419751-DEC 2014

DECEMBER 2014 / VOLUME 79 / NO. 3

Sweet HomeAerospaceAlabama is the Heartland of Aerospace Coatings

Take our

TOP SHOP Benchmarking Survey

PFonline.com

All marks used are trademarks and/or registered trademarks of Henkel and its afliates in the U.S. and elsewhere.

= registered in the U.S. Patent and Trademark Ofce. 2014 Henkel Corporation. All rights reserved. 13436_A (9/14)

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Industrial Maintenance CleanersCall 1-800-562-8483

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COLUMNSCLINICS ASK THE EXPERTS

6 The Finishing Touch Become an industry Top Shop.

8 News Aerospace companies attend ecoat primer seminar.

14 NASF Report OSHA says workplace exposure limits are unsafe.

42 Never Finished A good ground starts at the top.

44 By The Numbers October Index at 53.0fastest growth since June.

48 End of the Line A conversation with Asterion's Blair Vandivier.

16 New Life for Alabama Aerospace FinisherA shuttered coating plant has found new life in Alabama, where

there is a whos who of industry names among the 300 aerospace

and defense companies located in the state, including Airbus,

Sikorsky, Lockheed Martin, Bell Helicopter, Boeing, Northrop

Grumman, GE Aviation, Airbus Military, GKN, General Dynamics, BAE

Systems, Goodrich, Teledyne Brown, Pratt & Whitney and Raytheon.

30 Painting / William H. Goughenour Jr Painting nickel-plated parts; matching color.

32 Plating / Arthur S. Kushner Pitting in acid zinc plating; blisters and nickel plating.

34 Powder Coating / Rodger Talbert Temperature tolerance of chrome pretreatment.

36 Electrocoating / Jose A. Tirado Anode membranes; rust on zinc substrate.

16

22

25

38 NEW PRODUCTS HEPA efficiency in a three-stage aerospace

filtration system.

22 Batch System vs. Automated Line Tips on how to choose the right powder coating system.

25 Abrasive Control Factors for Mass Finishing Systems Gravity and weight are the most important elements affecting speed and time.

6 Take Our Top Shops Benchmarking Survey Read about PF's new Top Shops initiative in Editor Tim

Pennington's column on p. 6, then visit pfonline.com

to see how your company stacks upand potentially

earn the distinction for your shop!

2 DECEMBER 2014 pfonline.com

AEROSPACE

CONTENTSVOLUME 79 / NO. 3 / DECEMBER 2014EMPHASIS

PRODUCTS FINISHING

Aerospace Paint Shattering and Filtration Implications

During research and development of a new aerospace 3-stage paint fltration system, the HEPA-XFP, James Dralle of A.J. Dralle, Inc. made a breakthrough discovery low viscosity paint fractured during paint booth exhaust fltration. Chromate and other hazardous air pollutants (HAPs) shattered into particles small enough to escape standard fltration systems. Dralles fndings highlight a critical discrepancy between test agents and actual paint used during aerospace coating.

During development of the HEPA-XFP, Dralle began testing commonly used low viscosity paints on the top 3-stage fltrations systems. He discovered the paint shatter by counting the number of paint particles entering the system and comparing that amount to the number of particles exiting the system. The number of particles exiting the systems were smaller and more numerous than those entering. Somewhere in the 3-stage system, the paint was fracturing, or shattering. Depending on the paint manufacturer and paint formulation, the number of shattered particles also greatly varied, though consistently in excess of what is acceptable for test agent standards. Additionally, various manufacturers 3-stage systems test performance on the same paint varied dramatically.

Dralles research may be one of the most important developments in the aerospace painting industry. While discovering this faw in currently used 3-stage flter systems, he also developed a solution: HEPA effciency in a 3-stage paint fltration system.

For more than 3 years, Dralle worked on the innovative HEPA-XFP, securing the patent in July of 2014. This state-of-the-art fltration system is 99.98% effcient on feld tested low-viscosity paint; 99.986% effcient on neutralized KCL, on similar particle sizes; 99.979% effcient on feld tested high-viscosity paint; and 99.979% effcient on oleic acid, on similar particle sizes. This is accomplished by using HEPA media in the system, achieving HEPA fltration levels on paint arrestance and fractional

effciency, NESHAP Method 319 and ASHRAE 52.2 testing, with low pressure drop and high paint holding capacity.

Dralles HEPA-XFP fts into standard 3-stage fltration framework. There are no modifcations or HEPA framework needed. This allows the facility to meet HEPA standards, while decreasing all costs associated with HEPA required paint booths, including: construction, upgrading, monitoring, flter replacement, maintenance and disposal.

The HEPA-XFP is impressive. As a research-driven innovation, the HEPA-XFP uncovers and meets both the present and future needs of the aerospace painting industry. The industry will greatly beneft from Dralles testing methods and product development. And all facilities who use the HEPA-XFP should expect to have more effcient, environmentally friendly and compliant operations. If interested in learning more, contact Jim Dralle at 815-730-0505. All tests were performed at LMS Technologies, Inc. in Bloomington, Minnesota.

HEPA-XFP

6-Pocket Bag Filter for Aerospace Manufacturing and Reworking Facilities

1830 W. Mound Rd., Joliet, IL 60436www.ajdralle.net

Toll Free: 800-325-5339Phone: 815-730-0505

n Fits into standard 3-stage fltration framework. No modifcations or HEPA framework needed.

n 3rd and HEPA stage fltration combine into one flter with a low initial pressure drop.

n Decreases all costs associated with HEPA required paint booths, including: construction, upgrading, monitoring, flter replacement, maintenance and disposal.

ADVERTISEMENT

Publisher Todd Luciano

[email protected]

Regional Vice President Scott Walker

[email protected]

Editor Tim Pennington

[email protected]

Sr. Managing Editor Kate Hand

[email protected]

Assistant Editor El McKenzie

[email protected]

Contributing Editor Dr. Jim Lindsay

NASF Technical Editor

Art Director Aimee M. Reilly

[email protected]

Advertising Production Manager Dianne Hight

[email protected]

MarketingManager JessicaJefries

[email protected]

6915 Valley Avenue Cincinnati OH 45244-3029Ph 513-527-8800 Fax 513-527-8801 gardnerweb.com

Products Finishing is published by

MEMBER OF

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The information presented in this edition of Products Finishing is believed to be accurate. In applying recommendations,

however, you should exercise care and normal precautions to prevent personal injury and damage to facilities or

products. In no case can the authors or the publisher accept responsibility for personal injury or damages which may

occur in working with methods and/or materials presented herein, nor can the publisher assume responsibility for the

validity of claims or performance of items appearing in editorial presentations or advertisements in this publication.

Contactinformationisprovidedtoenableinterestedpartiestoconductfurtherinquiryintospecifcproductsorservices.

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P A R T S C L E A N I N G E X P O

April 2123, 2015 @ PMTS

Greater Columbus Convention Center

Columbus, OH USA

Where Cleaning Meets Machining

The Precision Machining Technology Show (PMTS) is all about machining high-volume,

precision parts parts that need cleaning. The Parts Cleaning Pavilion, co-located with PMTS,

offers attendees the opportunity to see new cleaning products, technologies and services on

the PMTS show foor , plus provides more educational and network opportunities to help

you do your job better.

pmts.com

PRESENTED BY: CO-PRESENTED BY:

Education Join us at PCx for 2 days of conference

sessions where well provide quality technical

information to improve your cleaning

processes and effciencies.

Networking Nothing takes the place of face-to-face

interaction, and theres no better place to

make connections in the cleaning

market than at PCx.

CO-LOCATED WITH:

R EG I S T E R E A R LY& SAV E !

Ph

oto

So

urc

es:

(to

p)

Mic

roC

are

Co

rp.

(bo

tto

m)

Th

inks

toc

k.

Early-Bird Deadline: March 23, 2015 REGISTER AT PMTS.COM

Go to pfonline.com to take

the survey. Have some of

your fnancial data available,

and it should take no more

than 20 minutes to complete.

Getting a copy of the industry

benchmarking survey will

probably make it the best 20

minutes youve spent all year.

