Finishing Talk Newsletter - April 2008

APRIL 2008

VOLUME 1, ISSUE 3

FINE TUNE CLEANING & RINSING WITH ULTRASONIC RETROFITS

CONTENTS FINE TUNE CLEANING

1

INDUSTRY EVENTS

2

NEWS & NOTES

3

FINISHING SPOTLIGHT

4

FROM THE FORUM

6

THE LAST WORD

15

By: Cheryl Larkin

The same characteristics of ultrasonics that make them an important component on a new cleaning or pretreatment line also make them a valuable retrofit on an existing process line… Ultrasonics can optimize the removal of some types of soils from certain parts, such as buffing compound from crevices and tiny particles from metalworking operations. Other excellent applications include precision cleaning of small objects and electronics

assemblies prior to other finishing operations, and cleaning of valve bodies, transmission parts and subassemblies, medical devices and injection molds. Sometimes ultrasonics will speed up a cleaning operation that would otherwise take much longer. For example, carbonization can be removed from injection molds in minutes instead of hours with the right combination of ultrasonics, heat, and cleaning solution. In other cases, ultra-

Spotlight: Interview with Dr. Art Kushner of Kushner’s Electroplating School (page 4)

Identifying the Cleaning Problem The pretreatment line in question has been cleaning small screw machine type parts, about one-fourth inch in diameter, which will become part of gas assembly valves. The parts have a drilled Continued on page 8...

Inside This Issue: Finishing

sonics are used to meet the challenge of removing small particles from inaccessible areas, as a major manufacturer recently discovered when looking to reduce rejects on a research and development pretreatment line about to go into production.

From the Forum: Hex Chrome on Hard Steel

(page 6)

The Future of Finishing (page 15)

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FINISHING TALK

INDUSTRY EVENTS 2008 April 9-10: Powder Coating School Denver, CO surfacefinishingacademy.com

April 21-24: NA 2008 I-X Center Cleveland, OH www.nashow.com

San Destin, FL

April 22-24: NASF Washington Forum Washington, DC www.nasf.org

[email protected]

April 28-29; May 1-2

April 20-23: SSCT Annual Tech. Conference

April 21-23: Coatings for Plastic Symposium Chicago, IL (888) 530-6714 www.coatingsforplastics.com

MacDermid Electroless Nickel School

Irvine, CA; Dallas, TX [email protected] May 4-7: RadTech 2008 Chicago, IL www.radtech2008.com

May 13-16: ET 2008 Orlando, FL www.et08.org May 14-16: Electrocoat 2008 Indianapolis, IN www.electrocoat.org June 3-5: American Coatings Show Charlotte, NC american-coatings-show.com

Have an upcoming event? Tell us about it at: www.finishingtalk.com!

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VOLUME 1, ISSUE 1

NEWS & NOTES Spartanburg, SC The Dürr Group has received a major order from the BMW Group for its U.S. plant in Spartanburg, SC, worth more than €100 million. BMW’s production capacity at the plant will be increased from 160,000 to 240,000 units by 2012. The required expansion of the paint shop will be realized largely by Dürr. While production is supposed to begin in the first two areas in mid-2009, the sealing line’s startup is planned for mid-2010. Capacity is to increase from 27 units per hour now to 46 as a result of expanding the paint shop. For more information, visit www.durr.com or www.bmwgroup.com.

Fridley, MN

DuPont Coating Solutions has formally certified Nor-Ell Inc. of Fridley, MN, as a Certified Star CoaterSM. As a member of the DuPont Star Coater program, Nor-Ell submitted a request for DuPont to audit its operations in an effort to qualify for certified status. For a Star Coater member to qualify as certified, an independent industry consultant examines 10 different areas that cover the operations of the business. These areas include safety, customer satisfaction and quality and consistency. For more info visit:www.dupontpowder.com or www.starcoater.com.

DEARBORN, MI

The Society of Manufacturing Engineers (SME) will host the NanoManufacturing and the co-located MicroManufacturing Conference and Exhibits, April 22-23, 2008,

at the Sheraton Hotel in Framingham, Massachusetts. This event will not only bring together two emerging manufacturing technologies, but also 13 of Greater Boston’s brightest engineering and science university students. Their participation will mark the launch of the conference’s Bright Minds Nano Program, a mentoring program which provides full conference passes to students from Boston University, MIT, Northeastern University and other schools. For more information or to register, please visit www.sme.org/ nanomanufacturing or www.sme.org/micro. Washington, DC The EPA has released its National Emission Standards for Hazardous Air Pollutants: Paint Stripping and Miscellaneous Surface Coating Operations at Area Sources final

rule. This action promulgates national emission standards for hazardous air pollutants (NESHAP) for area sources engaged in paint stripping, surface coating of motor vehicles and mobile equipment, and miscellaneous surface coating operations. EPA has listed "Paint Stripping," "Plastic Parts and Products (Surface Coating),"' and "Autobody Refinishing Paint Shops"' as area sources of hazardous air pollutants (HAP) that contribute to the risk to public health in urban areas under the Integrated Urban Air Toxics Strategy. This final rule includes emissions standards that reflect the generally available control technology or management practices in each of these area source categories. For more information, pleas e visit http://www.epa.gov/fedrgstr.

