AIRBUS ®

AIPS02-01-002
Issue 4
Page 1 of 17
April 2010

AIPS
Airbus Process Specification

Sulphuric acid anodising of aluminium alloys

Published and distributed by

AIRBUS S.A.S.
ENGINEERING DIRECTORATE
31707 BLAGNAC Cedex
FRANCE

Copyright reserved Ref No. AIPS02-01-002

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Contents

1 Scope

2 Normative references

3 Definition, applicability and limitations

4 Engineering requirements

5 Technical qualification

6 First part qualification

7 Series production inspection

8 Rework

9 Environment, health and safety

Annex A (normative)

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1 Scope
This Airbus Process Specification defines the Engineering requirements for Sulphuric Acid Anodising (SAA) of
aluminium alloys.
This specification does not give detailed instructions; these are given in the Process Instructions (PI) / Airbus
Process Instruction (AIPI) and the Work Instructions.
This specification shall not be used as an inspection document.
It shall be applied when mentioned in the relevant standard, material specification or Definition Dossier.

2 Normative references
Only normative references cited in the text are listed hereafter.
The latest issue of the publication referenced shall be used.

AIMS 04-04-001 Material specification – Corrosion inhibiting primer

AIMS 04-04-003 Material specification – Internal paint system – Primer + Top coat
AIMS 09-00-003 Material specification – Water Quality
AIPS 03-03-001 Process specification – Rework of scratches in aluminium alloys on external
surfaces
AIPS 05-02-011 Process specification – Rework of paints on metallic and nonmetallic structural
parts
AIPS 05-02-009 Process specification – Application of structural paint
AITM 3-0032 Test method – Analysis of Metals in Galvanic Bathes by ICP-Spectroscopy
AITM 3-0035 Test method – Determination of Chloride Contamination in Surface treatment Baths
AITM 3-0036 Test method – Determination of Hydrogen lons in Surface treatment Baths
ISO 1463 Metallic and oxide coatings – Measurement of coating thickness. Microscopically
Method
ISO 2360 Non-conductive coatings on non-magnetic electrically conductive basis materials –
Measurement of coating thickness – Amplitude-sensitive eddy current method
ISO 2409 Paint and varnishes – Cross-cut test
ISO 9227 Corrosion test in artificial atmosphere - Salt Spray Tests
EN ISO 10304-1 Water quality – Determination of dissolved fluoride, chloride, nitride,
orthophosphate, bromide, nitrate and sulphate ions, using liquid chromatography of
ions – Part 1: Method for water with low contamination
EN 12373-2 Determination of mass per unit area of anodic coatings – Gravimetric method
EN 9103 Quality management systems - Variation management of key characteristics

3 Definition, applicability and limitations

3.1 General description of process

SAA process is an electrochemical process used for both generating an aluminium oxide layer for corrosion
protection and surface treatment prior to application of a corrosion–inhibiting primer.

The SAA process is characterized by using an electrolyte of sulphuric acid.

The anodising step shall be performed with a sulphuric acid concentration of approximately (190 ± 30) g/l.

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To achieve the desired corrosion resistance of the anodic film, if it is not painted, SAA shall be sealed in hot,
deionised water.
In the unsealed condition SAA provides a receptive surface for coloured dye and in specific cases it may be used
as a pre-treatment for organic coatings.

SAA elevates the abrasion resistance.

The sealed film is an electrical insulator.

Surface preparation steps such as cleaning, alkaline etching, acidic pickling / desmutting and subsequent steps
such as rinsing and sealing are integral to the SAA process.
3.2 Definitions
De-anodising Process, which removes the anodic oxide.
Etching smut: Precipitations of alloying elements (e.g. Cu, Fe, Zn, Si) on the parts surface after a
process step (normally after alkaline etching step).
MDL: Mechanically disturbed layer: It is the layer that is present at the materials surface
resulting from the rolling process of the material.
Open time: Maximum allowed period of time between anodising and subsequent processes (sealing
or painting).
Pit: A surface corrosion defect at which the anodic film is penetrated.
Process instruction: Document that describes the detailed process, parameter, detailed steps, etc., which have
to be successfully qualified against this AIPS.
Process step: Partial stage of anodic process chain with a defined function, such as alkaline etching,
rinsing, etc..
Production relevant
alloys: All alloys, that are treated with the SAA process in the specific shop.
Re-anodising: Repetition of the anodising process step after previous de-anodising
Sealing: Sealing (of the anodised layers) is applied to close pores produced by the acid anodising
process. It is usually applied in hot, deionised water bath. Sealing can improve the
corrosion resistance performance of the anodic film.