Become an Industry Top ShopNew benchmarking survey will recognize best electroplating shops.


Does your shop have what it takes to be the best of the best?

If so, Products Finishing magazine is searching for the

best-run and most customer-driven electroplating and

anodizing operations to give them an award of distinction:

the title Top Shop.

Years ago, Products Finishing surveyed the largest

finishing shops in the U.S. to gather general data on the

status of the industry.

This time around, we are looking to determine which are

the best shops in the country, and we want to recognize them.

We estimate that about 20 percent of the survey respon-

dents will make the cut as a Products Finishing Top Shop.

It wont be easy to make the grade, but we already know

there are lots of electroplating shops out thereincluding

possibly yoursthat have everything it takes to land in the

top 20 percent and become a Top Shop.

What do we want to know?The comprehensive 40-question benchmarking survey is

broken into four categories:

Current Finishing Technology

Finishing Practices and Performances

Business Strategies and Performances

Training and Human Resources

For the Current Finishing Technology category, we want

to know what certifications your finishing shop currently

holds and what approvals you have received. We also want

to know which types of finishing operations your shop

offers. In addition, we want to know what type of testing

and lab work your shop performs for customers.

In the Finishing

Practices and

Performances

category, our ques-

tions center around

which practices

and improvement

methodologies your

operation uses, and

how you rank in order

of lead times, scrap/

rework percentages

and other customer-

oriented operations.

For the Business Strategies and Performances category,

we want to know about current supply chain practices your

shop uses and your annual sales growth rate.

Great finishing shops stand out in terms of how they treat

their employees, so the last category asks about the human

resource practices and

programs your shop uses

and the formal training

each full-time employee

receives annually.

What does a shop like yours get out of this?First, we want to recog-

nize all those shops that

meet certain criteria.

We wont give away

our entire benchmark

scoring methods, but

well tell you that our

computer scoring system

was designed with input

from actual job shops like yours. Those shops that score in

the top echelon will receive the Top Shop distinction in our

magazine and on pfonline.com. Well send these shops some

graphics to put on their websites, sales literature and esti-

mating forms.

Second, after you complete the survey well send you a

complete copy of the benchmarking report so that you can

compare your shops overall performance with other shops

in the finishing industry. Its a great way to see how you

measure up to the industrys best; use it as an improvement

tool inside your company.

In addition, several shops will be selected for special

profiles in an upcoming issue of Products Finishing magazine

to highlight the best business practices in the four catego-

ries. We want to share with everyone how the best-run shops

do it, and how you can do it too.

How do you participate?You can go to pfonline.com to take the survey. Have some

of your financial data available, and it should take no more

than 20 minutes to complete. Getting a copy of the industry

benchmarking survey will probably make it the best 20

minutes youve spent all year.

The deadline for the benchmarking survey is January 1,

2015. And dont worry if you have a powder coating and

painting operation; we will have a separate benchmarking

survey ready for those operations in mid-2015.

Do you think you work at a Top Shop? Prove it to yourself,

your employees and the entire industry at pfonline.com. If

you dont think you are there yet, take the survey and find

out where you stand.

THE FINISHING TOUCH

TIM PENNINGTON / EDITOR

[email protected]

ZERO hexavalent chromium

Meets automotive decorative plating specifications

Compatible with trivalent chromium decorative platingsystem

Suitable for all traditional plating grades of ABS andPC-ABS plastics

Excellent adhesion of the metal layers

Chromium-FreePretreatment of Plastics

So you want to chromium plate without the use

of chromium trioxide? MacDermid has rewritten

the rules with evolve, a hexavalent chromium-free

pretreatment process for Plating On Plastics.

At the heart of this pretreatment system is the evolve

etching solution. Designed for use on ABS and PC-ABS

substrates, it serves as a direct replacement for the

traditional chemical etching system.

New Technology

MacDermid began R&D programs some 5 years ago to

find and eliminate chromium trioxide for the etching of

plastics prior to metallization. In 2013 we began our first

industrial production trial at a major POP applicator in

Europe.

Key Features

Plating On Plastic Etch Process

For more information please contact:

245 Freight Street,Waterbury, CT 06702Phone: +1 203.575.5719

[email protected]

www.macdermid.com/industrial

MacuPlex evolve has virtually the same process footprint as the conventional etching process. It incorporates

a conditioning step that increases etching speed and enables a variety of plastics to be processed using similar

process conditions. Etching time is also very similar to standard chromium trioxide solutions and is adjusted based

on the plastic resin and injection molding characterizations.

In addition to extensive development of the new etch and surface conditioning steps, the avoidance of rack

plating was a high priority during the new process research program. This has been accomplished with a two stage

inhibition system. First, a new in-line chemical inhibitor has been developed for existing rack coatings which offers

short term protection. Secondly, a new pre-inhibited PVC rack coating can be applied when the rack undergoes its

periodic renovation.


NEWS

Aerospace Companies Attend Electrocoat Primer Seminar

European aerospace coatings customers of PPG Industries heard

the companys technical experts discuss the benefts of its elec-

trocoat primer and shared their experiences at a seminar in Marly,

France. Representatives from leading aerospace companies

also witnessed operation of a pilot ecoat system at PPGs Marly

coatings research center and an automotive production tank.

The two-day event supported PPGs continuing eforts to

educate customers about the environmental, productivity,

application and performance benefts of Aerocron electrocoat

primer technology for the aerospace industry, according to Daniel

Bencun, PPG coatings segment manager for Europe, the Middle

East and Africa.

Aerospace customers see large potential for PPG electro-

coat technology for tier-one suppliers and directly with OEMs,

Bencun says. They see it as eco-friendly and as a replacement

for chromated primers while enhancing corrosion resistance and

providing nearly 100-percent utilization.

In the electrocoating process, metal aircraf parts are dipped

into an electrically charged tank of Aerocron primer. Historically

sprayed onto metal parts, primer afords corrosion resistance

and enhances topcoat adhesion. The water-based, chromate-free

electrocoat primer produces near-zero waste, and the application

process can be fully automated.

Customers in various stages of electrocoat process implemen-

tation shared their frsthand accounts at the seminar, Bencun

says. The technical director of a parts coater operating a pilot

tank described the primer benefts, especially process eficiency

and environmental aspects. Results of tests done on the primer

as a chromate-free technology alternative were discussed by the

representative of an aerospace systems supplier. Two aerospace

company oficials talked about the companys potential fnancial

investment in the process as well as product performance.

Robin Pefer, PPG research associate at the companys Coatings

Innovation Center in Allison Park, Pennsylvania, described PPGs

work to adapt ecoat technology for aerospace use, including appli-

cation at lower bake temperatures and being able to withstand the

rapidly changing environment during fight.

Bencun told attendees that they have the ability to drive change

within the aerospace industry.

I ask our customers to be part of the adventure as game

changers and drivers of this new technology, he says.

PPG says it plans to hold similar seminars in other regions.

Information for this article provided by PPG. For more

information, visit ppg.com.

Benchmarking Survey Will Recognize Electroplating Top ShopsProducts Finishing magazine is launching a massive, industry-

wide survey and benchmarking program to determine which

electroplating shops meet the highest qualifcations and

processing standards.

The Products Finishing Top Shops program is currently surveying

all electroplating and anodizing operations to determine which

operations will receive the distinction of being recognized

as one of the best fnishing shops in the U.S.

The survey can be completed online by visiting pfonline.

com. A similar survey will be conducted in mid-2015 for

all powder coating and painting shops. The deadline for

completing the survey is Jan. 1, 2015.

The 40-question benchmarking survey is divided into four

categories:

Current Finishing Technology

Finishing Practices and Performances

Business Strategies and Performances

Training and Human Resources

Several questions in each category will be used to score

each shop based on its answers. The answers provided will

be kept in strict confdence and individual scores will not be

reported. However, the top tier operations will be recognized

as Top Shops in comparison to industry averages and their

results will be published.

Every shop that takes the survey will receive a copy of

the benchmarking report to

compare its overall

performance with

other shops in the

fnishing industry.

