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2005 Anodizing Conference Abstracts
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40-Year-Old Insurance Policies Could Be Worth Millions
Bret A. Stone, Paladin Law Group, LLP

Allegations of soil and groundwater contamination are becoming commonplace in many industries. Businesses are being targeted in civil actions seeking damages in the millions of dollars. While it is important to retain counsel experienced in environmental law, it is equally important that your attorney has the experience in locating, analyzing, and enforcing insurance policies. More often than not, businesses wait until there is a problem before understanding their historic insurance programs. Most businesses do not realize that insurance policies they purchased 20, 30, or 40 years ago may be worth millions of dollars in defense and indemnity coverage. The information, however, is literally disappearing. What economical steps can you take proactively to understand your historic insurance program and protect your business?

Aluminum Anodizers Council Marketing Initiatives
---Prepared by members of the AAC Marketing Committee

Marketing is pivotal to the member services offered by the Aluminum Anodizers Council. The core mission of the Council is to promote the use of anodized aluminum worldwide; one of the primary means of fulfilling that mission is to support the marketing efforts of its members. Last year saw the development and launch of the Anodizing branding campaign, with its trademark logo emphasizing the attributes of Protection, Beauty, Durability, and Confidence, all from within the natural aluminum substrate. The next step for the Marketing Committee is to develop a series of computer-based presentations that explain the features and benefits of anodized aluminum products. Members will be able to use these modules, personalized to reflect their own companies’ products and services, in marketing anodized aluminum to new customers and others.

Before You Begin: Aluminum Metallurgy and Anodizing
Terry Sjostrom, Henkel Surface Technologies

The results of the anodizing process are greatly influenced by the aluminum alloy being treated, so it is important for anodizers to have a basic understanding of aluminum alloy metallurgy. Learn what must be known about the alloy being anodized in order to obtain consistent results. Basic physical and mechanical properties of aluminum alloys, composition of aluminum alloy systems, temper designations, surface structure, and their respective effects on the anodizing process will be reviewed.

Before You Begin: Racking and Clamping Systems for a Modern Anodizing Plant
Ed Burlingham, Burlingham International

The move is on at anodizing plants around the world to improve productivity and reduce costs. To accomplish this, anodizers are evaluating every aspect of their finishing lines. One area that comes under constant scrutiny, because it so greatly impacts overall production efficiency, and ultimately profitability, is the racking function because of its influence on overall production efficiency. Learn how issues such as a company's labor force, customer requirements, new environmental regulations, and line automation can dramatically affect a plant's racking system. The findings from comprehensive case studies of the racking department in successful finishing plants will also be reviewed.

Boric-Sulfuric Acid Anodizing Salt Spray Failure Troubleshooting
W. John Fullen, Boeing Corporation

The purpose of the salt spray test is to validate the “health” of an anodize process line. This test requires two weeks, which makes effective corrective action decisions paramount to avoiding long periods of downtime. By assimilation of many decades of Boeing documentation, external literature and consultation, an Anodize Troubleshooting Guide (ATG) has been developed. The ATG is a simple checklist and is mostly categorized by process solution but also includes sections on other non tankline processes, equipment, and salt spray test conditions. Although this guide is specific to Boric Acid - Sulfuric Acid Anodizing many references can be applied to a broader application that can help guide process engineers to a quick and effective remedy.

Comparing Nonstick Property, Hardness, and Wear-Resistance of Hardcoat Anodizing to other Hard Coatings on Aluminum
Anne Deacon Juhl, Aluconsult

Normally hardcoat anodizing is used for its wear-resistant properties. This presentation by expert consultant Anne Deacon Juhl will examine hard anodizing used for its nonstick properties. She will evaluate four different hard coat applications using three test methods including the Suga Test ISO 8541 and Vickers microhardness.

Competing Technologies: Field Performance and the Application Process
Andy Jozwiak, Linetec

The field performance of architectural paint and anodize finishes will be compared. Application processes for a quality finish will also be discussed. Learn how different paint and anodize finishes rate when compared to architectural specifications. Participants will also learn about the application process to make sure a quality product is provided.

Different Methods of Etching Aluminum prior to Anodizing
Mores Basaly, Houghton Metal Finishing

Aluminum Alloy 6063 is the most common alloy that is used to produce anodized aluminum extrusions. The anodizing process is typically performed for decorative purposes and to improve adhesion and corrosion resistance. Thus, the visual appearance of the finished product is important. The etch step is one of the most important factors in contributing to the appearance of anodized extrusions. This paper presents different methods used to etch 6063 aluminum extrusions prior to anodizing.

