CORROSION ENGINEERING

Open Ended Lab

Submitted To:

Engineer Aqsa Amir

Submitted By:

M.Afnan MME-18-14

Topic:

Modify the Surface of Aluminum by Anodizing Process for

Corrosion Prevention

Subject:

Corrosion Engineering

IAM, BZU

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Contents
1. Aluminum

2. Anodizing Process

3. Aluminum Anodizing for Prevention of Corrosion

4. Working Principal

5. Aluminum Anodizing Process

6. Barrier Layer

7. References

8.

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1.Aluminum
Aluminum (Al), also spelled aluminium, chemical element, a lightweight silvery white metal of
main Group 13 (IIIa, or boron group) of the periodic table. Aluminum is the most abundant
metallic element in Earth’s crust and the most widely used nonferrous metal. Because of its
chemical activity, aluminum never occurs in the metallic form in nature, but its compounds are
present to a greater or lesser extent in almost all rocks, vegetation, and animals. Aluminum is
concentrated in the outer 16 km (10 miles) of Earth’s crust, of which it constitutes about 8
percent by weight; it is exceeded in amount only by oxygen and silicon. The name aluminum
is derived from the Latin word alumen, used to describe potash alum, or aluminum potassium
sulfate, KAl(SO4)2∙12H2O.

Element Properties
atomic number 13
atomic weight 26.9815384
melting point 660 °C (1,220 °F)
boiling point 2,467 °C (4,473 °F)
specific gravity 2.70 (at 20 °C [68 °F])
valence 3
electron 1s22s22p63s23p1
configuration
2.Anodizing Process

 Anodizing is an electrolytic passivation process used to increase the thickness of the

natural oxide layer on the surface of metal parts. The process is
called anodizing because the part to be treated forms the anode electrode of an
electrolytic cell.
 There are different types of anodizing, most commonly referred to as Type I-Chromic
Acid Anodize, Type II-Sulfuric Acid Anodize, and Type III Hard Anodize or Hard coat
from the Mil-A-8625 designation. Other less common types are phosphoric acid and
titanium anodize.
 Anodizing typically ranges up to 5 mils thickness. The three most common variations of
aluminum anodizing include chromic (type I), sulfuric (type II) and hard (type III). Þ
Chromic anodizing utilizes a chromic acid electrolyte and yields the thinnest coatings,
only 0.02 to 0.1 mils thick (0.5 to 2.5 microns).
 Unlike ordinary, lightweight aluminum pots and pans, which are highly reactive with
acidic foods (like tomatoes), anodized aluminum cookware is safe. It is also non-stick,
scratch-resistant and easy to clean. ... It can be present in the food we eat and the
water we drink.

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3.Aluminum Anodizing for Prevention of Corrosion

Anodizing is one of the most common surface treatments of aluminum. In all anodizing
processes, the basic reaction is conversion of the aluminium surface to aluminum oxide. The
aluminum part, when made anodic in an electrolytic cell, causes the oxide layer to become
thicker, leading to better corrosion and wear resistance. For decorative purposes, the oxide
layer formed on the surface can be dyed.

There are several types of electrolytically formed anodic coatings. The basic classifications
for MIL-A-8625 are:

Type I—Chromic acid anodizing: Conventional coatings formed from a chromic acid bath.
Chromic anodize coatings are principally used for aerospace applications requiring corrosion
resistance and good paint adhesion.

Type II—Sulfuric acid anodizing: Conventional coatings formed from a sulfuric acid bath.
Sulfuric anodizing is the most commonly used and most suitable process for colouring.

Type III—Hard coat anodizing: Low-temperature bath and higher current densities to

produce thicker coatings, which provide greater wear and abrasion-resistant surfaces. Type
III anodize finishes can be dyed or non-dyed.

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4.Working Principle

Anodising works on the principle of an electrolytic cell. In this procedure, the anodising tank is filled
with a suitable electrolyte. In this tank, the part is usually suspended to expose most of the surface
to the electrolyte. We then place plates of suitable elements (usually lead or aluminium) in the
tank. The next step is completing the circuit between the cathode and anode through a power
source. The aluminium product is connected to the positive terminal, and the plates are connected
to the negative terminal of the battery. As the circuit is now complete, the current passes through
it. The value and duration of the electrical current passed will determine final features such as the
thickness of the aluminium oxide layer on the anodised aluminium product.

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5.Aluminium Anodizing Process

Most anodising setups today still use the original sulfuric acid bath for the process. However, many
new features have been added to significantly improve the final result in terms of aesthetics and
functionality of the product. The modern aluminium anodising process is very technical. Generally,
aluminium anodising consists of the following steps.

Cleaning
The surface of the aluminium product needs cleaning prior to anodising. Exposing the surface uses
acidic or alkaline cleaning agents to clean grease/dirt from the surface.

Pre-treatment
This step eliminates any surface imperfections. The goal is to provide a visible finish with a clean
and smooth surface. This is done by using two main processes – brightening and etching.

Brightening
Brightening or bright finishing cleans any heavy metal residues left over from the cleaning process.
Using a concentrated mixture of nitric and phosphoric acids to chemically smoothen the surface
provides a metallic finish ready for anodising.

Etching
Etching removes a layer of aluminium from the product surface to provide a matte finish (see more
about gloss levels). A hot solution of sodium hydroxide is used to remove surface imperfections.

