REACH Compliant Aluminium Pre-treatments

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Back to Core Research Programme AMorph – 4D Printing for Field Morphing Structures Automation of Composite and Hybrid Joining Process Coaxial Wire Additive Manufacturing Processes and In-Line Monitoring Tools Development of Coded Excitation Technique for Non-Metallic Pipes Inspection Development of Digital Twin technology as a demonstrator for real-time integrity assessment of crack growth in tensile specimens Development of Friction Stir Welding (FSW) for Hydrogen Fuel Storage Tanks Development of Leak-Before-Break Hydrogen Storage Composite Pressure Vessels With Polymeric Liner Establishing Assessment Methods for Determining Safe Service Limits of High-Temperature Materials in Extreme Environments Fracture toughness in aggressive environments: effect of crack monitoring techniques on test results In-process detection and non-destructive testing of electron beam weld imperfections Internal Bore Coatings for Applications in Corrosion and Hydrogen Environment Joining of Additively Manufactured Materials Long term behaviour of polymeric liner materials/coatings in hydrogen service Techniques for High Temperature Ultrasonic Inspection of Arc Welding Ultimate Leverage Fund

Project Code: 33541

Objectives

Review available chromium-free conversion coating technologies for aluminium alloys and select suitable candidate processes.
Procurement and corrosion testing of current Cr-free conversion coating technologies, ranking them using industrially relevant key performance indicators.
Develop decision support tool to inform and guide industry to suitable REACH compliant surface treatments for selected applications.
Perform laboratory-based trials to develop innovative treatments for self-healing, chromium-free, anodised coatings.

Project Outline

This project seeks to address the current need for chromium-free aluminium alloy conversion coatings for improved corrosion resistance. There are a variety of chromium-free conversion coatings commercially available, however, there is little impartial information comparing their corrosion performance. The majority of testing that has been carried out has been performed in either an academic environment, not using commercial products, or comparing coating performance solely with Cr(VI) analogues, either chromating or anodising.

This project seeks to provide a clear understanding of the performance of alternative chromium-free conversion coatings with regards to both their corrosion resistance and self-healing capability. Technologies are expected to include phosphating, plasma electrolytic oxidation, zirconium/titanium conversion coatings, cerium conversion coatings, and chromium-free anodising. Results will be used to develop a decision support tool to guide industry in replacing chromium-based technologies.

Relevant Industry Sectors

Aerospace
Construction and Engineering
Electronics and Sensors
Medical
Oil and Gas
Power (Renewable energy)
Surface Transport (Automotive, Marine, Rail)

Benefits to Industry

The project will provide industry with a clear direction as to the most promising chromium-free conversion coating methods, in order to avoid the increasingly restrictive and costly Cr(VI) based approaches.

A decision support tool will be available online to recommend the most appropriate coating technologies as replacements for chromating and chromic acid anodising in different use cases.

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