Aluminum Coatings Turn Green IVD process delivers environmentally friendly corrosion protection. By Vernon Lee Holmes, Associate Technical Fellor, Environmental Assurance R&D, The Boeing Co.; and Mike Bridger, IVD Product Manager, Ipsen International
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on vapor deposition (IVD) is a physical vapor deposition process for applying pure aluminum coatings to workpieces of various alloys, mainly for corrosion protection. The process is applied in various styles of a vacuum coating machine called an Ivadizer. To prevent contamination of the pure aluminum coating from oxygen and water vapor in the atmosphere, the coating is applied to the substrates in a vacuum, which makes generation of the metal vapor easier because the boiling point is decreased from its atmospheric boiling point. In this process, the substrate, or workpiece being coated, is connected to a high-voltage source. A negative potential of 500 to 1,500 V DC is applied to the part to attract the metallic vapor, which is evaporated from electrically heated elements or from an a l u m i n u m slug by electron b e a m evaporation. Typically, aluminum alloy wire is fed into a resistively heated source called a "boat" inside the IVD coater. The boat is made from a high-temperature composite m a t e r i a l having the proper electrical characteristics for heating, while withstanding the intense heat and molten aluminum. The aluminum is evaporated from the boat in a process similar to water boiling or evaporating out of a pan. The vapor spreads out into the vacuum yessel, coating the part and the shell of the vacuum ves-
Figure 1: Extended-length IVD aluminum coater at Boeing.
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Figure 2: Barrel coater installation.
sel in the vicinity of the boat. The hot vapor condenses to form an aluminum coating on the parts much as water would condense on a metal plate held above a pan of boiling water. Parts being coated experience mild heating, mostly due to the heat of condensation as the vapor returns to the solid state. Generally, the workpiece t e m p e r a t u r e remains below 300°F (150°C). IVD a l u m i n u m coaters are a d a p t e d for specific applications. A rack-type coater is primarily used for coating large parts (Figure 1). The parts are hung from a rack, which is loaded into the coater. A coater designed for handling large volumes of small parts is called a barrel coater, which is often used to coat small cylindrical fasteners: bolts, pins, nuts, rivets, etc. (Figure 2). Inside the coater, the slowly rotating barrel tumbles the parts, thus assuring that all surfaces are coated evenly. A L U M I N U M COATINGS PROPERTIES The properties that are important for the ion vapor deposited aluminum coating are: • Adhesion: No separation from the base metal at the interface; • appearance: smooth, fine-grained, adherent, uniform in appearance; • composition: not less than 99.0% aluminum; www.metalfinishing.com
• corrosion resistance: no evidence of corrosion of basis metal in ASTM salt fog test; • coverage: all visible surfaces covered, including roots of threads and sharp corners; • substrate integrity: no adverse reaction between the coating and the substrate; • thickness: sufficient for intended protection, as per Class 1, 2, and 3 standards. These properties are described in detail in various m i l i t a r y s t a n d a r d s . The t h i n n e r coatings (Classes 2 and 3) achieve m a x i m u m corrosion performance t h r o u g h a s u p p l e m e n t a r y c h r o m a t e posttreatment. IVD is very adaptable for different thickness requirements. Typically, IVD aluminum is applied in the range of 0.0003- to 0.002-in. (8-50 ]am) in thickness. The classes and p o s t t r e a t m e n t s are described in Table I. Figures 3 (a) and (b) contain m i c r o g r a p h s of a s - p l a t e d and p e e n e d IVD aluminum, respectively.
AEROSPACE APPLICATIONS In many applications, IVD aluminum has replaced electroplated cadmium. Cadmium has excellent corrosion resistance and good wear resistance, paint adhesion, and
(a)
(b)
Figure 3: Photomicrographs of IVD aluminum coatings: (a) asplated, 1,000X; b) peened, 1,000X.
