41RBUS

PROCESS AND MATERIAL SPECIFICATION

PROCESS SPECIFICATION

01-02-09

DC Sulphuric Acid Anodizing without Sealing

Printed in Germany
 AIRBUS
PROCESS AND MATERIAL SPECIFICATION

RECORD OF REVISIONS

REV ISSUE INSERTED REV. ISSUE INSERTED

NO. DATE DATE BY NO. DATE DATE BY
01 Aug 01/10

80-T-35-2000
ROR 01-02-09
Page 1
Aug 01/10
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 AIRBUS
PROCESS AND MATERIAL SPECIFICATION

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE

RECORD OF REVISION 1 Aug 01/10

LIST OF EFFECTIVE PAGES 1 Aug 01/10

TABLE OF CONTENTS 1 Aug 01/10

01-02-09 2 Aug 01/10

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80-T-35-2000
LEP 01-02-09
Page 1
Aug 01/10
Printed in Germany
 PROCESS AND MATERIAL SPECIFICATION

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Previous issue: 10/2002

The reproduction, distribution and utilization of this document as well as the communication of its contents to others without explicit authorization
is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or
design.
80-T-35-2000
01-02-09
Page 1
Aug 01/10
Printed in Germany
 PROCESS AND MATERIAL SPECIFICATION

Page 2 80-T-35-2000 (01/2006)

1 SCOPE AND APPLICATION

This process specification describes the anodizing of aluminum and aluminum alloys by the direct
current sulphuric acid process, without subsequent sealing.

This specification is applicable if anodizing per 80-T-35-2000 or ident. no. 2000 per LN 9368 is
specified in the manufacturing documents.

DC anodizing is a process where an aluminum oxide layer is produced on the component surface by
application of direct current in a sulphuric acid electrolyte.

The layer produced by this process is electrically non-conductive and generally has a thickness of 10 to
15 urn. The layer only provides adequate corrosion protection in a sealed condition - the surface
hardness and resistance to abrasion are reduced.

2 RELATED DOCUMENTS
QVA-Z09-07-00 Surveillance of Baths for Chemical and Galvanic Surface Treatment
QVA-Z09-07-26 Determination of Hydrogen Ions in Surface Treatment Baths
QVA-Z09-07-28 Determination of Aluminum in Acid Surface Treatment Baths
QVA-Z09-07-33 Determination of Chloride Contamination in Surface Treatment Baths
QVA-Z10-50-03 Thickness Measurement of Electrically Non-conducting Layers on
Non-ferromagnetic Alloys
QVA-Z10-55-00 Penetrant Inspection
QVA-Z10-59-01 Salt Spray Test
QVA-Z20-01-00 Sampling Procedures, Selection and Application
80-T-35-0001 Vapour Degreasing
80-T-35-0014 Cleaning with Organic Solvents (Cold Cleaning Agents)
80-T-35-0020 Alkaline Cleaning
80-T-35-0090 Rinsing
80-T-35-0095 Water Quality
80-T-35-0100 Acidic Pickling of Aluminum and Aluminum Alloys
80-T-35-0110 Alkaline Pickling of Aluminum and Aluminum Alloys
80-T-35-0114 Pickling (Brightening) of Aluminum and Aluminum Alloys in Nitric Acid
80-T-35-2001 Sealing of Anodized Layers
80-T-35-2002 DC Sulphuric Acid Color Anodizing with Sealing
80-T-35-9120 Coating with Paints, General

80-T-35-2000
01-02-09
Page 2
Aug 01/10
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 PROCESS AND MATERIAL SPECIFICATION

Page 3 80-T-35-2000 (01/2006)

3 PREREQUISITES

3.1 Personnel
The individual work steps of this process shall be carried out by trained or qualified skilled personnel only.

3.2 Manufacturing documents

The manufacturing documents shall contain the following reference to this instruction:

Anodizing per 80-T-35-2000

4 MATERIALS AND EQUIPMENT

4.1 Bath fluid

Only the products specified in the data sheets of this process specification shall be used. Water of the qual-
ity B per 80-T-35-0095 shall be used to make up the bath.

