials is directly proportional to the amount of resinous solid materials present in the bath and may be calculated on the basis of the amount of solid that each liter of concentrate adds to the bath. As with any coating, the thinner it is deposited, the more area it will cover. The coverage can be calculated by figuring the volume of coating that the coated area will have on it. For example, if we were to coat a part having one square foot of area (144 in 2 * or 929 cm 2 ) with a thickness of 10 microns (0.001 cm) the volume of coating would be 0.929 cm 3 . Each liter of ClearClad concentrate contains approximately 50% solids, the resinous material that will make up the coating, at an approximate specific gravity of 1.1 grams (gm) per cubic centimeter (cm 3 ) (for clear and translucent colors). Therefore, in one liter of ClearClad concentrate there are 500 cm 3 (50% of 1 liter) divided by 1.1 gm/cm 3 or 454 cm 3 of solids available to form the coating. Since we needed 0.929 cm 3 of coating (1 foot square at 10 microns thickness) for the coating in our example, we will use 0.929 divided by 454 or .00205 liters of concentrate. Alternately, we can see that one liter of ClearClad concentrate will cover 454 divided by 1.1 or 489 ft 2 per liter. Some other coatings, such as opaque colors, cover less area since the specific gravity is higher due to the required pigments for coloring. For example, a liter of white (the worst case) has a specific gravity of approximately 1.6 gm/cm 3 so it's coverage, at 10 microns, is reduced to about 336 ft 2 . The following chart shows the coverage for ClearClad clear, or translucent colors, at various thicknesses. Coating Thickness Thickness Thickness Ft 2 per (microns) (cm) (inches) Liter 1 .0001 .00004 4890 5 .0005 .00019 978 6 .0006 .00023 815 7 .0007 .00027 698 8 .0008 .00031 61 1 9 .0009 .00035 543 10 .0010 .00039 489 1 1 .0011 .00043 444 12 .0012 .00047 407 13 .0013 .00051 376 14 .0014 .00055 349 15 .0015 .00059 326 Coverage of ClearClad Coatings (Cont..) Coating Thickness Thickness Ft 2 per Thickness (cm) (inches) Liter 16 .0016 .00063 305 17 .0017 .00067 287 18 .0018 .00070 271 19 .0019 .00075 257 20 .0020 .00078 244 21 .0021 .00082 232 22 .0022 .00086 222 23 .0023 .00090 212 24 .0024 .00095 203 25 .0025 .00098 196 10 Appendix A 15 20 25 30 35 Typical Pretreatments This is a most diverse subject. The variety of base metals and base metal conditions that are often required to coat can provide an almost endless range of possibilities for the pretreatment. One needs to address the problem of proper pretreatment for the particular base metal and conditions thereof and develop a pretreatment system practical for the specific applications required to be coated. The following examples are only a few of the possibilities that have been found successful. It must be remembered that the surface condition required before applying the ClearClad coating needs to be needs to be a clean, water break free, surface. The metal does not necessarily have to be "active" in the plating sense as if one were going to plate another metal on top of the surface being prepared. Brass The example below demonstrates the need to design an appropriate system depending on the type of base metal used within the family of brass alloys. In this example, the requirement is to apply a clear coating to solid polished brass parts (normal good rinsing procedures between steps are not shown). Brass type ... Common Brass Plumber's Brass Constituents.. Cu/Zn only Cu/Zn + Pb + Sn Steps.. Degrease Degrease Direct electroclean Soak clean, mild alkali (30 seconds typical) Acid dip (5% H 2 S0 4 ) Organic acid dip ClearClad coating, etc. ClearClad coating, etc. The sequence shown above for common brass is well established and perfectly adequate for most applications using this base metal. In the case of Plumber's brass (with lead and tin components) the normal sequence can cause problems, especially with highly polished surfaces due to the presence of lead and tin left on the surface of the brass due to the heat generated in polishing. The problem is that the non-organic acid dip will not dissolve the lead/tin. Use of an organic acid dip, such as sulfamic acid at a concentration of approximately 5 - 10 oz/gallon can correct this problem. As is often the case, the finisher does not always know the type of brass alloy used for the parts to be coated. In that case, it is wise to use the sequence for Plumber's brass as the best choice to cover all eventualities. Also, use of direct electrocleaning in the normal brass sequence should be done cautiously so as not to darken or dull the polished brass surface. This is especially true when coating "brass plated" metals instead of solid brass. In that case it may be wise to avoid electrocleaning and use only an alkali soak clean. Zinc The following sequence, using proprietary products, has proved very successful on zinc base metals (normal good rinsing procedures between steps are not shown). Degrease 10 Zinc brightener (MacDermid, Metex 8901 or equivalent) Zinc activator (Luster On, DCA or equivalent) ClearClad coating, etc. Silver plate 15 The following sequence has proved very successful on silver plated base metals almost regardless of the thickness of sliver plate (normal good rinsing procedures between steps are not shown). Soak clean, mild alkali Organic acid dip (sulfamic, acetic, lactic, etc.) 0 ClearClad coating, etc. Steel The following sequence has proved successful over steel base metals (normal good rinsing procedures between steps are not shown). 25 Soak clean, mild alkali Direct electroclean Acid dip (phosphoric 1%) -, ClearClad coating, etc. 35 Miscellaneous Tests Curing A good test for proper curing is through the use of an Acetone Rub Test. It is performed as follows: a) Take a cotton ball, similar to those available for medical and first aid purposes, and saturate it with acetone. b) On the coated part to be tested for curing, rub an area by pushing forward with moderate 10 pressure about 1 " (2.5 cm). Pull back the same distance. This constitutes one double-rub. Each double rub should take about one second. c) Continue rubbing until the signs of break through of the coating to base metal are noticed keeping track of the number of double-rubs. As a practical matter, properly cured ClearClad coatings will stand many hundreds of rubs, some even in excess of 1000 doubie-rubs. However, if the coating is not properly cured, break through will occur 15 at a relatively small number of double-rubs, perhaps in the area of 10-50 double-rubs. Adhesion Adhesion of the deposited and cured coating is very ' important and needs to be checked periodically. Generally speaking, poor adhesion is a function of the pre-cleaning and preparation of the base metal 20 before entering the coating bath. A quick test to prove adhesion after curing is outlined below. It is a good idea to take frequent samples throughout a production mns to insure good adhesion is maintained. This is sometimes referred to as a "Crosshatch Adhesion test". 1 ) Allow the coated part to return to room temperature after curing. 2) Using a straight edge and a sharp blade instrument like a single edge razor blade or an ^ "Exacto" knife cut some lines through the coating down the base metal on the item being tested about 3/8"-l/2" long. Make a series of cuts (about 8-10), all in the same direction, and about .040" (1 mm) apart. For reference, 1/16" is approximately .060" and 1/32" is approximately .030". 3) Turn the straight edge 90°, perpendicular to the lines created in 2) above and make a similar cuts so that there is created a series of small squares in this pattern approximately .040" (I mm) square. 30 4) Apply a piece of transparent tape, pressing down hard to insure adhesion, to the "Crosshatch" 35 area created leaving a length of tape as a tab. Pull up quickly on the tape tab removing the tape from the Crosshatch area. Examine the tape and the Crosshatch area to see if any of the small squares have lifted from the base metal. If none have lifted, re-tape and do this test several times. An indication of good adhesion is if no "squares" lift from the substrate. If some do lift, the number may give a relative indication of the adhesion but good adhesion dictates that none should lift. Other Product, Process and Operation Tips Corrosion Resistance Often, especially for exterior parts that will be exposed to "weather" it is required to improve the corrosion resistance of the coated metal part. With proper design of the coating system the "salt spray" or "weatherability" of the coated metal parts can be improved dramatically. One way to accomplish this is to use the "Interpas" version of the appropriate ClearClad product being used. These are ClearClad products HDX-I and LCB-I. In some applications, such as brass, there is a down side to their use in that there is a slight darkening of the coated part. 10 An alternative method is to use an electrolytic chromate step which is introduced after the acid dip before the ClearClad bath. In the case of the Plumber's brass sequence described under the Typical Pretreatments section preceding, the acid dip may be replaced by the chromate step. Very thorough rinsing must be done after this chromate step before entering the ClearClad bath! Chromate coatings are also available for zinc base metals as well. 15 Additionally, the use of phosphate coatings on steel base metals before coating will significantly improve the corrosion resistance of the finished part. They can be of either the zinc or iron type phosphate coatings. ClearClad Coatings, Inc. can provide information on recommended chromate conversion coatings or phosphating coatings for your particular applications. ClearClad Stripper 20 It sometimes becomes necessary to strip deposited ClearClad coatings. The simplest method is to use a "Green stripper", i.e. one that is used immediately after coating and before curing. An effective green stripper formulation follows. 1) Acetic Acid 50 mis/liter - , 2) Solvent Replenisher (430A264) 50 mis/liter 3) Rinse Aid (460 A 1 14) 10 mis/liter Balance water This stripper will strip uncured coatings in approximately one minute by immersion at room temperature. 30 Strippers for cured coatings are available in both proprietary and generic formulations. Because of the 35 unique na re of cured ClearClad coatings, stripping cured coatings is much more difficult. Consult your ClearClad distributor or ClearClad Coatings, Inc. directly for further information on strippers for cured coatings. Notes -- CLEARCLAD BATH LOG ClearClad Coatings, Inc. O ro APPENDIX 2 1022 N. Sabina St., Anaheim, CA 92801 Phone (714) 774-9319 * Fax (714) 774-9379 SOAK 715 ■■l.WHMIMIwV* SOAK 715 is a granular, free flowing, non-silicated mildly alkaline 'non-etch' soak cleaner for aluminum. SOAK 715 is a unique chemical blend incorporating emulsifiers, surfactants and disperants. It is formulated to remove a wide variety of oils and buffing compounds normally encountered in aluminum processing. IMPORTANT FEATURES 1 Provides an active wetted surface 2. Holds, emulsifies and disperses oils and soils 3. Excellent choice where hard water conditions exist 4. Well buffered pH 5. Can work well at low temperatures 6. Biodegradable surfactant package 7. Economical to use OPERATION INFORMATION Concentration: Range: 4.0 to 8.0 oz gal (30 - 60 g/1) Temperature: Range: 120 to 160° F (49 - 71° C) Time: As needed 5 to 10 minutes NOTE: Slight corrosion protection can be achieved by using a solution of 4.0 oz/gal (30 g/1) of SOAK 715 as a final dry-on finish. CONTROL AND MAINTENANCE • 1. Pipette a 10 ml sample of the bath into a 250 ml flask. 2. Add 25mls deionized water. 3. Add 3 to 5 drops Methyl Orange Indicator. 4. Titrate with 1.0 N Sulfuric Acid from yellow to orange. CALCULATION: Mis of 1.0 N acid x 1.2 = oz gal SOAK 715 Mis of 1.0 N acid x 9 = g/1 SOAK 715 Page 1 of 2 Page 2 of 2 EQUIPMENT SOAK 715 solutions should be operated in mild steel tanks. Heating coils may also be constructed of mild steel. STORAGE AND HANDLING SOAK 715 is a slightly alkaline material. Care should be taken to avoid contact with skin or eyes. When handling this product, do not breath dust as it is irritating to the upper respiratory tract. For further information consult Material Safety Data Sheet. DISCLOSURE The information contained herein is based upon data developed through laboratory and production experience and is believed to be correct. However, Alchem makes no warranty, expressed or implied, regarding the accuracy of these data or the results to be obtained from the use thereof. Alchem assumes no responsibility-for the injury from the use of the product described herein. APPENDIX 3 MATERIAL SAFETY. DATA SHEET ================== i. PRODUCT INFORMATION ============ Trade name (as labeled) AC-25 Chemical name's, common names liquid acidic detergent Manufacturer's name Solin Products Address 1022 N> Sa bi na St. Anaheim, CA 92801 Emergency phone (71 . t'.:0-4050 Name of Freparer J- Camp b e iJ . Business phone (71 )630- 050 Date prepared 4 9° Cheratrec Emergency }8O0—42 -93OO ================== II. HAZARDOUS-'.INGREDIENTS Chemical Names CAS Numbers . Percent* Exoosure Limits in Air NOTE ACGl (Ϊ V) OSHA(£έL) Other Phosphoric Acid 7 664-38-2 lmg/ra 1 (1) ================== ril . PHYSICAL PROPERTIES ===================== Vapor density (air-l) Non-volatile Melting point or range, F Specific gravity 1.09 Boiling point or range, F 2 12*P Solubility in water Complete Vapor pressure, mmkg at 20 C nonτvolatile Evaporation rate (butyl acetate ■ *■ 1) slower <1 Appearance and odor clear brown liquid with mild odor HOW TO DETECT THIS SUBSTANCE* (warning properties of substance as a gas, vapor, dust, or mist) '————■—•—"" NOTES .—— ■ ——- ■ —- • - ■ — ■ - This chemical is subject to the reporting requirements of . section 313 of SARA title III. IV. ,.<E AND EXPLOSION ====== ^' ^ . -^Jf. iash Point, F (give method) None Autoignition temperature, F N/A Flammable limits in air, volume %: lower N/A upper N/A Fire extinguishing materials: j water spray χ_ carbon dioxide other foam χ_ dry chemical Special firefighting procedures: Wear self-contianed breathing apparatus Unusual fire and explosion hazards: Thermal decomposition emits toxic fumes of oxides of ghpsEhorous == V. HEALTH HAZARD INFORMATION ========== SYMPTOMS OF OVEREXPOSURE for each potential route of exposure. 10 Inhaled: headache Contact with skin or eyes: irritation will occur. Burns exposed tissue Absorbed through skin: Swallowed: Nausea, dizziness and vomiting 15 HEALTH EFFECTS OR RISKS FROM EXPOSURE Explain in lay terms. Attach extra page if more space is needed. Acute: Irritation of eyes and skin, headache, nausea, dizziness and vomiting Chronic: Slightly toxic with repeated inhalation or ingestion. Burns exposed tissue. 20 FIRST AID: EMERGENCY PROCEDURES Eye Contact: Immediately flush with large amounts of water, holding eyelids apart, for at least IS minutes. Obtain medical attention Skin Contact: Flush with plenty of water. If irritation persists, obtain medical attention. 25 Inhaled: Remove to fresh air. If breathing is difficult or discomforting, call a physician Swallowed: Rinse mouth with water. Give copious amounts of water or milk to dilute in stomach. Induce vomiting. Give additional liquids. Obtain medical attention. SUSPECTED CANCER AGENT? NO: This product's ingredients are not found in the lists below. -, YES: Federal OSHA HTP IARC Cal/OSHA(see note)* NOTE: California employers using Cal/OSHA-regulated carcinogens must register with Cal/OSKA. MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE None known 35 RECOMMENDATIONS TO PHYSICIAN ====.=============== ... REACTIVITY DATA ======-========•============ S t ability: X Stable Unstable Conditions to avoid: I ncompata b ility (materials to avoid): Reaction with reactive metals ( eg. mild steel & aluminum) May produce lammable/explosive hydrogen-air mixtures. Stong alkalies. Hazardous * decomposition products (including combustion products: Burning will produce carbon monoxide, carbon dioxide & phophoric ,acid fumes Hazardous polymerization: May occur X Will not occur Conditions to avoid: VII. SPILL, LEAK AMD DISPOSAL PROCEDURES Spill response procedures (include employee protection measures): Dilute with water, neutralize with .lime or soda ash. Flush with large quantities of water. Preparing wastes for disposal (container types, neutralization, etc * l): Atomize into a furnace and incinerate or neutralize and dispose of in a landfill 15 for solvents per local, state, and federal requirements. NOTE: Dispose of a <i wastes in accordance with federal, state and local regulations. VIII. SPECIAL HANDLING INFORMATION Ventilation and engineering controls Prefer local exhaust, although mechanical is acceptable. ' srs Respiratory protection All purpose canister mask if ventilation is inadequate. Eye protection (type) Chemical safety goggles or face shield Gloves (specify material) Rubber or neoprene Other clothing and equipment Hhere contact is likely, rubber apron and boots ic Work practices, hygienic practices Hash hands after handling the product and before eating, drinking or smoking. Other handling and storage requirements Store in cool, dry, well ventilated area. Protective measures during maintenance of contaminated equipment 30 ======================= ιχ. LABELING Labeling (precautinary statements)* Corrosive liquid n.o.s. Corrosive Material, U.N. 1760 (contains Phosphoric Acid) D.O.T. Label* 5 108- BRIGHT DIPPING ALUMINUM TECHNICAL INFORMATION BULLETIN [ 09- IMPORTANT NOTICE All information, technical advice recommendations provided herein or by Albright & Wilson personnel are intended for use by persons having skill and knowledge in the handling of industrial chemicals, and no such information shall be deemed as a representation or such warranty with respect to the Product or Products discussed Product information and handling procedures are based on our past expeπence and common practice in the industry We believe all information given herein and by Albright & Wilson personnel is accurate and off er such information in good faith, BUT WITHOUT GUARANTEE OR OBLIGATION AS TO THE ACCURACY OR SUFFICIENCY THEREOF AND WITHOUT ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE No such information is intended as a recommendation or as permission to use the Product or Products in a manner that would infringe any patent TABLE OF CONTENTS introduction 4 Technical Assistance 4 5 Additional Information 4 Mechanical Finishing 5 Buffing 5 Optimizing Conditions 5 Buffing Problems 7 Cleaning 8 Alkaline Cleaners 9 10 Acid Cleaners 9 Albright & Wilson Phosphoric Acid Cleaners 9 Control of Cleaning Baths 10 Analysis of Albright & Wilson's Acid Cleaners 11 Bright Dipping 12 Mechanism 12 Operation and Control of Bright Dip 14 Recommended Operating Parameters for Bright Dipping 15 15 Effects of Major Variables 16 'Phosbrite' 172 17 Operation of a 'Phosbrite' 172 Bath 17 Safety & Handling 18 Aluminum Alloy 19 Procedures for Analyzing the Bright Dip Bath 19 Measurement of Specific Gravity 20 20 Water Addition Chart 21 Determination of Nitric Acid 23 Nitric Acid Addition Chart 24 Determination of Aluminum Concentration 25 Rinsing 27 Number and Configuration of Rinses 27 Types of Rinses 29 Drain Time 29 25 Rack Design, Size, and Shape of Parts 29 Construction of System 30 Design Pointers 30 Phosphoric Acid Recovery 30 Anodizing 33 Coating Mechanism 33 Parameters Effecting Anodizing 34 30 Control of Anodizing Bath 35 Anodizing Problems 35 Determination of "Free" Sulfuric Acid and Aluminum 37 Sealing 39 Nickel Acetate Pre-Seal 39 Operating Parameters 40 Preparation of Nickel Acetate Pre-Seal 40 Hot Water Seal 41 •* >5 Nickel Acetate Seal 41 Seal Problems 42 Maximum Limits of Contaminants 44 INTRODUCTION * 5 The phosphoric acid/nitric acid chemical polishing bath (bright dip) is widely used to produce specular finishes on a variety of aluminum alloys used for automotive, appliance