lubricity characteristics, which have made cadmium the corrosion-resistant platings of choice in the aerospace industry for many years. However, cadmium is toxic, carcinogenic, and is on the EPA 17 list for reduction or elimination from the workplace. Because cadmium electroplating is typically applied using an alkaline bath containing sodium cyanide, the health, safety, and environmental concerns are further complicated by- the toxic
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cyanide. Finally, for Table I: Coating Classifications high-strength steel Coating Thickness applications, cadmium 0.0010 inch thick (0.026 ram) minimum platings must be baked 0.0005 inch thick (0.013 mm) minimum for 24 hours to alleviate hydrogen embrittle0.0003 inch thick (0.008 mm) minimum ment concerns. Unlike cadmium, Table I1: Exposure T i m e s for Corrosion-Resistance Tests in aluminum is environN e u t r a l Salt Fog Test per A S T M B- I 17 mentally benign, nontoxic, and therefore safe to handle and use. Its high performance has been demonstrated in aerospace applications formerly requiring cadmium electroplate. From February 1988 to August 1992, Boeing tion on the performance of IVD aluminum, while (St. Louis) conducted a three-phase program at the Phase II addressed such areas of concern as coverage Air Force Air Logistics Center (ALC), the goal of which was to evaluate IVD aluminum as a substitute for of internal surfaces, lubricity, and erosion resistance. In P h a s e III, a s t a t e - o f - t h e - a r t IVD aluminum cadmium. Phase I consisted of extensive data collec-
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HOW DOES IVD A L U M I N U M PERFORM COMPARED TO CADMIUM? The performance of IVD aluminum in neutral salt fog is provided in Table II. In tests comparing the corrosion protection of cadmium versus aluminum, the following has been established: • In acidic salt environments, a l u m i n u m coatings are vastly superior to cadmium platings. ° In n e u t r a l salt fog, c a d m i u m platings are equal to or better t h a n a l u m i n u m coatings. ° In outdoor exposure tests, a l u m i n u m coatings are equal or superior to cadmium platings. In most industrial or military applications of either December 2004
cadmium or aluminum, the atmospheric conditions tend to be acidic due to combustion products of fossil fuels containing sulfur. Therefore, the performance of IVD aluminum is expected to be generally superior to cadmium. In addition, IVD aluminum withstands up to 925°F (495°C), whereas cadmium is limited to 450°F (230°C). IVD aluminum can be used on titanium where cadmium cannot because of solid metal embrittlement concerns. IVD aluminum also can be used for space applications, whereas cadmium is unsuited because it sublimes in the vacuum of space. 9
IVD a l u m i n u m is not as lubricious as cadmium plating. However, the application of a suitable lubricant (cetyl alcohol) compensates for this, providing very similar torque-tension characteristics for threaded fasteners. CONCLUSION Twenty-five years of experience demonstrates that IV]) aluminum coatings provide proven high-performance corrosion protection for aerospace and industry, with significant environmental, health, and safety benefits over cadmium electroplating. REFERENCES
Military Detail Specification, Coating, Aluminum, High Purity, MIL-DTL-83488. Holmes, V.L., Muehlberger, D.E., and Reilly, J.J., The Substitution of IVD Aluminum for Cadmium, Phase I Report, ESL-TR-88-75, Air Force Engineering & Service Center, Engineering and Service Laboratory, Tyndall Air Force Base, Florida 32403; August 1989 Holmes, V.L. and Reilly, J.J., The Substitution oflVD. Aluminum for Cadmium, Phase II Report, ESL-TR-9028, Air Force Engineering & Service Center,
Engineering and Service Laboratory, Tyndall Air Force Base, Florida 32403; May 1990. Holmes, V.L. and Reilly, J.J., The Substitution of IVD A l u m i n u m for Cadmium, Phase III Report, AL/EQTR-1993-0003, Armstrong Laboratory Environics Directorate, Tyndall Air Force Base, Florida 32403; August 1992. Holmes, V.L. and Reilly, J.J., Ion Vapor Deposition Aluminum Qualification Tests, Pollution Prevention Project PRJY 921609, Environmental Management Directorate, McClellan AFB, CA 95652; June 1995. Holmes, V.L., Expanded Ion Vapor Deposition (IVD) Aluminum Program, Pollution Prevention Project PRJY 961610, Environmental Management Directorate, McClellan AFB, CA 95652; September 1998. IVD Aluminum for EMI Compatibility, McDonnell Douglas Corp. Data Sheet.
The Boeing Co., P.O. Box 516, St. Louis, MO 63166; vernon. I. holmes@boeing, corn; w ww. boeing, corn
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