Metal finishing hanbook

904 Pages·2012·85.916 MB·English

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metal finishing
THE INDUSTRY’S RECOGNIZED INTERNATIONAL TECHNICAL AUTHORITY SINCE 1903
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80th Universal Metal Finishing Guidebook
Published as a 9th Issue by Metal FinishingMagazine
Fall 2012 VOLUME 110 NUMBER 9A
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Publisher: David Hopwood
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Editor: Reginald E. Tucker
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Metal Finishing (ISSN 0026-0576) is published 10 times per year in January/February, March, April, May, June,
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table of contents
cleaning, pretreatment & surface preparation
Everything You Need to Know About Mechanical/Mass Finishing . . . . . . . . . . . . . . . .11
Eugene Holzknecht
The Science of Scratches—Polishing and Buffing, Mechanical Surface Preparation .18
Alexander Dickman Jr.
Buffing Wheels and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
David J. Sax
Impact Blasting with Glass Beads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Robert C. Mulhall and Nicholas D. Nedas
Metal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Robert Farrell and Edmund Horner
Electrocleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Nabil Zaki
Ultrasonics—A Practical Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Kenneth R. Allen
Aqueous Washing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Edward H. Tulinski
Pickling and Acid Dipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Stephen F. Rudy
Electropolishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Kenneth B. Hensel
Cleaning and Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Brad Gruss
Vapor Degreasing with Chlorinated Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
James A. Mertens
Non-Phosphate Transition Metal Conversion Coatings NEW . . . . . . . . . . . . . . . . . . .112
David Chalk, Bruce Dunham
Zinc Phosphating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
John Donofrio
Paint Pretreatments for Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Anthony O. Ita
Preparation of Nonferrous Metals for Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Earl Groshart
Ensuring Readiness for Phosphate-Free Conversion Coatings NEW . . . . . . . . . . . . . .147
Ken Kaluzny
Surface Preparation of Various Metals and Alloys Before Plating and Other
Finishing Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Stephen F. Rudy
coating materials & application methods
High-Solids, Low-VOC, Solvent-Based Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Ron Joseph
Low-VOC Waterborne Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Ron Joseph
4
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Introduction to Paint Application Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Ron Joseph and Michael Murphy
Powder Coating with Robots and Dense Phase Technology—A Critical Blend of
Advanced Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
John Binder
Dip Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Thomas C. Jones
Spray Application Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Jerry P. Hund
Electrostatic Spray Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
Joel Rupp, Eric Guffey, and Gary Jacobsen
Converting to Waterbornes, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
Ronald Konieczynski,
Autodeposition of Organic Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
Thomas C. Jones
Powder Coating Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
Nicholas P. Liberto
Powder Spray Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
Alan J. Knobbe
Electrocoating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
Lisa E. Merlo
plating processes, procedures & solutions
Technology for Electroplating Metal Layers Aims to Improve Thickness Control . .262
G. Carrasco, Dr. J. Harris, T.Beckett, E. Rubel
Determination of Phosphorous Electroless Nickel Deposits . . . . . . . . . . . . . . . . . . . .270
Dr. V. Persits
Gold Post-Dip to Improve Corrosion Resistance Properties . . . . . . . . . . . . . . . . . . . . .274
Olaf Kurtz, Jürgen Barthelmes, Florence Lagorce-Broc, Taybet Bilkay, Michael Danker, and
Robert Rüther
Zincate-or Stannate-Free Plating of Magnesium, Aluminum, and Titanium . . . . . . .283
John W. Bibber
High-Temperature Acid Copper Process for Plating Through-Holes, . . . . . . . . . . . . .288
Maria Nikolova, Jim Watkowski, Don DeSalvo, and Ron Blake
Decorative Chromium Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293
Donald L. Snyder
Functional Chromium Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304
Gene Barlowe
Copper Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313
Romualdas Barauskas
Gold Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
Alfred M. Weisberg
Nickel Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334
George A. DiBari
