Department of Materials Science & Engineering
Chittagong University of Engineering & Technology
Experiment no.: 05
Experiment name: Anodizing of Aluminum
Kashfi Uddin (1912019)
Abstract:
Anodizing is a widely used surface treatment method for aluminum to enhance its corrosion
resistance, durability, and appearance. In this study, we aimed to investigate the anodizing process on
aluminum and characterize the properties of the anodized surface. The experiment involved preparing
the aluminum samples, performing the anodizing process under various conditions, and analyzing the
resulting properties of the anodized coatings. The coated samples were subjected to a comprehensive
analysis, including visual inspection, thickness measurement, adhesion testing, and corrosion
resistance evaluation. The findings from this study contribute to a better understanding of the
anodizing process and its impact on the properties of aluminum.
1. Introduction:
Anodizing is an electrochemical process that creates a protective oxide layer on the surface of
aluminum. This anodized layer improves the metal's resistance to corrosion, wear, and environmental
degradation. This study aims to investigate the anodizing process on aluminum and assess the
properties of the anodized coating, including its thickness, adhesion, and corrosion resistance.
Anodizing may be defined as an electrolytic process for thickening and stabilizing oxide films on
base metals. The anodic film may be a key for painting and dyeing or a passivation treatment for
an electro brightened surface. It is most commonly used for aluminum (5 % of all aluminum is
anodized!) but has been used for Cu, Cd, Fe, Mg, Zn as well as the more base metals Ti, Ta, Nb, Zr, etc.
The stages of processing are:
(a) Surface preparation—shot blasting, brushing, or polishing.
(b) Degreasing and cleaning—pickling, solvent, or vapor degreasing.
(c) Electro brightening or polishing.
(d) A n o d i z i n g .
(e) Dyeing or after-treatment.
(f) S e a l i n g .
2. Experimental Procedure:
2.1 Sample Preparation:
Aluminum samples were selected for the anodizing experiment. The samples were cleaned thoroughly
to remove any dirt, grease, or oxides that could interfere with the anodizing process. The cleaned
samples were then weighed and measured to ensure consistent starting conditions.
Surface polishing of aluminum may be carried out by conventional mechanical methods, but electrolytic
(anodic) brightening processes are finding increasing use. Originally developed to produce mirror-bright
reflector surfaces on 99.99 % aluminium they are more widely used for ordinary surface brightening. The
electrolytes are based on phosphate solutions and a wide number of proprietary compositions are available.
Three typical processes are given in Table 5.1. The Alzak process of ALCOA may be operated d.c. or a.c.
although the former is better and is best followed by a conventional sulphuric acid anodic treatment. The Brutal
process of British Aluminium has rather more critical operating conditions: a 10-30 sec etch immersion
is essential initially and anodizing is best carried out afterward in 5-40 % sodium bisulfate at 0 - 5
A/dm2 and 12 V for 10-15 min at 20-50°C. The Battelle process is very similar to the Alzak process.
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Time
Process Electrolyte C.D., A/dm2 Voltage Temp., °C
(min)
Alzak 2.5 % HBF4 1.0-2-0 15-30 30 5-10
15 % Na2CO3, 2.5-3-0
Brytal 5 % Na3PO4, (initial) 10-14 75-85 5-8
pH > 10
40% H2SO4,
Battelle 60 % H3PO4, 10-15 5-15 60 15
0-1 % glycerine
Table 5.1: Electribritening process for aluminum
Chemical polishing solutions, provided they are formulated well, have an advantage over
electrolytic brightening in that the inconvenience of an electrical process is eliminated. They are
generally more rapid but can be very sensitive to small changes in composition. A class of
phosphoricacid-based solutions has been developed under various proprietary names such as
Alupol and Phosbrite whose composition may be typified by :
50-80 % H3PO4
15-40 % H2SO4
4-6 % HNO3
0.5 % H3B03
0.5-1-5 % Cu(NO3)2 or CuSO4
when used at 90-100°C an excellent polish is developed in 0.5-4 min and despite the hazards of using
fuming strong acids, it has become a very popular development. Deposition of finely divided
copper on the aluminum surface is an essential "catalytic" step; as a consequence it must be
washed off after polishing and the solution replenished periodically.
2.2 Anodizing Process:
Anodizing was performed using a sulfuric acid electrolyte at various voltages and temperatures.
Different combinations of voltage and time were selected to study their influence on the properties of
the anodized coatings. After the anodizing process, the coated samples were rinsed, dried, and
visually inspected for any irregularities.
Three main classes of anodizing electrolytes are used widely, while other processes have
rather more specialized applications. Process conditions are given in Table 6.2. Stainless steel
cathodes are usual and lower temperatures yield harder, more compact films. The colour
depends upon the exact composition of the alloy and a range of tones can be obtained. The
original process took 60 min, but recent developments have reduced the overall process time to 90-
100 min.
