Aluminum Finishes

1. Mill Finish
2. Anodized Finish
3. Powder Coated Finish
4. Super Durable Powder Coated Finish
5. Polyvinylidene Flouride (PVDF) Finish
6. Alodine
7. Chromated Finish
1. Mill Finish

Simply means the

raw or bare finish
of material as it
comes out of the
extrusion or
milling machines.
2. Anodized Finish
Anodizing, or anodising, is an electrolytic passivation process used to
increase the thickness of the natural oxide layer on the surface of metal
parts.
A - History:
 Anodizing was first used on an industrial scale in 1923 to protect
Duralumin seaplane parts from corrosion. This early chromic acid
process was called Bengough-Stuart process.
 In 1927 Gower and O’Brien patented the first sulfuric acid anodizing
process. This remain the most common anodizing electrolyte.
 Oxalic acid anodizing follows in was patented in Japan in 1923 and later
widely use in Germany, particularly for architectural applications.
 Anodized aluminum extrusion was popular architetural material in the
1960s and 1970s, but has since been displaced by cheaper plastics and
powdercoating.
Anodized Finish
A - History: (cont.)
 In most recent major development, the phosphoric acid anodizing
process so far is only used as pretreatments for adhesives or organic
paints. Although a wide variety of proprietary and increasingly complex
varuation of all these anodizing processes continue to be developed by
industry.
Anodized Finish
A - Advantages:
 Increases corrosion resistance and wear resistance.
 Provides better adhesion for paint primers and glues than bare metal.
 Prevent galling of threaded components.
 Increase surface hardness.
 Allow dyeing (coloring).
 Improved lubrication and adhesion.
 It is non- conductive.

B - Disadvantages:
 Have a much lower thermal conductivity and coefficient of linear
expansion than aluminium. As a result, the coating will crack (but will
not peel) from thermal stress if exposed to temperatures above 80°C.
Anodized Finish
 Anodic films are most commonly applied to protect; Aluminum alloys,
Titanium, Zinc, Magnesium, Tantalum and Niobium.

 This process is not a useful treatment for iron or carbon steel because
these metals’ iron oxide (also known as rust) flakes off, costantly
exposing the underlaying metal to corrosion.

 Anodizing is one of the more environmentally-friendly metal finishing

processes.
Anodized Colors & Film Thickness
 Chromic acid = 0.5µm to 18µm
(0.00002” to 0.0007”)
 Sulfuric acid = 1.8µm to 25µm
(0.00007” to 0.001”) moderate
= 25µm to 150µm (0.001” to
0.006”) hard anodizing
 Organic acid = up to 50µm
 Phosphoric acid = see ASTM
D3933
Film thickness range from 0.5µm
to 150µm.
3. Powder Coating Finish
 Powder coating is a type
of coating that is applied
as a free-flowing, dry
powder. The main
difference between a
conventional liquid paint
and a powder coating is
that the powder coating
does not require a solvent
to keep the binder and
filler parts in a liquid
suspension form.
Powder Coating Finish
 Powder Coating Finish
 The coating is typically applied electrostatically and is then cured under
heat to allow it to flow and form a "skin." The powder may be a
thermoplastic or a thermoset polymer. It is usually used to create a hard
finish that is tougher than conventional paint. Powder coating is mainly
used for coating of metals, such as "whiteware", aluminium extrusions,
and automobile and bicycle parts. Newer technologies allow other
materials, such as MDF (medium-density fibreboard), to be powder
coated using different methods.

Normally the powders cure @ 200°C (390°F) in 10 minutes. The curing

schedule could vary according to the manufacturer’s specifications.
Powder Coating Finish
A - Advantages:
 Emit Zero or near zero volatile organic compounds (VOC).
 Can produce much thicker coatings than conventional liquid coatings
without running or sagging.
 Overspray can be recycled and thus it is possible to achieve nearly 100%
use of coating.
 Production lines produce less hazardous waste than conventional liquid
coatings.
 Capital equipment and operating costs are generally less than
conventional liquid lines.
 Items generally have fewer apprearance differences between
horizontally and vertically coated surfaces than liquid coated items.
 Wide range of specialty effects can easily accomplished compare to
other coating processes..
Powder Coating Finish
B - Disadvantages:
 Not easy to apply smooth thin films. As the film thickness is reduced, the
film becomes more and more orange peeled in texture due to the
particle size and TG (glass transition temperature) of the powder.

For optimum material handling and ease of application, most powder

coatings have a particle size in the range of 30 to 50 micrometres and a
TG > 40°C.
Powder Slurry process is a specialized operation where powder
coatings is less than 30 micrometers or with a TG < 40°C.

Powder coatings have a major advantage in that the overspray can be

recycled. However, if multiplt colors are being sprayed in a single spray
booth, this may limit the ability to recycle the overspray.
Powder Coating Finish
C – Types of Powder Coatings:

 Thermosets variety – incorporates a cross-linker into the formulation.

When the powder is baked, it reacts with other chemical groups in the
powder polymer and increases the molecular weight and improves the
performance properties.
 Thermoplastic variety – does not undergo any additional reactions
during the baking process, but rather only flows out into the final
coating.

The most common polymers used are polyester, polyester-epoxy (known

as hybrid), straight-epoxy (Fusion bonded epoxy) and acrylics.
Powder Coating Finish
D – Removing Powder Coating:

Methylene Chloride is generally effective at removing powder coating.