Palladium and Palladium-Nickel Alloy Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350
Ronald J. Morrissey
6
Silver Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352
Alan Blair
Zinc Alloy Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359
Edward Budman, Toshiaki Murai, and Joseph Cahil
Zinc Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .366
Cliff Biddulph and Michael Marzano
Alternatives to Dichromate Sealer in Anodizing Operations . . . . . . . . . . . . . . . . . . . .372
R. Mason, S. Clark, M. Klingenberg, E. Berman and N. Voevodin
Trivalent Passivates Need Trivalent Post-Dips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384
Björn Dingwerth
Trivalent Chromium for Enhanced Corrosion Protection on Aluminum Surfaces . .395
Harish Bhatt, Alp Manavbasi, Danielle Rosenquist
Update on Alternatives for Cadmium Coatings on Military, Electrical Connectors 404
Rob Mason, Margo Neidbalson, Melissa Klingenberg, Parminder Khabra and Carl Handsy
Barrel Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .417
Raymund Singleton and Eric Singleton
Selective Plating Process, (Brush Plating, Anodizing and Electropolishing) . . . . . . . .433
Sifco Applied Concepts
Mechanical Plating and Galvanizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .446
Arnold Satow
Electroless (Autocatalytic) Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .454
James R. Henry
Anodizing of Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .465
Charles A. Grubbs
Chromate Conversion Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .479
Fred W. Eppensteiner and Melvin R. Jenkins
Trivalent Chrome Conversion Coating for Zinc and Zinc Alloys . . . . . . . . . . . . . . . . .490
Nabil Zaki
troubleshooting, testing & analysis
Accurate Thickness Testing Via Phase-Sensitive Eddy Current . . . . . . . . . . . . . . . . . .500
Mike Justice
Volumetric Complexometric Method to Determine Sulfate Content in Chromium
Plating Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .504
Dr. V. Persits
Control and Chemical Analysis of Plating Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . .510
Sudarshan Lal
Examining the Hull Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .523
Joe Fox
Chemical Analysis of Plating Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .533
Charles Rosenstein and Stanley Hirsch
Thickness Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546
Norbert Sajdera
Choosing an Accelerated Corrosion Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .558
Frank Altmayer
pH and ORP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .565
Michael Banhidi
7
Microhardness Testing of Plated Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .570
John D. Horner
The Effects of Solvent Entrapment on Coating Adhesion . . . . . . . . . . . . . . . . . . . . . .575
Ricardo Zednik and Ron Joseph
The Value of Optical Microscopy in the Forensics of Paint Failures . . . . . . . . . . . . . .581
Ron Joseph
Accelerated Corrosion Testin UPDATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589
Ray Singleton
Coating Thickness Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
David Beamish
Troublehshooting Paint and Powder
Coatings—Frequently Asked Questions NEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .608
Ron Joseph and Kevin Biller
environmental controls
Critical Factors Affecting Wet Scrubber Performance . . . . . . . . . . . . . . . . . . . . . . . . .620
Kyle Hankinson
Wastewater Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .624
Thomas Weber
Waste Minimization and Recovery Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .637
W.J. Mclay and F.P. Reinhard
Reducing Operational Costs Environmental Impact Via Rigorous,
Plating/Finishing Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .663
Dave Fister
Filtration and Purification of Plating and Related Solutions and Effluents . . . . . . . .674
Jack H. Berg
Air Pollution Control in the Finishing Industry, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .690
Gordon Harbison
Water Pollution Control for Paint Booths, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701
Alan Monken
Wastewater Treatment Systems for Finishing Operations . . . . . . . . . . . . . . . . . . . . .708
Alan Monken
Wastewater Treatment for Electrocoating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .713
Gordon S. Johnson
Conversion of Plating Line Rinses to a Closed-Loop Deionization System NEW . . .715
Dave Fister
Operational Benefits of Delisting Hazardous Wastes NEW . . . . . . . . . . . . . . . . . . . . .723
William Miller
finishing equipment & plant engineering
Immersion Heater Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .732
Tom Richards
Considerations in the Finishing Equipment Selection Process . . . . . . . . . . . . . . . . . . .740
CJI Systems
Fundamentals of Plating Rack Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .745
Steen Heimke
Finishing System Efficiency Upgrades for a Capital-Constrained Market . . . . . . . . .754
Timothy Kurcz
8