Several shops will

be selected for

special profles in

an upcoming issue

of Products Finishing

magazine.

PRODUCTS FINISHING pfonline.com 9

NEWS

Historically sprayed onto metal parts, primer affords cor-

rosion resistance and enhances topcoat adhesion. In the

electrocoating process, metal aircraft parts are dipped into

an electrically charged tank.

Axalta Coating Systems Breaks Ground on Houston Paint/Powder Training Facility; Celebrates 50 Years in Powder CoatingsAxalta Coating Systems recently broke ground on a unique training

facility in northwest Houston on the property of its powder manu-

facturing site.

This new facility will have two distinct training sections. The frst

will support Axaltas Automotive Refnish customers. The other

section is designed to train and support powder coating customers

such as industrial OEMs, job coaters and those from architectural,

agricultural and construction equipment industries. This facility

will be the ninth Axalta training facility in the U.S. It will be the frst

training center that also educates powder coaters.

In other news from the company, Axalta Coating Systems

celebrates 50 years of commercially produced latest generation

powder coatings, making it one of the oldest powder coating

manufacturers in the world.

Axalta got its start in commer-

cial powder coatings in 1964

with the acquisition of the

Teodur brand that had been

manufactured by Wagemakers

Lekbrieken, a Dutch family-

owned paint company founded

in 1848 that sold its frst archi-

tectural grade thermosetting

powder at its site in Teodur.

This facility will be

the ninth Axalta

training facility in

the U.S. It will be the

frst training center

that also educates

powder coaters.

Axaltas powder capabilities continue to grow. Earlier

this year, Axalta announced investments to expand produc-

tion in two locations in China. Also in China, Axalta received

Qualicoat Class 2 certifcation for the production of Alesta

Super Durable (SD) powder coating at its joint venture

manufacturing facility in Donguan. Earlier in October, Axalta

announced the expansion of its global product portfolio

to include Alesta ZeroZinc, the next generation of zinc

free anticorrosion primers. For more information, visit

axaltacoatingsystems.com.


NEWS

Cincinnati-based DuBois Chemicals Inc. has completed the

acquisition of American Finishing Resources in Chilton, WI.

The acquisition combines DuBois paint pretreatment exper-

tise with AFRs coating line fixtures, material handling and

coating removal solutions to reduce total cost and provide

quality improvements for customers.

The AFR acquisition will expand the service, chemical

solutions and lean manufacturing capabilities that DuBois

and AFR currently provide to customers.

AFR services premier U.S. manufacturers in the

transportation, agricultural, consumer products, appliance,

telecommunications, lawn and garden and surface finishing

industries, says Jeff Welsh, CEO of DuBois Chemicals. With

the talents, products and services of AFR, DuBois is uniquely

positioned as having the most comprehensive manufacturing

and paint line offering of any competitor in the market.

The addition of AFR to the DuBois portfolio expands both

organizations' ability to assist customers in increasing paint

line transfer efficiency and throughput.

"We are so very pleased to join the DuBois team, Matt

Kirchner, President of AFR, says. If

anything, our service levels will be

even stronger as 125 DuBois sales and

technical representatives across North

America collaborate and partner with

the AFR team to effectively respond

to the needs of our customers and

deliver additional value."

Founded in 1920, DuBois manufac-

tures specialty chemical solutions.

DuBois has substantially increased its

position in metalworking fluids and

surface treatment recently through

the acquisition of Perkins Products,

Galaxy Associates and Angler

Industries. The company is committed

to creating innovative, sustainable

products including Pearl-Z biocide-

free metalworking fluids and PACRE

heavy metal- and phosphate-free

surface treatment, which reduce the

total cost of ownership for customers

and improve working conditions.

DuBois specializes in the areas of

metal finishing/paint pretreatment,

metalworking/lubricants, water/

wastewater treatment, maintenance/

equipment cleaning, paper chemicals,

food processing cleaning/sanitizing,

and transportation cleaning.

For more information, please visit

duboischemicals.com.

DuBois Chemicals Acquires American Finishing Resources

You should. Custom designed and engineered paint racks and hooks from PPC Magic

Rack not only ensure defect-free finishes; they also make optimum use of rack space

for maximum parts density and improved productivity.

Plus:

Unique patented Magic Rack technology protects electrical connecting points from

paint build-up to reduce maintenance andreplacement costs.

25 years of experience in custom solutions ensures your Magic Rack andhooks are

designed and built to respond to the size, shape and weight of your specific parts.

Custom hooks are designed to control parts, maintain ground, drain liquids

and eliminate blemishes.

Racks are reusable over many production cycles.

Standard, in-stock Magic Racks and hooks are

always available for fast ship.

RACKING UP SOLUTIONS.

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The addition of AFR to the

DuBois portfolio expands

both organizations ability

to assist customers in

increasing paint line

transfer eficiency and

throughput.


NEWS

Celebrating 30 years of excellence in the United States of America

To find out more and to schedule a presentation, contact your TIGER Sales Manager.

Anodized Effect Powder Coatings

A novel polyester Super Durable AAMA 2604-compliant color selection.

Ideal for architectural applications, architectural lighting, railings, window and door frames,

metal constructions, automotive accessories, patio and garden furniture.

Transform your blueprints into environmentally friendly formations.

[email protected] | [email protected] | T 1-800-243-8148 | F 877-926-8148

A BETTER FINISH. FOR A BETTER WORLD.

Florida Finishers Mid-Winter Surface Finishing Conference to Be Held Jan. 28-29The ffh annual Mid-Winter Surface

Finishing Conference and Exposition, spon-

sored by the Florida Finishers Corp., will be

held January 28-29 in Orlando, Florida.

The event will be themed Yesterday,

Today and Tomorrow in Metal Finishing,

and will feature speakers and presenta-

tions on Wednesday and Thursday of that

week, followed by an optional golf outing

on Friday. The event will be at the Hilton

Double Tree Resort at Sea World.

This year, Lockheed Martin is ofering

two tour opportunities. The Missiles and

Fire Control tour will involve a tour of the

fre control factory, the machine opera-

tions center and the companys museum.

The estimated time for this tour is two and

a half hours.

The Mission Systems and Training

tour will include a brief presentation by a

program manager regarding the impact

of the plating industry on MSTs products

and services, a tour of the machining areas

at MST and a tour of the new demo center

showcasing the latest technologies and

simulators. The organizers are trying to

add an opportunity for team members to

use a fight simulator. The estimated time

for this tour is four hours.

To register for the event, visit forida fnisherscorp.com. For information,

contact Dave Roach at 407-291-1023.

Attendees to the Mid-Winter Surface

Finishing Conference and Exposition

can tour Lockheed Martins Mission

Systems and Training facility.


FINISHING INDUSTRY

ON THE MOVE

NEWS

Pavco welcomes the addition of Wesley Schmitt to its growing

technical service team. Schmitts direct feld experience in both

steel manufacturing and numerous metal fnishing processes

will aid current Pavco customers both domestically and

internationally.

Senior VP of Regional Procurement Christopher Toomey has

assumed responsibility for the BASF Coatings business in North

America. He succeeds Senior VP Juan Carlos Ordoez, who

will move to lead the BASF Performance Materials division in

Wyandotte, Michigan.

PPG Industries is acquiring Consorcio Comex, an architectural

and industrial coatings company with headquarters in Mexico

City. In other news, PPG Industries coil and building products

group received three 2014 Chairmans Awards from the Metal

Construction Association at Metalcon for its involvement with

three community development projects.

Deimco Finishing Equipment held a ceremony for a new 10,800

square-foot addition to its current facility.

Bjrn Dingwerth will lead Enthone's global business and

product development teams to the ensure voices of the

customers are well-understood and incorporated into the

company's CRC product portfolio.

Haviland Enterprises has named Brett Calvin as the companys

new COO. Upon joining Haviland in May of 2014, Calvin has

served as joint COO with Wayne Thornton, who is retiring.

In other news, Haviland received recognition as it celebrated its

80th anniversary as one of the largest employee-owned chemical

distribution companies in the U.S.named as a 2014 winner of

The Principal 10 Best Companies for Employee Financial Security.

