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Elimination of Chromates in Paint Preparation Elimination Of EliminationElimination ofof ChromatesChromates InIn PaintPaint PreparationPreparation Richard H. Buchi, Ken Paterson & Clyde J. Gowers Reduction and elimination of From a corrosion preventive point in the metals finishing industry where chromate-containing wastes is a of view, continuing to use both the the corrosion protective properties major pollution prevention goal. chromate conversion coating and the imparted by chromium compounds One of the most pervasive uses of chromate-containing primer would be are unequaled. Treating aluminum material containing chromate is in preferable. Laboratory testing has with chromates to form a chromate the treatment of aluminum with shown, however, that as long as there conversion coating on aluminum is a chromate conversion coating. is chrome in the primer, the corrosion- common way to enhance corrosion Researchers at Hill Air Force Base protective properties of modern resistance and to prepare the metal to in Utah have found an environmen- aircraft paint systems will suffer little. accept paint. When the coating is tally friendly solution that leaves a A study of a substitute for the scratched—leaving the metal bare and thin film on the substrate, which chromate conversion coating was susceptible to corrosion—chromate passivates the surface and enhances conducted at Hill AFB. The candidate from the surrounding area is believed paint adhesion. The solution has and the process developed for its use to leach into the scratch, providing been accepted for the prepping of were tested extensively against the additional corrosion protection. This aircraft. This paper contains test current process. is a valuable conversion coating data and a model of the new In adhesion and flexibility tests, the function. Chromates in primer coating conversion coating, and covers new environmentally friendly process serve the same purpose. some of the Hill AFB work on the performed better than the chromate Elimination and reduction of cleaning of substrates. conversion coating. It performed chromates in Air Force maintenance equally well in all other testing. In operations has long been a goal of the Because chromium is a confirmed addition, it was found that this environmental community. Modern human carcinogen, reduction and candidate could eliminate two solvent aircraft coating systems consist of elimination of chromate-containing wipe-downs and the corrosion- chromated epoxy primer and tough wastes is a major prevention goal. removing compound used in the polyurethane topcoats. They do an Material containing chrome is used conventional paint preparation excellent job for corrosion prevention. extensively in the treatment of procedures. The use of this product As long as the primer contains aluminum with chromate conversion also reduces the need to sand anod- chromate, the paint system will coatings. Chromate conversion ized surfaces before repainting. continue to provide very good coatings help prepare aluminum for Operational tests have been corrosion protection, even if the the application of paint, as well as conducted on several aircraft, and the chromate conversion coating is provide a corrosion preventive barrier. paint shop at Hill AFB is now using eliminated. Many vendors of propri- In aircraft paint systems, chromate this product on its production line. At etary products have been working on conversion coatings are used in the time of this study, more than 50 “non-chromate” conversion coatings, conjunction with modern epoxy aircraft had been painted using this and have made various claims for primers, which also contain chromate, product. The study recommended their effectiveness. Several factors to guard against corrosion. The expanded use of this product to make such non-chromate conversion primers are topped with a tough layer eliminate a major source of pollution coating desirable. of polyurethane paint. Landing gear, and hazardous waste. This new wheels and brakes of military aircraft product simplifies and reduces the • The process by which the conver- are similarly treated. paint preparation steps, saving time sion coating is applied is ineffi- ________________ and money in painting aircraft. cient, especially for large areas Editor’s Note: This is an edited (entire aircraft). The chromate- version of a paper presented at the Background containing compound is brushed, AESF/EPA Conference for Environ- Chromate (chromium VI) in all forms wiped or sprayed on the alumi- mental Excellence, held January 17– is known to be a serious environmen- num surfaces. A small portion 19, during AESF Week 2000 in tal pollutant. On the other hand, contacts the metal and forms the Orlando, FL. chromate compounds have many uses conversion coating, but the bulk 10 PLATING & SURFACE FINISHING Preparation Steps 1. Scrub with an alkaline cleaner 2. Hydroblast 3. Dry 4. Wipe clean MEK 5. Sand 6. Rinse with water 7. Apply a corrosion-removing compound 8. Rinse with water The Air Education and Training Command 9. Apply chromate conversion (AETC) tested Product D on various mili- tary aircraft, such as the T-37 (above) and coating the T-38 (right). 