Product-specific characteristics: see data sheet.

4.2 Bath system and baths

The bath system, associated racks and attachments shall be made of materials resistant to the bath me-
dium.

The DC anodizing system shall be equipped as follows:

• steel bath - with solid rubber or plastic lining

• cooling equipment (controllable)
• direct current voltage (infinitely variable)
• bath circulation
• temperature indication
• lip fume extraction
• fill level marking

4.3 Materials
The alloying constituent of copper shall not exceed 5 % and that of silicone not 2 %. The total alloying con-
stituent shall not be > 13 %.

80-T-35-2000
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 AIRBUS
PROCESS AND MATERIAL SPECIFICATION

Page 4 80-T-35-2000 (01/2006)

4.4 Components
All mechanical processes such as punching, trimming, drilling, forming, dimpling, deburring, welding
and heat treatment must have been completed prior to DC anodizing.

The components must be free from foreign coatings, surface flaws - especially pores and cracks.

If necessary, a crack inspection per QVA-Z10-55-00 shall be carried out prior to DC anodizing.

Note:

• Assembled parts which have been riveted, spot-welded, screwed or tacked or have been
welded on one side may not be treated by this method.

• Color differences between the weld and base metal are permissible in the case of seams
welded on both sides.

• Bonding connections must be specified exactly by the designer. They must be masked during
anodizing and must be indicated in the manufacturing documents.

• The components must either have been produced with oversize to provide for the contact
points or the contact points must be defined by the design.

4.5 Equipment
4.5.1 Anode
Consists of the rack and component. There must be a sufficiently large contact surface between the
rack and the component to warrant good current flow.

4.5.2 Cathode
Consists of suspended electrodes made of pure aluminum. The cathode can be protected against the
components suspended in the anodizing bath by plastic net screening to avoid the danger of short-
circuits.

4.5.3 Racks
• Material: aluminum or titanium alloy
• The cross-section must be adapted to the component surface.
• Al racks must be de-anodized every time prior to making up a new bath.
• Ensure correct contact installation.

4.5.4 Masking material

Only masking materials which are resistant to the bath fluid, e.g.

• aluminum tape Scotch 427 of 3M

• rubber plugs

and which are also resistant to all pretreatment processes and temperatures shall be used.

80-T-35-2000
01-02-09
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Printed in Germany
 AIRBUS
PROCESS AND MATERIAL SPECIFICATION

Page 5 80-T-35-2000 (01/2006)

5 PROCESS
Observe the process flow chart per 8.

5.1 Pretreatment
5.1.1 Cold agent cleaning
Per80-T-35-0014.

5.1.2 Alkaline cleaning

Per80-T-35-0020.

5.1.3 Alkaline pickling

Per80-T-35-0110.

5.1.4 Acidic pickling of aluminum

Per80-T-35-0100.

5.1.5 Pickling (brightening')

Per80-T-35-0114.

5.1.6 Rinsing
Per80-T-35-0090.

5.2 Masking
Areas to be masked must be cleaned thoroughly with a cleaning agent per 80-T-35-0014 prior to mask-
ing. The masking materials specified in 4.5.4 shall be used. Precision holes should preferably be sealed
with rubber plugs.

5.3 DC anodizing
5.3.1 Bath control
Temperature : 18± 2° C

Components must be suspended in the bath to the rack in such a way that they neither touch nor cover
one another and that the gases developing during the anodizing process can escape. It is very important
to ensure that the components to be anodized have a proper contact to the rack and that they are com-
pletely immersed in the electrolyte. Pipe interiors can only be anodized to lengths of up to 2 Ŷ 0 from the
pipe end.

5.3.2

80-T-35-2000
01-02-09
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 AIRBUS
PROCESS AND MATERIAL SPECIFICATION

Page 6 80-T-35-2000 (01/2006)

Anodizing program

Rated .· ag
1.2 D 18.

· · nl om la t [mitt] ...

An exposure time of about 35 minutes is reguired for layer thicknesses of 10 to 15 —rn.