MacDermid held a Plating-on-Plastic Summit this fall at the

Chrysler Museum in Auburn Hills, Michigan, where attendees were

updated on advancements in POP technology, including a new UV

lacquer process, advances in double shot molding and a qualifcation

process for decorative fashion fnishes.

The MFASC presented its Lifetime Achievement Award to Bill

Wiggins, owner of Automation Plating Corp. and former mayor

of Burbank, California. Hosted by the MFASC and MFANC, this is the

seventh year the two California chapters have held their annual

fall outing.

A supplier of precision engineering products and services, Nasmyth

Group purchased California-based Technical Metal Finishing (TMF)

to create Nasmyth TMF. These processes complement those ofered

by Nasmyth Groups four metal surface fnishing businesses in the

UK providing precise, aerospace industry and Nadcap-approved

treatments for metals.

Parker Trutec recently implemented divisional structure changes

impacting the organizational alignment of their North American

operations. Facilities in Sevierville, Tennessee and Paragould,

Arkansas will become the responsibility of William Moore. Facilities

in Springfeld and Urbana, Ohio will become the responsibility of

Joseph Gummel. The Mexican company, Parker Trutec Mexicana

S.A. de C.V., which began operations in 2009, is in the process of

adding a second location in the state of Guanajuato.

The Q-Lab Corp.s laboratories in Homestead, Florida, and

Saarbrucken, Germany now ofer contract-testing services for

automotive corrosion tests requiring relative humidity control. The

labs also include multiple QUV weathering, Q-SUN xenon arc, and

standard salt spray and cyclic Q-FOG corrosion test chambers. Color,

gloss and other expert visual evaluation services are also available.

Afer a management buyout, Stefan Nettesheim and Klaus Forster

took over Reinhausen Plasma GmbH, which included all assets and

patents. The company is renamed relyon plasma GmbH.

Reliable Plating Works/Elite Finishing has selected Roberto

Berto Flores as its new planner and scheduler to meet customer

satisfaction needs and ensure all products are delivered on time.

Submission Deadline Approaches For 2015 Powder Coating Show Papers

The 2015 Powder Coating Show, held in Louisville, Kentucky,

May 6-7, 2015 will attract over 1,200 powder coating professionals

seeking networking and training opportunities for a variety of

powder coating-specifc topics. The paper deadline is December

12, with suggested topics including: intermediate to advanced

application, surface preparation, recovering, troubleshooting,

and benefts of using powder versus alternatives. To submit a

paper, simply complete an online form. Conference papers are

peer reviewed and will be published online as part of the Powder

Coating 2015 proceedings. Accepted technical sessions will be

announced by Jan. 9, 2015. Visit powdercoatingshow.com.

Enthone Receives European Patent For Plating-On-Plastics Chromium-Free Etches

Enthone was granted a European patent for chromium-free

etches for plastic substrates. It covers chemical processes for

the preparation, treatment and etching of plastic surfaces.

Current and emerging environmental regulations, such as

the European REACH chemical regulatory No. 1907/2006 will

have a signifcant impact on plating-on-plastics (POP) applica-

tors, including further restrictions of plating chemistries.

To ensure compliance with pending regulations, over

the last several years Enthone has developed technologies

specially formulated for POP substrates without making use of

chromium (VI) etches. For more information, visit enthone.com.

www.uyemura.com

Corporate Headquarters: Ontario, CA ph: (909) 466-5635 (800) 969-4842 fax: (909) 466-5177 Tech Center: Southington, CT ph: (860) 793-4011 (800) 243-3564 fax: (860) 793-4020

Antitarnish 616 PLUS is an organic antitarnish process based on

nanotechnology. Special nanopolymers absorb on the surface of silver, gold,

copper or tin, and crosslink to form an invisible, impervious layer

a few nanometers thick.

616 PLUS protects, and permanently preserves, metal brightness and luster.

It penetrates the grain structure, preventing oxidation of nickel or copper, so when

gold is applied at the low end of the specication, parts pass corrosion tests.

616 PLUS is proven to reduce gold costs 20-30%.

Antitarnish 616 PLUS has good sliding properties and solderability, and low

contact resistance. Its aqueous, moisture-resistant formula is chrome-free and

RoHS compliant; it is also hypoallergenic and stain repellent.

For more details, or to arrange test processing,

contact your Uyemura representative.

Antitarnish 616 PLUS was developed by Umicore Galvanotechnik and is available in North America exclusively from Uyemura.

Antitarnish 616 PLUS Permanently Preserves Silvers Brightness,

Seals Gold Porosity More Effectively

Than Alternatives

NASF TECHNICAL PAPER EDITED BY DR. JAMES LINDSAY, NASF TECHNICAL EDITOR

OSHA Says Workplace Exposure Limits

are Unsafe, Update Necessary

Agency issues request for informaton on chemical

management and Permissible Exposure Limits (PEL).

On October 10, OSHA issued a request for information on its overall

approach to managing chemicals and workplace exposures. The

agency is considering updating the Permissible Exposure Limits

(PELs) and identifying strategies to address workplace exposures

to potential harmful chemicals. OSHA is particularly interested in

possible modifcations to the existing approaches for chemical

management and potential new sources of data and alternate

approaches to minimize harmful workplace exposures.

OSHA has indicated that it believes that existing PELS are

outdated and not protective of workers health. In order to update

the limits, OSHA must meet several legal criteria:

They must substantially reduce a signifcant risk of

material harm.

Compliance with the new standard must be technically feasible.

Compliance with the standard must be economically feasible.

The standard must reduce risks of adverse health to workers to

the extent feasible.

The standard must be supported by substantial evidence in the

record consistent with prior OSHA practice (or supported with

justifcation for departing from the practice or policy).

In 1989, OSHA attempted a wholesale update of PELs in the Air

Contaminants Rule. The courts vacated the fnal Air Contaminants

Rule, in part because OSHA failed to meet the legal requirements

listed above. Since that time, OSHA has updated only a handful

of individual PELs in separate, highly resourceintensive

rulemakings.

As part of this request for information, OSHA is seeking informa-

tion to support a reconsideration of its approach to the current

rulemaking process for PELs. This efort entails a very comprehen-

sive approach to addressing chemical management and PELs to

protect workers health. Consistent with this approach, comments

on the request for information must be submitted by April 8, 2015.

NASF will continue working on this issue on behalf of the surface

fnishing industry. If you have any questions or would like addi-

tional information on this regulatory initiative, please contact

Jef Hannapel at [email protected].

Aluminum Surface Finishing Corrosion Causes and TroubleshootingBy W. John Fullen, Boeing Research and Technology, and Jennifer Deheck, Boeing

Aluminum corrosion is commonly encountered when performing

chemical process operations involving surface fnishing, predomi-

nantly in preparation for paint application. The protective oxide

flm of aluminum is only stable in a pH range of 4.5-8.5. However,

many process solutions intentionally exceed this pH range for

the purpose of cleaning, metal removal and subsequent smut

removal. These process solutions are formulated so as not to

cause deleterious pitting or preferential etching. However, the

susceptibility of aluminum to pitting depends on many extra-

neous factors, such as chloride ion concentration, pH control

and initial surface condition. Electrochemical measurements

via potentiodynamic scans have been shown to be an efective

tool in analyzing the propensity of certain process solutions to

contribute to observed pitting conditions.

In this paper, a review of several process solutions, examining

coolants, solvent cleaning, alkaline clean/etch and deoxidizing/

desmutting, listing intended and unintended chemical reac-

tions along with possible mechanisms that would favor

corrosion formation. Further explanation is provided for

the role of incoming water that is used for process solution

make-up and the myriad of rinse tanks. Recommendations

are provided for electrolytic processes that might be prone

to stray currents afecting auxiliary equipment and thereby

introducing deleterious contaminants into process solu-

tions as a result of the corrosion products of compromised

piping, fttings and fasteners from heating and cooling

units. Strict adherence to process specifcation controls,

regular monitoring of suspect contaminants, sound

housekeeping and part handling best practices can

alleviate many aluminum part processing corrosion

occurrences. The full paper can be accessed and printed

from short.pfonline.com/NASF14Dec1.