Anodizing
After pre-treatment, the product is ready for anodising. As mentioned above, sulfuric acid is the
go-to electrolyte for aluminium anodising. Alternatives that are sometimes used are organic acid,
borate, tartrate, phosphoric acid, and chromic acid.

Coloring
There are several methods to add colour to anodised aluminium. Different colours need different
methods. Let’s look at two of the most popular methods of colouring anodised aluminium.

Electrocolouring
One of these methods is the electrocolouring method. This method is used for darker shades. In
electrocolouring, the anodised aluminium product is introduced to inorganic metallic salts through
an electrolyte. The anodised aluminium product becomes one electrolyte, and graphite (or
aluminium) becomes the other. The oxide or hydroxide precipitates in the pores adding colours
such as black, brown, blue, yellowish grey, and bronze to the film.

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Dyeing
Dyeing is the other popular method of adding colour to an anodised aluminium product. The pores
that are formed during the electrochemical process readily absorb dies or pigments. They fill the
pores through the entire thickness of the aluminium oxide layer. Since the thickness of this layer
can be up to 50 microns in some cases, this method is quite durable. Scratching or rough usage of
the part doesn’t affect the colour due to the layer’s thickness. Also, the range of available colours is
wide.

Sealing
Sealing is the final step in the aluminium anodising process. This prevents water leakage and
improves corrosion resistance of the anodised aluminium product. There are three methods of
doing this hot method, cold or a combination of the two.
Sealing reduces the chances of staining, scratching, colour degradation and crazing of the surface.

Types of Anodizing
Based on the thickness of the aluminium hydroxide layer, there are 2 types of anodising.
1.Decorative anodizing
Decorative anodising, as the name implies, has its focus on providing a nice aesthetic finish first
and providing protection as more of a nice extra. For decorative anodising, the recommended layer
is between 5µm to 25µm. To get the best result when dyeing the parts, its best to keep the
thickness between 15µm to 25 µm. ISO 7599:2018 specifies the method for decorative anodising
for aluminium and its alloys.
2.Hard anodizing
In cases where we need superior protection of aluminium alloys (marine applications or exposure
to corrosive chemicals), we recommend opting for hard anodising. The thickness of the oxidation
coating must be between 25µm and 50µm. ISO 10074:2017 provides the specifications for hard
anodic oxidation coatings.

Final Finish
Anodising gives the aluminium surface a superior appearance. As we know that the surface
consists of the pores with pigments as well as the uncoloured portions where the surface reacted
with oxygen to prevent further oxidation. As the light strikes both these surface features at the
same time, it interferes on reflection, giving the metal an attractive metallic shine.
The surface also has very few imperfections as it reacts uniformly with the electrolyte giving it a
smooth finish.

Automation
Automating the process line provides the most reliable results for the anodizing process. All
parameters can be monitored and computer-controlled, eliminating human error. 

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Rectifiers can be automatically set using part information stored in a database, and process
control information can be saved to files for generating reports showing process times,
operating conditions of each process, system alarms, etc. Statistical process-control analysis
can be included to monitor and analyze data to improve product and process quality.

The control system can make chemical additions, log amp-hours, and signal maintenance
routines. Touchscreen terminals allow easy operator access to process information, set-
points and load status. Loads can be processed by a fixed timeway cycle, running the same
process repeatedly, or by a random loading cycle, which runs an unlimited product mix.
Fixed timeway operation provides maximum machine throughput, while random loading
provides maximum flexibility.

6.Barrier Layer
When aluminium is anodised in an acidic solution, its surface starts to lose aluminium ions. This
causes erosion of the aluminium surface and to counter this, the surface reacts with negatively
charged oxygen ions in the electrolyte. While the points where the initial erosion takes place
continues to be eroded, the rest of the surface forms an aluminium oxide layer that acts as a
barrier against further erosion. This layer is known as the barrier layer. It is quite thin compared to
the porous layer formed due to anodising.

7.Anodized Aluminium Benefits

 The aim of the process is to increase the thickness of aluminium oxide on the surface of the
product.
 Aluminium oxide layer is extremely hard. On the Mohr’s scale, it has a score of 9 and is
second in hardness only to diamond. It is so hard that it is commonly used as an abrasive in
sandpapers. Depositing a layer of this material on the product ensures that the product will
have high wear resistance.
 The thickness of this layer depends on the purpose of anodising. For decorative purposes, a
thin layer is enough. A thicker layer protects the surface besides improving the appearance.
 Having a thick layer of aluminium oxide also makes the metal surface more receptive to
dying as pores are created on the surface when it is anodised. Then, desired pigments are
introduced that fill the pores from the surface to its very depth. This makes the pigment
quite durable as it cannot be scratched away.
 Anodising can also act as an excellent primer for a regular coat of paint on the surface
instead of accommodating it into the actual oxide layer.
 Anodising aluminium improves the insulation properties of aluminium as aluminium oxide is
not a good conductor of electricity.

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References
 The Metallurgy of Anodizing Aluminum: Connecting Science to Practice, Book by Jude
Mary Runge.
 Anodizing and Coloring of Aluminum Alloys, Book by Satoshi Kawai.
 Anodic Oxidation of Aluminium and Its Alloys, Book by V. F. Henley.
 Pfone.com

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