and architectural trim. Consistent production of a high quality finish requires a thorough understanding of the bright dip bath and its function, as well as careful control of the entire finishing process. This process manual addresses all phases of the bright aluminum finishing process, including pretreatments as well as the anodizing and sealing steps required to protect the bright finish. Mechanical finishing may be used to provide a variety of surface textures on aluminum. For bright , trim, buffing is required to remove surface scratches, rolling marks and die lines, thus providing a surface which is free of surface defects. A properly designed and operated cleaning cycle is required to remove all lubricants, buffing compounds and surface oxides which would interfere with the brightening process. The bright dip bath functions by leveling the microscopic roughness of the aluminum surface, thus reducing the amount of light which is scattered and increasing the specularity of the surface. After bright dipping, most finishers utilize a sulfuric acid anodizing process to produce a clear, protective oxide coating on the metal surface. That oxide coating is then partially converted to an insoluble, hydrated alumina which closes the coating's microscopic j 5 pores and protects it from corrosion. Bright Dipping Aluminum discusses the function of each of these process steps, and outlines the control requirements for each. TECHNICAL ASSISTANCE Combining the individual finishing steps to produce an integrated bright anodizing system frequently results in a system with additional, highly specific process requirements not discussed 20 in this manual. This is particularly true when other types of finishes are produced by the same system. Recognizing that individual process requirements exist, Albright & Wilson maintains a Technical Service staff which can assist in tailoring any portion of the bright anodizing process to individual requirements. Technical Service Representatives are available to assist in determining the cause of finishing problems, and to develop specific modifications to prevent their recurrence. In addition, Albright & Wilson conducts Principles of Anodizing courses on a regular basis. The course covers all the process steps discussed in Bright Dipping Aluminum, as well as other < processes frequently used in conjunction with bright anodizing. ADDITIONAL INFORMATION Bright Dipping Aluminum provides insight into many of the requirements of producing high quality bright anodized aluminum. While this is as complete as possible, all requirements and potential problems could not be addressed. Therefore the recommendations contained herein must be -i evaluated and applied by a competent, well-trained staff. Because all chemicals used in bright anodizing present health and safety hazards, every person assigned to work where they are used or stored must be instructed in their hazards and in their proper handling. The manufacturer of each chemical should be contacted to obtain complete handling, health and safety information. Material safety data bulletins are available for all of Albright & Wilson's cleaners and specially formulated phosphoric acids for bright dipping. Material safety data bulletins, storage and handling 35 information or other technical assistance may be obtained by contacting Albright & Wilson's Technical Service Department. ALBRIGHT & WILSON AMERICAS 2 Gibbs Road, Islington. Ontario M98 1 R1 P.O. Box 26229, Richmond. VA 23260-6229 Telephone: (416) 239-7111 Telephone: (804) 550-4300 FAX: (416) 232-2146 FAX: (804) 550-4385 MECHANICAL FINISHING M echaπical finishing refers to operations which aiterthe surface and appearance of an aluminum part by physical means such as grinding, polishing, buffing, shot blasting or tumbling. The main objectives of these processes are to ( 1 ) remove metal surface irregularities and imperfections in order to smooth the metal surtace or (2) apply a texture to the surface of the part The method and extent to which mechanical finishing is used will depend upon the initial state of the metal surface, the method of manufacture of the article and the finish desired. There are five types of wheel grinding and polishing operations commonly used on aluminum: 1 ) Texture or Scratch Brushing 2) Grinding 3 Roughing 0 4) Polishing 5) Buffing Although all of these operations are used by bright anodizers to some extent, buffing is the most freαuently used type of mechanical finishing. BUFFING 5 Buffing is used to remove minor scratches and die lines and to increase the specularity of the aluminum part. It is as much an art as a science since the skill and experience of the operator play a significant role in the final results. The buffer must strike a balance between the quality and the cost of the finish by tailoring buffing sequences and materials to the alloy, shape, and surface condition of the part. Although prior experience is invaluable in tailoring the process conditions to the part, following a few basic guidelines can minimize buffing problems and rejection due to improper buffing. 0 Finishing begins the moment raw material is received in the plant. Material handling, storage, tools and press practice all may effect both the buffing operation and the final appearance of the part. Further, the best of buffing procedures and techniques can be completely negated by careless handling after buffing. Freshly buffed surfaces should be protected against fingerprint corrosion by wiping them with a whiting compound such as calcium carbonate. In addition, buffed parts should be carefully racked on suitable trays to prevent traffic damage. OPTIMIZING CONDITIONS 5 In the mechanical finishing of aluminum it is best to use only buffing operations and to avoid polishing whenever possible. The coarse abrasives of the polishing belts cause scratch patterns which are extremely difficult to remove with subsequent buffing. This becomes even more significant in the finishing of long sections where all work is unidirectional. If uniform chemical treatment is to be accomplished, all preexisting oxide must be removed and removed uniformly. A common error is to under-buff. Many times the parts appear visually "clean ' ' -, or bright after buffing yet show defects after bright dipping. Tests have shown superior coloring results when a caustic treatment is added between cutting and coloring. Although this sequence may not be economical, it does point out the need for adequate oxide removal. Pressure The contact pressure of the buff on the work piece is as important as the selection of compound and buff material, and must be determined empirically for each part. Excessive contact pressure 35 will distort the buff and cause uneven wear and an infeπor surt ice finish. Furthermore, buffs under excessive pressure do not retain the compound which does Me cutting or coloring. The wheel is simply a soft cloth acting as a carrier for the compouπα, and cutting action does not come from the contact of the cloth on the metal High contact pressures are also a cause of rapid heat buildup on the work. Temperatures beyond , 400°F / 204 β C can cause metallurgical changes in the aluminum and can cause cloudiness of the anodic coating in the areas where overheating occurred. Other factors which eflect temperature are the buff material, degree of ventilation and thread count of cloth. Compound Application The application of compound to the buff is a critical operation. Beyond the optimum amount, additional compound will not increase metal removal. Excess compound results in the buildup of 10 residues on the parts which are often difficult to remove. As a rule excessive compound is applied when compound is applied infrequently; the wheel then has either too much or too little material at any given time. At low compound levels there is little metal removal. At high compound levels too much compound is deposited on the work. Ideally, the compound should be applied frequently in small amounts to minimize deviation from the optimum. Speed 15 A peripheral wheel speed of 7000 ft min. has been found most desirable for buffing aluminum. This is an average speed and some adjustment based on part configuration and size is necessary. The direction of part travel in relation to buff rotation has an effect on surface condition. Considerably more cutting occurs when the part is passed opposing or "against" wheel rotation than when the part is passed complementing or with wheel rotation. Preferably cutting and coloring should be done in the same direction and with the rotation of the wheel to prevent skip and drag. 2o For best results, cutting and coloring should be accomplished using different compounds and wheels. Alloy Metal selection has an effect on the surface obtained after buffing and bright anodizing. Harder metals with finer grain size give best results. In addition, they tend to be more "ding" resistant during subsequent handling. For best results, the hardest material temper compatible with required 25 formability should be utilized in fabricating the part. Buffing Compounds An abrasive material is the significant ingredient of either solid or liquid buffing compounds. A bar of buffing compound is a cutting material (abrasive) held together by bonding agents such as greases, stearic acid, and waxes. The abrasive material may also be formulated as a water -.n emulsion of oils to make the composite sprayable. Automatic multiple station buffing operations will normally use liquid compounds. Bar compound use is restricted to hand operations. For a compound to be effective it must be tenacious enough to adhere to the wheel, but this is the same property which makes a part difficult to clean prior to bright anodizing. By working with suppliers and on-the-job testing, the proper binder can be chosen. The abrasive most commonly used is tripoli, a naturally occurring material composed primarily of amorphous silica with up to 5 percent iron oxide. Iron oxide is responsible for the reddish color, 35 and increasing amounts of iron oxide deepen the color. Tripoli is the most widely used buffing compound for aluminum finishing because of its availability and low cost. However, there is the potential hazard of iron oxide retention on the surface of the buffed piece. The iron oxide is not apparent after buffing, and is probably chemically bonded to the surface. If not removed with a mild-etching cleaner, the particles may cause dull or lightly pitted areas during bright dipping. White amorphous silica, an iron-free abrasive, is occasionally used for color buffing aluminum. This substance is quite soft, however, and accomplishes little cutting. A third abrasive, aluminum oxide (Al j O,), is very hard and has good cutting and coloring properties. Formulations containing this abrasive are more costly than the others. However, where metal removal and surface contamination are critical, it may be less expensive in the long run. In a multiple station buffing sequence (cut and color), alumina should be used for the coloring stations. Buffs A great many buff types are available and they, too, should be tailored to the job. Again, vendors' recommendations and shop testing determine the best buff type for a particular operation. The most common buffs are bias-cut muslin. Their buffing performance is determined by thread count, number of piles and number of folds around the circumference. For the hard buffing or cutting operations, a wheel of high thread density (86-93) and large number of folds (No. 8 bias) might be used. For coloring a low thread density (64-68) and few folds (No. 2 bias) should be used. Since heat is a problem in buffing aluminum, the buffs must be designed and constructed to dissipate heat rapidly. The color buffing wheel must have good shedding ability. That is, it must throw off metal particles and compound, otherwise the face will become "solid" and gouging will occur on the metal surface. The buffs must then be "raked" to remove the hard facing. BUFFING PROBLEMS Pitting If the buffing compound is driven into the aluminum surface due to excessive pressure, a pit will result. The pit may not be apparent after buffing, or even after cleaning, but will show up after bright dipping. Mottling Elevated surface temperatures during buffing may be caused by excessive pressure, friction due to lack of lubrication, or hard buffs. Surface temperatures above 400°F / 204°C can cause metallurgical changes in the aluminum which appear in the anodized part as gray areas. No defect will be apparent until after bright dipping or anodizing. Cloudiness Areas on parts which have been "double" buffed, i.e., buffed more heavily than the rest of the part due to overlap in buffing from both directions, may appear cloudy after bright dipping. Cloudiness may also be due to inadequate or incomplete cleaning of the buffed surface. A compound which resists cleaning can be formed due to the reaction between aluminum and the stearates in the binder. This compound can be removed only in an etching bath, either an etching alkaline cleaner or a caustic etch. CLEANING Metal cleaning is a broad term covering the preparation of metal surfaces for an infinite variety of finishing processes, in the aluminum industry, a prerequisite for the success of nearly every finishing system is a clean surface. While the choice of the cleaning method for aluminum is 5 determined by a ' number of factors, the most important considerations are: type of contaminant to be removed, surface condition required for subsequent finishing and size and shape of parts to be cleaned. The soils prevalent on aluminum are usually fairly easy to remove. Because of the ease of working aluminum, drawing and machining lubricants need not be of the types that are very resistant to cleaning. The somewhat unique soil on aluminum sheet of marking inks and buffing compounds represents the most difficult soils to be removed. Several other contaminants are found. Among the 10 most common ones are oil, grease, wax or protective films remaining after rolling, drawing, extruding and fabricating operations. Shop dust, mill scale and metal oxides are some other contaminants that may also be present and must be taken into consideration. Cleaning has been said to be the most common operation performed in the transformation of aluminum from raw metal to the finished product. Its importance, therefore, cannot be overemphasized. Many a costly anodizing job has been rejected because of improper or inadequate cleaning. Careful attention to cleaning will go a long way toward avoiding expensive rejections and 15 insuring a quality product. The problems relating to the cleaning of aluminum are not simple, largely because of the sensitivity of the metal and its reactivity with many commonly used cleaners. Most aluminum finishers use alkaline cleaners or acid cleaners, separately or together in various combinations. ALKALINE CLEANERS 2u Alkaline cleaners are used to remove drawing and stamping oils and buffing binders. They are also used where heavy soil loads are encountered. The cleaning ability of an alkaline cleaner comes from its ability to saponify fatty acids and fats and emulsify other oils and greases. Additives in the alkaline cleaners enable them to wet soils and to keep them suspended or dissolved. Formulations of effective cleaners also contain water softeners which sequester or chelate calcium and magnesium salts in hard water to minimize the possibility of insoluble soap formation. They -, < - also contain buffering agents, which enable a cleaning solution to maintain a constant pH where its cleaning action is most effective. Even mildly alkaline cleaners will attack aluminum, particularly at higher temperatures unless an inhibitor is present. Sometimes a slight, attack causes an etched appearance which is not objectionable, but is usually not desirable for bright work. Inhibitors are sometimes incorporated into the cleaner to reduce or prevent this etching in the cleaning stage. The most commonly used cleaner inhibitors, sodium silicate and sodium chromate, are not suitable for use on the bright 30 anodize line. Silicated cleaners, operated in the pH range 11.3-11.7, protect the aluminum by forming a thin surface film. If this is not removed completely in hot cleaner rinses, upon entering any acid bath (an acid cleaner, bright dip or anodize bath), the silicate is converted to silicic acid which is insoluble. The insoluble silicic acid adheres to the parts and may cause pitting or an uneven streaked appearance. Chromate inhibited cleaners are usually operated at a pH of 10 or less. They are not as effective 35 as silicate cleaners, and the chromate disposal problem has all but eliminated their use in anodizing. Othercompounds may be used to give alkalinity and at the same time not be as harsh on the aluminum base metal. Such systems are preferred in the operation of the bright dip line to avoid the silicate contamination and chromate disposal problems. These other systems may contain sodium carbonates, sodium phosphates, sodium metaborates or sodium tetraborate (borax). Frequently two or more these are blended together to maintain a reasonably high pH upon the addition of acid soils These may also be blended as buffers with sodium hydroxide to overcome the hygroscopic nature of sodium hydroxide and make for easier mixing and handling ACID CLEANERS The maior advantages of using an acid cleaner are- (1 ) better metal oxide removal in an acid cleaner • these oxides include aluminum oxide and magnesium oxide which may be present due to in-plant corrosion or even rolled into the metal upon forming: (2) chloπnated and viscous paraffin oils are more easily emulsified in an acid cleaner - these oils are often used in the stamping and forming operations; (3) embedded buffing abrasives are more easily removed in an acid cleaner; (4) any other residues remaining after other cleaning operations are removed. The metal surface is termed "activated"; that is, the surface is free from any surface films and pure base metal is presented to the next operation The ideal cleaning cycle then should have, as a final cleaning step, an acid cleaner The acid cleaner could follow an alkaline cleaning stage or may be used by itself if the soil load is not too heavy These types of acid cleaners are in use in the anodizing industry today: ( 1 ) Phosphoric acid cleaners like Albrrte 342-AC, 343-OC and 344-SC are superior for removing buffing compounds and metal oxides. In addition the surface is left "activated" or oxide free, which produces superior bnght work (2) Sulfunc acid cleaners require inhibitors to prevent the parts from being deeply etched. Without tight control, parts may be dulled by these cleaners. (3) Citric acid cleaners use a very mild acid as their base. They do not have the cleaning power of phosphoric acid cleaners, nor do they leave the surface etched or "activated" for further processing They are used m areas where phosphate restrictions prohibit the use of phosphoric acid cleaners. ALBRIGHT & WILSON PHOSPHORIC ACID CLEANERS Albright & Wilson offers three phosphoric acid based cleaners: Albπte 342-AC, Albrite 343-OC and Albrrte 344-SC. T ese cleaners are designed for the removal of ground-in, caked-on buffing compounds and drawing oils from drawn, stamped or extruded aluminum parts. They will also remove some heat and water marks which are normally carried through conventional alkaline or neutral cleaners. When operated in the recommended ranges shown in Table 1 , these cleaners leave the aluminum parts slightly frosted. This frosting, unlike that produced in a caustic etch, w.ll not reduce the brightening or smoothing action of the bright dip. In fact, parts will bnghten or etch more uniformly because the surface is "activated" and pure base metal, rather than a heavy oxide film, is presented to the next treatment bath. Albrfte 342-AC is designed as a second-stage cleaner following an alkaline cleaner, although it may be used as a single-stage cleaner where the soil load is light. This formulation is superior for the removal of caked-on ground-in buffing compound, and will leave the aluminum surface "activated" for subsequent bright dip or etch operations Albrite 343-OC is used as a first-stage or single-stage cleaner for unbuff ed parts. It is designed to hold large cuantrties of oils in solution, but unlike alkaline cleaners Albrite 343-OC leaves the aluminum s ^ace "activated ' Albrite 344-SC is used as a second-stage cleaner where soil loads are light The first stage cleaner must remove most of the soils leaving Albrite 344-SC to remove only residual oils and to "activate ' the aluminum surface For heavy soil leads Albπte 342-AC is recommended TABLE 1 OPERATING PARAMETERS OF ALBRITE ACID CLEANERS 342-AC 343-OC 344-SC Cloud Point (°F) 180 160 180 Temperature (°F) 160-180 150-155 160-180 Time (min.) 1 -2 2-5 1 -2 Concentration (% by vol.) 8-9 8-9 8-10 Specific Gravity (60°F/60°F) (of concentrate) (16°C/16°C) 1.273 1.295 1.255 Foradditional information of Albright & Wilson's cleaners contact Albright & Wilson. Technical Service n Department, Richmond, Virginia (804) 752-6100. CONTROL OF CLEANING BATHS The chemical control of cleaning baths will vary with the type of cleaner and time allotted for laboratory control. These controls are usually supplied by the manufacturer of the chemicals and are based on extensive experience. c The tests usually used to analyze aluminum cleaners are as follows: (1 ) Emulsion cleaners - break the emulsion with acid and measure the solvent separation. (2) Etching, buffered alkaline cleaners and silicated cleaners - titrate with standard acid solutions. (3) Acid cleaners - titrate with standard base. (4) High detergent cleaners - detergent titrations, surface tension, acid-base titrations, cloud point Q determinations or surfactant analysis. The control procedure used for each cleaner should be specified by the manufacturer of the cleaners. "How long will a cleaner last?" is a common question. Since soil load, dragout of solution and type of soil are different for each operation, this is difficult to determine without a production test. Cleaners which etch usually require more maintenance than the non-etching cleaner. The qualify of the part produced and the number of rejects attributed to poor cleaning are the real measures 5 of a cleaner's value. The simple water break test remains the most widely used method, in shop practice, to test for cleanliness. A cleaned metal panel, after being submerged in cold, clean, clear water, should show a continuous film of water over the entire surface. The presence of any residues will cause the water film to break, leaving those areas not wetted. Sometimes small areas will fail to show up immediately with this test, so sufficient time should be allowed to ensure that the film is continuous over the entire surface. 