 Organic solvents (Acetone, thinnerss, etc.) are completely ineffective.
 Most recently MC is being replaced by Benzyl alcohol with great success.
 Can also be removed with abrasive blasting.
 98% sulfuric acid commercial grade also removes powder coating film.
 Certain low grade powder coats can be removed with steel wool, though
this might be a more labor-intensive process than desired.
Powder Coating Finish
E – Powder Coating Colors:
4. Super Durable Powder Coated Finish
Super Durable Powder Coating - Specially formulated to satisfy
the highest requirements of the building industry regarding aesthetic
performance, UV and humidity resistance. Outstanding properties
regarding gloss retention and resistance to color change are
combined with optimum functional properties ensuring the highest
levels of protection.

A. Application:
 Primary areas of application are aluminum extrusions and claddings
for architectural work. When screen-printing or sealants are in use,
we advise separate trials to ensure compatibility and that the
required performance criteria are met.
Super Durable Powder Coated Finish
B. Advantages:
 Has an expected lifetime which is 3X as long as today’s high quality
architectural powder coatings. Backed by a 25 year guarantee.
 Cost effective compared to expensive fluorocarbon-based wet paint.
 Truly environment friendly because it’s solvent free and recyclable.
 It surpasses Qualicoat Class II industry requirements.
 Available in a wide range of colors and in three gloss levels; high gloss,
reduced gloss and matt finish.

C. Disadvantages:
 Shall be keep in a dry cool area. Max 25°C/ relative humidity 60%.
5. Polyvinylidene Flouride (PVDF) Finish
PVDF is a specialty plastic material in the fluoropolymer family; it is
used generally in applications requiring the highest purity, strength, and
resistance to solvents, acids, bases and heat and low smoke generation
during a fire event. Compared to other fluoropolymers, it has an easier
melt process because of its relatively low melting point of around 177°C.

A. Usage:
 A fine powder grade, KYNAR 500 PVDF or HYLAR 5000 PVDF, is also
used as the principal ingredient of high-end paints for metals. These
PVDF paints have extremely good gloss and color retention, and they are
in use on many prominent buildings around the world, e.g. the
Petronas Towers in Malaysia and Taipei 101 in Taiwan, as well as on
commercial and residential metal roofing.
Polyvinylidene Flouride (PVDF) Finish
B. Advantages:
 Resistant to most acids, alkalis, salts, halogens, alcohols and chlorinated
hydro-carbons
 High mechanical strength,
 Operating temperature range -20°C to 140°C
 Displays high excellent flame retardant properties.

C. Disadvantages:
 A strong polarized solvents, such as ketones and esters, can cause the
material to swell.
 Polyvinylidene Flouride (PVDF) Finish

D. PVDF Colors
6. Alodine Finish
Alodine is a coating based on Titanium
Metal Oxide (TiO2) electrodeposited from
the electrical assisted hydrolysis of metal
complexes. The TiO2 Coating provides
superior corrosion and wear resistance for
harsh and demanding applications such as
marine and high temperature engine
environments.

Alodine is a brand of Chromate conversion

coating products used on aluminum alloy
and to a lesser extent magnesium alloy
metals, primarily in the aerospace industry.
Alodine Finish
A. Advantages:

 A new electrolytic process provides a 3-12 micron thick layer of TiO2

 Virtually eliminates corrosion
 Drastically improves wear resistance
 Enables the use of lower cost materials (e.g., aluminum instead of
stainless steel)
 Excellent bonding capability when combined with branded adhesives.
 Provides superior wear, corrosion, and thermal protection over
aluminum, titanium, and aluminized surfaces
 Thousands of times harder and more flexible than paint
 Impervious to fuel and fuel vapor, powertrain lubricants, oil, and
ethylene glycol
 Withstands temperatures up to 600°C (1112°F) without corrosion
performance loss
7. Chromated Finish
Chromate coatings - are soft and
gelatinous when first applied but
harden and become hydrophobic as
they age. Curing can be
accelerated by heating up to 70°C,
but higher temperatures will
gradually damage the coating over
time. Some chromate conversion
processes use brief degassing
treatments at temperatures of up
to 200°C. Coating thickness vary
from a few nanometers to a few
micrometers thick.
Chromated Finish
A. Chromate Conversion defined:
 When aluminum and aluminum alloys are immersed in a controlled
chromic acid bath with special additives, a chemical conversion reaction
occurs at the metal’s surface. This reaction produces a complex, non-
crystalline, non-porous coating consisting of a thin aluminum oxide film
with entrapped chromates and dichromates. The coating’s corrosion
resistant properties are due primarily to the chromates, specifically the
hexavalent chromium.

A type of conversion coating applied to passivate aluminium, zinc,

cadmium, copper, silver, magnesium, tin and their alloys to slow
corrosion.
Chromated Finish
 The protective effect of chromate coatings on zinc is indicated by color,
progressing from clear/blue to yellow, gold, olive drab and black. Darker
coatings generally provide more corrosion resistance. Chromate
conversion coatings are common on everyday items such as hardware
and tools and usually have a distinctive yellow color.
Chromated Finish
B. Typical Applications:

 Aluminum frames and weldments for the computer and defense

industries. Chromating technology deals effectively with poor drainage
and entrapped chemicals, a complex problem ccommon to frames
manufacturerd of welded tubing and pipe
 Aluminum extrusions, tubing and structural assemblies. These
can be chromated in lengths of 4800 to 6000mm and cross sections of
1200 to 1500mm.
 Any aluminum part that requires painting for corrosion
resistance.
Chromated Finish
C. Advantages:
 Low-cost option for corrosion and wear protection
 A bonding agent for paint and adhesives
 A lubrication carrier
 Final finish
 Minimal electrical resistance
 No effect on critical dimensions, in most cases