NASF REPORT


Upcoming NASF Events

Visit nasf.org for event details and registration.

Industrial & Precious Metals Finishing Web-Based CourseDecember 2, 3, 9, 10Cost: Member $615 / Non-member $800

Join us online for the Industrial & Precious Metals Plating

course, designed for operators, supervisors and sales-

people for job shops and captive shops performing a range

of surface fnishes on a variety of substrates. The goal of

this course is to provide students with a range of informa-

tion related to methods of preparing parts for precious

metals plating and to understand each precious metals

plating process, what can go wrong and how to solve plating

problems.

Register online, or contact Matt Martz at 352-445-7294 or

[email protected] for more information.

Annual Scholarship Competition Accepting ApplicationsTodays students are the future of surface technology, and

the annual NASF Scholarship Award Program is committed

to supporting their research eforts. If you know of a student

currently pursuing research in surface fnishing science or engi-

neering, encourage him or her to apply. Qualifed candidates must

be currently enrolled in a college or university and a junior or

higher in standing (graduate and international students are also

eligible). Applications are due December 9. For complete program

details, visit nasf.org/scholarships.

2015 Management Conference Chooses KeynoteNASF has announced an internationally recognized author and

trainer Daniel Feiman as the keynote speaker for the associations

2015 Management Conference. A highly sought after consultant and

author of three books, including his latest, THE Book on Business from

A to Z: The 260 Answers You Need to Know, Feiman has spent the past

37 years training top leaders and organizations in many industries,

including automotive, aerospace, consumer products, distribution

and manufacturing, among others. In addition to earning his MBA,

Feiman received the CMC designation from the Institute of Management

Consultants, which is awarded to the top 1 percent of management

consultants in the country.

To learn more about Feiman, visit builditbackwards.com.

The 2015 NASF Management Conference will be held February 15-19, in

Palm Springs, California. Reserved for industry executives and managers,

this annual event provides fve days of in-depth sessions focused on taking

your business to the next level. Participants enjoy an atmosphere neces-

sary for focused thinking that is productive and enjoyable, while promoting

collaboration of thought among some of the industrys most successful

and infuential companies. For complete details and registration, visit

nasfmanagementconference.com.

NASF Identifying Uses of Chemicals, as EPA Proposes Significant New Use Rule for Nonylphenols and Nonylphenol EthoxylatesOn October 1, EPA proposed a signifcant new use rule (SNUR) for 15

nonylphenol (NP) and nonylphenol ethoxylate (NPE) substances (79

Fed. Reg. 59186). For 13 of these substances, EPA is proposing that

any use is a signifcant new use, and for two of the substances EPA

is proposing that any use other than a use as an intermediate or

use as an epoxy cure catalyst is a signifcant new use.

If a use is designated a significant new use, then persons

subject to the SNUR would have to submit a pre-manufacture

notice to EPA at least 90 days prior to manufacturing, importing

or processing the chemical substances. The notification would

allow EPA to evaluate the use and prevent any risks from

potential exposures before any commercial activity with the

chemical occurs.

NPs are used as intermediates to produce NPEs, which are

used in some surface fnishing applications. Since the SNUR

would apply only to uses that are not ongoing as of October,

NASF is in the process of identifying any uses in the surface

fnishing industry so that they're not designated as signifcant

new uses. For more information, contact Jef Hannapel at

[email protected].

NASF Welcomes New MembersThe NASF welcomes these suppliers as its newest

members: Precious Metal Sales, ESPI, Caplugs and Viron.

NASF members generate a solid return on investment and

support essential programs designed to advance surface

engineering and technology, nationally and worldwide.

NASF has the strength, commitment and resources to

connect member companies and individuals, promote

their educational advancement, advocate for their best

interests and help them plan for the future. To learn

more about joining NASF, visit nasf.org.

NASF's Analysis: 2014 Midterm ElectionsWhat many predicted would be a marginal

Republican victory in the midterm elections

turned into a Republican rout across the country,

leaving President Obama and Democrats reeling.

Republicans handily took control of the Senate,

gained the largest Republican majority in the

House of Representatives since World War II, and

now control 31 state governorships.

Sweeping across geographies that Obama and

the Democrats won handily in 2012, Republicans

presented a unifed, conciliatory message that

they would move beyond the status quo to break

the gridlock that has dominated Washington.

And the voters response was clearit is indeed

time for a change.

To read the NASF's full post-election

analysis, visit short.pfonline.com/election.

BECOME A MEMBER AT NASF.ORG

Advanced Technical Finishing grows business with new certifcations.

New Life for Alabama Aerospace Finisher

BY TIM PENNINGTON EDITOR


AEROSPACEAEROSPACE

Helping to design, build and oversee a $10 million metal

finishing facility revitalization project isnt the most monu-

mental task Aaron Stinson has faced since he joined Advanced

Technical Finishing in Huntsville, Alabama, a few years back.

Rather, the integration of quality control measures and a

Nadcap certification programand more importantly, getting

the right employees on board to implement themhas been

his chief undertaking.

Without a doubt, getting the most qualified people in

here and getting them to buy into all the things we need to

be doing has been one of the biggest challenges weve faced,

ATF Vice President Stinson says. But its that important to

us, and so that it is the most crucial aspect of our plan for

success.

Such has been the challengeand successsince ATFs

parent company, Advanced Technical Aerospace, purchased

what was formerly J&A Finishing several years ago. It brought

the company out of distress with plans to make it one of the

top finishing shops in the U.S.

Three CompaniesAdvanced Technical Aerospace is a combination of three

complementary aerospace service companies:

Advanced Technical Finishing, which specializes in top-

quality customized treatments in the aerospace, medical,

transportation, military and defense industries,

Advanced Technical Avionics, which focuses on aircraft

structural and avionics maintenance and repair, custom

cable and wire harness assemblies, custom box builds

and electromechanical assemblies,

Advanced Cert Works, which provides solutions for

civil aircraft certification needs, including both Federal

Aviation Administration and international validation

assistance.

Improvements include a 70-ton, self-contained chiller

unit, a DI water system for process lines that include

large reserve tanks, and an automatic Controlstik II rinse

tank monitoring system that maintains optimal water

quality and provides water savings of up to 85 percent.


SWEET HOME FOR PLATING

ATF offers metal finishing services for aerospace, commer-

cial, and military/defense industries nationwide, with opera-

tions specializing in anodizing in Mil-a-8625 Types 1, 2, 3;

chemical conversion coat in Mil-dtl-5541 Type 1, 2; electro-

less nickel, zinc, phosphate (zinc and manganese), black

oxide, passivation, sand and glass bead blasting, non-destruc-

tive testing, and also paint and powder coating.

Its been a major step up from the J&A days, but that was

the reason Advanced Technical Aerospace purchased the

shop to begin with.

Even though the facility had been here for more than

30 years, it really was a mom-and-pop shop with mainly

a commercial clientele, Stinson says. But we knew

being right here in Huntsville, in the heart of the defense

industry and all the arsenals, that we had to get Nadcap

and other certifications because almost all the primes are

requiring that.

Whos Who of AerospaceIndeed, the Alabama area, especially around Huntsville, is a

whos who of industry names among the 300 aerospace and

defense companies in Alabama, including Airbus, Sikorsky,

Lockheed Martin, Bell Helicopter, Boeing, Northrop

Grumman, GE Aviation, Airbus Military, GKN, General

Dynamics, BAE Systems, Goodrich, Teledyne Brown, Pratt &

Whitney and Raytheon.

The nearby Redstone Arsenal does work for almost

all major programs, including the U.S. Army Materiel

Command, U.S. Army Space and Missile

Defense Command, Marshall Space

Flight Center, the Missile Defense

Agency, U.S. Army Aviation and

Missile Command, two Program

Executive Offices and the Defense

Intelligence Agency.

Thats why ATF began painstaking

accreditation processes when it took

over the plant, including going after

the Nadcap certification, which it

received this past May.