0 The preparation of metals for finishing is a most important consideration and, therefore, the cleaning operations require a considerable amount of planning. The appearance and acceptability of the finished article depends primarily on a sound cleaning process and clean foundation for the finish. A properly designed cycle will result in a quality part; likewise, an improper cleaning cycle will lead to rejects and higher costs. Therefore, the importance of proper cleaning cannot be overemphasized. 5 ANALYSIS OF ALBRIGHT & WILSON'S ACID CLEANERS Reagents Required: 1 . Sodium Hydroxide Solution - 0.5 N 2. Indicator Solution (Bromphenol Blue) - Dissolve 0.1g BromphenolBlue(FisherScien- tific Co.) in 7.1 ml of .02 N Sodium Hydroxide and dilute to 250 ml with distilled water. Apparatus Required: 1. 250 ml Erienmeyer Flask 2. 10 ml Burette 3. 10 ml Pipet Procedure: 1. Pipet 10 ml of the acid cleaner solution into the 250 ml Erienmeyer Flask. 2. Add about 40 ml of water and 2-3 drops of the indicator. 3. Tritrate with the 0.5N NaOH to the end point (change from greenish yellow to the first distinct blue or pH 4.5). Calculation: % cleaner (by volume) = ml of 0.5N NaOH x 0.92 BRIGHT DIPPING Bright dipping is a process for increasing the specularity or brightness of aluminum by leveling the microscopic roughness or "peaks and valleys" on the surtace of aluminum parts. The application lor bπght dipping is somewhat limited because it does little macropolishiπg or smoothing of scratches or pits This limitation underscores the need for proper buffing and careful handling prior to bright dipping The bright dip bath used commercially, to the exclusion of almost all others, consists primarily of phosphoric and nitric acids Albright & Wilson's phosphoric acid solution for bright dipping contains additives to reduce nitrogen oxide fumes and to enhance the brightening ability of the bπght dip bath The range of typical operating conditions for bright dip baths is shown in Table 2 TABLE 2 BRIGHT DIP BATH COMPOSITION Phosphoπc Acid 70-82%, by weight Water 15-22 Nitric Acid 2-4 Dissolved Aluminum 1 -4 Additives Less than 1 Temperature 190-240 β F / 88-1 6 β C MECHANISM The surface of an aluminum part can be visualized as a series of "peaks and valleys" or high and low areas. For the bright dip bath to smooth this surface, there must be a faster rate of attack and more metal removed at the 'peaks ' than in the "valleys ' When aluminum is placed in a hot bright dip solution composed of phosphoric and nitric acids, the nitric acid reacts with the aluminum to form an aluminum oxide film This film is immediately dissolved by the phosphoric acid, as shown in Figure 1 These reactions occur more rapidly at the peaks than in the valleys because the bright dip solution is very viscous There is less agitation m the valleys than at the peaks, therefore, the rate of the reaction in the valleys decreases as the solution becomes saturated with aluminum phosphate and the nitπc acid is depleted Figure 1 BRIGHT DIPPING REACTION MECHANISM IN1T|AL RUCTION PEAKS FATTEN AS BRIGHT 0IPPING PROGRESSES The bright dip bath must be carefully balanced to obtain the optimum amount of metal removal. For a given smooth, buffed piece, tne maximum brightness will occur when the minimum amount of metal necessary to get beneath the buffing marks is removed. More metal removal will decrease the image clarity. This is because the brightening activity proceeds along the crystal interfaces and can result in orange peel, or a bumpy, wavy effect. ALBRIGHT & WILSON PHOSPHORIC ACIDS Albright & Wilson 80 and 85% phosphoric acids for bright dipping and can be formulated to contain any or all of the following additives: 1. Copper Metallic Brightener 2. Fume Suppressant 3. Wetting Agent Metallic Brightener The preferential attack of the bright dip at the peaks is enhanced by the copper metallic brightener in Albright & Wilson phosphoric acids. During bright dipping, a galvanic cell is set up between aluminum and copper. The copper will plate out on the aluminum surface. This film of copper, like the film of aluminum oxide, forms and dissolves faster at the peaks than in the valleys. The film plated in the valleys protects that aluminum from further attack as shown in Figure 1. By using Albright & Wilson phosphoric ac j, the maximum brightness is obtained with minimum metal removal. Fume Suppressant The fume suppressant in Albright & Wilson phosphoric acids reduces the amount of the irritating, red NO, fumes produced from the reaction of nitric acid and aluminum and reduces the amount of nitric acid consumed. The following reactions illustrate the effects of a fume suppressant. Without Fume Suppressant: 7AI + 5HN0 3 + 21 H 3 PO < = . 7AI (H.PO - + 13H.O 2N 2 NO. Aluminum Nitric Phosphoric Monoaluminum Water Nitrogen Nitrogen Metal Acid Acid Phosphate Dioxide (brown fumes) With Fume Suppressant: 10 At + 6HNO : + 30H.PO 4 = . 10AI (H 2 PO 4 ), + 18H 2 0 3N, Aluminum Nitric Phosphoric Monoaluminum Water Nitrogen Metal Acid Acid Phosphate Additive A (Wetting Agent) Albright & Wilson's wetting agent, Additive A, can be incorporated to reduce the surface tension of the bright dip. It increases the rate of attack and metal removal. Additive A will permit bright dipping when the aluminum content is above 50 gm/l, and will decrease the time required to bright dip when the aluminum content is below 50 gm/l, although the use of Additive A is not recommended in bright dip baths containing less than 25 gm/l aluminum. Albright & Wilson's Additive A will also decrease drag out because the reduced surface tension causes the bright dip solution to drain faster. This property limits the use of Additive A to small , light parts. When used on heavy extrusions or parts, transfer etch may result. OPERATION AND CONTROL OF THE ALUMINUM BRIGHT DIP The bright dip bath must be carefully balanced and maintained to produce the maximum brightness possible. As the bath is operated, the bath composition changes due to the following: ^ 1 . Nitric Acid Reaction (reduces acid content) 2. Water Boil Off (reduces water content and increases specific gravity) 3. Nitric Acid Boil Off (reduces nitric acid content) 4. Aluminum Dissolution (increases aluminum content) Drag-out on the parts removes total solution but does not change the actual composition of the bath. However, the addition of makeup solution containing no aluminum reduces the aluminum content. 10 The aluminum bright dip bath can be controlled very simply by adopting the following daily operating procedures. Methods of analysis for specific gravity, nitric acid, and aluminum are discussed in "Procedure for Analyzing the Bright Dip Bath". 1. Add phosphoric acid to maintain level in the tank. Any one addition should not exceed 5% by volume of the bright dip solution. 2. Add nitric acid on a regular schedule to maintain a preestablished operating range. Only 42° 15 Baume nitric acid should be used to avoid an excessive drop in the specific gravity of the bath. Any one addition of nitric acid should not exceed 1/2% by volume (preferably 1/4%) of the bright dip solution. A nitric analysis should be made at least once per shift (and preferably twice), and the schedule of nitric additions modified as necessary to maintain the correct range (see Table 6). 3. Add water on a regular schedule to maintain a preestablished specific gravity range. A specific measurement should be made at least once a shift (and preferably twice), and the 0 schedule of water additions modified accordingly (see Table 5). Water is also lost overnight by evaporation, therefore .it is recommended that a "blanket" of water, usually 1/2 to 1 inch, be added to the bath at the close of work to prevent precipitation of aluminum phosphate ("ice"). 4. The aluminum content usually stabilizes under the given set of operating conditions but should be checked about once a week. For a fresh bath, the increase in aluminum due to dissolution exceeds the loss of aluminum due to drag-out. Thus, the aluminum content of 25 the bath increases. Higher aluminum contents, however, slow down the rate of dissolution and increase the drag-out of aluminum (due to highercontent of aluminum in the solution and higher viscosity). Eventually, the increase in aluminum by dissolution is offset by the loss of aluminum by drag-out, and the aluminum content becomes stabilized. The above schedule of control procedures should work very well if the physical operating conditions (time of immersion, temperature, agitation, and transfer time) are kept constant during each operating shift. Changes in any of the foregoing will produce a change in the additions 30 required to keep the bath in balance, as will a change in the number or shape of parts on the rack. The ranges recommended in Table 3 and Figure 2 are based on average operating conditions and represent best practice under such conditions. However, conditions quite different from normal may be encountered in actual practice. In particular, the alloy and physical characteristics of the aluminum may require alteration in operating conditions from those given. 35 TABLE 3 RECOMMENDED OPERATING PARAMETERS FOR BRIGHT DIPPING 1 Aluminum Content 1 , g/1 20 30 40 50 Specific Gravity at 80°F/27°C Maximum 171 172 173 174 Minimum 1.69 170 1.71 1.72 Nitric Acid Content (as%HNO. by wt.) With Additive "A" 2 Not. Rec. 2.1-2.3 2.4-2.6 2.7-2.9 With No Wetting Agent 2.4-2.6 2.7-2.9 3.0-3.2 3.3-3.6 Temperature °F 190-195 195-200 205-210 215-220 Temperature °C 88-90 90-93 96-99 102-104 Time, Minutes 3 1-2 1 1/4 to 21/2 1 1/3 to 3 2-4 Agitation Vigorous air combined with mechancial agitation is preferred Notes 1 Bright dip operating parameters should be selected based on aluminum content 2 Additive "A" Is not recommended for use in baths with aluminum contents tess than 25 grams/liter because the increased activity may cause rough, dull work 3 With Additive "A * the optimum time will probably be toward the lower end ol the operating range and on the higher end without Additrve "A * Figure 2: RECOMMENDED OPERATING RANGE 10 15 20 25 30 35 40 45 50 55 60 ALUMINUM CONTENT, GRAMS PER LITER of Al TABLE 4 EFFECTS OF MAJOR VARIABLES The effects of the major variables of the bright dip bath on smoothness and the rate of metal removal (brightness) are explained in the following table Variable Rate of Metal Removal Smoothing Action Temp , °F/°C Increases approx. 5% for each 5°F / Maximum smoothing action appears 3°C except for a leveling out effect to occur at end of leveling out somebetween 195°F/90°C and 205°F/ where between 195°F/90°C and 96°C, but above 205°F/96°C the in205°F'96°C crease in rate becomes linear again Time, mm First 5-10 seconds quite rapid, then Maximum smoothness usually ocrate becomes linear with time curs at point of minimum metal removal necessary to get under surface blemishes but before grain boundary lines are emphasized. Agitation Where agitation is not sufficient to The more agitation the better the renew the surtace solution rapidly, smoothness. Insufficient agitation the rate of attack may be reduced can lead to pitting and gassing (and pitting tendencies may be enmarks hanced) by as much as one half Transfer Time, sec Attack continues until parts are Parts may be etched due to the cooled down continuing reaction of bright dip, or the bright dip solution may dry on the hot parts leaving white streaks along the top edge (transfer etch) Nitric Acid Addition of nitric acid reduces the Smoothing action decreases with inContent, as rate of attack of pure phosphoric creasing nitric (above 1%) How% HNO, by wt until a certain mm concentration ever, pitting tendency is greater at Beyond this point (about 1 % HNO. lower nitric contents Best nitric for a bath containing 40 g/l of Al) an level is the lowest concentration that increase of 1 /4% HN0 3 increases does not produce pitting rate of attack approximately 3% Water Content, If water content is higher than the Smoothing action decreases with aass %% I H.O solution crystallization point, rate oi water content. Max. smoothing acby wt metal removal increases approxition occurs |ust below crystallization mately 10% for each 1 % increase in point or point of "low-water" pitting water content Aluminum Content, Rate of metal removal decreases Increasing aluminum content does as g. l of Al rapidly with increasing aluminum not change smoothing action How(80°F*60°F) content At 45 g/l the rate of metal ever, importance of agitation beremoval is less than 1/4 that at zero comes more critical and at high alualuminum content (other factors minum contents enough agitation to being constant) renew solution at the surface becomes almost impossible PhosDhoπc Acid, Because the amount of phosphoric Phosphoric acid is used to maintain % by wt acid, 70-82%, is so high, small the high viscosity and specific gravchanges in phosphoric acid content ity necessary to selectively dissolve have little effect on the rate of metal the aluminum at the "peaks removal PHOSBRITE " 172 Phosbrite ' is a phosphoric acid-sulfuric acid-nitric acid solution which was developed by Albright & Wilson in the 1950's. Throughout the years the formulation has been modified to address the technological improvements which have occuσed in the aluminum brightening industry. ' Phosbrite * 172 is a unique formulation for superior chemical polishing of aluminum which offers several advantages over conventional phosphoric acid-nrtπc acid solutions. " Phosbrite- 172 advantages include: 1 Increased specular reflectance on a wide range of alloys. 2 Removal of fine scratches and other imperfections. 3 Greater tolerance for soil contamination without producing contamination pits. 4 Wide operating parameters. 5. Elimination of transfer etch 6 Lower emission of fumes than similar processes containing nitric acid and sulfuric acid. OPERATION OF A PHOSBRITE ' 172 BATH The operation and control of a "Phosbrite" 172 bath is similar to a conventional phosphoric acid- nitnc acid bath. The most significant change is the specific gravity at which the bath operates. TABLE 7 RECOMMENDED OPERATING PARAMETERS FOR " PHOSBRITE " 172 Aluminum Content, g/l 15 30 45 Specific Gravity at 80°F Maximum 1.79 1.80 1.80 Minimum 1.76 1.76 1.76 Nitric Acid, % by wt 35-45 3.0-40 2.5-3.5 Temperature, °F 205-220 205-220 205-220 Temperature, °C 96-104 96-104 96-104 Time, mm. 1 5-4.5 1 5-4.5 1.5-6 0 Fresh ' Phosbrite ' 172 is added to the bright dip tank as necessary to maintain tank working volume (replacement of dragout losses). The only other necessary operating additions are nitric acid and water. As with the previously described R-5 bπght dipping bath, the nitric acid additions should be made with 42° Baume (-70%) nitric acid to avoid excessive reduction of specific gravity Stainless steel tanks and heaters rely on the presence of nitric acid to prevent corrosive attack, so the nitric acid content should not be allowed to drop below 2% The addition of water to lower the specific gravity is only necessary if the specific gravity exceeds 1 80 (80°F/60°F) / (27°C/16°C) Water addition should be made only when the appropriate amounts of virgin Phosbrite 172 solution and mtπc acid have been made and the specific gravity exceeds tne recommended parameter Occasionally when the water content of a Phosbπte bath drops too low a condition called "icing" may occur. Unlike the phosphortc/nrtπc acid bath, the "ice" formed in a 'Phosbrite' bath produces small needle - like markings on the surface of the part This condition is usually accompanted by a decrease in the specific gravity as the aluminum sulfate precipitates from the solution Should this problem aπse, add water and increase bath temperature until the "ice" is dissolved Then, bring the bath to its normal operating parameters before resuming production Contamination due to oils, greases and buffing compounds which have been dragged into the 'Phosbrite bath will create a black scum on the surface of the solution This should be skimmed off if it occurs Contamination of this nature will increase the rate of attack and may lead to reduced brightening Proper cleaning and rinsing will minimize this situation Air agitation is not required while operating Phosbrite 172 Air agitation should only be used to thoroughly mix the solution after a chemical addition Mechanical agitation which moves the aluminum while immersed in the solution is preferred Removal of the copper salt smut is required prior to anodizing A 35% by weight, nitπc acid solution or any proprietary desmut which will remove copper salts is acceptable The analytical procedures for determining nitric acid concentration, aluminum content, and the specific gravity, which have been described previously are all applicable to the analysis of a Phosbπte 172 solution Tables 5 of 6 can also be used to determine the amount of water and nitric acid to add to the bath to maintain proper operating conditions SAFETY & HANDLING Phosbrite 172 is a mixture of strong acids and is corrosive to skin, eyes, and mucous membranes The fumes evolved durng the use of Phosbrite 172 are toxic and corrosive The product does not burn but will emit toxic fumes when heated to high temperatures Rubber gloves, apron and full face shield or chemical goggles must be used when handling this product The Material Safety Data Bulletin for Phosbrite 172 must be reviewed with all personnel who handle or come into contact with the product A Material Safety Data Bulletin may be obtained by calling Albright & Wilson Americas ALUMINUM ALLOY The brightness and smoothness of the finished part are also dependent on metallurgy of the aluminum itself The metallurgical factors effecting brightness are: the amount of impurities (including alloying elements), the condition in which the impunties are present, and the crystalline grain structure of the aluminum (from either heat treatment or physical stretching or bending) Magnesium is the only element that can be alloyed with aluminum to increase strength without drastically reducing brightening characteristics. Because magnesium is the metallic element with properties closest to aluminum, it is not surprising that magnesium interferes least with the brightening operation 10 Iron is the most common impurity causing loss of brightness; therefore, control of this impurity is important in all bπght work alloys. All so-called super-bright alloys have a limit of approximately 0 1 % iron maximum. Silicon also reduces brightening characteristics and must be carefully controlled. Important exceptions to this are extrusion alloys such as 6063 and 6463 which contain 0.2 to 0.6% silicon for improved formability The silicon, if bound in the form of magnesium silicide apparently does not J 5 interfere with brightening as much as large aggregates do when precipitated at the grain boundaries. This precipitation normally results from poor quenching after extrusion or heat treatment and by over-buffing. It can appear as white "mottling" or white blotches after bright dip rinses or after anodizing. In addition to the presence of elements other than aluminum, the grain structure of the alloy is important. From a brightening viewpoint, the alloy should be as small grained as possible and in addition, all impurities (including alloying elements) should be homogeneously distributed. 