5.4 Rinsing
Immersion spray rinsing per : 80-T-35-0090
Rinsing time : 10 to 30 minutes
Water guality per 80-T-35-0095 : B

or

Cascade rinsing by counter-current process per: 80-T-35-0090

Rinsing time 1st step : 2 to 5 minutes
nd rd 1)
2 /3 step : 15 to 30 minutes

Water guality per 80-T-35-0095 : B2)

1)
If the third step is also selected, the total rinsing time (2nd and 3rd steps) amounts to 15 to 30
minutes.
2)
The last rinsing bath must always correspond to water guality B.

5.5 Drying
Components are dried in a drying tank or an air circulation oven at max. 50 °C [time: 20 to 60
minutes].
The drying process can be assisted by prior warm rinsing.
Warm rinsing per : 80-T-35-0090
Rinsing time : 3 minutes
Temperature : approx. 40 °C
Water guality per 80-T-35-0095 : B

5.6 Further treatment

80-T-35-2000
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 AIRBUS
PROCESS AND MATERIAL SPECIFICATION

Page 7 80-T-35-2000 (01/2006)

• All DC anodized components [e.g sealing per 80-T-35-2001 or coloring and sealing per 80-T-
35-2002], must immediately be further treated. For the allowable interval up to paint
application, see 80-T-35-9120.
• The components must be handled with clean gloves.
• The components shall be protected from deformation.

5.7 De-anodizing
5.7.1 Alkaline pickling
Per80-T-35-0110.

Note: Particular care is required for components with fits!

5.7.2 Rinsing
Immersion spray rinsing per : 80-T-35-0090
Rinsing time : 3 to 5 minutes
Water quality per 80-T-35-0095 : B

5.8 Defect sources

Occurring defects and their causes

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80-T-35-2000
01-02-09
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Aug 01/10
Printed in Germany
 PROCESS AND MATERIAL SPECIFICATION

Page 8 80-T-35-2000 (01/2006)

6 QUALITY ASSURANCE
Unless otherwise specified in process- or component-specific design, manufacturing or QA
documents, the competent organization unit shall ensure that the following measures are taken.

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Scope of sampling per QVA-Z20-01 -00

6.1 Visual inspection

The surface of the anodized components shall be free from scorching marks, contamination and
corrosion.

6.2 Inspection of layer thickness

 Layer thickness measurement (eddy current method)
Per QVA-Z10-50-03.

6.3 Test of corrosion resistance

For this test, two samples of the material 3.1354 T35 orT42 with the dimensions 80 mm x
150 mm x 1 mm are anodized (layer thickness 10 to 15 urn) and sealed per 80-T-35-2001.

The specimens are subjected to a salt spray test per QVA-Z10-59-01 for 500 hours.

After the test, the sealed samples together should reveal maximally 10 individual marks or pits with a
maximum diameter of 0,8 mm each. Corroded areas within 1,5 mm from the edges, clamping etc. are
not affected by this.

80-T-35-2000
01-02-09
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Printed in Germany
 PROCESS AND MATERIAL SPECIFICATION

Page 9 80-T-35-2000 (01/2006)

7 SAFETY AND HEALTH

Apply the local safety regulations.

It is the responsibility of the user of this standard to establish appropriate safety and health practices
and determine the applicability of regulatory limitations prior to use.

80-T-35-2000
01-02-09
Page 9
Aug 01/10
Printed in Germany
 41RBUS
PROCESS AND MATERIAL SPECIFICATION

Page 10 80-T-35-2000 (01/2006)

8 PROCESS FLOW CHART

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~80-T~114

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fl'unher trell'lmlln'l Rinsing pe;r !S ,4

80-T-35-2000
01-02-09
Page 10
Aug 01/10
Printed in Germany
 PROCESS AND MATERIAL SPECIFICATION

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Previous issue: 10/2002

The reproduction, distribution and utilization of this document as well as the communication of its contents to others without explicit authorization is
prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

80-T-35-2000
01-02-09
Page 11
Aug 01/10
Printed in Germany