Its an extensive process,

but it is what we had to do in

order to get the customers and

the businesses we wanted to

work with, Stinson says. And

now that weve gone through

the chemical process side

of Nadcap, we want to get

certified in all of our areas,

especially in non-destructive

testing.

On the physical side of the

operation, ATF is adding

16,000 square feet to the

shop to help speed its processes and decrease turnaround

times to meet customer demand for tight-tolerance, mission-

critical work, says David Clarke, CFO at Advanced Technical

Aerospace.

The project included upgrading the companys existing

anodizing lines to allow for increased capacity on Type I, II

and III coatings, as well as installing new electroless nickel

lines, a titanium Type II and III finishing line and a new, larger

zinc processing line.

Hit the Ground RunningWe purchased the shop to build a world-class aerospace

plating and finishing facility, Clarke says. It was important

to us to hit the ground running and start to build a real solid

foundation for the business and establish a baseline for the

industry.

Along with building the new addition, ATF also renovated

its 3,000-square-foot painting facility with BR127 capabili-

ties with large sandblasting booths, new temperature- and

humidity-controlled paint booths; walk-in curing ovens for

paint and powder coating, a 70-ton self-contained chiller unit,

a DI water system for process lines that includes large reserve

tanks, and an automatic Controlstik II rinse tank monitoring

Alabamas aerospace sector employs 83,000 people at more

than 400 companies. With the Airbus A320 family assembly line

under construction in Mobile, optimism is high that the sector

is ripe for expansion.

We are working hard to attract elements of the Airbus

supply chain to Alabama while also increasing aerospace

research and engineering activities that take place here,

Alabama Secretary of Commerce Greg Canfeld says. Our goal

is to create more high-paying aerospace jobs and to spur more

product development in the state.

Airbus and Boeing are ferce competitors in the marketplace,

but they have found common ground in Alabama, where both

have substantial operations.

The Boeing Co. employs more than 2,600 people in

Huntsville and is adding another 300-400 there to establish a

technical research center. The company has been in Huntsville

for more than 50 years, assisting NASA and playing a major role

in the nations space program.

As for Airbus, before it began building its A320 family

Final Assembly Line at Mobile Aeroplex in 2013, it already

operated an engineering center there, with more than 220

employees performing work on A350 XWB and A380 aircraf.

In addition, Airbus North American military aircraf unit has

a maintenance, repair and overhaul (MRO) facility at Mobile

Regional Airport.

Aerospace Finds a Home in AlabamaBut Airbus and Boeing arent the only big-

name aerospace names operating in Alabama:

GE Aviation has a plant in Auburn that

produces high-pressure turbine airfoils used in

the companys advanced jet engines.

Lockheed Martin is adding an annex to

produce cruise missiles at its Pike County plant,

where the Joint Air-to-Surface Standof Missile is

made. Lockheed Martin also makes unmanned

aerial systems in Huntsville.

Raytheon is expanding a futuristic factory in Huntsville

where SM-3 and SM-6 missiles are assembled.

Other major players with a presence in the state include

Northrop Grumman, GKN Aerospace, UTC Aerospace

Systems, ST Aerospace and Sikorsky.

Alabama also is a hotbed of helicopter-related activity.

We have a robust rotorcraf presence in Alabama. Fort Rucker

is the largest helicopter training center in the world, and there

is obviously a large nucleus of maintenance techs to support

the training craf feet, says Bob Smith, the Department of

Commerces assistant director of business development and

point man on aerospace.

Fort Rucker, near Ozark, has been the training center for

U.S. Army helicopter pilots since 1955. In addition, the U.S.

Armys helicopter command is located at Redstone Arsenal in

Huntsville. Bell Helicopter has worked with Northrop Grumman

on an unmanned helicopter program at Bells facility in Ozark.

(Bell also has a research center in Huntsville that focuses on

unmanned aerial vehicles.)

Plus, Sikorsky has a manufacturing and assembly operation

in Troy and a research and engineering center in Huntsville.

Alabama Aircraf Support plans to open a MRO facility for

helicopters in Enterprise, while Vector Aerospace last year

announced plans to expand its helicopter overhaul facility in

Andalusia. Source: Alabama Power and Alabama Department of Commerce


AEROSPACEAEROSPACE

system that maintains optimal water quality and provides

water savings of up to 85 percent.

We had a strategic plan for how we wanted to renovate

and expand, so we took things one step at a time and made

sure to walk before we ran, Clarke says. It was a matter

of getting existing systems refurbished, getting things

cleaned up and functional, and bringing in new wherever

we needed. That is the strategy weve been following these

past two years.

That strategy also included a new ventilation system that

Clarke says creates a healthier and cleaner workplace for

employees.

The surface treatments now offer by ATF are a perfect fit for

winning new customers in the aerospace and defense industry:

Anodize Per MIL-A-8625: Type II Class I & II,

Type III Class I & II

Chromate Conversion per MIL-DTL-5541: Type 1 and 2

Class 1A and 3



Phosphate per MIL-DTL-16232

Zinc: Zinc phosphate per TT-C-490, Type I, III

Black Oxide per MIL-C-13924: Class I

Manganese Phosphate Per MIL -DTL-16232 Type M Class

I, II, III, IV

Expanded CapabilitiesWith plating tanks measuring up to 48 by 60 by 80 inches,

ATF says it can compete with any shops vying for work from

the top aerospace and defense tiers. In addition, the company

expanded its painting capabilities and added powder coating

applications to serve whatever needs an OEM might have.

The plants chemical agent resistance coating (CARC)

qualifies for Mil-DTL-53039 and MIL-DTL-53072 specs, as

well the painting of dry film and solid film lubricants. The

physical plant houses two walk-in paint booths of 10 and

8 feet in size, each with separate automatic conveyor lines

running. Besides another walk-in oven that can handle

Auto Supplier Bolta Werke Opening Tuscaloosa Plant


AEROSPACEAEROSPACE

German auto supplier Bolta Werke GmbH will build its frst U.S.

production facility in Tuscaloosa, expanding the states vast

network of auto suppliers serving major assembly plants in

the region.

Bolta, a member of the Purico Group, says it will invest

$39.5 million in the Alabama facility and create more than

350 jobs by 2016. The Bolta Werke facility will produce

high-quality parts for automotive manufacturers, primarily

Mercedes-Benz U.S. International in Vance and Volkswagen

in Chattanooga, Tenn.

Christian Falk, CEO of Bolta Werke, says the companys

presence in the Southeastern U.S. is of strategic value.

With a new production facility in Tuscaloosa, Alabama,

Bolta will not only be able to support Mercedes-Benz

and Volkswagen in close proximity, but also valued Tier 1

suppliers like Rehau, a Mercedes supplier thats expanding

in Cullman, Falk said.

Alabama Governor Robert Bentley, right, welcomes

Bolta Werke officials.

temperatures up to 400F, ATF has a Dri Quik infrared oven

used for drying polyurethane enamel, polane and other

light-gauge materials.

Its important to bring in new technologies that our

customers expect us to have, Clarke says.

ATFs process of getting the plating, painting and powder

coating operations up and running was eased by being a part

of the Advanced Technical Aerospace family, which has had a

footprint in aerospace and defense for many years.

Finishing is a very complimentary operation to the other

processes and organizations that are under our corporate entity,

Clarke says. Weve now built a machine that offers a very wide

breadth of capabilities, but it also offers our customers many

more options for which services they actually need.

Clarke attributes much of ATFs quick rise to Stinson and his

efforts to get those certifications and accreditations as quickly

as he hasalmost at breakneck speedwhile still meeting all

the qualifications. Its really come together much faster than

we had thought, thanks to what Aaron has done, he says.

Non-Destructive TestingOn the project board now for Stinson is an expanded facility

that will help grow ATFs non-destructive testing capabilities, a

function that company management feels is crucial to offer Tier

1s and other industries.

Non-destructive testing (NDT) operations will enable evalua-

tion of properties of materials and components without causing

damagecrucial in an industry such as aerospace where even

small parts can costs big bucks. By offering NDT, the shop can

be a higher value partner to manufacturers, saving them both

money and time in material evaluation, troubleshooting and

data acquisition.