3.3 Applicability
This Airbus specification is applicable when invoked by the drawing directly or through another document for the
purpose given in the scope. When processing to AIPS 02-01-002 is required, it shall be invoked on the drawing by
the words “Sulphuric acid anodising of aluminium alloys” according to AIPS 02-01-002. Process instructions shall
not be called on drawing.
3.4 Limitations of the process
All processes that can compromise the anodic layer (e.g. machining, welding, forming, or heat-treatment) shall be
performed prior to surface preparation of the parts.
SAA anodising shall not be applied:
- For metal bonding applications
- For fatigue critical parts
- Inside of oxygen pipes
- For tubes, pipes and open holes with a length to diameter ratio greater than 4:1
- Trapped holes with a length to diameter ratio greater than 2:1
- Parts or assemblies (e.g. spot-welded and riveted)

Note: The formation of the oxide layer influences the dimensions of the part and shall be considered for close
tolerance parts.

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4 Engineering requirements

4.1 Technical requirements

Prior to anodising step:

- The parts shall be free of oil, grease, marking inks and other surface contaminants.
- The surface shall be free from precipitations or smut from alloying elements or pre-processes indicated by
the bright and uniform appearance of the surface.
- Parts/areas that do not require anodising shall be masked accordingly
- MDL shall be removed either by mechanical or chemical processes.
- In case of chemical pre-treatment, the final step prior to anodising shall be acidic pickling.
- In case of re-anodising all residuals from the previous anodising shall be completely removed.

During the anodising process:

- The parts shall not be subjected to any tensile, flexure, torsion or other stress.
- The process shall be performed such, that parts do not dry between the single process steps (pre-
treatment, anodising, etc).
- The parts shall be fully immersed in the electrolyte.

After the anodising procedure:

- Parts have to be adequately rinsed.
- Afterwards the parts shall be either:
- Dried and painted according to AIPS 05-02-009 and AIMS04-04-001.
- Sealed (if not painted) in hot deionised water

Water quality:
- All water used for preparation of the SAA bath and for final rinsing step as well as for sealing process shall
be in accordance with grade A of AIMS 09-00-003.

4.2 Requirements of the anodic film

4.2.1 Visual aspects

The anodic film shall be continuous, smooth, adherent and uniform of appearance. It shall be free of powdery
areas, burnings, blisters and discontinuities such as scratches, ruptures or other damages.
4.2.2 Film thickness

The thickness of the anodic film shall be in a range from 8 to 15 µm or 15 to 25 μm (dyed anodic films) and
uniformly distributed on top of the base material. The thickness of the film shall be checked either eddy current
(ISO 2360) or optical microscope (ISO 1463).
4.2.3 Corrosion resistance
When tested in accordance to ISO 9227 taking into account the definitions of chapter 5.2.1.1 of this specification
the anodised and (hot dionised water) sealed specimens shall show
- Less than 2 pits/dm2 and
- No pit shall exceed 0.8 mm in diameter and
- No patchy dark grey areas (spots, streaks or marks)

after an exposure time of minimum 500 h for 2024 T3 (or T42) unclad or 7075 T651 (or T73) unclad or 7175 T7351
unclad.

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4.3 Paint adhesion on anodic film

The damage of painted specimens shall not exceed
- Gt 0 for specimen at initial stage and
- Gt 1 for specimen after 14 days of water immersion at 23 ± 2 °C

when tested in accordance with ISO 2409 taking into account the definitions of chapter 5.2.1.2 of this specification.