20 However, physical working properties of the alloy are as important as the finishing characteristics, and often additional treatments must be given to the alloy to give the desired forming characteristics regardless of the effect on brightness. For a given aluminum composition a slightly faster rate of attack will occur with hard temper metal as opposed to fully annealed or soft metal. In general, harder tempers produce the brighest work. Large gram size causes "orange peel" which becomes more pronounced as increasing amounts of metal are removed for the surface. PROCEDURE FOR ANALYZING THE BRIGHT DIP BATH 25 The operating aluminum bright dip bath is composed of four maior components - phosphoric acid, aluminum, nitric acid and water. Determination of three of these components allows calculation of the fourth, usually water, by difference. The specific gravity of the bath is also a function of the composition. Common practice is to use the specific gravity as a direct indicator of the water content (if the approximate aluminum content is known). 1. Sampling Procedure 30 Obtain approximately 200 ml of sample (in a 400 ml breaker) from the bright dip tank. Be sure the tank is thoroughly agitated and that the sample is withdrawn from under the surface (to avoid contamination by impurities floating on the surface). If additions have been recently made, allow enough time for thorough mixing Cover the beaker and allow it to coo! to room temperature (using a cooling bath if available), or the sample may be cooled in a graduated cylinder or hydrometer ]ar in preparation for the specific 35 gravity determination Allow to stand long enough so that all air bubbles have escaped from the sample (thirty minutes is usually sufficient) 2. Specific Gravity Determination A specific gravity measurement should be made at least once and preferably twice a shift Water additions can be calculated using Table 5, the water addition chart on Page 21 3 Nitric Acid Determination A nitric acid analysis should be performed using the procedure on page 23 The sample for the nitric acid determination should be taken at the same temperature the specific gravity is measured, and the uncorrected specific gravity used for the nitric acid calculation 4 Aluminum Determination o The aluminum concentration should be determined using the procedure on page 26 The aluminum concentration should be checked at least once each week, but preferably once each day MEASUREMENT OF SPECIFIC GRAVITY Applicability 5 This method is applicable to the determination of specific gravity or relative water content of phosphoric acid aluminum bright dipping baths Principle For a given aluminum concentration, the amount of water in the bright dip solution is directly related to the specific gravity (weight) of the bright dip solution The amount of water necessary to correct for boil out can be calculated using the specific gravity and Table 4 0 Apparatus 1 Hydrometer (60°F/60°F) / (16°C/16°C) - Range, approximately 1 68-1 74 2 Graduated Cylinder 100 ml or hydrometer jar 3 Thermometer - 0-212°F, -18-100°C 4 Constant Temperature Bath - Optional Procedure 5 1 Pour approximately 80 ml of the sample into a 100 ml graduate (or other suitable tube) Measure the temperature of the sample (A standard reference temperature such as 80°F / 27°C should be selected, and the sample cooled or heated to within ± 3°F of this temperature) 2 Introduce the hydrometer into the graduated cylinder or hydrometer jar. Read the specific gravity value only after the hydrometer has come to equilibrium (approximately 5 minutes) and record the solution temperature 0 3 If the solution has not cooled to 80°F / 27°C. a correction factor must be used to calculate the correct specific gravity The specific gravity decreases 0 00038 for each degree that the bright dip sample exceeds 80°F / 27°C 4 Water additions necessary to correct the specific gravity are listed in Table 4 Calculations: 5 Corrected Specific Gravity = Measured Specific Gravity + Correction Factor Correction Factor = (actual temperature 80°F / 27°C) (0 00038) TABLE 5 WATER ADDITION CHART (Specific Gravity Correction) Specific Volume Grivity Units 300 400 500 600 700 800 900 001 04 06 07 08 10 10 13 003 13 17 21 25 29 36 38 005 21 28 35 42 49 56 63 007 29 39 49 59 59 78 88 009 38 50 63 76 88 100 113 010 42 56 70 84 98 112 126 011 46 62 77 92 108 124 138 013 56 73 91 109 127 146 164 015 65 84 105 126 147 168 194 017 73 95 119 146 166 190 219 019 82 106 133 163 186 212 245 020 86 112 140 172 196 224 258 021 90 118 147 181 206 236 271 023 99 129 161 198 225 258 297 025 105 140 175 210 245 280 315 027 113 151 189 227 264 302 340 029 122 162 203 243 284 324 365 030 126 167 210 251 294 334 378 031 130 174 217 260 303 348 390 033 138 185 230 277 323 370 415 035 147 196 245 294 343 392 414 037 155 207 259 310 362 414 466 039 164 218 273 327 381 434 491 WO 168 234 280 336 392 468 503 0 5 189 252 315 378 441 504 566 Specific Volume Gravity Units 1000 1200 1400 1500 1600 1800 2000 001 14 17 20 21 22 25 28 003 42 50 59 63 67 76 84 005 70 84 98 104 112 126 140 007 98 117 137 147 157 176 196 009 126 151 176 189 201 226 252 010 140 167 196 210 224 252 280 Oil 154 185 215 231 246 277 308 013 182 218 253 273 291 327 364 015 210 252 294 315 336 387 420 017 238 292 333 357 380 439 476 019 266 327 372 399 425 490 531 020 280 338 392 420 448 516 559 021 294 361 41 1 441 470 542 537 023 321 396 450 453 515 593 643 025 350 420 490 524 560 629 699 027 378 453 529 566 604 680 755 029 406 487 568 608 649 730 81 1 030 420 503 587 629 671 755 839 031 431 520 607 650 694 780 867 033 461 554 646 692 738 837 923 035 490 587 635 734 783 881 979 037 517 621 724 776 828 931 1035 039 545 655 764 818 873 982 1091 040 559 671 783 839 895 1007 1119 045 629 757 881 944 1007 1133 1259 To decrease the specific gravity oy the amount in column one, determine the volume of bright dip solution on the top row and add the corresponding amount of water WATER ADDITION CHART (cont.) Specific Volume Gravity Units 2100 2200 2400 2500 2600 2800 3000 001 19 31 34 35 36 39 41 003 88 92 101 105 109 117 126 005 147 154 168 175 182 196 210 007 206 215 235 245 255 274 294 009 264 277 302 315 327 352 378 010 293 308 336 350 364 392 420 011 323 338 369 385 400 431 462 013 332 400 436 455 473 509 545 015 441 462 503 524 545 587 629 017 499 523 585 594 618 666 713 019 558 585 654 664 691 744 797 020 587 615 676 699 727 783 839 021 617 646 722 734 764 822 831 023 676 798 791 804 836 901 965 025 734 769 840 874 909 979 1049 027 793 831 906 944 988 1057 1133 029 852 892 973 1014 1055 1136 1217 030 881 923 1007 1049 1091 1175 1259 031 910 954 1041 1084 1127 1214 1300 033 969 1015 1108 1154 1200 1292 1385 035 1028 1077 1175 1224 1273 1371 1469 037 1037 1138 1242 1294 1345 1449 1552 039 1145 1200 1309 1364 1418 1527 1636 040 1175 1231 1343 1397 1455 1566 1678 045 1322 1335 1510 1573 1636 1762 1888 Specific Volume Gravity Units 3200 3400 3500 3600 3800 4000 5000 001 45 48 49 50 53 56 70 003 135 143 147 151 159 168 210 005 225 238 245 252 266 280 350 007 315 339 323 3S 2 372 392 490 009 406 428 44 I 453 478 503 630 010 451 475 490 503 531 559 699 Oil 496 523 538 554 585 615 769 013 586 618 636 655 691 727 909 015 676 713 734 774 797 839 1049 017 766 808 832 877 903 951 1189 019 856 903 930 981 1010 1063 1329 020 901 951 979 1032 1063 1119 1399 021 946 999 1028 1034 1116 1175 1469 023 1037 1094 1126 1187 1222 1287 1608 025 1127 1189 1224 1259 1329 1399 1 48 027 1217 1284 1322 1359 1435 1510 1888 029 1307 1379 1420 1460 1541 1622 2098 030 1357 1427 1469 1510 1594 1678 2098 031 1397 1474 1517 1561 1648 1734 2168 033 1487 1569 1615 1662 1754 1846 2308 035 1577 1664 1713 1462 1860 1958 2448 037 1668 1759 181 1 1863 1966 2070 2587 039 1 53 1855 1909 1964 2073 2182 2727 040 1803 1902 1958 2014 2126 2238 2797 045 2028 2140 2203 2266 2392 2517 314 - To decrease the specific gravity by the amount in column one, determine the volume of bright d i p solution on the top row and add the corresponding amount of water DETERMINATION OF NITRIC ACID (FERROUS AMMONIUM SULFATE TITRATION) Applicability This method is applicable to the determination of nitric acid in phosphoric-nitric acid type aluminum chemical polishing or bright dipping baths Principle In the presence of sulfuric acid, ferrous ammonium sulfate (FeSO (NH .SO 6H.O) reacts with nitric acid to form ferric sulfate and nitric oxide. At the endpoint of the titration, excess ferrous ammonium sulfate reacts with the dissolved nitric oxide to form an intense brown complex- [Fe(H.O),NO]. P0 4 6FeS0 4 + 2HNO : + 3H 2 SO,= 3Fe 2 (SO 3 + 2NO + 4H.0 Reagents 1 Phosphoπc Acid - 85% Reagent Grade 2 Ferrous Ammonium Sulfate - with factor of approximately 0 70 Preparation and standardization described at end of procedure Apparatus 1 Pyrex Beaker - 150 ml 2 Graduated Cylinder - 100ml 3 Hot Plate 4 Titrating Burette - 10 ml 5 Syringe - 2 ml 6 Thermometer - 0-212°F, -18-100°C 7 Hydrometer (60°F/60°F) - 1 6-1 8 Range / (16°C/16°C) Procedure 1 Measure a 2 0 ml sample of bright dip solution by introducing the syringe tip just below the surtace of the sample and withdrawing the plunger halfway. The syringe should then be inverted and the air bubble forced out of the tip Then fill the syπnge past the 2 ml mark and push the plunger carefully back to the 2 ml mark The tip of the syringe should be touched to the side of the sample beaker to remove any droplets The 2 ml sample should be forced into a 150 ml beaker containing 50 ml of 85% phosphoric acid, touching the tip to the side of the beaker at the end of the delivery Use the thermometer to stir the solution Do not use a flask as the fumes evolved must be freely released from the solution 2 Heat the beaker to 125°F/52°C and titrate dropwise with the ferrous ammonium sulfate solution stirring well until a permanent brownish color appears Towards the end of the titration the acid will "boil" or effervesce with each addition of ferrous ammonium sulfate, and the characteristic reddish brown fumes of nitrogen dioxide will be given off The final temperature must be between 130°F/54°C and 140°F/60°C Calculation % HNO, ml x factor (by weight) Specific Gravity Notes Preoa/ation ol Ferrous Ammonium Su'late Dissolve 230 g ol Fe(NH,) I (SO,), δH C P m 500 ml ol distilled water containing 50 ml ot concentrated H j SO, in a 1000 mi volumetric flask Dilute to tne mark witfi distilled water ■■" his solution should be stand&'dtzed by titrating a 2 ml sample ol solution (made by mixing 95 parts by volume of 85% reagent H > PO i and 5 parts by volume of 70% reagent HNO,) by the procedure as listed previously The HNO, should be pipetted and both nitric acid and phosphoric aαd should be at room temperature (about 80-F) The lactor is calculated as follows Factor . 95 ml ol Ferrous Ammonium Sullate Solution Required Factor on Iresh solution should be about 07 TABLE 6 NITRIC ACID ADDITION CHART Volume HNO, 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1 5 7 9 10 1 2 1 4 15 1 7 19 21 22 24 26 2.7 2 1 3 1 4 1 7 21 24 27 3 1 34 38 4 1 44 48 5 1 55 3 1 5 2 1 26 3 1 36 4 1 46 5 1 56 62 67 72 77 82 4 21 27 34 4 1 48 55 62 68 75 82 89 96 103 109 5 26 34 43 51 56 69 77 86 94 103 11 1 119 128 137 6 31 4 1 51 62 72 82 92 103 113 123 133 144 154 164 7 36 48 60 72 84 96 108 120 132 144 156 168 180 192 8 4 1 55 88 82 96 109 123 137 15 1 164 178 192 205 219 9 46 63 77 92 108 123 139 154 168 185 200 21 5 231 246 10 5 1 68 86 103 120 137 154 17 1 188 205 222 239 256 274 1 1 57 75 94 11 3 132 15 1 170 188 207 226 244 263 282 301 1 2 62 82 103 123 144 165 185 205 225 244 267 287 308 328 13 67 89 11 1 134 156 177 200 222 244 267 289 31 1 333 356 1 4 72 96 120 144 168 192 216 239 263 287 31 1 335 359 383 1 5 77 103 128 154 180 206 231 257 282 308 333 359 385 410 16 82 110 137 164 192 219 246 274 301 328 356 382 410 438 1 7 87 11 6 145 175 204 233 262 29 1 320 349 378 406 436 465 18 93 123 154 185 21 6 24 7 277 308 338 369 400 430 462 492 1 9 98 130 163 195 228 260 293 325 357 390 422 454 437 520 20 103 137 172 206 " 240 274 308 342 374 410 444 478 51 3 547 % by we light Voi lume HNOj 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 1 29 3 1 32 34 36 38 39 4 1 43 44 46 48 50 51 2 58 62 65 72 72 75 79 8 2 86 89 92 96 99 103 3 87 92 97 103 108 11 3 118 123 128 133 139 144 149 154 4 116 123 130 137 144 150 157 164 17 1 178 185 192 198 205 5 145 154 162 17 1 180 188 197 205 21 4 222 231 239 248 257 6 174 185 195 205 21 5 226 236 246 257 267 277 287 298 308 7 203 216 227 239 251 263 275 288 299 31 1 323 335 347 359 8 233 246 260 274 287 301 315 328 342 356 369 333 397 410 9 262 277 292 308 323 339 354 369 335 400 416 431 446 462 1 0 291 308 325 342 359 376 393 410 428 445 462 479 496 513 1 1 320 339 35 7 376 395 41 4 433 451 470 489 508 527 545 564 1 2 349 369 390 410 43 1 45 1 472 492 513 534 554 575 595 616 1 3 378 400 422 445 467 439 51 1 534 556 578 600 622 645 667 1 4 407 431 455 479 503 527 551 575 599 622 646 670 694 718 1 5 436 462 437 513 539 564 590 616 64 1 667 693 718 744 770 i 6 465 492 520 547 575 602 629 657 634 71 1 739 766 793 821 1 7 494 523 552 58 1 610 0 0 669 698 727 756 785 81 4 843 872 1 3 523 -54 535 51 6 646 o77 70S 739 770 800 831 862 893 923 19 552 585 61 7 650 63 1 -' 5 747 '30 81 2 845 877 910 942 975 20 56 1 61 6 650 6θ 4 71 8 '52 787 82 1 855 839 923 958 992 1026 06° Ov wl = 1 °'o Oy vol 3% by i = 5% by voi To increase the nitric acid concentration by the percent in column one determine the volume of bright dip solution on the top row and add the corresponding amount of 70% nitric acid DETERMINATION OF ALUMINUM (EDTA METHOD) Applicability This method is applicable to the determination of aluminum in commercial phoεphoπc-nitπc acid aluminum brightening baths. An appreciable amount of any polyvalent cation other than dissolved aluminum will interfere in this titration Principle This method uses EDTA which is a chelating agent that reacts slowly with aluminum In this titration excess EDTA is added to the bright dip solution and allowed to react with the aluminum for at least 10 minutes to insure complete reaction. Copper, which reacts quickly with EDTA, is used for the back titration to determine the excess EDTA, using pyrocatechol-violet as the indicator. Free copper, present only at the end of titration, turns this indicator from pale yellow-green to bright blue Reagents 1 Dilute Ammonium Hydroxide Dilute reagent grade ammonium hydroxide 1 to 4 with distilled water 2 Pyridine Solution 10% Solution, Dilute 100 ml reagent grade pyridme with 900 ml distilled water. The final pH should be 6 0-7 0 3 Indicator Solution Dissolve 0.1 grams reagent grade pyrocatechol violet in 100 ml distilled water. 4 EDTA Stock Solution 0.1 M , Dissolve 37.21 grams of reagent grade disodium ethyiene-diamine tetraacetate dihy- drate (EDTA) in distilled water in a one liter volumetric flask and dilute to the mark with distilled water. 5 EDTA Working Solution 0.01 M, Dilute 100 ml of the EDTA Stock Solution to the mark in a 1 liter volumetric flask with distilled water. 6 Copper Sulfate Stock Solution 0.1 M, Dissolve 24.97 grams of CuS0 4 - 5H.0 in distilled water and dilute to the mark in a 1 litervolu- metric flask. 7 Copper Sulfate Working Solution 0.01 M, Dilute 100 ml of the Copper Sulfate Stock Solution to the mark with distilled water m a 1 liter volumetric flask (Note 1 ) Appai • atus 1 Volumetric Flasks 1 liter, 250 ml. 100 ml 2 Erienmeyer Flask 250 ml 3 Titrating Burette 50 ml 4 Syringe 1 0 ml 5 Pipets 10 ml 1 5 ml 6 pH Meter or pH paper Range pH 6-7 7 Hydrometer (Specific Gravity) Range 1 6- 1 8 Procedure 1 Introduce 0.5 ml of the sample (using the 1 0 ml syringe) into a 100 ml volumetric flask and dilute to the mark with distilled water - mix well (Note 2) 2 Pipet 10 ml of the diluted solution (Step 1 ) and 15 ml of the 0.01 M EDTA Solution into a 250 ml Erienmeyer flask. Allow a waiting period of 10 minutes. 