Professional Documents
Culture Documents
Surlon KE Datasheet Hard Ceramic Hard Anodizing With Lubrication 29AUG17
Surlon KE Datasheet Hard Ceramic Hard Anodizing With Lubrication 29AUG17
Surlon KE Datasheet Hard Ceramic Hard Anodizing With Lubrication 29AUG17
00
1.0. SCOPE
This specification covers the requirements for electrolytic formed Surlon K.E.
hardcoatings on aluminium and aluminium alloys for industrial applications.
This results in a continuous, lubricating plastic-ceramic surface of which the
Surlon particles become an integral part.
2.0. CLASSIFICATION
Surlon K.E. coatings for aluminium and aluminium alloys shall be of the following
types.
Tabel 1
3.0. GENERAL
3.2. The Surlon K.E. process provides a permanent, dry lubricating surface and
provides an unusual degree of lubricity combined with hardness. By leveling off
the surface asperity with the Surlon, surface tension is drastically reduced and
lubricity greatly increased.
3.6. The Surlon K.E. process yields excellent dielectric properties and strength. The
Surlon K.E. process converts the surface to one with excellent dielectric
characteristics, without affecting the high conductivity of the parent metal.
3.7. The Surlon K.E. process becomes an integral part of the parent metal. Since
Surlon is really the surface of the metal converted to a ceramic and then
interlocked with K.E. it cannot peel or strip.
And because it is harder than casehardened steel, it cannot be nicked, scratched
or flaked by ordinary means.
Coating thickness in µm
Alloy type 30 40 50 60
Dimensional growth approx.
Wrought aluminium
AA 6061 (AlMgSi1) 27 36 45 55
AA 2024 (AlCuMg2) 24 32 40 48
AA 7075 (AlZnMgCu1,5) 24 32 40 48
Aluminium Silicon Magnesium casting
alloys
235 (AlSi5Mg) 26 34 43 51
236 (AlSi7Mg) 23 31 39 47
341 (AlMg8) 23 30 37 45
Tabel 2
To allow for this processing growth, parts should be dimensioned under size
proportionately. Surlon finishing within the limits of processing growth can bring
worn parts or those rejected because they are below the required dimensions to
the desired tolerances.
3.16. Masking.
Assemblies containing metals other than aluminium alloys shall be disassembled
or masked. Chemical surface preparation shall be followed immediately by the
conversion process.
4.1. Quality.
The coating shall be continuous, smooth, adherent, uniform in thickness and
appearance and shall be free from powdery areas, discontinuities such as breaks
and scratches and other detrimental defects, except that porosity, roughness and
other irregularities common to die castings and not detrimental to the function of
the part shall not be cause for rejection of die cast parts. The size and number of
contact marks shall be minimal, consistent with good practice.
4.2. Lubricity.
The lubricity of the coated surface shall be evidenced by the exhibition of
hydrophobic characteristics when tested as follows:
Thoroughly wash the surface to be tested with trichloroethylene. With the test
surface in a horizontal plane, facing up, rinse it thoroughly with distilled water.
Upon completion of rinsing examine the condition of the water remaining on the
test surface. If the water is in the form of droplets (beaded) the surface has a
hydrophobic character. If the water forms a continuous film, the surface does not
exhibit hydrophobic characteristics.
5.0. REQUIREMENTS
5.1. Materials.
The materials used shall be such as to produce coatings that meet the
requirements of this specification.
5.3. General.
Unless otherwise specified in the contract, order or applicable drawing, parts and
assemblies shall be treated after all heat treatment, machining, welding, forming,
and perforating have been completed.
Surlon parts which contain non-aluminium materials such as steel, brass or
organic substances, which would be attacked by chemical or would prevent the
uniform formation of the Surlon K.E. on the aluminium surfaces or cause attack
of the aluminium alloy, shall not be treated as assemblies, unless the non-
aluminium surfaces are masked or electrically insulated in a manner which
produces satisfactory Surlon parts.
Parts shall be so handled during all pretreatment that mechanical damage or
contamination will be avoided. Soiled parts shall be cleaned with such materials,
which will remove the soil without damaging the part or coatings. Parts shall be
free of all foreign substances, oxides and soils, such as greases, oil, paint and
welding flux. Parts shall have oxide and other interfering film removed by the use
of proper cleaning procedures so as to be cleaned and have water break free
surfaces.
Unless otherwise specified in the contract, order or applicable drawing, Surlon
coatings shall not be applied to assemblies, which will entrap the electrolyte in
joints or recesses. Surlon coatings shall not be used for assemblies where the
electrolyte cannot be removed. When authorized by the contract, order or
applicable drawings, edges shall be masked to prevent electrolyte entry.
Spot welded assemblies are examples of assemblies requiring edge masking.
Residual electrolytes will engender corrosion of aluminium. Where coating of
assemblies is not authorized, parts of assemblies shall be coated before
assembling.
5.4. Thickness.
Thickness of Surlon coatings shall be as specified in the contract, order, or
applicable drawing.
If a definite thickness is not specified in the contract, order or applicable drawing,
the nominal thickness of the coating shall be 45 – 55 µm. Unless otherwise
specified, the thickness of the coating shall not vary by more than plus or minus
ten percent. Unless otherwise specified in the contract, order or applicable
drawing, Surlon coatings shall not be applied to aluminium alloys with a nominal
copper content in excess of 5 percent or nominal silicon content in excess of 7
percent.
Alloys with a higher nominal silicon content than 7 percent may be coated
subject to approval of the procuring activity provided data is submitted by the
supplier which shows that such coatings are equivalent to those obtained on
alloys of lower silicon contents.
6.3. Control.
The supplier should maintain a permanent record of the history of each
processing bath, showing all additions of chemicals to the bath, the results of all
analysis performed and the quantity of parts of each kind treated in the bath.
6.7. Method.
Specimens shall be washed in distilled or deionized water, dried with a soft cloth
and then subjected to a 5 percent salt spray test in accordance with Method 811
of Fed. Test Method Std. No. 151 or A.S.T.M. B 117, Method of Salt Spray
(Fog) Testing, except that the significant surface shall be inclined approximately
6 degrees from the vertical.
After exposure, specimens shall be examined and compared with unexposed
specimens for the effects of corrosion.
AL 99 ALZnMgCu1,5 ST 37
5
Weight decrease in mg.
Hardcoat
1 Surlon K.E.
0
0 1 2 3 4 5 6 7 8 9 10
Abrasion cycli (x100)