The fulfilment of these requirements shall be demonstrated using two sets of specimen, whereby the second set is
required only when the maximum open time (time between anodising and paint application) applied at the shop
exceeds 24 h.
- Set 1: specimen shall be painted 16 h to max. 24 h after anodising taking into account storage under
ambient conditions of the shop (standard)
- Set 2: specimen shall be painted after the maximum open time and environmental conditions applied at the
shop, however maximum open time shall not exceed 168 h.

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4.4 Key Characteristics

Key Characteristics acc. to EN9103 are defined by responsible engineering based on a risk analysis for parts
manufactured by this process. Key characteristics shall be defined on product level and if necessary also on
process level.
They shall be subject to variation control by production organization according to EN9103.
Key Characteristics do not relieve the production organization from meeting all engineering requirements defined in
this document.

Table 1: Key Characteristics

Product Key Characteristics Process Key Characteristics

Requirement/ Sub.- Requirement/
No. Designation Designation
Limit No. Limit
No intermediate
Part surface condition
drying (‘wet-in-
during all pre-treatment
1 wet’)or surface
steps until final rinsing after
contamination
anodising
allowed
continous,
smooth,
adherent and
uniform of
appearance.

free of powdery
2 Visual aspect
areas, burnings,
blisters and
discontinuities
such as
scratches,
ruptures or other
damages
8 to 15 µm
(dyed anodic
3 Film thickness
films:
15 to 25 µm)
less than 2
pits/dm2 and no
Corrosion prevention pit > 0.8 mm
4 performance of hot water and no patchy
sealed anodic film dark grey areas
after 500 h SST
exposure
Paint adhesion on anodic Gt0 (dry) and
5
film Gt1 (wet)
(continued)

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Table 1: Key Characteristics

Product Key Characteristics Process Key Characteristics

Requirement/ Sub.- Requirement/
No. Designation Designation
Limit No. Limit
Product concentration depending on
6.1 of alkaline cleaning product, refer to
bath AIPI 02-01-002
Maximum chloride depending on
6.2 content of alkaline product, refer to
Contamination
Parts suface condition after cleaning bath AIPI 02-01-002
6 and pitting free
alkaline cleaning Operating temperature depending on
surface
6.3 and time of alkaline product, refer to
cleaning bath AIPI 02-01-002
Rinsing times (in case
refer to
6.4 of subsequent acidic
AIPI 02-01-002
pickling)
Product concentration depending on
7.1 of alkaline etching product, refer to
bath AIPI 02-01-002

Parts suface condition after Defect free Operating temperature depending on

7
alkaline etching surface layer 7.2 and time of alkaline product, refer to
etching bath AIPI 02-01-002
shall not be used
7.3 Use of rinsing bath(s) for rinsing after
alkaline cleaning
depending on
Product concentration
8.1 product, refer to
of acidic pickling bath
AIPI 02-01-002
Maximum content of
major alloying depending on
Parts suface condition after Smut free
8 8.2 elements other than product, refer to
acidic pickling surface
aluminium of acidic AIPI 02-01-002
pickling bath
Operating temperature
refer to
8.3 and time of acidic
AIPI 02-01-002
pickling bath
Sulphuric acid
9.1 concentration of the 160 to 220 g/l
SAA bath

Max. aluminium
Parts suface condition after
9 refer to 2 9.2 content of the SAA 14 g/l
anodising
bath

Max. chloride content

9.3 0.15 g/l
of the SAA bath

(continued)

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Table 1: Key Characteristics (concluded)