3 Add 100 ml of distilled water and adjust the pH to between 6.0 and 6 2 with the diluted ammonium hydroxide (using pH meter). This should take 5 to 8 drops. (Note 3) 4 Add 10 ml pyridine and 6 to 10 drops of the indicator solution and titrate rapidly with the 0.01 M Copper Sulfate Solution. Record the number of ml required to reach the end point. (Note 4) Calculations:- π S • ml cooper sulfate solution) x 2.44 = % AIPO. specific gravity (1 5 - ml copper sulfate solution) 0.54 = % AI specific gravity (15 - ml copper sulfate solution) x 5 40 = g/l of Al Notes: 1 The O OI copper sulfate solution should be standardized against e 0 01 EDTA solutton by running a blank through the procedure, eliminating the 10 ml of sample solution and the subsequent neutralization with the dilute ammonium hydroxide Exactly 15 0 ml of the copper sullate solution should be required to reac-h the end point II more or less is require . fresh solution exactly 0 01 should be obtained from Albright 4 Wilson's Technical Service Department 2 The speofic gravity of trie bπght dip solution at the temperature at which the sample is taken should also be obtained so that the aluminum may be calculated by weight 3 II the pH ol the solution is ad * usted over 6 8 the sample must be discarded and a fresh sample taken 4 The end point is a color change from yellow-green O bπght blue Speed is essential as the end point will lade ba<* to the yellow-green upon standing The trtraooπ should be performed seveτa-1 Drnes with tie "blank" unol the operator becomes fam i liar with the method References 1 Chemist Analyst, Vol. 45, No 2, Page 35. June 1956 [34- RINSING Though rinsing is not usually considered to be a finishing process, proper rinsing is essential to the production of high quality bright anodized aluminum Proper rinsing is required to reduce contamination of the processing tanks and leave the parts clean for subsequent finishing steps Chemicals used in one finishing step are contaminants that interfere in subsequent process steps. For example, cleaners carried into the bright dip can cause pitting, dull parts and transfer etch because cleaners reduce the surface tension ol the bright dip, and therefore, interfere in the chemical brightening process Bπght dip solution (phosphoπc acid) carried over to the anodize tank will cause a soft anodic coating to form Phosphate in the seal tank will interfere with sealing and cause smutting, and high levels prohibit sealing altogether. Thorough rinsing is achieved by optimizing the following 1 Number and configuration of rinses 2 Type of rinse 3 Drain time 4 Rack design 5 Size -and shape of parts 6 Contaminants being rinsed Each of these factors must be considered to optimize πnsing NUMBER AND CONFIGURATION OF RINSES The first consideration is the number of rinse tanks available The more πnse tanks that are available, the lower the total water flow required to achieve proper πnsing Whenever more than one rinse tank is available, counter-current rinsing should be used The basic concept of counter- current rinsing is to use the water from previous rinsings to contact the more contaminated work Fresh water enters the process at the final rinse stage and then moves in the opposite direction of the work flow to serve as rinse water for preceding rinse tanks as shown in Figure 3 Figure 3 COUNTER-CURRENT RINSING E NT E RS WATE R F L OW OU TGOING ro ' R E - T KE sT OR S TOR A GE COUN T E R C U R R E N T R IN S ES OV E R F LOW R I NSE The amount of water required to properly πnse parts is greatly reduced when counter-current πnses are used. For example, if a flow rate of 1 ,000 gallons/hour is required to rinse parts properly using one rinse tank, 80- 120 gallons/hour would be required for proper rinsing using a two-stage counter- flow rinse system, and only 8-12 gallons hour would be required for a three-stage counter-flow system as shown in Figure 4 As sewage and waste treatment costs increase, the need for reduction in water usage becomes more important. Increasing the number of πnses and counter-flowing those πnses is an easy way to reduce water usage. Another factor to consider when installing a multistage system is the need for agitation. In cases where water is cascading over a work piece, the high flow may provide adequate agitation. As more πnse stages are added to reduce the amount of water used, a point will be reached where the flow of water itself is not sufficient to provide adequate agitation. At this point air agitation will be required. This breaks up the interfacial resistance between the rinse water and the work surfaces and can penetrate recesses or hard to reach areas. Whenever possible, dπp pans should be installed between the tank lips. The pans should slant back toward the the tank from which the rack is exiting to return some of the dragout to that tank. Figure 4- WATER SAVINGS WITH COUNTER CURRENT RINSING. N U M B E R C F C0UN T E R - C U R R E N T R I N SES TYPES OF RINSES In addition to immersion rinsing, two types of spray rinses are used in the bright anodizing process. The most common form is an immersion and spray technique (see Figure 5). In this type of rinse the pans are immersed in an immersion rinse tank to remove the bulk of the contaminants. Then, as the parts exit the rinse tank, they are sprayed with clean water. The impact spray rinse is advantageous in removing stubborn films and permit lower water flows to the main immersion rinse because the last water contacting the part is clean and uncontaminated. This type of rinse is used primarily as a final rinse. Impact spraying can also be used alone to remove contaminant films by both impact and diffusion. It uses less water than immersion rinsing, but it only rinses exposed surfaces. Spray rinsing cannot be used to rinse nested parts, tubing or other parts with inaccessible areas. Figure 5: SPRAY AND IMMERSION RINSE COMBINATION. DRAIN TIME Drain time over processing tanks should be as long as possible, without causing solution to dry or leave permanent marks on the parts. This will keep dragout to a minimum. RACK DESIGN, SIZE AND SHAPE OF PARTS Racks themselves should be designed to drain easily. Cup shaped parts of racks which can hold solution should be avoided whenever possible. Dragout is also affected by the shape and position of the work. Racks should be designed to hold parts for maximum drainage. In some cases, holes have been drilled in parts to help drainage of cupped areas. Occasionally, parts or racks are encountered that have crevices or folded areas. These recesses open in hot process tanks, like bright dip or cleaner tanks, but close up when they go into a cold rinse. This traps the process solution, and makes rinsing in a cold rinse impossible. Parts or racks with crevices or folds may require warm rinses to avoid contamination of processing tanks lurther on down the line. RECOVERY OF PHOSPHORIC ACID One of the most effective cost-reduction measures available to the aluminum finisher is the recovery of phosphoric acid nnse water from the bright dipping operation In addition to reducing phosphate discharge by up to 95 percent, a system can be designed to provide improved πnsing while recovering a valuable commodity for sale or reuse on the finishing line The actual savings realized via πnsewater recovery can vary greatly, depending upon the design of the system and the operating practices of the finisher A brief review of some of these considerations should be beneficial to the individual installing a new system, as well as the finisher seeking to upgrade an existing one 10 CONSTRUCTION OF SYSTEM The counter current system shown in Figure 3 on page 27 includes a series of recovery rinses that can be counterflowed, followed by a free-flowing rinse A pump can be included for transferring the recovered πnsewater to a storage tank Proper design provides for the correct number of tanks adequate rinsing, and a recovered phosphoric acid of consistent quality , - The number of tanks added to an existing finishing line ultimately will be a compromise between recovery efficiency and available space Because cost reduction is directly proportional to the volume of acid recovered, close attention should be paid to the ratio of recovered phosphoric acid vs that used in the bright dip A nnse system with one stagnant tank can recover only 45 to 50 percent of the acid that is used A two-tank system can recapture 60 to 65 percent, a three-tank system 80 to 85 percent, and a four-tank setup can recover 90 to 95 percent of the phosphoric acid used The addition of a spray rinse on the final πnse tank can increase recovery efficiency 3 to 7 percent 20 In each case, the series of recovery tanks must be followed by a free-flowing rinse to remove all remaining phosphates before anodizing The three and four-tank systems provide a higher recovery efficiency, and also reduced water consumption and less phosphate dragout from the final nnse tank All phosphoric acid not recovered must be neutralized or precipitated and removed by the waste-treatment system Therefore more efficient recovery systems permit the construction of smaller waste treatment facilities and the reduction of associated chemical costs 25 DESIGN POINTERS Overlooking any of a number of elementary design factors may drastically reduce the overall efficiency of the finishing line The following are some important considerations Water Flow The counterflow system must be designed to prevent "short circuiting" during solution transfers As 30 solution is removed from the bottom of one end of each tank, rmsewater from the following tanks should counter-flow into the top of the opposite end Solution Depth Each successive rinse tank should cover 1 to 2 inches more of the splines than the previous πnse to insure complete removal of the more concentrated solution The final, flowing rinse should also allow the work bar to be completely immersed This helps prevent phosphate contamination of seal tanks ^- > by reducing dπed-oπ bπght dip solution that would be washed into the seal tanks by steam condensation on the work bar Spray Rinsing Though called a free flowing nnse, the final πnse tank may have all its makeup water supplied by high- pressure spray rinsing of each rack as it emerges from the tank as shown in Figure 5 Agitation Good agitation is essential for complete removal of the viscous film of bright dip solution from the pans Each rinse tank must have two air lines running the length of the tank to supply high-volume, low-pressure, oil-free air On a manually operated hoist line, the first recovery rinse should be large enough lor the operator to rock or swing the work bar Drip pans should be installed between all tanks so the solution drainage duππg transfer is returned to the most concentrated tank Freeboard Adequate freeboard height must be provided to prevent solution from being splashed over the sides during rinsing Six to eight inches is sufficient for most lines OPERATING POINTERS Even a well-designed recovery system can achieve a lower-than-expected recovery ratio due to poor control A well-operated system will prevent fluctuations in the efficiency of ππsing and in the concentration of recovered acid The following operating parameters will increase the amount of phosphoric acid recovered Pumping The most efficient recovery systems have automated controls to pump a portion of the first recovery rinse to storage when the specific gravity reaches 1 28 (about 36 percent phosphoric acid) Because the bright dip solution is more readily miscible in πnsewater than in water, no more than 20 percent of the tank should be replaced at any one time Concentration Control If 20 percent of the first recovery nnse is replaced at one time, the acid concentration in that rinse will vary from 33 to 36 percent Optimum recovery operation is achieved when the concentration variations are in this range. Recovery of acid at 38 percent or higher should be avoided due to the marked reduction in recovery efficiency at that concentration Temperature Control The temperature in the first recovery rinse may be critical to the appearance of the parts High temperatures can cause etching, mottling or pitting, while low temperatures result in poor πnsing The temperature must be low enough to cool the parts rapidly and halt the action of the bright dip solution but high enough to rapidly dilute the film of acid solution clinging to the part Heat transferred to the first rinse by the parts will rapidly raise the rinse temperature to the point that problems will occur Cooling must therefore be provided The cooling system must be able to hold the rinse temperature at 80°F / 27°C for extrusions and at 90 to 100°F / 32 to 37°C for stampings It should be designed to prevent fluctuations of more than two degrees above or below the desired operating temperatures because a change of four or five degrees can drastically change the performance of the rinse ADDITIONAL INFORMATION The cost of phosphoric acid represents approximately 90 percent of the total chemical costs for bright anodizing lines. Even a small improvement in recovery efficiency can significantly reduce direct processing expenditures. In addition, any phosphoric acid not recovered must be neutralized before it can be discharged to a sewage system. This neutralization represents a substantial cost. Approximately one pound of 50% sodium hydroxide is required per pound of 80% phosphoric acid discharged. Albright & Wilson's Technical Service representatives are highly experienced in improving recovery efficiency. They are always available to provide the technical backup required to install, operate, or improve phosphoric a d recovery systems. ANODIZING Anodizing is an electrochemical process for thickening the natural oxide coating always found on aluminum This natural oxide coating is only 00005 mils thick, but the anodizing process can ease this film thickness to between 008 and 20 mils This thicker oxide coating is more resistant to corrosion and abrasion than either the underlying aluminum or the aluminum with only Us natural oxide coating In addition, most anodized coatings are porous and have the ability to absorb dyes and pigments before they are sealed This produces an attractive colored oxide coating, integral to the metal itself, and thus less likely to chip or peel than painted coatings With proper care and handling anodized aluminum articles can last a lifetime MECHANISM OF COATING FORMATION The formation of the aluminum oxide coating on aluminum involves two competing processes which occur simultaneously Briefly, the aluminum parts are made the positive pole, or anode in an electrochemical cell using an acidic electrolyte As current passes through the solution, oxygen is generated at the anode and immediately reacts with the aluminum parts to form the aluminum oxide coating Simultaneously, the aluminum oxide coating, which is soluble in the electrolyte is dissolved by the acid and will become porous and less dense (See Figure 6) Figure 6 MECHANISM OF ANODIC COATING FORMATION ACIDIC ELECTROLYTE DISSOLVES THE ALUMINUM OXIDE COATING WHICH CAUSES THE COATING TO BECOME POROUS TABLE 7 PARAMETERS EFFECTING ANODIZING Recommended Parameter Operating Range Increased Level Decreased Level Acid Clear: 15% (by t.; The higher the acid conLower acid concentraConcentration Dye: 18% (by wt ) centration the faster the tion decreases the anodic coating is disbath's conductivity and solved and the more the porosity of the coatporous the coating. ing. Higher voltages Darker dye color results, required for anodizing. but more difficult to seal. Temperature Clear: 68-72--F As the temperature inDecreasing the temcontrolled ± 2°F creases the rate of anperature decreases the Dye: 68-88°F odic coating dissolution porosity of the coating. controlled ± 1°F increases. Coating, The lack of porosity detherefore, becomes very creases the conductivity porous. A ± 2°F change of the coating and oxyin temperature will gen diffusion rate. cause a significant Higher voltage will be change in porosity. For required to continue dye work control ± 1°F or coating formation. color change will be apparent. Current Clear: 8-12 amps/ft 2 Current density (not voltDecreasing the current Dye 10-15 amps/ft' age) controls the rate of density decreases the coating formation. Inrate of coating formacreasing the current tion, and may cause density - above 18-25 high porosity because amps/ft can cause the coating dissolves as burns. it forms Dissolved 2-12 gm l Above 12 gm l Al the Below 2 gm l Al burning Aluminum coating is noticeably occurs at the contacts cloudy because aluminum has a buffering effect in the bath and distπbutes current more evenly. Voltage Clear: 12-18 volts Controls barrier layer Voltage is usually self Dye: 10-22 volts cell size and wall thickregulating. It increases ness. Increased voltage as the anodic coating is due to poor contact or builds on the parts and racks. its resistance increases Time Clear: 10-30 mm Coating thickness inDecreasing time deDye. 10-60 mm creases with time until creases the anodic coatthe point where the coating thickness. ing dissolves at the same rate at which it forms (usually after 75 m .) Air Agitation Required for all Air agitation mixes the Decreased or insuffianodizing anodize solution to allow cient agitation can uniform conditions in all cause streaks due to pans of the tank. Heat overheating, streaks generated at the parts due to accumulation of by the anodizing procgases generated by ess is removed. Agitaanodizing and πoπ-uπi- tion is necessary for uniform anodic coating due form anodizing to solution variation CONTROL OF ANODIZING BATHS As the anodize bath is operated, solution is lost by dragout on the parts and must be replaced by additions of sulfuric acid and water to maintain the proper solution level and strength in the anodize bath in addition, aluminum oxide which is dissolved from the coating duππg anodizing, causes alu- minum to build up in the anodize bath. Proper monitoring of the chemical composition of the anodize bath is necessary to produce anodic coatings of good and uniform quality. At least once per shift the "free" sulfuric acid, specific gravity, and aluminum should be determined. Procedures for determining "free" sullunc acid and aluminum are included at the end of this section. In addition, agitation, dwell time, current density and temperature must be regulated to insure an adherent, clear protective coating. Sufficient agitation is required to disperse the heat generated duπng the anodizing process. For the best quality work, there must be sufficient agitation to prevent the temperature at the part surface from rising more than 1.0°F (0.5°C) above the temperature of the anodize bath. Localized temperature variations will cause differences in porosity which become apparent if the part is subsequently dyed. Cooling or refrigeration is required to control the temperature of the anodize bath within the ±2°F ±1°F for dye work) required for consistent anodizing. ANODIZING PROBLEMS Rainbow Variations in coating thickness along the length of a part produce color variations known as "rainbow". This may be caused, by loose or insufficient number of contacts, or by applying the current too rapidly. "Rainbow " may also be caused by improper cathode placement, causing thicker coatings near high cathode density areas Grayness Grayness may occur when aluminum content in the anodize bath is too high or may be due to impurities in the alloy In general, coatings with higher density tend to be darker or more cloudy Dullness Alloying elements intentionally added to the aluminum for strength and forming characteristics can have a great effect on the color and clarity of the anodic coating. Alloys high in iron and silicon, even within the designated specification ranges, may produce noticeably dull coatings. In addition, high aluminum in the anodize solution will cause dull coatings. Alloying elements have the following effects on the coating color and clarity Iron: Detracts from specularity; yellow to gray color Silicon: Causes cloudy, gray appearance Magnesium- The only alloying element that does not detract from the color or clarity of the coating Manganese: May cause brown, discolored anodic coatings Magnesium Si cide (Mg.Si) May cause a cloudy appearance known as mottling Contamination Phosphate contamination above 1 ,000 ppm will produce soft coatings that are difficult to seal. Chloride contamination may cause pitting above 100 ppm. Soft Coatings Soft coatings result when the anodic coating is applied too rapidly, when the temperature or acid concentration are too high, when the part is anodized too long (over 1 hr.) and when phosphate contamination is over 1 ,000 ppm. Burns Burns result from poor contacts or too few contacts, insufficient aluminum (below 2 gm/l) to buffer the current, large surges of power and poor agitation (causing extensive localized overheating). Brown burns near the end of the part may result from low acid concentrations. Thin Coatings Thin coatings may result from poor contacts, short time, low current density or high phosphate. Parts having thin coatings will typically be very bright and have a rainbowed appearance. /58024 DETERMINATION OF "FREE" SULFURIC ACID IN ALUMINUM ANODIZING BATHS Reagents 1 1.0 N Sodium Hydroxide (Standardized) 2. Methyl orange indicator solution Apparatus 1 . Pipet - 10 ml 2. Erienmeyer Flask - 250 ml 3. Titrating Burette (Teflon Stopcock) - 50 ml 4. Hydrometer (Specific Gravity) - Range 1.0-1.225 5. Graduated cylinder - 100 ml Procedure 1. Pour sample into the 100 ml graduate and measure the specific gravity with the hydrometer, adjusting the temperature to 70°F i2°F. 2. Introduce 10 ml of the anodizing solution (using a 10 ml pipet) into a 250 ml Erienmeyer flask. J. Add 50 ml of distilled water and 4 drops of methyl orange indicator. 