A lot of the orders that are starting to come in, now that we

have Nadcap, call for non-destructive testing, often in fluores-

cent penetrant or in magnetic particle inspection, all of which

we do, Stinson says, adding that the sequence is usually a fluo-

rescent penetrant, a chem film, and then a paint application. In

addition, most of the orders call for complex masking, which

ATF is also set up to do.

So

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e :

Ala

ba

ma

De

pa

rtm

en

t O

f C

om

me

rce

When ATF took over the J&A

operations, there were 20

employees on staff. The new

coating operations and

testing capabilities have

grown that to 35

employees, with

more scheduled

to be hired.



Is Aerospace Finishing Filled to Capacity?

As Boeing and Airbus demand more finishing capacity, the challenges

faced by owners of finishing businesses are pressing, as both customers

and regulatory agencies amp up demands for management attention

and resources.

short.pfonline.com/capacity

Heres how it works. Fluorescent dye penetrates the metal surface. After

wiping off the extra dye, an ultra violet light will detect any cracks or imperfec-

tion, where dye has seeped in, that might need to be reported by the manufac-

turer. In magnetic particle examinations, specialized equipment is used to find

cracks, laps or seams on the surface of ferromagnetic materials.

We really think there is a huge market for non-destructive testing, Stinson

says. We already have in-house Level 3 testing capabilities, which significantly

helps with prime approvals. So our goal is to tap into the market that we know

exists in our region.

Growing Company CultureWhen ATF took over J&A operations, there were 20 employees on staff. The new

coating operations and testing capabilities have grown that to 35 employees, with

more scheduled to be hired and trained. We are working hard to find people

with the right mindset and culture ingrained in them so that they both know and

respect the quality management system we are building here, Clarke says.

He adds that although his company is growing quickly, it is at a rate they both

planned and acticipated in the extremely competitive aerospace and defense

industry.

We are very excited about all the growth ATF is experiencing this year,

Clarke says. Not only are we expanding both operations and capabilities, but

our expansion is creating jobs. To help manage this growth, we have assembled

a new management team composed of seasoned leaders with more than 120

years of combined industry experience.

In addition to Stinson and Clarke, the new management team includes Scott

Dennis as quality manager, Randy Reno as operations manager, and Josh

Smithson as manager of NDT.

Process ManagementStinson says they wont budge on getting the proper personnel working in

the plant.

Its been the most difficult part of all that we have dealt with in the past few

years, he says. Its fairly easy to anodize or to plate a part, but when you are

working with a Boeing part and there are certain specifications that need to be

followed and met, its often hard to get that to sink in to someone who maybe

has just done nickel plating with no spec. There is a process we follow.

Fortunately, ATF has been able to find trained, qualified personnel who have

a passion for demanding work required in aerospace and defense. And thats

made Stinsons job a lot easier when he brings on critical aerospace jobs. We

want the technical work, we want the difficult stuff, he says. We know that is

what will set us apart.

For more information on Advanced Technical Finishing, please visit

advancedtf.com, or call 256-534-8426.

Contact us today!

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BY JOSH STRICKLAND AND MIKE SCHUERER RELIANT FINISHING SYSTEMS

Tips on how to choose the right

powder coating system.

Batch System vs. Automated Line


POWDER COATING


BATCH VS. AUTO

One of the most common questions asked of those in the

powder coating integration industry is whether to use a

manual batch-type system or an automated line.

The answer isnt always easy: Batch systems and auto-

mated lines use different approaches to powder coating,

each with their own advantages.

For those unfamiliar with the terms, an automated

system (or automated line) is a powder coating system

that moves parts automatically through the various steps

of the powder coating process. These steps usually include

using a chemical wash to prepare the surface of the parts,

drying the parts, applying the powder coating media,

curing the powder coated finish onto the parts, then

allowing them to cool.

The parts typically move in one direction from device

to device, and all tasks are done to different parts simul-

taneously. A batch system, on the other hand, allows the

operator to manually prepare and accumulate parts, then

coat and cure the parts in batches. The parts are typically

moved from one device to another by hand using carts.

Here are some of the most useful tips for deciding

whether a batch or automated system best suits a

coaters needs.

Consider the Volume of Work and the Nature of the Parts If youre dealing with thousands of similarly sized parts

per shift, an automated system is probably your best

bet. The more varied the shape and size of the parts,

the less advantage an automated system typically

offers. A batch system provides significant benefits

in terms of equipment cost and workflow versatility,

but relies on workers to move parts, prep parts and

apply powder coating media. So, if the volume

of parts is quite large, the advantages of a batch

system are lost.

Determine How Quickly Youll Need Parts to be CoatedIf the coating process outpaces the manufac-

turing process, a batch system is ideal. If the

powder coating process delays output, an

automated system may help. You can coat

large quantities of similar items quickly,

since parts dont have to be handled between

stages. If the automated line is designed for

rapid throughput, a constant flow of parts

can be coated at a rate that usually cant be

matched by manual techniques.

Evaluate Floor SpaceBatch systems generally take up less room,

so theyre better for businesses that cant

spare extra space. Batch systems sometimes

A batch system allows the operator to manually prepare and

accumulate parts, then coat and cure the parts in batches.

An automated system moves parts automatically through

the various steps of the powder coating process.

If youre dealing with thousands of similarly sized parts per

shift, an automated system is probably your best bet.


POWDER COATING

use one oven to do the work of both drying and curing parts,

which further reduces cost and saves on floor space. By

using ovens where the parts move back and forth multiple

times inside relatively short but wide enclosures, some

automated lines fit into surprisingly tight spaces. But most

automated lines involve restricted access to at least some key

Powder Coater Is Fencing Out The CompetitionA Texas fabricator uses U.S.-built powder coating

equipment to compete against foreign imports.

short.pfonline.com/fence

components, especially in cramped spaces. This drives main-

tenance and repair costs up.

Consider Your BudgetBatch systems are significantly cheaper than comparable auto-

mated lines, usually costing less than half as much, so if your

budget is tight it might be best to start with a batch system.

Batch equipment requires more manpower, but also tends to

have lower maintenance costs. Batch systems can also provide

lower operating costs because you only use equipment as it

is needed. With automated systems there is almost always a

constant process of coating taking place, so relative operating

costs can increase if the system is not being used to full capacity.

No matter what type of system is used, have a plan for

growth and size your equipment accordingly.

For more information, please visit reliantfinishingsystems.

com or whatispowdercoating.com.

Made in U.S.A.

Advanced

model

New

www.PosiTector.net

Now Advanced models come withWiFi and PosiSoft Mobile for complete

portability and expanded functionality.portabilit and e

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ande

DeFelsko Corporation Ogdensburg, New York +1 (315) 393-4450 [email protected]

1-800-448-3835 www.defelsko.com

TheMeasure of Quality

Simple. Durable. Accurate.

BY A. F. KENTON NOVA FINISHING

Gravity and weight are the most important

elements afecting speed and time.

Abrasive Control Factors

for Mass Finishing Systems

A growing concern in the surface finishing industry is the

aging of those in the business. As the trade matures, more

and more is left up to the people performing the surface

finishing work. This graying trend is especially noticeable in

the mass finishing industry, where subtle processing control

factors (rather than say, software programs) are what mark

distinctions in quality. And its for that reason that certain

basic fundamentals of material removal and surface finishing

should be passed along to the next generation.

As a general statement, what you put into a mass finishing

system determines what you get out of it. All mass finishing

systems are designed to perform uniform edge or surface

modification on machined or cast parts. The biggest differ-

ence between the various finishing systems is the application

of energy forces, which relates to the speed or time necessary

to produce the desired surface modifications.

Next to equipment, the specific gravity and weight of the

abrasive is the most important element affecting speed or

time, as well as actual surface texture and smoothness. Just as

all equipment will eventually do the job of material removal,

so too will all abrasives. However, there are literally hundreds

of media compositions, sizes, and shapes available. As a

general rule, the greater the pressure that can be exerted onto

a part, either by equipment or the weight of the media, the

greater the material removal.