Product Key Characteristics Process Key Characteristics

Requirement/ Sub.- Requirement/
No. Designation Designation
Limit No. Limit
Operating temperature
9.4 18°C (± 2°C)
of SAA bath
12 to 18 V
(depends on
alloy), 5+x min
with x depending
Anodising cycle on film thickness
9.5
(voltage and time) (5 min ramp and x
min plateau;
example x=30 for
10 to 15 µm); see
figure 1
Max. anode:cathode
9.6 1.5:1
ratio
9 Racking situation
during anodising to
refer to
9.7 ensure proper
AIPI 02-01-002
contacting and to
avoid shielding effects
Maximum currentless
9.8 remaining time in the 3 min
SAA bath
Rinsing times after refer to
9.9
anodising AIPI 02-01-002
grade B per
Final rinse water
9.10 AIMS 09-00-003
quality
or better
refer to
9.11 Handling of parts
AIPI 02-01-002

5 min
(±0.5 min)
x min

12 to 18 V
(depending on alloy)
Anodising voltage

5 + x min
(plateau time x depending
Anodising time on required film thickness)

Figure 1: Electrolytic cycle during SAA anodising

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5 Technical qualification
The Technical Qualification shall be performed, according to the relevant Airbus procedure.
5.1 Basic qualification requirement
The general process qualification, the qualification of industrial facilities and Airbus quality assurance are described
in prevailing procedure documents.

The SAA process must be stable and reproducible before launching the technical qualification, so that the selected
set of process steps and parameters is taken for the qualification.

The production shop must use its facilities under serial production conditions for the performance of the
qualification tests.

Process parameters, environmental conditions etc. applied for qualification shall ensure process performance
within the entire process window applied at the relevant shop.

Qualification of the SAA-process shall consider all paint or paint schemes that are subsequently applied at the
specific shop.

Qualification test program (QTP):

The means for showing compliance with the requirements for achieving technical qualification of the SAA process
must be defined by the qualification test programme. This includes the standard qualification test defined by this
AIPS hereinafter (chapter 5.2) as well as any amendment or deviation.
5.2 Standard qualification test program
This chapter provides the details of the standard test programme, which shall be taken into account for the
definition of the specific qualification test programme (QTP) for the technical qualification of a shop.
In addition to the acceptance criteria, specific test requirements are defined as amendment and/or deviation from
the specified test method.
5.2.1 Demonstration of the required performance and quality level

5.2.1.1 Requirements to the anodic film

The compliance with the requirements defined chapter 4.2 of this specification shall be demonstrated.

Visual aspects
The acceptance criterion defined in chapter 4.2.1 shall be demonstrated by inspection of the relevant parts with
naked eyes under constant light conditions.

Film thickness
The acceptance criterion defined in chapter 4.2.2 shall be demonstrated by using either:

Non destructive method:

The measurement shall be performed in accordance to ISO 2360. It shall be performed on 2 anodised specimens
in unsealed conditions. 10 measurements on each specimen shall be made.

and

Destructive method – Micrographic section:

The measurement shall be performed in accordance to ISO 1463 or by SEM. It shall be performed on 2 specimens
in unsealed condition. 2 measurements on each specimen shall be made.

The measurement shall be performed in a minimum distance of 10mm from the edge.

Corrosion resistance
The acceptance criterion defined in chapter 4.2.3 shall be demonstrated.

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Regarding the test to be performed according to ISO 9227 the following shall be considered:
- Specimen shall be exposed to a 5% neutral NaCl solution.
- At least 3 specimen shall be tested in (hot water) sealed conditions.

With regard to the assessment of test results the following shall be considered:
- At the end of the exposure, the specimen shall be visually examined for evidence of corrosion.
- In case, the extent of corrosion attack shall be described by means of visual and metallographic
examinations.
- Photographs shall document the representative results.

5.2.1.2 Paint adhesion on anodic film

The acceptance criteria defined in chapter 4.3 shall be demonstrated
Regarding the test to be performed according to ISO 2409 the following shall be considered:
- Use of an adhesive tape
- Pulled off it at a steady rate at an angle as close as possible to 60 degrees.

The test specimen shall be manufactured in accordance with AIPS 05-02-009 and AIMS 04-04-003.