4. Titrate with 1.0 N Sodium Hydroxide from a red to a yellow-orange color. (pH = 3.2) Calculations: 1. ml of Sodium Hydroxide x N x 0 49 <*- % "Free" Sulfuric Acid Specific Gravity at 70°F ml of Sodium Hydroxide x N x 4 9 « grams/liter "Free" Sulfuric Acid 2. Aluminum in grams/liter may be obtained from the graph (Figure 7). Aluminum may also be determined by the EDTA titration method (p 24-25). The sample size in step 1 is increased to 1.0 ml and the calculation is: (15 ml - ml of copper sulfate solution) x 2.7 = g l Al 00/58024 Figure /.RELATIONSHIP BETWEEN SPECIFIC GRAVITY, FREE SULFURIC ACID AND ALUMINUM CONTENT OF ANODIZING BATHS. 10 II 12 13 14 15 16 17 18 20 21 22 23 % Free H 2 SO„(8y Weight) SEAUNG The anodic film produced on aluminum by sulfuric acid anodizing is very porous. This is due to the nature of the sulfunc acid electrolyte and its solvent action on the aluminum oxide film. This porous film must be "sealed " to fully protect the aluminum from corrosion Although the coating is hard and abrasion resistant, moisture and corrosive elements can penetrate to the underlying aluminum unless the pores are sealed The resulting corrosion is unattractive and can cause weakening of the metal The p urpose of sealing is to increase the corrosion resistance of the anodic coating The most widely accepted theory of the mechanism of sealing is that a portion of the anodic film (aluminum oxide) is converted to an aluminum hydrate by immersion in hot water. Also occurring during sealing is the removal of acidic contaminants and the partial plugging of the pore openings of the 0 coating with an hydrated aluminum oxide gel. There are several types of seal baths, all composed of hot water with or without sealing additives. Nickel acetate and potassium dichromate have been popular as sealing additives Nickel acetate has also proven very effective in what is known as the pre-seal, which came into use in the early 1970's and has become the standard in the industry for producing high quality seals. 15 NICKEL ACETATE PRE-SEAL As its name implies, the pre-seal is a preliminary sealing step and does not actually seal, or hydrate, the coating. It must be followed by a conventional seal such as hot water, nickel acetate or dichromate seal. The pre-seal prepares the anodic film for sealing by incorporating nickel ions in the film, thus partially plugging the pores While the nickel is being incorporated in the film, the pre- seal is also removing sulfunc acid and aluminum sulfate from the film, thus preparing it to be rapidly 2Q hydrated in the final seal. The final seal is able to more completely and rapidly seal the anodic film and provide much greater corrosion resistance The pre-seal does not seal the anodic film because its operating temperature is too low for hydratioπ to occur. Hydration of the coating will only occur in a seal bath having a temperature of at least 203°F / 95 C C, the most effective hydration occurs above 208°F/98 β C. There are no catalytic systems or other special bath additives known which can reduce the temperature requirements for rapid hydration of the coating -- ' The nickel acetate pre-seal should not be confused with the conventional nickel acetate seal. The pre-seal is operated at a high pH (6 8-7 2) and a low temperature ( 145-165°F) / (63-74°C), while the conventional nickel acetate seal is operated at a lower pH and a temperature close to boiling. The pre-seal also employs a dispersing agent not normally used in the conventional nickel acetate seal. Contrary to popular belief, the nickel acetate pre-seal does not function better if the nickel is precipitated as the hydroxide. Early in its history, it was believed that the nickel must be present 30 as nickel hydroxide. Current evidence indicates that only the nickel in solution is effectively incorporated in the anodic film. Operating Conditions for the Nickel Acetate Pre-Seal Proper pre-seal operation is required to provide adequate corrosion resistance for the anodic film. and also to maximize the pre-seal's operating life. Successful operation requires close attention 35 to proper πnsing, proper control of operating conditions, and proper bath preparation. The following table indicates optimum conditions as well as normal operating ranges for the pre-seal TABLE 8 RECOMMENDED OPERATING PARAMETERS FOR THE NICKEL ACETATE PRE-SEAL Range Recommended Nickel Acetate 1.5-4.0 grams/liter 2.0 grams/liter Dispersant 1.5-4.0 grams/liter 2.5 grams/liter pH 6.8-7.2 6.8-7.2 Temperature 140-165°F / 60-74°C 160°F / 71°C Time 10-120 seconds 40 seconds The dispersant should be of the condensed naphthylmethane sulfonate type, with a very low sulfate content. Lignin sulfonate dispersants have given erratic results in the past and should be avoided. There are currently a number of acceptable dispersants available which claim to be identical, but which have vastly different performance characteristics. It is extremely important to thoroughly investigate available dispersants and select the one which provides optimum performance in a given system. The pH of the pre-seal should be checked every two hours and adjusted with acetic acid or 10% (by volume) ammonium hydroxide. The pH must never be adjusted higher than 7.2. If the parts are rinsed well, the pH should rise slowly during operation due to volatilization of acetic acid. Frequent additions of ammonia to raise the pH are an indication of poor rinsing prior to the pre- seal. This causes increased smut formation and reduces the bath life. Agitation must be provided to maintain uniformity and to prevent smut. The air should be supplied via two parallel air lines. The air must be oil-free blown, not compressed, air. Use of compressed air contaminates the tank with compressor oil and can cause a smut-like film on the parts. The pre-seal bath must be carefully prepared. During the years that the pre-seal has been in use, the method for preparing the bath has evolved into one which has given excellent sealing, with minimum smut formation. PREPARATION OF NICKEL ACETATE PRE-SEAL 1. Thoroughly clean and rinse the tank, then fill with deionized water. 2. Preheat the tank to 1 10°F-120 0 F / 43-49°C. 3. Adjust pH to 3.5-4.0 with acetic acid. 4. Predissolve the dispersant (2 g 1) in deionized water, making sure all the dispersant is in solution before adding to the bath. Usually a bucket is used for the predissolving step. Two grams per liter is equal to 17 pounds of dispersant per 1 ,000 gallons of solution. When adding the predissolved dispersant to the bath make sure adequate agitation is used and make sure the dispersant is evenly distributed in the bath before the next step. 5. Predissolve the nickel acetate (2 g/l) in deionized water as above and add to the bath with agitation. 6. With good agitation, slowly raise the pH to 6.8 with dilute (10% by volume) ammonium hydroxide. 7. Predissolve 1 g l sodium acetate and add to bath. This will buffer the solution and prevent pH fluctuations, making control of the pre-seal much easier. Do not add sodium acetate until after the pH has been adjusted to 6.8 (step 6). The pre-seal is controlled by maintaining proper pH, nickel acetate and dispersant levels. Adjustment of pH is made with acetic acid or 10% (by volume) ammonium hydroxide. Nickel acetate is monitored by titrating Nι(ll) with EDTA. It is assumed that consumption of nickel acetate and dispersant will be equal, therefore equal amounts of nickel acetate and dispersant are added to adjust the concentrations. As solids build up in the bath due to pH adjustment, drag-in from preceding tanks and the addition and evaporation of makeup water, sealing smut becomes harder to control. The dispersant concentration will probably have to be increased to help prevent smut. The concentration should be increased before severe smut problems develop. Once severe smutting begins, it is extremely hard to stop, yet proper dispersant levels are effective in preventing smut initially. Also important in preventing sealing smut and obtaining quality seal is thorough rinsing after the pre-seal tank to prevent carry-over of nickel acetate and dispersant into the final seal tank. After pre-sealing, the anodic film is ready for the final seal. Hot water, nickel acetate, or potassium dichromate may be used for the final seal. HOT WATER SEAL The hot water seal has the widest acceptance of any seal system in industry. Properly maintained, it is capable of producing a high quality seal. It is comparatively easy to maintain and produces minimal water pollution problems. TABLE 9 HOT WATER SEAL PROCESS CONDITIONS Range Recommended Water D.I., preferred D.I. pH 6.5-7 0 6.8 Temperature 208-212°F / 98-100°C 210°F / 99°C Time 5-20 minutes 10 minutes Phosphate 2-10 ppm 2.5 ppm Silica less than 5 ppm 0.5 ppm NICKEL ACETATE SEAL A final seal containing 0.25-0.50 grams/liter nickel acetate is required for some automotive and dye applications. The final nickel acetate seal provides slightly better performance in FACT and ADT tests, and is more resistant to phosphate contamination than the final hot water seal. Recommended operating conditions are as follows: TABLE 10 NICKEL ACETATE SEAL PROCESS CONDITIONS Range Recommended PH 5.8-6.5 6.2 Nickel Acetate 0 2-0.5 g/l 0.5 g/l Temperature 203-208°F / 95-98°C 208°F / 98°C Time 5-10 minutes 5 minutes Phosphate 2.5-20 ppm 2.5 ppm Water D.I , preferred D.I. As in the pre-seal and hot water seal, proper rinsing and proper agitation are essential. Continuous 'iltration should also be provided for the nickel acetate final seal to remove any precipitated nickel or ■minum hydroxide. Filtration has been shown to increase seal life by up to 50% SEAL PROBLEMS There are many "unknowns" that can interfere with hot water or modified hot water sealing. However, in most cases the problem can be solved by simply considering the four most common problems encountered: LOW pH. LOW TEMPERA TURE. HIGH PHOSPHA TE, and HIGH SILICA. pH (Acidity - Alkalinity) To gain a better understanding of pH, obtain a descriptive booklet from a manufacturer of pH equipment. A good pH meter is essential; pH papers are not accurate enough for checking seal solutions. Meters should be standardized with known buffers at pH 4.0 and pH 7.0. Standardization with a single buffer at pH 7.0 is not satisfactory because variation may occur in the lower range. Read the instructions with the meter; pH meters often "drift" or do not hold constant. pH meters are delicate and should be treated with care. A good bench model mounted on a stable, vibration-free bench in a non-corrosive atmosphere is recommended. Every effort should be made to avoid checking the pH of hot solutions (180-210°F) / (82-99°C). Although this is theoretically possible, we have not encountered a case where accurate pH's were obtained on hot solutions. Temperature compensation is provided with most pH meters but it compensates only for electrode potential changes with temperature and not for the actual solution pH changes. All solutions change pH as the temperature changes, and all recommended operating ranges are based on the pH at 70-80°F / 21 -ZVC Since this is such an important factor in sealing, the sample should be cooled to 80°F / 27°C before taking a reading. It is also difficult to check the pH of a new seal bath of deionized water because of lack of ions in solution to activate the meter. A rapid decrease in pH is an indication of poor rinsing resulting in sulfuric acid and phosphoric acid contamination being carried into the seal. Good rinsing results from an adequate number of rinse tanks, ample water flow, proper drain time and sequence of processing. The final rinse before each seal tank must be a well-agitated D.I. rinse. Carrier bars or conductor bars should be rinsed after bright dipping and again after anodizing to wash off acids that will later drip into the seal bath due to condensation of hot water vapor on the bar during sealing. When designing racks, avoid a design that could trap acid solution (especially bright dip which is difficult to rinse) between various flat sections or in pockets Parts should be racked to rinse and drain properly The pH of all seal tanks should be measured and adjustments made on a regular basis, preferably every two hours. Wide fluctuations in pH will adversely affect seal quality. At high pH's (usually above 7.0) the appearance of smut becomes a problem. At pH's less than 5.3, no sealing takes place at all. When adjusting the pH upwards, always dilute the ammonium hydroxide with water before adding to the bath to avoid the formation of solids due to localized areas of high pH Ammonia adjustments to nickel acetate or pre-seal tanks should also be made slowly to prevent precipitation of nickel hydroxide at the point of addition. Temperature A minimum temperature of 208°F / 98°C is recommended for a hot water seal This solution should be operated near boiling. Often people are not aware of the exact temperature of the seal Many depend upon steam pressure gauges and temperature gauges which are often inaccurate. Always insist that the temperature of the seal be checked with an accurate glass thermometer. Often, dial reading, stainless steel pocket the r mometers are used, but these become inaccurate from rough handling It is recommended that the seal be equipped with some form of mechanical agitation because it is possible to have varying temperature in the tanK due to placement of the steam coils or stratification of water at different levels Mechanical agitation in the seal is far supeπor to air agitation which is effective only in the top one-third of the bath. T e use of air agitation may cause a continual decrease in pH due to the absoφtion of carbon dioxide (CO 2 ) from the input air, thus forming carbonic acid. Air from low pressure blowers is recommended. Compressed air must not be used because air from compressors carries compressor oils which can leave a smut-like film on the part. Phosphates In general. 10 ppm phosphate is the recommended maximum concentration allowable. "Poor" sealing will occur at higher concentrations, although the anodizing specifications of at least one automotive manufacturer sets 5 ppm as the maximum acceptable limit for phosphates in a hot water seal. Phosphate contamination can be controlled only by thorough rinsing before and after the anodizing step to eliminate or reduce the "drag-in" of phosphoric acid bright dip solution to the , Q anodize tank and from the anodize solution to the seal tank. Every laboratory should be equipped with and use a phosphate test kit. Approximately 50% of all the sealing problems are due to phosphate contamination. The FACT Test is quite sensitive to phosphate contamination and seals cannot be operated with much more than 7 ppm of phosphate and consistently pass the FACT test. The need for small amounts of phosphate (2-3 ppm) in the seal has been proven. This concentration helps to decrease smut formation. To maintain 2-3 ppm phosphate in a new D.I. seal ■ * ■ 5 bath, 7 5 ml of 85% reagent grade H^PO, should be added for every 1 ,000 gallons of seal solution. This should be monitored by a phosphate test kit. For further information on the effects of phosphate in the seal, contact Albright & Wilson's Technical Service Department. Silica Silica contamination above 5 ppm will hinder sealing and result in poor values on corrosion tests. One ppm silica is the maximum recommended level. The dye stain test cannot be passed with silica 20 levels above 10 ppm which indicates no sealing at all. Silica may be found in the tap water supply and can also enter the seal solution from a deionizer. Silica is an extremely weak acid and will not register on the conductivity meters of the deionizing unit. As the resins become saturated, the stronger acids displace silica which goes into the output deionized water, either to the seal tank or storage tank. There are special instruments capable of detecting silica, but in most cases to prevent "silica 25 breakthrough ', it is necessary to regenerate the ion exchange resin before the standard conductivity instruments indicate a need for regeneration. This can be controlled by installing water meters on the line to the deionizer. Operating experience will establish the maximum amount of water that can be deionized before the "silica breakthrough point" is reached. Close monitoring of silica in seal tanks is mandatory. A regular dumping schedule should be established to maintain a high quality seal at all times. Silica test kits are an inexpensive and easy method for determining silica levels in both the seal tank and the deionized water. 30 Smutting Much has been written about "smutting " or "chalking" in the seal tank. Smutting refers to the deposit of a foreign substance on the part during sealing which can affect the appearance or the adhesion of subsequent coatings. There are a number of different types of sealing smut. Frequently, the type of smut present is difficult to determine The following are a few of the most common. 35 a) Aluminum Sulfate - Approximately 95% of all smutting problems are caused by poor rinsing after anodizing, resulting in aluminum sulfate contamination of the first seal tank Aluminum sulfate is insoluble above a pH of 4 5, with a minimum solubility at approximately 5.7 li is always present in the seal tank as a dispersed solid which can be deposited on the parts The aluminum sulfate precipitate is always powdery and can be removed easily by wiping the parts. It does not smear or feel sticky unless there Is also a substantial amount of phosphate present b) Nickel Acetate - All nickel acetate seals and pre-seals leave a small amount of nickel hydroxide on the surface of the part Nickel acetate smut can also form when parts are rinsed in an acidic rinse immediately after the pre-seal If the rinse pH is below 5 5-6.0, the nickel can be leached from the pores and deposited as nickel hydroxide on the surface of the part. These deposits can be heavy enough to be seen as a powder, and will interfere with paint adhesion. All parts to be painted should be πnsed in a hot D.I. rinse (pH 6-7) after a nickel acetate pre-seal As with aluminum sulfate, nickel acetate smut is always powdery and easily removed, unless the bath is also contaminated with large amounts of phosphate c) High Phosphate • High phosphates cause two smut-related problems, especially when the pre-seal is used First, aluminum and nickel phosphates are less soluble than their sulfates, therefore, they are more likely to precipitate in high phosphate baths. Second, phosphates inhibit sealing, so the nickel deposited in the pores during the pre-seal is leached out during the final seal. This type of smut may not be visible until the part is touched, and then the surface will "smear" The smut tends to get worse as the surface is rubbed, and cannot be removed d) Low Phosphate - Although the mechanism is unclear, seal baths with no phosphate at all produce a coating which smears when touched even though it is well sealed. The smears or streaks cannot be completely removed All seal baths should have at least 2 0 ppm phosphate e) Hard Water - Tap water frequently contains contaminants that make it unacceptable for sealing High levels of calcium and magnesium can cause a powdery, easily removed smut due to their precipitation as sulfates Minimum makeup water quality for acceptable sealing and bath life is as follows TABLE 11 MAXIMUM LIMITS OF CONTAMINANTS Bath Makeup Water Silica 5 ppm 0 5 ppm Phosphate 10 ppm 2 ppm Hardness 15 grains 1 grain Sulfate 250 ppm 0 ppm Chloride 100 ppm 10 ppm Fluoπde 5 ppm 0 5 ppm f) Dispersant - The use of dispersants or wetting agents in the final seal is of questionable value and should be avoided Frequently these will be left on the surface of the part as a clear film which smears or feels sticky when touched Residual dispersant or wetting agent prevents adhesion of paint or vinyl to the part, therefore, it cannot be tolerated on most automotive lines Compressor oil coats the parts much like a dispersant or wetting agent in the final seal, therefore, compressed air should neverbe used for seal agitation Always use low pressure blown air [ 52- APPENDIX 5 r. 0. lox (ISO?. $475 . 