With that in mind, here are some guidelines that can be

helpful for selecting media supplies for specific applications

and working particular parts.

Random, Preformed ShapesThe most typical application of mass finishing equipment is to

deburr parts en masse in the cheapest and fastest way possible

without getting stuck or creating other finishing problems. To

do this, you want to select the largest abrasive possible that

is still small enough to reach all the part areas that have to be

worked without getting stuck.

Unfortunately, finding the perfect abrasive size isnt always

easy. One size or shape does not fit all; media choice depends

on the surface finishing requirements that are affected by ABOVE: Plastic media is softer and more flexible than

ceramic media, so it is usually used on nonferrous parts.


MECHANICAL FINISHING

different part configurations, which limit access, and the

raw material of the part, which determines the hardness

and size of the abrasive. An abrasive that works well on

one part may not be able to achieve the desired end result

on another. That is because there is a relationship to the

abrasive size, its hardness, and the part to be worked. For

that reason, nonferrous or soft metals are not normally

finished with the coarsest abrasivethe surface of the

metal will have a rougher finish after processing than it did

before being worked.

For cost purposes, the cheapest form of any abrasive is

usually loose, random-shaped, naturally occurring mineral

compounds classified by screen sizes. Although this material

is commonly used with abrasive blast finishing equipment, it

is rarely used in mass finishing systems, because it varies in

size and shape, making it more likely to jam. More commonly,

manmade shapes are used in mass finishing systems for their

controllable and predictable nature.

Unlike loose, random, natural abrasives, which can

be more than 1 inch in size, the largest abrasive particle

in a preformed shape rarely exceeds .060 inches in size.

Manmade media is made with uniform-size particles, which

predetermine the surface finish of the part being worked.

Technically, you can not have a surface finish finer than the

largest abrasive particle used in the make up of the media.

However, overall media size is usually referred to by its

physical size in L W

H and abrasive composi-

tion first, followed by its

preformed shape.

Ceramic, Plastic Preformed ShapesMost preformed, deburring

shaped media used in mass

finishing systems is made

with either a ceramic or

plastic bonding agent to

hold the uniform abrasive

particles together. Ceramic

media is made like cement,

extruded and cut to size

to make a shape. Whereas

plastic media is made like an

epoxy and then injected into

small molded shapes. Both

are then baked to achieve a

very hard abrasive shape.

Ceramic shapes are made

with inorganic materials,

primarily aluminum oxide

abrasive grits, but silicon

carbide, silicon, zirconia,

and porcelain compositions

are also available. The binders used to hold the abrasive shape

together are formulated to decompose at a predetermined

rate to expose new sharp, abrasive particles. The harder the

bond, the longer the shape lasts, and the finer the surface

finish of the part being worked. The faster the bond breaks

down, the faster the media removes material and the coarser

the finish on the end product. Ceramic preformed shaped

media is relatively hard and very rigid, similar to a grinding

wheel, so it is typically used on hard carbon steel parts or

parts requiring a lot of material removal.

Plastic media is softer and more flexible than ceramic

media, so it is usually used on nonferrous parts. Even though

the abrasives used to make the shapes are the same as

ceramics, the media behaves differently. Plastic media will

produce the same surface finishing results on nonferrous

parts as ceramic will on steel, but plastics will take a long time

to abrade steel parts and therefore are not recommended for

that application.

While ceramic media comes in a number of inorganic

bonds that determine their rate of decomposition, plastic

comes with either a polyester or urea bonding agent varia-

tion. Urea formulations are typically a little softer and cheaper

than the polyester bonds. Ceramic media compositions are

basically shades of gray or brown and plastic is multi colored

resin formulations that also comes in many more shapes than

ceramic, because they are molded. Generally speaking, the

Specific gravity and

weight of the abrasive

are the most important

elements affecting speed

and time, as well as

actual surface texture and

smoothness.


POWDER COATING

darker the color of ceramic media, the faster the material

removal rate. However, plastic media has no industrial stan-

dards or uniform color code that relates to the speed of cut or

decomposition; so be careful and go

by the description of the composition

and not the color.

Gravity and WeightEarlier I mentioned that after equip-

ment, the specific gravity and weight

of the abrasive are the most impor-

tant factors affecting the speed of

processing parts. So, the more media

and parts you can get into a machine

system, the faster it works, with a

couple of exceptions. A barrel system needs a definite air gap

for the media to properly slide during processing. For normal

deburring in vibratory and high energy systems, the process

requires about 60 percent media to parts by weight, and up

to 80 or 90 percent for burnishing and good looking finishes.

Also, remember that typically, the faster the media breaks

down or decomposes, the faster it works.

As a guide for deburring, abrasive media averages 100

pounds per cubic foot, but can weigh between 90 to 120

pounds per cubic foot, some fine polishing porcelains can go

as high as 150 pounds per cubic foot, and on the opposite

side are some hybrid lightweight ceramics that are used on

both ferrous and nonferrous materials that come in around

60 pounds per cubic foot. Plastic media normally weighs

anywhere from 55 to 80 pounds per

cubic foot, and some zirconia abrasive

plastic shapes approach 100 pounds

per cubic foot range.

Because both ceramic and plastic

media are formulated solids, they have

a porosity factor that affects moisture

content and the weight of the abrasive

media. That means with age and

depending on the storage environ-

ment, moisture content can and will

vary. Even though this problem does

not significantly affect processing, it does affect compara-

tive test results. When one tries to contrast one media against

another, the media is weighed before and after testing to

determine performance and attrition. The weight factor due

to moisture is the real wild card that can play havoc with

testing, and there is almost no way to accurately compare

apples to apples.

Shape EffectivenessGenerally, preformed media comes in two basic shapes, or the

shapes have two different behavior characteristics, plus one.


ABRASIVE CONTROL FACTORS

In the last fve years, a new

media bonding resin process has

been developed that uses small,

loose, random organic and

inorganic materials to create a

media shape and run only dry.

Both work, and there is no conclusive studies to indicate one

shape is better than anotherits like comparing a bulldozer

to a steamroller.

Spherical shapes, such as cylinders, cones, or spheres/balls

have a lot of rounded surface features and are therefore very

mobile like a steamroller. As they move, they rotate en mass

and by themselves. These shapes work extremely well on parts

with holes, because the media tends to poke itself slightly into

holes and rotate before moving on. They also work flat areas

very well without marking.

Because these shapes are so mobile en masse, they do not

hold, support, or restrict parts from reaching the bottom of

the work chamber. That means the full weight of the media

and mass is used to put pressure on the parts. These shapes,

especially the balls, are not necessarily effective for finishing

inside corners and angles, resulting in a shadow appearance

in these areas.

Angular geometric shapes, such as triangles and tri-stars

move more slowly than curved shapes because their align-

ment and edges resist movement, creating a pushing effect

like a bulldozer. This resistance seems to transmit more

energy or pressure to the parts on a more constant basis,

making this shape very good for working edges and inside

angles on parts. This resistance also keeps parts from sinking

en mass and creates a slightly louder sound while processing.

As mentioned, there is a plus-one hybrid shape that needs

special clarification. A cylinder wedge is probably the best

general purpose shape media of all applications because it

uses both a round and angular configuration. There is also

something else interesting about this shape that makes it

unique. Unlike all the other shapes that have their center of

gravity directly in or near the center, this shape has its center

of gravity on the outside edge, meaning it is the least stable

and most mobile of all the shapes and therefore less likely to

get stuck in part recesses.

Dry Finishing OptionsAll of the media shapes discussed up to this point, even

the random shape materials, are typically used in wet

processing systems, because dry inorganic materials

do not leave parts clean and may also produce surface

finishes rougher than before processing. Also, when used

dry, inorganic materials become easily contaminated and

cannot be easily removed or separated from the media.

Therefore, water and a chemical compound are used in

most deburring processes.

Better dry alternative media include wood, wood sawdust,

corncob and shell products. When used alone, these organic

materials dont

419751-DEC 2014

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