The number of specimen to be tested:

- 3 specimen shall be tested at initial state and
- 3 after 14 days of immersion in deionised water at (23 ± 2) °C

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5.2.2 Specimens for the standard qualification test program

Table 2: Specimen selection for the standard qualification test program

Materials Specimens
Requirement Property SAA unsealed Number
SAA (hot water)
SAA unsealed + primer per Dimension
sealed
+ top-coat alloy
On all samples On all samples
Visual
used for used for - - -
aspect
qualification qualification
2024 T3 (or T42)
Chapter unclad
Film
5.2.1.1 n.a. n.a. 2
thickness
Requirements and all production
to the anodic relevant alloys
film
2024 T3 (or T42)
unclad
Corrosion at least
n.a. 3 3
resistance 1dm²
and all production
relevant alloys

2024 T3 (or T42)

Chapter
unclad
5.2.1.2 Paint 150 x 80
n.a. n.a. 3
Paint adhesion adhesion mm²
and all production
on anodic film
relevant alloys

5.3 Qualification test report (QTR)

The qualification test report shall document the qualification tests performed and its results. It shall be written in
English language.

The test report shall make reference to this AIPS and include at least all the following information:
- Name and address of the production shop
- Process instruction
- All the details regarding surface preparation (alkaline degreasing, acidic pickling etc.)
- Detailed process parameters (bath compositions, temperatures, times, voltage, current density, etc.)
- Date of the anodising film realisation and date of the tests
- Equipment, test method, test parameters and test conditions used, etc.,
- Detailed report of the test results. This report shall present all the test values. For the visual inspection, the
workshop to be qualified shall supply pictures of treated samples (specially after salt spray exposure)
- Any incident that may have affected the results and any deviation from this AIPS.

6 First part qualification

Not applicable.

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7 Series production inspection

The shop shall perform the following series production inspections under serial conditions.
7.1 General requirements
When processing according to this AIPS all installations shall be continuously operated within the parameters
defined in the Process Instruction.

All installations shall comply with the general and cleanliness requirements as defined in the Process Instruction.
This shall be ensured by permanent control of:
- the facilities (installation and equipment) and the products used.
- conformance of the application process conditions to the requirements of this document and the Process
Instruction.

All records of test / inspection results shall be stored adequately under the control of the quality assurance of the
shop.

All operators of the process shall be adequately trained.

7.2 Test frequency
The frequency for permanent and regular quality control checks shall be defined by the quality assurance of the
shop considering:
- the ageing, contamination and the efficiency of the bath,
- the production rate
After specific events as re-adjustment of refilling of the bathes appropriate performance of the process shall be
ensured by additional quality tests.

7.3 Bath composition

The bath composition shall be in the limit as specified in the Process Instruction.

The analytical determination of the contents of sulphuric acid, aluminium and chloride can be performed according
to the follwing test methods or standard:
Sulphuric acid content: AITM 3-0036
Aluminium content: AITM 3-0032
Chloride content: AITM 3-0035 or EN ISO 10304-1

7.4 Visual inspection of the bath

The bath shall be clean and free of any contaminants as parts fallen off the racks, oily residuals etc.. Agitation of
the bath (if applicable) shall be working and homogenously.
7.5 Visual aspect of the parts
All areas of the parts have to be covered by the anodic film. The anodic film shall be continuous, smooth, adherent
and of uniform appearance. It shall be free of powdery areas, burnings, blisters and discontinuities such as
scratches, ruptures or other damages. There shall be no water stains on surfaces to which an organic finish is to be
applied. The parts have to be inspected by naked eyes under constant light conditions. Checking of powdery areas
or dusting is made with the help of a white and dry rag, which is slightly rubbed on the part to check. A slight
dusting may be accepted so far as the paint adherence is not altered.
7.6 Film thickness
Refer to 4.2.2.
The thickness of the anodic film shall be checked either by eddy current method (ISO 2360) or optical microscope
(ISO 1463).

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7.7 Film weight

The film weight shall be > 110 mg/dm² when tested on 2024 T3 (or T42) unclad.
The film weight shall be determined according to EN 12373-2.
This measurement can be used alternatively to the thickness measurement as requested in 7.6.