10. Scrub it on for five minutes 11. Apply second coat and dwell for one minute of it either drains off, is rinsed off This is a difficulty unique to 12. Rinse with deionized water or is wiped off. The operation aircraft rework, as opposed to 13. Let dry results in a hazardous waste original manufacture. 14. Prime stream that must be collected and Fig. 1—Preparation for paint process. treated or properly disposed. Testing for cleanliness on the • Because chromates are suspected surface of the aircraft to determine well to the fresh, porous anodize carcinogens, personnel must whether the surface is ready for paint coating. Repainting of anodized protect themselves from the is traditionally accomplished using aluminum is a different story. Paint chemicals by wearing protective the “Water Break Test” (T.O. 1-1-8). retained in the pores after stripping clothing and equipment. This test is fairly sensitive to oily adversely affects the adhesion of the • Special facilities are required for contaminants on the metal surface, if paint system. Adhesion difficulties large-scale chromate conversion conducted properly. The presence of were reported when repainting the coating jobs. surface-active agents or flooding of stripped aircraft using conventional the surface with water can give paints, but the problem intensified History erroneous results. For whatever when environmentally compliant This study represents a multi-year reason, painters were obtaining good paints were applied. The F-16 prime effort at Hill AFB to reduce or water break results, but the surface contractor was asked for recommen- eliminate the use of chromate com- was still not clean enough to accept dations. In 1990, it recommended that pounds in the paint-preparation the new high-solids primers. A joint the anodized coating be sanded off in process for aircraft, especially for the study was initiated with the paint shop order to obtain the required paint F-16s. To understand the approach, to determine when the surface was adhesion. Hill AFB engineers decided priorities and evolution of this project, clean enough for priming. The best that this solution must be a last resort. a brief history is helpful. simple measure of cleanliness came to If at all possible, the anodized coating In 1989, the paint shop at Hill AFB be the reaction of the surface with the needed to be preserved as a corrosion began to use the new volatile organic chromate conversion coating. When barrier. compound (VOC)-compliant primers the color imparted by the chromate Eventually, Hill discovered that and paints (commonly known as conversion coating was uniform and light sanding of the bead-blasted, “compliant” or high-solids coatings). fairly dark (depending on the alloy anodized surface removes residual The first efforts were unsuccessful and previous surface treatment), paint primer in the pores of the anodize. By because the new paints failed to give bonded well. removing the residual primer, good adequate adhesion. The Science and New cleaning and preparation adhesion is obtained. In practice, Engineering Laboratory was asked to procedures were established at Hill however, this “light sanding” is find a cause and cure for the adhesion AFB to consistently give a uniformly difficult to achieve. The visual problem. Use of the compliant colored chromate conversion coating indicator that the primer has been coatings was suspended until the paint (Fig. 1). Painters were taught to clean removed is difficult to see, and only adhesion problems could be resolved. areas again on the aircraft where the an experienced eye can tell. As a Studies conducted between the chromate did not take well, as result, the anodized layer is often laboratory and the paint shop revealed indicated by the color. For this reason, totally removed. Finding a way to two separate, but related, problems: one of Hill’s top priorities for a non- bond environmentally compliant paint chromate conversion coating was a without destroying the anodized 1. The cleanliness of the aircraft visual indication of cleanliness. coating became another priority in the was not sufficient for the The F-16 is manufactured with an search for a non-chromate conversion compliant primer to form a good anodized aluminum aircraft skin. The coating. bond. anodized surface has proven invalu- The non-chromate conversion coat 2. Bonding the primer to the able in the fight against corrosion. project was
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