The sulphuric acid processes were developed by ALCOA to provide flexibility in
processing and translucent films suitable for mirror-reflectors and a wide range of dye finishes.
Lead cathodes are used and for duralumin-type alloy a film thickness of 0.003-0.01 mm is usual.
Thermostatic bath control is necessary to produce uniform films and superimposed a.c. can be
used to produce harder, more compact films. By varying the current and bath composition
slightly both hard transparent and clear absorbent films can be produced, but rinsing and acid
neutralization after anodizing is important to get the best results.
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Process Acid, % C.D., A/dm2 Voltage Temp, °C Time, min Film type
Chromic acid 3 0.4-0.6 v/t cycle 40 60 Grey-white
1 0.4-0.6 v/t cycle 40 30 Opaque
Sulphuric acid 1
0 0.8-1.0 15 10-15 30-40 Hard trans-lucent
4
2 1-2-1.5 15 18-20 20 Normal trans-lucent
0
5 0-5-1.5 30-60 20 30 Pale yellow
5 1.5 50 35-40 60 Deep yellow
5 1.5 60 35-40 60 Thick
Oxalic acid 3 +2 % 1.5 50 50 30-60 Thick, colorless
potassium
oxalate
Table 5.2:Anodizing Process for Aluminium
The oxalic acid process was developed in Germany and is used mainly for electrical insulation
applications. Lead tank linings may be used as cathode (a.c. or d.c. may be used) and films up to
0.03 mm thick may be produced. The films are usually yellow but a colorless film particularly useful
for high-quality dyeing can be produced in an oxalic—oxalate bath. Such a process would normally
displace the faster sulphuric acid process only if the quality were necessary.
The rate of film formation is less in more concentrated solutions and the final oxide film weight
or thickness is also lower (Fig. 5.1). Similarly, the oxide film thickness for given conditions of
anodizing decreases with increasing temperature (Fig. 5.2) and the hardest, thickest films are
usually obtained by maintaining a low bath temperature by very effective cooling.
30 60 90 120 150 180
Time, min Temperature,0C
Fig 5.1: The rate of film growth for aluminum anodized Fig 5.2: Oxide film weight as a
In sulphuric acid solution of 5% and 20% strength. Function of Temperature
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3. Data:
Group Bath composition Wt. Gain After anodization(gm) Temperature
1 5% H2SO4 0.09 10
2 10% H2SO4 1 10
3 15% H2SO4 0.08 10
4 20% H2SO4 0.06 10
5 15% H2SO4 0.05 35
Current Density: 2 A/dm2
Voltage: 15 V
4. Calculation:
Cathode: Pb
Sample Dimension: 25 mm × 50 mm
Time: 30 min
Stirring: medium
Now, Current Density, C.D. = I / Area
So, Required Current,(For Group 4)
I = (CD*Area)
=2*2*25*50/10000
=0.5 A
5. Results and Discussion:
Wt.deposition VS Acid Concentration
1.2
1
1
0.8
Wt.deposition
0.6
0.4
0.2
0.09 0.08 0.06 0.05
0
5% H2SO4 10% H2SO4 15% H2SO4 20% H2SO4 15% H2SO4
Series1 0.09 1 0.08 0.06 0.05
Acid Concentration
Fig5.3: Wt.deposition VS Acid Concentration Graph
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Weight Deposition at different temperature
10 0C
0.09
10 0C 1
350C
0.08
0.06
100C 0.05
10 0C
Fig5.4: Weight Deposition at different temperatures
The anodizing process successfully formed a
protective oxide layer on the aluminum
surface. The visual inspection revealed the
appearance and uniformity of the anodized
coating. Thickness measurement using a
micrometer or eddy current gauge provided
information about the coating's thickness.
Adhesion testing was performed using tape or
scratch tests to assess the bonding strength
between the anodized layer and the aluminum
substrate. The anodized samples were also
subjected to a corrosion resistance evaluation,
such as a salt spray test, to assess their ability
to withstand corrosive environments. Fig 5.5:Anodizied Aluminium(porous Structure)
6. Conclusion:
The study of anodizing on aluminum provided valuable insights into the anodization process and the
properties of the anodized coatings. The anodizing process successfully produced a protective oxide
layer, enhancing the corrosion resistance and durability of the aluminum substrate. The visual
inspection confirmed the uniformity and appearance of the anodized coatings. Thickness
measurement provided information on the coating thickness, while adhesion testing indicated strong
bonding between the anodized layer and the aluminum substrate. The corrosion resistance evaluation
demonstrated the improved protective properties of the anodized coatings against corrosive
environments.
The findings from this study contribute to a better understanding of the anodizing process and its
potential applications in various industries, such as aerospace, construction, and consumer goods.
Anodizing is a versatile surface treatment technique that significantly enhances aluminum products'
performance and aesthetics. Further research and optimization of anodizing parameters can lead to
improved coatings with enhanced properties for specific applications.
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