Following Through: Sealing Anodic Coatings
Kong Choa, Henkel Surface Technologies

The advantages and disadvantages of different sealing chemistries and the influence of anodizing condition and pore structure on sealing efficiency will be discussed. Contaminants that negatively affect the sealing process will also be explored. ASTM test methods and industry specifications will be reviewed.

Further Processing: Coloring Aluminum
Mark Jozefowicz, Clariant Corporation

This session will explore the theory and communication of color in anodized aluminum. A closer examination of application details on a variety of coloring technologies will be followed by a discussion of defects. Bring your questions and problems that you have encountered to this interactive session.

Further Processing: Fundamentals of the Bright Dip Bath
Barrie Winn, PCS Sales

The Aluminum Bright Dipping process will be discussed and parameters for a healthy bath will be briefly reviewed. Bright dip formulations that contain sulfuric acid, as well as those that do not, will be discussed and compared.

Getting Under Way: Cleaning and Anodizing
Richard Mahn, Houghton Metal Finishing

Preparation of the aluminum surface is essential to the anodizing process. Cleaning, Etching, Bright Dipping, and Desmutting will be examined, with special emphasis on identifying and controlling the main parameters that will make for a quality anodic coating. The anodizing process, itself, also will be explored from both technical and practical points of view.

Hardcoat Anodizing on High Temperature Aluminum Alloys
Leonid Lerner, Sanford Process Corporation

High temperature aluminum alloy 8009 is a rapidly solidified powder metallurgy aluminum-iron-vanadium-silicon alloy. This alloy in combination with hard oxide film has unique engineering properties which may recommend its use in compressors and impellers for aerospace applications. Various anodizing processes for these tasks will be evaluated and normal chemical composition, physical properties, and microstructures of 8xxx alloys will be presented.

Performance Benchmarking
Angela Flood, Michigan Manufacturing Technology Center, Performance Benchmarking Services

The Michigan Manufacturing Technology Center (MMTC) is a not-for-profit Manufacturing Partnership Extension center that serves manufacturers by helping them become more competitive and find ways to reduce waste in their operations. The Performance Benchmarking Service, created by MMTC, provides a survey for members to confidentially report data in order to measure performance against other companies in the industry. The program will be explained and results of the survey distributed to AAC members earlier in the year will be revealed.

Personal Protective Equipment (PPE) Use in Anodizing
Andy Reyburn, Bowers Manufacturing

The regulatory and practical use of PPE will be presented. Subtopics will include application of the Occupational Safety & Heath Administration (OSHA) General Duty Clause, specific requirements for eye, hearing, and respiratory protection as they apply to various aspects of anodizing. Workplace Hazard Assessment and program development, as well as equipment use and options will be discussed.

Product Stewardship
Charlie Simmons, Law Offices of Charles T. Simmons, LLC

Product Stewardship has been defined as an integrated business process for identifying, managing, and reducing safety, health, and environmental risk through all stages of a product's life. An effective Product Stewardship Program can achieve a "green manufacturing" image, enhancing an industry's ability to maintain regulatory compliance and lower the probability of enforcement action. An explanation of the philosophical concept of Product Stewardship and how having a formalized approach to manufacturing can have a positive influence on workplace safety and the environment will be discussed. The Product Stewardship concept as it applies to the anodizing industry will be examined including Energy Use and Conservation, Environmental Regulatory Compliance, Air and Water Emissions, Transportation, and Solid Waste and Pollution Prevention. Emerging occupational safety concerns that could be amenable to Product Stewardship, including Hexavalent Chromium, Sulfuric Acid Mists, Nickel, and Cobalt, will also be considered.

Safety and Productivity in the Workplace: How to improve performance without sacrificing productivity
Brian Stratton, Lintec

Requirements, tools and methods used to ensure low safety risk operation while maintaining or even improving productivity will be explained. Learn how safety risks can be minimized or removed. Application of training on appropriate protocol and camaraderie to apply peer pressure to significantly reduce accidents and recordable incidents will also be discussed.

Six Sigma
Mark Wisniewski, AaCron and Kevin Janis, Clariant Corporation

Six Sigma is a highly-disciplined, data-driven approach and methodology for eliminating defects—a measure of quality that strives for perfection. This session is presented by anodizers who have guided their companies through the process. Learn the fundamental objectives of the Six Sigma approach and how applying the principles to your operation can improve processes and yield quantitative results.

The Effectiveness of Various Scrubber Liquors in the Removal of NOx Gases
Melvin Todd, PCS Sales

The effectiveness of various scrubber liquors will be examined in their ability to remove Nitrous Oxide (NOx) gases emanating from the bright dip process. The NOx gases that are not captured in the scrubber are collected and analyzed by ion chromatography (IC).