7.8 Corrosion resistance

Refer to section 4.2.3.
The specimen size shall allow an evaluation of an area of at least 1 dm². Areas 2 mm from markings, edges and
electrode contact marks remaining after processing shall not be considered for evaluation.
7.9 Sealing quality
The sealing quality shall be checked by the test method defined in Annex A. Sealing is correct if it does not remain
any trace or dye on the surface of the test specimen. A very faint colour stain is permitted.
7.10 Paint adhesion
Refer to section 4.3 however
- specimen shall be painted 16h to max. 24 h after anodising taking into account storage under ambient
conditions of the shop (standard)
- adhesion testing is performed at initial stage only.

7.11 Quality check of the process - summary

All series production checks are summarised in table 3 below.

Table 3: Serials checks and minimum checking frequencies

Number of
Property Requirement Frequency Material specimens
per alloy
• Regular
Bath
Chapter 7.3 • After bath adjustment Not applicable Not applicable
composition
• After bath refilling
Visual aspect of
Chapter 7.4 • Regular Not applicable Not applicable
bath
Visual aspect of
Chapter 7.5 • 100% of the parts All parts Not applicable
parts
• Regular • 2024 T3 (or T42) unclad or
Film thickness Chapter 7.6 • After bath adjustment • 7075 T651 (or T73) unclad or 2 specimens
• After bath refilling • 7175 T7351 unclad
• Regular • 2024 T3 (or T42) unclad or
Film weight Chapter 7.7 • After bath adjustment • 7075 T651 (or T73) unclad or 2 specimens
• After bath refilling • 7175 T7351 unclad
• 2024 T3 (or T42) unclad or
Corrosion
Chapter 7.8 • After bath refilling • 7075 T651 (or T73) unclad or 3 specimens
resistance
• 7175 T7351 unclad
Sealing quality Chapter 7.9 • Regular Production relevant alloys 3 specimens
• 2024 T3 (or T42) unclad or
Paint adhesion Chapter 7.10 • Regular • 7075 T651 (or T73) unclad or 3 specimens
• 7175 T7351 unclad

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8 Rework
For rework parts can be de-anodised (e.g. by alkaline etching) and re-anodised. The maximum number of rework
steps is limited to three de-anodizing and two re-anodizing steps.
For clad parts the maximum number of de- and re-anodising steps is limited in order to ensure the minimum
cladding thickness for the relevant production alloy.
For close tolerance parts the maximum number de- and re-anodising steps is limited to ensure the required
dimensions of the parts.

9 Environment, health and safety

Process shall be in line with Airbus environmental policy.
Banned substances, as per relevant Airbus procedure, shall not be applied.
Hazardous materials shall comply with rules defined in relevant Airbus procedure.

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Annex A
(normative)

Anodising of aluminium and its alloys - Estimation of quality of anodic oxide coating
after sealing. Dye drop test.

A.1 Introduction
The dye drop test is a method of estimating, by dye absorption after dye drop application (blue Sanodal G blue or
Waterman ink), the loss of absorptive power of anodic oxide coatings that have undergone a sealing treatment.

A.2 Test solutions

- Dye solution A : Water solution with Sanodal G 5 g/l
- Dye solution B : Blue and black Waterman ink

A.3 Procedure
Clean the surface to be tested and remove any grease with a piece of cotton wool soaked with an appropriate
solvent.

Apply few drops of test solution A or B to 1 cm2 area.

After 5 minutes, clean the surface by rubbing it under running water with a clean cotton cloth, then with a cotton
cloth soaked with neutral soap solution.

Rinse copiously and dry with a cotton cloth.

Examine the test area and assess the intensity of the stain by comparison.

The sealing is correct if there is no stain on the test specimen surface. A slight stain is admissible. The stain
intensity shall be appreciated by comparison with the following table. In this case the sealing is acceptable until
degree 2.

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RECORD OF REVISIONS

Clause
Issue Description of modification
modified

1 New standard
09/02

2 General revision
04/06

3 General revision
01/10

4 4.4 Implementation of Key Characteristics

04/10

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