SURFACE FINISH 101

Presented by: Brad Doornbos and Hugh Smith

Hosted by: Taylor Topper
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SURFACE FINISH 101 AGENDA

Discovery

Process Control

Coatings

Questions
DISCOVERY
What needs to be considered when
choosing a finish.
FUNCTION OF PART

• What are you looking to do? • Wear characteristics?

• What is the purpose of the finish coating? • Wear resistance?
• What testing requirements does it need to
pass?
• Does it require a specific thickness?
PRICE CONSIDERATION

• The finish that you specify needs to be in-line • Knowing what options are available
with your requirements
• Advancements in die cast alloys
PROCESS CONTROL
The quality of the substrate is crucial to the
overall success of the project.
SUBSTRATE SURFACE CONDITION

Things that affect the surface condition:

• Surface cleanliness
• Prewash process (die lubricant, buffing)
• Fill rate (air entrapment)
• Quality of substrate
• Secondary surface finish preparation

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DESIGN CONSIDERATIONS

Parting Lines Fillet & Radii

• Parting line location • Avoid sharp corners

• Design inside corners with fillets
• Design outside corners with radii
• Improves metal flow through reduced
turbulence

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COATINGS
Overview of most commonly used finishes
 ANODIZING

Clear

• Anodizing creates a non-conductive protective

coating
• Good corrosion resistance
• Can be dyed virtually any color or shade. Black,
blue, red, etc.

• Type 2- Sulfuric Anodized Class 1 – Non-dyed,

clear (natural) color.

Black • Type 3- Hard Anodized Class 2 – Dyed, color

must be specified.

• Salt spray test: 190 hours

• Thickness: 0.00005” - 0.0005” (Class 2)

• Cost: $$

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TRIVALENT CHROMATE

• Does not contain hexavalent chromium which

eliminates chrome reduction in waste treatment.
• RoHS compliant
• Rust resistant
• 150+ hours salt spray
• Cost: $$
• Thickness: less than .000001”

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CHROMATE WITH ZINC

• Finishes over the Zinc Plate -

Yellow, Clear, Black
• Soft, ductile and decorative

• Clear, Black, Yellow Salt spray 150+

• Excellent paint base.

• Seals are also offered for after

chromates to increase corrosion
resistance

• Thickness: Less than .000001”

• Cost: Clear - $$

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E-COAT

• E-coat is an electrically-applied paint coating

• Oxidation/Rust resistance
• Cosmetic Finish
• Good corrosion resistance

• Thickness: Regulated to range between 0.0002”

to 0.001” depending on requirements.
• Cost: $$

Chromium Plating + E-
Coating.

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BLACK OXIDE

• Uniform black finish

• No Dimensional change
• Will not chip or peal
• Acts as an absorbent to hold oils or wax
• Cost: $

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POWDER COAT

• Powder coating provides a higher uniformity of

thickness and color consistency than standard wet
paints

• Thickness: 0.004”
• Cost: $$-$$$

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DECORATIVE CHROME

Bright, Brushed, Satin

• Good wear resistance
• Bright chrome thickness: 0.0015
• Cosmetic applications
• Salt spray – varies depending on thickness of
each layer of plating – up to 1,000 hours salt
spray.
• Design consideration for dimensional changes
should be considered – plating build up will vary
from part to part – part feature to part feature
• Thickness varies depending on part application
• Copper, Nickel, Chrome

• Cost: $$$$

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BRIGHT NICKEL

• Nickel Plating is a yellowish white, hard reflective

finish used for wear resistance, and solderability

• Thickness: 0.0008”

• Cost $$

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CHEM FILM

• Chem Film is comprised of two types class 1A &

class III
• Class 1A used as a corrosion preventative film, also
as primer for paint which helps in its adhesion.
• Class III used for corrosion protection where low
electrical resistance is required

• Classified as conversion coating

• Cost: $
• Plating thickness is .00001

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COPPER NICKEL TIN

• Tin plating is normally done to improve

solderability to a variety of base metal
substrates.

• Thickness:0.0011”

• Cost: $$

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COBALT TIN

• Similar in appearance to chrome yet less

expensive
• Plated with bright nickel, then flashed with cobalt
tin
• Cost: $$$
• Thickness: .001”

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ELECTROLESS NICKEL

• No electric current required for deposition.

• Uniform plate build up around corners and blind
holes. No high current density areas
• Types of Electroless Nickel
• Low Phos – Primarily used for hardness and wear
properties
• Mid Phos – Most commonly used deposit
• High Phos – Superior corrosion resistance, ductile
finish with excellent adhesion properties

• Cost: $$

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GOLD PLATING

• Types of Gold Plating:

• Pure Gold – 99.90%, 90 HK25
• Hard Gold – 99.7%, 130-220 HK25
• Electroless Gold – 99.90%, 90 HK25
• Immersion Gold – By substituting nickel as an
undercoat instead of electroless nickel, immersion
is only about 10% more expensive than electroless
nickel alone. It is relatively inexpensive and an
affordable finish.

• Thickness:
• Electroless – 0.000005”
• Bright – 0.000015”
• Pure – 0.000015”

• Cost: $$$

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SILVER

• Highest thermal and electrical conductivity

of any metal

• Thickness: 0.0002”

• Cost: $$

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NICKEL-FREE COATING

• Decorative finish very similar to chrome plating

• No nickel layer which may cause skin irritation
• Application primarily used with wearable
products which require a decorative finish
• Dynacast Singapore has created 18 variations of
a nickel free option including, Gold, Rose Gold,
Silver, Black and Gray
• Cost: $$$$

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POLYURETHANE PAINT

• These coatings are very long lasting and are

recommended for exterior use. Can be painted
smooth or textured.

• Thickness: 0.001”

• Cost: $$

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IMPREGNATION

• Seals porosity - leak free casting

• Thickness: 0.001”

• Cost: $

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TEFLON

• Teflon is a thermally cured solid film lubricant

• Provides improved torque/tension control
• Good corrosion resistance
• Salt Spray: 500 hours

• Thickness: 0.0003-0.001”

• Cost: $$-$$$

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THANK YOU
PLATING AND E-COATING
Cosmetic requirement on a luxury product

Developed plating and e-coating process that achieves a vibrant surface finish on an aluminum casting

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