84ltι Sr, β-J, ludiuuupulii, Iπ-iano 467(8 317 175 0051 100 4*1* 0719 fau n / «7» OI4» BENCHMATE 320 P CHROMATE FOR ALUMINUM PESCRIPT1QN BENCHMARK 320 P is a self-contained, single dip chromate for aluminum and its alloys. Provides added corrosion protection and serves as an e*ceHeru;base forpajnfc Product Feature Customer Benefit • Produces a tightly adherent chromate • Added corrosion protection for base film on aluminum aluminum Minimal effect on electrical Will not appreciably effect dielectric characteristics of processed parts properties Qualified under MflL-C-81706 Ideal for applications which must meet military specification Chromated surface is very receptive to Excellent base for improving paint paint adhesion BENCHMATE 320 P Page 2 of 5 OPERATIONAL PARAMETERS Optimum Bangs CLEAR COATING BENCHMATE 320 P 1.25 oz gal 1.0 - 1.5 oz/gal Temperature 80 g F 70 - • 90 °F pH 1.45 1.3 - ■ 1.6 Immersion Time 1.75 min 0.5 - 3 min *NOTE* If for a desired cycle time some yellow color develops, you may leach it out using 200 ' F water. Use an immersion time from 30 to 60 seconds. Do not overleach, otherwise some of the protective value of the coating is lost due to removal of too much chrome. DICHROMATE COATING BENCHMATE 320 P 2.0 oz/gal 1.5 - 2.5 oz gal Temperature 80 "F 70 - 90 β F pH 1.25 1.1 - 1.4 Immersion Time ** 1 - 5 min ** - depends on alloy SPRAY APPLICATIONS BENCHMATE 320 P 2.0 oz/gal 1.5 - 2.5 oz/gal Temperature 80 °F 70 - 90 °F PH 1.25 1.1 - 1.4 Spray Time 2 min 1 - 3 min Spray Pressure 30 psi 10 - 50 psi *NOTE* A continuous flow is better than a fine spray. All spray equipment must be constructed of acid resistant materials. BENCHMATE 320 P Page 3 of 5 OPERATIONAL PARAMETERS (cont.) Optimum Range BRUSH OR SWAB APPLICATION BENCHMATE 320 P 4.0 oz gal 3.0 - 5.0 oz gal Temperature 80 β F 70 - 90 °F pH 0.95 0.8 - 1.1 Swab or Brush Time ** 15 - 30 sec ** - Depends on desired color. It may be necessary to repeat the process to obtain a darker color. SOLUTION CONTROL For a given alloy, a set immersion time, pH and temperature will yield a given color. As the bath depletes in strength, the color will lighten and eventually go to a gray. To offset this, add 20% of the original BENCHMATE 320 P used for bath make-up and repeat as needed. Once this docs not correct the bath, adjust the pH to the proper value with small increments of nitric acid. BENCHMATSXQ P Equipment 10.0 ml volumetric pipet 500 ml Erienmeyer flask 25 ml graduated cylinder 25 ml buret Reagents 25% (voi) Sulfuric Acid solution 20% Potassium Iodide solution 0Λ H Sodium Thiosulf te titrating solution Starch Indicator solution APPENDIX 6 IVI αteriαl Safety Data j I'RUDUCT NAME BENCHMATE 320-P ι..-= = = .sr-)ι -. ■ :_:5i-[-.'.-ι-is: 3 s'.-!' uss-i-!!. < ..ae- '.*lhι.-.*.*. ' ik at- z.sx-.Bb ■ .■*« * ( * .E=: * : = L * : * :':I * . --. s SECTION 1 - IDENTIFICATION INFORMATION PROVIDED BY BENCHMARK PRODUCTS INC S42D k-IONSVI E KOAD P.O. BOX 68809 INDIANAPOLIS, IN 46268 TELEPHONE NUMBER 317-875-0051 800-424-9300 (ONLY IN THE EVENT OP CHEMICAL EMERGENCIES INVOLVING A SPILL, LEAK, FIRE, EXPOSURE, OR ACCIDENT) DATE PREPARED 07/16/86 DATE REVISED 08/0S/91 R4 CHEMICAL FAMILY CHROMATE CHEMICAL FORMULA NOT APPLICABLE GENERAL DESCRIPTION CHROMATE FOR ALUMINUM DIRECTIONS FOR USE REFER TO THE BENCHMARK PRODUCTS INC TECHNICAL DATA BULLETIN FOR THIS PRODUCT. SF.CTIUH II - HAZARDOUS INGREDIENTS (>π UMLKSS CARCINOGENIC, THEN > . IX) jjSB.&s...s_=_._: .s3.....jsj..s.*:Sii*:.a':.^fts8':*i':..-s.3B..j.s*ικs'i^-'=':*:'':':':'l.e')J4 The chemicals specified by Chemical Abstracts Service (CAS) registry number below are toxic chemicals subject to the reporting requirements oi section 313 of the Emergency Planning and Community* Right-To-Know Act of 1986 and of 40 CFR 372: INGREDIEHT OSHA PEL ACKIH TLV OTHER CHROMIC ACID Q. U mg/m° .05 mg/ **** * 3 N. E. 3bV. CAS 41333-82-0 SODIUM SILICAFLUORIDE Z.' mg/m* 3 2. L> mg/m=» N. E. 19 * /. SODIUM NITRATE N. E. N. E. N- E. &'/. IABC OSHA CARCIHUGEHIC NTP MONOGRAPHS . REGULATED HEXAVALENT CHROMIUM YES YES NO COMPOUNDS L&n:as;BsauLi aιιιibi,ιιs33^G::^';3suLL333L3U.'iBfaiι.sι.BSt:siλ:: ::^ 5KCTXOH III - PHYSICAL DATA : as5H β aw ; 3:κi:t:κβB-*rs^fc:B:s-a.BβCi*.&» = PRODUCT NAME BENCHMATE 320-P MELTIN3 POINT NOT ESTABLISHED FREEZING POINT NOT APPLICABLE BOILING POINT NOT APPLICABLE VAPOR PRESSURE (mm Hg> NOT APPLICABLE VAPOR DENSITY (Air=l) NOT APPLICABLE SOLUBILITY IN WATER APPRECIABLE SPECIFCC GRAVITY (H20=l) NOT APPLICABLE VOLATILE BY VOLUME(X) NOT APPLICABLE EVAPORATION RATE (BuAc=l>... NOT APPLICABLE pH (As Ca) NOT APPLICABLE pH (IX Solution) 1.3 APPEARANCE AND ODOR REDDISH POWDER/PUNGENT ODOR SECTION IV - FIRE AND EXPLOSION HAZARD DATA FLASH POINT NOf APPLICABLE LOWER FLAME LIMIT NOT APPLICABLE HIGHER FLAME LIMIT NOT APPLICABLE EXTINGUISHING MEDIA WATER, FOAM, DRY CHEMICAL OR CO a SPECIAL FIRE FIGHTING PROCEDURES WIRE FIGHTERS SHOULD WEAK PROPER PROTECTIVE EQUIPMENT AND SELF-CONTAINED BREATHING APPARATUS WITH FULL FACE PIECE WHEN FIGHTING CHEMICAL FIRES. MOVE CONTAINERS FROM FIRE AREA IF IT CAN HE DONE WITHOUT RISK. UNUSUAL FIRE AND EXPLOSION HA ARDS CONTACT WITH ACTIVE METALS MAY PRODUCE FLAMMABLE HYDROGEN GAS. MAY KEACT VIGOROUSLY WITH ORGANIC MATERIALS. MAY RELEASE TOXIC FUMES IF SUBJECTED TO EXCESSIVE HEAT. ^•■ ■ ■■•■■■■■■■■■■-i'iu- --ia-iβab',.u'ι..-.-._--_---__-.... ..-._.-..■..._-...-.--._.--. ~. — -JECTIOH V - REACTIVITY DATA .STABILITY STABLE INCOMPATIBLE MATERIALS ORGANIC MATERIALS, COMBUSTIBLES, ALKALIS, OILS, GREASES, CYANIDES, SULFIDES CONDITIONS TO AVOID AVOID STORAGE AND CONTACT WITH INCOMPATIBLE MATERIALS, HIGH HUMIDITY AND EXCESSIVE HEAT. POWDER BECOMES CORROSIVE WHEN WET. HAZARDOUS DECOMPOSITION PRODUCTS WILL REACT WITH CYANIDE SALTS TO GENERATE POISONOUS HYDROGEN CYANIDE GAS. WILL REACT WITH S1ULFIDES TO PRODUCE POISONOUS HYDROGEN SULFIDE GAS. S PRODUCT NAME BENCHMATE 320-P HAZARDOUS POLYMERISATION.... WILL NOT OCCUtt -■* * " β '*' β*B »- JJ*β '» JS »' β* »J*β 8B8β»-ι_ιBBasββSBBaBβaj-ϊjaββBββa-ιβaaαBαΛJβB-ι_:-5_t*=-3s-!*s*=*3_;s! :-IB - . SEGTIUH VI - HEALTH HAZAHD DATA * - * - * =- * -s-.a. aaaasaawai ■ -aaaasa-.i t_ι _,_,-.. _,_.sa»aa --.-.ι.*. a a a _ α a & -,aaas.aat 8SS3 = sss sa'* , . = .= *.* , .8S*. EFFECTS OF OVEREXPOSURE CONTACT WITH EYES WILL RESULT IN EXTREME BURNS 10 THAT MAY RESULT IN PERMANENT DAMAGE TO THE EYES. EXPOSURE TO THE LOW LEVEL CONCENTRATIONS MAY CAUSE MODERATE IRRITATION. CONTACT WITH SKIN MAY CAUSE BURNS OR ULCERATION. SKIN CONTACT WITH HEXAVALENT CHROMIUM COMPOUNDS MAY CAUSE ALLERGIC DERMATITIS. MAY HE ABSORBED THROUGH BROKEN SKIN. PERSONS WITH CUTS, BRUISES OR DERMATITIS SHOULD TAKE ADDED PRECAUTIONS TO AVOID CONTACT. INHALATION OF PRODUCT DUST OR MIST MAY CAUSE 1 IHRITATION OF THE NASAL SEPTUM AND RESPIRATORY TRACT. 1NGESTION WILL CAUSE DISCOMFORT AND PAIN. 1NGESTION WILL CAUSE SEVERE IRRITATION AND/OR BURNS TO THE MOUTH, THROAT, ESOPHAGUS AND STOMACH. SINCE THIS PRODUCT IS A PROPRIETARY PLEND OF HAW MATERIALS, SPECIFIC HEALTH EFFECTS ARE UNKNOWN. CHHONIC HEALTH HAZARDS DESCRIBED HEPRESENT HAZARDS FOR THE CONCENTRATED CONSTITUENTS. CHRONIC EYE EXPOSURE MAY CAUSE f) CONJUNCTIVITIS. CHRONIC SKIN CONTACT, ESPECIALLY WJTH HROKEN SKIN, MAY. CAUSE "CHROME SORES". MASSIVE SKIN OVEREXPOSURE COULD LEAD TO KIDNEY FAILURE AND DEATH. CHRONIC INHALATION OF DUSTS AND MISTS MAY CAUSE ULCERATION AND PERFORATION OF NASAL SEPTUM. UNDER SOME CIRCUMSTANCES METHEMOGLDBINEMIA OCCURS IN INDIVIDUALS WHEN THE NITRATE IS CONVERTED BY BACTERIA IN THE STOMACH TO NITRITE. NAUSEA, DIZZINESS, KAPID HEART HEAT, IRREGULAR BREATHING, COMA AND DEATH CAN 5 OCCUR IF THIS CONVERSION TAKES PLACE. EMERGENCY AND FIRST AID PROCEDURES t-YES IMMEDIATELY FLUSH EYES IN A DIRECTED STREAM OF WATER FOR AT LEAST lϋ MINUTES WHILE HLINKING EYELIDS TO ENSURE COMPLETE IRRIGATION. GET MEDICAL ATTENTION. SXIH IMMEDIATELY REMOVE CONTAMINATED CLOTHING AND SHOES. FLUSH SKIN THOROUGHLY WITH COOL WATER 0 l-'CS AT LEAST 15 MINUTES. WASH CLOTHING. IF IRRITATION PERSISTS, GET MEDICAL ATTENTION. INHALATION REMOVE VICTIM TO FRESH AIR. IF NOT BREATHING GIVE ARTIFICIAL RESPIRATION. IF HREΛTHING IS DIFFICULT GIVE OXYGEN. GET MEDICAL ATTENTION. 5 PBUDUCT NAME BENCHMATE 320-P 1NGESTION. . DKINK SEVERAL GLASSES OF WATER AND INDUCE VOMITNG. KEEP AIRWAY CLEAR. NEVER GIVE ANYTHING BY MOUTH TO AN UNCONSCIOUS PERSON. GET MEDICAL ATTENTION IMMEDIATELY. IBaiBBa33B3hl.a: •.ssaassasac*. £.ECTION VII - SPECIAL PROTECTION :33SB3Ba&BB3BSSSS3. SSBbCSBBI RESPIRATORY PROTECTION WEAR A NIOSH/MSHA APPROVED RESPIRATOR OR DUST MASK WHERE MIST O ' DUST MAY BE GENERATED. VENTILATION REQUIRED........ SUFFICIENT TO COMPLY WITH ALL WORKPLACE ENVIRONMENTAL STANDARDS AND TO ENSURE WORKER EXPOSURE DOES NOT F.XCFED THE THRESHOLD LIMIT VALUES FOR ANY OF THE INGREDIENTS CONTAINED IN THIS PRODUCT (IF ESTABLISHED) PROTECTIVE GLOVES NEOPRENE, LATEX, NITRILE OR MILLED NITRILE FYE PROTECTION SAFETY SPLASH GOGGLES. OTHER PROTECTIVE EQUIPMENT SYNTHETIC APRON, EYEWASH. SAFETY SHOWER AND SYNTHETIC SAFETY BOOTS WORK/HYGENIC PRACTICES WASH CLOTHING AND PROTECTIVE EQUIPMENT AtTER CONTACT WITH PRODUCT. ALWAYS WASH HANDS AND FACE WITH SOAP AND WATER AFTER CONTACT WITH ANY CHEMICAL. IKCTION VIII PRECAUTIONS STORAGE. STORE INDOORS IN A COOL DRY AREA. KEEP CONTAINER CLOSED. AVOID CONTACT WITH ORGANIC AND COMBUSTIBLE MATERIALS. DO NOT GET IN EYES, ON SKIN OR ON CLOTHING. DO NOT BREATH DUST OR MIST. DO NOT STORE IN HUMID AREA. SPILLS. WEAR PROPER PROTECTIVE EQUIPMENT AND SHOVEL SPILL INTO DOT-APPROVED WASTE CONTAINER FOR PROPER DISPOSAL. NEVER FLUSH INTO SEWER OR tn-REAM. COMPLY WITH ALL APPLICABLE GOVERNMENTAL REGULATIONS ON SPILL REPORTING. DISPOSAL. WATER RUNOFF WILL CONTAIN HEXAVALF.NT CHROME AND SHOULD NOT BE ALLOWED TO ENTER THE SEWER OR WATERWAYS. WF.DUCF. HEXAVALEHT CHROME 10 THE TKIVALENT STATE. FOLLOW ALL FEDERAL, STATE AND LOCAL REGULATIONS. PRODUCT NAME BENCHMATE 320-P OTHER PRECAUTIONS. . SINCE EMPTY CONTAINERS RETAIN PRODUCT RESIDUES, ALL LABELED HAZARDOUS PRECAUTIONS MUST HE OBSERVED. DO NOT REPACKAGE PRODUCT. ADD PRODUCT SLOWLY TO AVOID SPLASHING. PRODUCT IS HYGROSCOPIC. POWDER BECOMES CORROSIVE WHEN WET. bBBB3S3Cei3Lt.33: = 3 = l.L =:::^S'.. '-L. = 5 = >. = L' La«al.BB>βBlιat.. aBβlBBbLBβaS^Sl.tLLESe.Si.baSB UECTION IX - TRANSPORTATION DOT SHIPPING NAME CHROMIC ACID MIXTURE, DRY DOT CLASSIFICATION OXIDIZER DOT IDENTIFICATION NUMBER... NA 1463 DOT LABEL REQUIRED OXIDIZER CORROSIVE t mmmmmmm SΛ ns ΛSW 9^ Ω sasx^^s^ iτs9muammm m»u Λt .as asi S ^i^ssummmm^ umMm utmΛSΛa S9aΛSΛU iiECTIOM X - HAZARDOU MATERIALS IDENTIFICATION :: SBflaB aa B a B aα BBBBIBB : :3S: : :33I»aUB8aBa833BCS : s:GBBBBB BBBBIβ8SBS8 33BS3t.SL.^S:& HEALTH 3 FLAMMABIL1TY O REACTIVITY 1 PERSONAL PROTECTION X SEE SECTION VII THE INFORMATION SET FORTH WITHIN THIS MATERIAL SAFETY DATA SHEET IS FURNISHED FREE OF CHARGE AND IS BASED UPON INFORMATION AND DATA WHICH WERE BELIEVED TO BE ACCURATE AND RELIABLE AT THE TIME THIS MATERIAL SAFETY DATA SHEET WAS PREPARED. IT IS INTENDED TO BE USED BY PERSONS HAVING TECHNICAL SKILL AND AT THEIR OWN DIRECTION AND RISK. NO GUARANTEE OR WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED IS MADE BY BENCHMARK PRODUCTS INC, NOR IS ANY LIABILITY ASSUMED HY HKNCHMAkK PRODUCTS INC CONCERNING THE APPLICATION OF THE INFORMATION CONTAINED HEREIN TO THE PARTICULAR CIRCUMSTANCES OF ANY USE OF THIS PRODUCT OR ITS SAFETY OR TOXICITY IN CONNECTION WITH SUCH USE. NOTHING CONTAINED HEREIN IS TO BE CONSTRUED AS A LICENSE TO OPERATE UNDER OR A RECOMMENDATION TO INFRINGE UPON ANY PATENT OR PROPRIETARY RIGHT OF ANY THIRD PARTY. ADDITIONAL INFORMATION MAY UK REQUIRED WHEN EXCEPTIONAL CIRCUMSTANCES EXIST. BENCHMARK PRODUCTS INC SPECIFICALLY DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE WITH RESPECT TO THIS PRODUCT. THE PRODUCT TO WHICH THIS DATA RELATES MUST ONLY BE USED IN ACCORDANCE WITH APPLICABLE STATE, FEDERAL AND LOCAL LAW AND REGULATIONS. GLOSSARY OF TERMS In order that users of Benchmark Products, Inc. products fully understand thu information pn-scnlcd in die Material Safety Data Sheets prepared by Benchmark Products, Inc., we have prepared this definitional material. This glossary is intended for use only will* Material Safety Data Sheets prepared and supplied by Benchmark Products, Inc.. Questions concerning any of these Material Safety Datasheets or thee definitional material contained herein should be directed to the Technical Director, Benchmark Products, Inc., P.O. Box 68800, 8425 Ziυiisville Koad, Indianapolis, Indiana 46268. SECTION I - IDENTIFICATION This section identifies Benchmark Products, Inc., the preparer of MSDS, its addresses and telephone number. General Description: Basic function of the product. SECTION II - HAZARDOUS INGREDIENTS This section lists any known hazardous ingredients in the product. A hazardous ingredient is one which meets one or more of the following criteria: 1. It has an Occupational Safety & Health Administration (OSHA) established, eight-hour time-weighted average permissible exposure limit (PEL) or acceptable ceiling concentration (C) or an American Conference of Governmental Industrial Hygicnists (ACGIH) threshold limit valuc-timc-wcighted average (TLV-TWA). 2. It contributes to one or more of the following hazards of product: a. flashpoint below 200° F, or subject to spontaneous heating or decomposition: b. causes skin bums; c. strong oxidizing or reducing agent: d. subject to hazardous polymerύation; e. toxic or highly toxic. . 3. It is listed as a carcinogen by one of the following organization's latest publication: a. Occupational Safety & Health Administration (OSHA) Regulations: b. International Agency for Research on Cancer (IARC) Monographs; c. Nadonal Toxicology Program (NTP) Annual Report on Carcinogens. 4. It is subject to the reporting requirements of Section 313 of the Superfund Amendments and Reauthorization Act. Each ingredient meeting one or more of the criteria is listed in SECTION II if it is present in the amount of 1% by weight, or above. Ingredients which are claimed to be carcinogens, teratogens. mutagens, or causitive agents of other reproductive disorders are listed if known or believed to be present in the amount of 0.1 % by weight, or above. SECTION III-PHYSICAL DATA Melting Point: Temperature at which solid becomes liquid. Freezing Point- Temperature at which liquid becomes solid. Boiling Point: Temperature at which vapor pressure is equal to atmospheric pressure. Vapor Pressure: The pressure characteristic of a vapor in equilibrium with its liquid or solid form. Vapor Density: Listed only for volatile portion of the product. Vapor density of the product is compared to that of air. Solubility in Water: Describes dissolution properties of the product in water. Specific Gravity: Lists specific gravity of liquid and powdered products. Percent Volatile: Lists approximate percent by weight of volatile components of liquid products. Not shown for solid materials. Evaporation Rate: Compares evaporation rate of the product to that of butyl acetate. Does not apply for solid materials. pH (as is): A value taken to represent the acidity or alkalinity of an aqueous solution. pH (l% solution): The resultant pH of a solution consisting of 99% water and I % (w/w) of the product. Appearance and Odor Describes physical characteristics and any distinguishing odors of the product. APPENDIX 7 Silicones UVHC8558 Abrasion Resistant Silicone Hard Coat Fast Cure PRODUCT DESCRIPTION UVHC8558 UVHC8558 silicone hardcoat resin has been found to yield a Performance Data clear, mar-resistant film when applied to a suitably prepared (.2 to .4 mil Coating builds) plasύc substrate. It can be applied by flow, dip, spin, or spray Taber Abrasion. 5 - 15% Λ Haze coating. 500cycleι 500O measured per ASTM on unprimed poly D1003ϋigherhaze UVHC8558 hardcoat is designed to give primeriess adhesion carbonate suggests greater to many thermoplastic substrates that are cast, extruded, (CS10F wheels) abrasion. * molded or blow molded. It offers mar-resistance, high gloss, and protection from chemical attack. UVHC8558 is suited for •Humidity during coatiπξ and testing will affta final valua. indoor environments. Chemical/Solvent Resistance KEY PERFORMANCE PROPERTIES ■Solvent Result • Fast cure • Abrasion resistant • Mar-resistant Acetooe No change Gasoline No change « Scratch resistant • Optical clarity Methanol No change • Chemical resistant • Solvent resistant Toluene No change Sodium Hydroxide (10*) No change Compatible Test Conditions: (Using two fusion H Lamps at 2.1) GE Silicones tests have shown UVHC8558 is suitable for use on certain grades of the following polymers. These tests, 1. Place a cottonball saturated in the tea solvent onto the coated surface and cover with a panel. however, did not include all grades of these polymers nor did they reflect conditions created by use in particular 2. At 30 minutes (continuous saturaϋon) remove panel, cottonball applications. GE Silicones recommends customers test the and solvent and check for changes in appearance. coating on the specific grade or grades of polymers to be used and the tests be done under the actual environmental conditions the specific application will encounter before SPECIFICATIONS committing to production using UVHC8558. Typical property data values should not be used as • Ultem • Polycarbonate • Valox • Polystyrene specifications. Assistance and specifications are available by contacting GE Silicones at 800/255-8886. • Polycarbonate/Polyester • Filled Nylon • Acrylic INSTRUCTIONS FOR USE • Polyoleftn • Cycolac • Melamine • Polyester General Requirements Some substrates may require pretreatment (i.e., flame, corona discharge) to achieve primeriess adhesion. Coating area should be clean, dust-free, well ventilated and with the relative humidity controlled to 50% or less if product Typical Product Data is not being used at 100% solids. The parts should be washed or wiped clean with isopropyl alcohol; a mild detergent Property UVHC8558 solution and clean water rinse; or a Freont TF or TE Solids Content, % 100 ultrasonic bath; followed by a ftltered-air blow-off and a final Flash Point. ionized-air blow-off. Cleanliness is critical for production of Pensky-Mardn Closed Cup 81CU78F) good pans. The material should be filtered continuously or Density, lbs gal 10 just before use through a 0.5 to 1.0 micron filter. UV equipment with good convection and air exchange is Viscosity, cstk 20 - 80 recommended. Warranty Period 3 months min. at 24C(75F) in fFreon is a Registered Trademark ofD ponl Company. original sealed containers. UVHC8558 Hard Coat CAUTION The UV hardcoat can be applied to clean unprimed parts by Compatibility of GE Silicone hardcoat and polycarbonate dip, spray, spin, or flow coating. To cure the product we resin, including GE LEXAN' resin, is dependent on a number recommend the use of a UV lamp that can supply light at 250 of factors including operational stresses, chemical exposure, to 360 nm with 75 mj/cm* 1 of minimum energy. Production temperature levels, impact and exposure to ultraviolet light. speeds will depend on the type of UV lamp used to cure this While it is up to the end user to determine what application product. specific testing is appropriate, it is suggested that all The product may be diluted in isopropyl alcohol to achieve any polycarbonate resin appUcations be tested for at least 30 days required solids level for the required build. It is recommended for compatibility and crazing with this hardcoat before use. to dilute the product to 30% by weight for spraying, 50%-70% There is no dependable substitute for careful testin of for spin coating, 40%-45% for dipping, and 10%-40% for flow prototypes of production parts in typical operating coating. The product maybe used at 100% solids. environments. To reduce the chance of the coating blushing, it is STORAGE WARRANTY PERIOD recommended to apply the coating in a controlled humidity The warranty period is 3 months from the date of shipment environment of less than 40% if solvents are going to be used from GE Silicones if stored in the original unopened container to dilute the material. If the product is used with no solvents at 75F(24C). then higher humidity is acceptable. The flash off times of the Store material between 50F(10C) and 90F(68C). It is solvent can vary due to the humidity present. Because of this recommended not to leave this product exposed to any tight it is important to control the humidity to less than 40% when since it will cure over time. coating polycarbonate to alleviate the hazing that can occur. It is recommended to not allow the coating to remain on a polycarbonate part for more than 90 seconds before curing under UV lights. If hazing occurs then the contact time of the AVAILABILΠΎ coating with the polycarbonate part should be reduced until GE Silicone products may be ordered from GE Silicones, the hazing disappears. Other thermoplastics have found this Waterfotd, NY 12188, the silicones sales office nearest you. product not to be as aggressive and longer flash times can be or where appropriate, an authorized GE Silicone product held without hazing. distributor. HANDLING & SAFETY Material Safety Data Sheets are available upon request from GOVERNMENT CONTRACTS GE Silicones. Similar information for solvents and other Prior to considering use of a GE Silicones product in chemicals used with GE products should be obtained from fulfilling any government requirement, contact GE Silicones your suppliers. When solvents are used, proper safety Customer Service department to determine if all government precautions must be observed. requirements can be met. 'Registered trademark of General Electric Company Ui O i o LIMITED WARRANTY GE Silicones warrants that its products will conform to GE Silicones' internal specifications at the time of application or use, provided that the product is stored in accordance with GE Silicones' recommendations and used or applied before the earliest of (1) any "Use Before Date" indicated on the product package, (2) one year from date of shipment by GE Silicones, or (3) expiration of such other period or recomrnended storage time stated in GE Silicones' product literature for such product If notified in writing of a claim within six months of a product's use or application, GE Silicones will, at its option, replace, or refund the purchase price of, any GE Silicones product which does not satisfy the foregoing warranty. THE FOREGOING SHALL CONSTITUTE THE SOLE AND EXCLUSIVE REMEDY FOR DEFECTS IN. OR FAILURE OF, ANY PRODUCT, AND THE SOLE AND EXCLUSIVE LIABILITY OF GENERAL ELECTRIC COMPANY THEREFOR. THE WARRANTY STATED ABOVE IS CM LIEU OF ALL OTHER WARRANTIES, WRITTEN OR ORAL, STATUTORY, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MIΪRCΗAΝTABILΠΥ OR FITNESS FOR PURPOSE. LIMITATION OF LIABILITY: GE Silicones shall in no event, whether the claim is based on warranty, contract, tort, strict liability, negligence or otherwise, be liable for incidental or consequential damages, or for any other damages in excess of the amount of the purchase price. NOTE: For many products, GE Silicones may be able to offer a more extensive, application specific warranty. For further information, contact your GE Silicones field representative. GE Silicones World Wide Offices General Electnc Company General Electnc Canada. Inc βε Plasacs Paαfc. Ltd. GE SBcones Korea GE S&cones 260 Hudson River (load 1300 Ueadowvaht Bhid. βEPaoScPTE Ud. CO Dongyeng SΛcones Co, Ltd. 1 Ptasϋcstaaπ Waterrbrd. NY I21SB Mαstssauga. Ontario 2*0 Tangong Pagar Λt G PK Btdg. 4 FL P.O. Sor t 17 Technical Assistance Canada LSN SP9 GE Tσeer lO^OO 231-0 Norέiyυn-dong. 4600 AC Bergen op Zoom βoo-zss-assβ Phone: eOO-332-3390 Singapore. 020$ KangneπyKu The Net/ienands Customer Service Phone: 65-290-1322 Seoul, Korea 13S-010 Phone: 31-0164-29- 1171 BOO-332-3390 Phone: 62-2-518-2616 GESltones General Electnc Tectncal GE SBcones Mexico Genet* Electnc Plastics 175 Hamrαn] Road Service Co.. Inc. λv. Prdongaαon Relcr e Room 1008, Tower 1 Oandenong. Te wn Brand) ■ GE SBcones ≠490-Piso 4 The Gateway Vκtoria.3175 Hung Tat Center - I3tι Floor H66 Cot Santa Fe 2S Canon βoad Aυstrata Tun Hue North Rd. CJ>. 01207 Mexico. OF. Tsansftatsυi Kσwtoon. Hcng Kong Phone- f 1-39-794-4205 Taipei. Taiwan Phone: 52-5-2S7-609S Phone: 652-2629-0686 Phone- 886-2-51 -9849 βε SJkx es/IOth Floor General Electnc Company General Electric Technical General Electric International Opera fans βeneral Electric Company General Electnc de Brasi S . Boulevard de Sabana Grande. Sende Co.. Inc. Urrf HCO * 11F Oetsetn Tower <B) * *po Plaza. 8ft Floor Av Nova αe Jufto, S229 Cnjce con Cane VXaΛor 25th Floor UBH Tower. Letter Box 41 93 1 Wmess Road J1. Jend. Sudbman Kav. 2S 01407-907 Sao Rauto. SP Cαntro Comerαal Sabana Grande No. 10 Jalan P Ramlee Umpmee. Pattxxπwam. Bangkok 10330 Jakarta 12920. Indonesia βrvi Pool SO2S0 Kuala Lumpur. Malaysia Thai** Phone: 62-21-510-3353 Phone 55-011-697-61** Caracas 1010-Λ. Venezuela Phone: 603-23*33*4 Phone: 662-2SS-3369 Phone: 56-2-708-SI 61 Phone: 662-256-7766 4979 (12/94) General Ele tte Company. U SΛ. β not Cύπnβcttd *Mth tse Eng-sl-* company of * slrπtaf natm. C CopyngM 1994 Genial Efc-anc CcR-par**- Prteeύ on racy-dad paper. APPENDIX 8 GE Silicones FORMAT :USA MATERIAL SAFETY DATA SHEET COPYRIGHT GENERAL. ELECTRIC CO. PRODUCT : UVHC8558 HARDCOAT-SOLVENTLESS, UV CURE PAGE : 01 1 . CHEMICAL PRODUCT AND COMPANY IDENTI FICATION MANUFACTURED BY: SUPPLIED BY: GE SILICONES GE SILICONES 260 HUDSON RIVER ROAD 260 HUDSON RIVER ROAD UATERF0RD, NY 12188 WATERFORD, NY 12188 EHERGENCY PHONE (24 HRS) EMERGENCY PHONE (24 HRS) (518) 237-5330 (518) 237-3330 REVISED: 02/12/93 PREPARER: CE HANNIGAN CHEHICAL FAMILY/USE: SILICONE COATING FORMULA: MIXTURE 2. COMPOSITION/INFORMATION ON INGREDIENTS PRODUCT COMPOSITION/ APPROX. ACGIH TLV OSHA PEL CAS REO NO. WGT. • /. TWA STEL TWA STEL UNITS A. HAZARDOUS 1,6-HEXANEDIOL DIACRYLATE 13048-33-4 10-30 NE NE NE NE NA BENZENE 71-43-2 .1PPM 0.5 2.5 1 5 PPM TOLUENE 108-88-3 <1 50(SKN)NE 100 150 PPM TRADE SECRET COMPONENT 30-60 NF NE NF ' NE NA B. NON-HAZARDOUS TRADE SECRET COMPONENT 5-10 NA NE NA NE NA TRADE SECRET COMPONENT 10-30 NE NA NE NA NA See Section 15 for description of any UHMIS Trad* Secret(s). 3. HAZARDS I DENTI FICATION EMERGENCY OVERVIEW: Clear Liquid Acrylate Odor Harmful if absorbed through the skin. Avoid breathing vapors. Avoid contact with skin and eyes. Causes skin burns which nay not ba immediately painful or visible. Causes severe eye burns which may not be immediately painful or visible. Causes severe eye irritation will damage tissue. *** CONTINUED ON NEXT PAGE *** PRODUCT: UVHC8558 HARDCOAT-SOLVENTLES ,V CURE PAGE: 02 Refer to other MSDS sections for detailed information. POTENTIAL HEALTH EFFECTS: INGESTION: May be harmful if swallowed. SKIN CONTACT: May cause an allergic skin reaction. Harmful if absorbed thru the skin. Hay cause moderate skin irritation. May cause skin burn . May cause blistering of skin if contaminated clothing is worn. Contains a component which is a known or suspected skin sensitizer. Effects on skin may be delayed for 24-48 hours. INHALATION: May cause mild respiratory irritation. Vapors that are toxic as well as irritating to the respiratory tract may be produced upon heating this material . EYE CONTACT: Causes severe eye irritation may damage tissue. Administration of a similar product to the eyas of rabbits caused vascularization resulting in loss of vision. MEDICAL CONDITIONS AGGRAVATED: Dermal ailments. SUBCHRONIC (TARGET ORGAN) EFFECTS: This product contains a conponant that is a suspected mutagen. CHRONIC EFFECTS/CARCINOGENICITY: This product or one of its ingredients present 0.1X or more is NOT listed as a carcinogen or suspected carcinogen by NTP, IARC, or OSHA. PRODUCTS/INGREDIENTS This space reserved for special use. PRINCIPLE ROUTES OF EXPOSURE: Oral. Dermal - skin. Eyes. Inhalation. Absorption through skin. OTHER: None known. 4. FI RST AI D MEASURES INGESTION: Do not induce vomiting. Slowly dilute with 1-2 glasses of water or milk and seek medical attention. Never give anything by mouth to an unconscious person. SKIN: In ease of contact, immediately flush skin with plenty of soap and water for at least 15 minutes. Get medical attention. Remove contaminated clothing and launder before reuse. INHALATION: Move person to fresh air. EYES: In case of contact, or suspected contact, immediately flush eyes with plenty of water for at least 15 minutes and get medical attention immediately after flushing. NOTE TO PHYSICIAN: None known. 5. FI RE FIGHTI NG MEASURES FLASH POINT: >100 (C) >212 (F) METHOD CC IGNITION TEMP »** CONT I NUED ON NEXT PAGE *»* PRODUCT : UVHC8558 HΛRDCOAT-SOLVENTLE'. UV CURE PAGE : 03 NA (C) NA (F) FLAMMABLE LIMITS IN AIR - LOWER ): NA FLAMMABLE LIMITS IN AIR - UPPER ): NA SENSITIVITY TO MECHANICAL IMPACT (Y-N): NO SENSITIVITY TO STATIC DISCHARGE: Sensitivity to static discharge is not expected. EXTINGUISHING MEDIA: Carbon dioxide Dry chemical SPECIAL FIREFIGHTING PROCEDURES: Cool exposed containers with water spray after extingushing fire Positive pressure, self-contained breathing apparatus Polymerization may take place during a fire due to elevated temperature where closed containers could violently rupture. Toxic vapors are emitted in a fir* condition. Wear full protective clothing. 6. ACCIDENTAL RELEASE MEASURES ACTION TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED: Wipe, scrape or soak up in an inert material and put in a container for disposal. Wear proper protective equipment as specified in the protective equipment section. Warn other workers of spill. Increase area ventilation. Person not trained should evacuate area. HANDLING AND STORAGE PRECAUTIONS TO BE TAKEN IN HANDLING AND STORAGE: Avoid breathing vapors, if exposed to high vapor concentration, leave area at once. Avoid contact with skin and eyes. Use only in a well ventilated area. Do not inhala vapors. Emptied containers may retain hazardous properties. Do not cut, puncture or weld on or near the container. 8. EXPOSURE CONTROLS/PERSONAL PROTECTION ENGINEERING CONTROLS: Showers. Eyewash stations. Use in a well ventilated area. RESPIRATORY PROTECTION: Use approved NIOSH respiratory protection if TLV exceeded.... Or over exposure is likely. Cartridge respirator. PROTECTIVE GLOVES: Rubber gloves. Neoprene. EYE AND FACE PROTECTION: Monogoggles. OTHER PROTECTIVE EQUIPMENT: Rubber apron. Wear eye protection and protective clothing. Rubber boots VENTILATION: Use only in well ventilated area. Mechanical ventilation. «** CONTINUED ON NEXT PAGE **» PRODUCT : UVHC8558 HΛRDCOAT-SOLVENTLESi. , .V CURE PAGE : 04 PHYS ICAL AND CHEMICAL PROPERTIES PRODUCT INFORMATION: BOILING POINT : "250 (C) "482 (F) VAPOR PRESSURE(20 C)(MM HG): UNK VAPOR DENSITY (AIR=1) : UNK FREEZING POINT : UNK (C) UNK (F) MELTING POINT : -4 (C) -39.2 (F) PHYSICAL STATE : LIQUID ODOR ACRYLATE COLOR : CLEAR TO AMBER ODOR THRESHOLD (PPM) : UNK • /. VOLATILE BY VOLUME : UNK EVAP. RATE(BUTYL ACETATE=1): UNK SPECIFIC GRAVITY (WATER=1) : -1.08 DENSITY (KG/M3) : "1080 ACID/ALKALINITY (MEQ/G) : UNK PH : UNK VOC EXCL.H20 t EXEMPTS(G/L): NT SOLUBILITY IN WATER (20 C) : INSLOUBLE SOLUBILITY IN ORGANIC SOLVENT (STATE SOLVENT): ISOPROPANOL 10. STABILITY AND REACTIVITY STABILITY: STABLE HAZARDOUS POLYMERIZATION: WILL NOT OCCUR HAZARDOUS THERMAL DECOMPOSITION/COMBUSTION PRODUCTS: Carbon monoxide . Carbon dioxide. Silicon dioxide. INCOMPATIBILITY (HATERIALS TO AVOID): Contact with oxidizing agents. Light. CONDITIONS TO AVOID: Keep away from heat,sparks and flame. UV light exposure. 11 . TOXICOLOGICAL INFORMATION 1,6-HEXANEDIOL DIACRYLATE ACUTE ORAL LD50 (HG/KG): 5,000 (RAT) ACUTE DERHAL LDS0 (MG/KG): 3,700 ACUTE INHALATION LC50 (MG/L): NONE FOUND OTHER: Non-irritating to the eyas. Severe skin irritant. Positive sensitization. Equivocal Ames assay. Positive mouse lymphoma assay. Non-teratogenic at maternally toxic dose. No skin tumors produced upon chronic exposure. AMES TEST: BENZENE ACUTE ORAL LD50 (MG/KG): 3 ,800 (RAT) ACUTE DERMAL LDSO (MG/KG): NONE FOUND ACUTE INHALATION LCSO (MG/L): 10 ,000 PPM/7HR(RAT) OTHER: Tested for acute oral LD50 and LC50 AMES TEST: UNKNOWN TOLUENE *** CONTINUED ON NEXT PAGE **« PRODUCT : UVHC8558 HARDCOAT-SOLVENTLE * --. , UV CURE PAGE : 05 ACUTE ORAL LD50 (MG/KG): 5000 (RAT) ACUTE DERMAL LD50 (MG/KG): 14,000 (RBT) ACUTE INHALATION LC50 (MG/L): 5320 PPM /8HR(HUS) OTHER: Tested for acute oral, dermal and inhalation AMES TEST: UNKNOWN TRADE SECRET COMPONENT ACUTE ORAL LD50 (HO/KG): 5,190 (RAT) ACUTE DERMAL LD50 (MG/KG): 5,170 (RBT) ACUTE INHALATION LC50 (HG/L): NONE FOUND OTHER: Eye irritation persisting for 7 days. Corneal opacity reversible in 7 days. Moderate skin irritant. Positive sensitization. Negative Ames assay. Equivocal mouse lymphoma assay. No skin tumors produced on chronic exposure. AMES TEST: TRADE SECRET COMPONENT ACUTE ORAL LD50 (Mβ/KG): 1,694 (RAT) ACUTE DERMAL LD50 (Mβ/KG): 6,929 ACUTE INHALATION LC50 (MG/L): NONE FOUND OTHER: None. AMES TEST: TRADE SECRET COMPONENT ACUTE ORAL LDSO (HG/KG): UNKNOWN ACUTE DERMAL LD50 (MG/KG): UNKNOWN ACUTE INHALATION LC50 (MG/L): UNKNOWN OTHER: None. AMES TEST: UNKNOWN 12. ECOLOGICAL INFORMATION ECOTOXICOLOGICAL INFORMATION: No data at this time CHEMICAL FATE INFORMATION: No data at this time 13. DISPOSAL CONSI DERATIONS DISPOSAL METHOD: Disposal should ba made in accordance with federal, state and local regulations. 14. TRANSPORT INFORMATION REGULATED SUBSTANCES, LIQUID N.O.S. III 9 2 9 UID N.O.S. (ORGANIC ACRYLATES) 9i *** CONTINUED ON NEXT PAGE *** PRODUCT : UVHC8558 HARDCOAT-SOLVENTLESϊr, JV CURE PAGE : 06 NONE ADR (ECE) : NONE RAR (IATA) : NONE 15. REGULATORY INFORMATION SARA SECTION 302: None Found SARA (311,312) HAZARD CLASS: ACUTE HEALTH HAZARD CHRONIC HEALTH HAZARD SARA (313) CHEMICALS: NONE CPSC CLASSIFICATION: NA WHNIS HAZARD CLASS: B6 REACTIVE FLAMMABLE MATERIAL D2B TOXIC MATERIALS WHHIS TRADE SECRET: None EXPORT: SCHDLE B/HTSUS: 3910.00 Silicones in Primary Form ECCN: EAR99 HAZARD RATING SYSTEMS HM S FLAMMABILITY REACTIVITY HEALTH NFPA FLAMMABILITY REACTIVITY HEALTH CALIFORNIA PROPOSITION 65 THIS PRODUCT CONTAINS CALIFORNIA PROPOSITION 65 CHEMICALS WHICH ARE LISTED BELOW. BENZENE (71-43-2) TOLUENE (108-88-3) 16. OTHER INFORMATION These deta are offered in good faith as typical values and not as a product specification. No warranty, either expressed or implied, is made. The recommended handling procedures are believed to be generally applicable. However, each user should review these recommendations in the specific content of the intended use. C • ceiling limit NEGL • negligible EST- estimated NF * none found NA " not applicable UNKN • unknown NE ■ none established REC w recommended ND • none determined V recomm. By vendor By-product » reaction bySKN skin product, TSCA inventory TS trade secret status not required under R recommended 40 CFR part 720.30(h-2) MST mist STEL « short term exposure NT not tested limit Califonia Proposition 65... Warning ] This product contains a chemical known to the State of California to causa cancer. Califonia Proposition 65... Warning] This product contains a chemical known to the State of California to causa birth defects or other reproductiva harm. »»» CONTINUED ON NEXT PAGE »»»

Claims: CLAIMS 1. A coating composition comprising a top coat layer of silicon-containing curable synthetic resin bonded to a base coat layer of polyurethane-containing resin. 2. A coating composition comprising a top coat layer of a condensation product of colloidal silica and a silyl acrylate bonded to a base coat layer of polyurethane-containing resin, the silyl acrylate having the formula where R4 is a C(l-13) monovalent organic radical, R5 is a C(l-8) alkyl radical. R6 is selected from hydrogen, R4. radicals or mixtures thereof, R7 is a divalent C(l-8) alkylene radical, a is a whole number equal to 0-2 inclusive, b is an integer equal to 1-3 inclusive, and the sum of a+b is equal 1-3 inclusive. 3. A coating composition comprising a base coat layer of polyurethane-containing resin, and a top coat layer of silicon-containing resin and colloidal silica, the top coat layer having an inner surface and an outer surface, the inner surface being bonded to the layer of polyurethane-containing resin, most of the colloidal silica being in a zone within about 2 microns from the outer surface of the top coat layer. 4. A coating composition according to claim 1 or 2 in which the top coat includes colloidal silica, and in which the top coat has an exposed surface, most of the colloidal silica being within about 2 microns of the exposed surface of the top coat. 5. A coating composition according to claim 1, 2, or 3 in which the top coat is between about one and about ten microns thick, and the base coat is between about two and about 100 microns thick. 6. A coating composition according to claim 5 in which the base coat is between about two and about 15 times thicker than the top coat. 7. A coating composition according to claim 1, 2, or 3 in which the silicon-containing resin includes colloidal silica in the amount of between about 5 to about 500 parts resin for each 100 parts of colloidal silica by weight. 8. A coating composition according to claim 1, 2, or 3 in which the silicon-containing resin includes colloidal silica in the amount of between about 50 to about 200 parts resin for each 100 parts of colloidal silica by weight. 9. A coating composition according to claim 1, 2, or 3 which includes a photoinitiator for accelerating the curing of the silicon-containing resin. 10. A coating composition according to claim 8 which includes a photoinitiator for accelerating the curing of the silicon-containing resin. 11. An article of manufacture comprising a body having a metallic surface, a base coat layer of polyurethane-containing resin bonded to the metallic surface, and a top coat layer of silicon-containing curable synthetic resin bonded to the base coat to provide a hard protective coating for the metallic surface. 12. An article according to claim 11 in which the base coat is between about two and about 100 microns thick, and the top coat is between about 1 and about 10 microns thick. 13. An article according to claim 12 in which the base coat is between about two and about 15 times thicker than the top coat. 14. An article according to claim 11, 12, or 13 in which the top coat has colloidal silica and an exposed surface, and most of the colloidal silica is within about 2 microns from the exposed surface of the top coat. 15. A method for coating a metal surface, the method including the steps of coating the metal surface with a base coat layer of uncured polyurethane-containing resin, curing the base coat resin, coating the cured base coat resin with an uncured top coat layer of silicon-containing curable synthetic resin, heating the uncured top coat resin and the cured base coat resin above aboutl40°F., and thereafter curing the top coat resin. 16. A method according to claim 15 in which the cured and uncured resins are heated to between about 140°F. and about 190°F. 17. A method according to claim 15 or 16 in which the cured and uncured resins are heated for at least about 30 seconds. 18. A method according to claim 15 or 16 in which the thickness of the cured base coat resin is between about two and about 100 microns, and the thickness of the final coating composition is between about three and about 110 microns. 19. A method according to claim 15 or 16 in which the thickness of the layer of the cured base coat resin is between about two and about 15 times that of the difference between the thickness of the final coating composition and the thickness of the layer of the cured base coat resin.

Inventors: LAPOINT DAVID A, LAPOINT, DAVID, A.
Applicants: LAPOINT DAVID A, LAPOINT, DAVID, A.
Application year: 2000
Main classification: B05D1
IPC codes: B05D1, B05D5, B05D7, C08G18, C08L33, C09D5, C09D143, C09D175, C09D183