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FINISHING TALK FINISHING SPOTLIGHT:

T

his month, Finishing Talk interviewed consultant, educator, and director of the Kushner Electroplating School based in Sunnyvale, CA. Dr. Art Kushner earned his Ph.D. in Chemistry from Penn State University, and has been training individuals in the electroplating business for over 25 years. In addition to the Electroplating School, Dr. Kushner has served as President and Education Chairperson of the Santa Clara Valley Branch of the American Electroplaters and Surface Finishers Society (AESF). FTalk: How long have you been

involved in the finishing industry, and what initially attracted you to this sector?

AK: I have been around the electroplating industry since I was 7-8 years old. The Kushner Electroplating School (KES) was founded by my dad in 1947. He had worked in electroplating in the 1930's, and after working on the Manhattan Project decided to get into consulting and training after WW2. He often stated that he wanted to play a part in bringing the electroplating industry into the 20th century. I started out by stuffing envelopes, then was promoted to working in his lab, and later worked on some of his research projects. I was not initially attracted to this industry, and in fact I was heard to say a number of times when I went off to college that I did not want to have anything to

do with the industry. Well, as life teaches you do not make statements like that because they well come back and bite you! I trained as a chemist, and received a Ph.D. in Physical Organic Chemistry. I did the college professor bit for a while, and worked for private industry in various chemical related industries, but continued to work with my dad on special projects. When my father died in 1978, I took over the business and operated it on a part time basis. In 1993 my wife, Bobby, and I expanded the business and started offering seminars as well as consulting on a full time basis. FTalk: How old is the Kushner

Electroplating School, and how has it changed since its early days?

AK: This year the business will be 61 years old. The basic principles of electroplating have not changed. Faraday's Law has not bee repealed by Congress, thank goodness! Some of the things that have changed are: A much better understanding of the basic principles of electroplating: the way plating is performed (better chemistries, better control, etc.); environmental concerns (you can't dump your plating waste in the city sewer, etc.). In addition the method of business has changed: Use to be phone calls, mail and paper checks. Now it is e-mail, credit card, electronic transfer of funds. FTalk: What courses do you cur-

rently offer through the school?

DR. ART KUSHNER

AK: We offer a wide range of programs:

Electroplating Know How II

A 20 volume comprehensive correspondence program (distance learning)

Electroplating Know How Custom Programs Custom

training programs using selected volumes from the comprehensive program (correspondence)

Electroplating Know How Basics Two day basic principles

seminars at various locations

On-site Training Programs

that can be as general or detailed depending what a company requires.

FTalk: Who organized/compiled

the 20 volume correspondence course? How long did it take to do so? AK: Our original was written in 1947-48, and consisted of ten volumes. The original program took approximately one year. The 20 volume program was written over a three year period, 1973-1975. Both were written by my father. Since that time, a good portion of the 20 volume program has been edited, updated, and rewritten by me.

FTalk: In addition to being the director of the Kushner Electroplating School, you also offer consulting services for metal finishing businesses. In your experience, what has been the most challenging part of this job, and what was the most difficult problem you had to solve?

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VOLUME 1, ISSUE 1 AK: The most challenging part of my job is to prepare training programs/ seminars that teach/ educate and are enjoyable. Anybody who has ever taken a class or seminar remembers speakers/trainers/professors that put you to sleep. The trick is to pass on information and make it a pleasant experience. Consulting can be difficult at times because your client is not really giving you the complete "skinny". Trying to get the real facts on a consulting gig can be very difficult at times. Strangely enough, what I find most frustrating when consulting is that the customer is paying you to help solve a problem, but at the end of the day is not willing to follow your suggestions and recommendations. FTalk: Do you have any plans

for expanding the school to encompass more programs, courses, or subjects in the future? AK: I am hoping to prepare a few programs that will be available on the internet. People today are short of time and have a much shorter attention span than individuals growing up in the 50's and 60's. They do not like long seminars or reading manuals. Use of the internet for training is a good solution for this problem. FTalk: Have you seen an overall

increase or decrease in interest in the study of Electroplating since you took over as director of the school? AK: There definitely is a downward trend in interest in the study of electroplating. Electro-

plating is not a "cool" profession in most people’s eyes. Electroplating can not compete with computers, software, and multimillion dollar business deals. In addition, much of our industry is moving and has moved off shore. The companies that remain in North America are stronger because they have made commitments to better technology and improving environmental operating conditions; but many smaller shops could not, or chose not to, and they have disappeared. In short, electroplating in North America is not a growth industry. FTalk: What is the percentage

(estimate) of youth that are showing interest in the area of electroplating, from your observation? AK: I can't really give you an estimate but I suspect that individuals interesting electroplating

as a career is probably less than 0.001%. FTalk: Is the Kushner Electroplating School currently, or planning on, making an effort to promote metal finishing education and careers to college and high school aged students? AK: No, we are not. Perhaps as part of a consortium or partnership we would get involved, but not by ourselves. ~FT~

If you would like more information on the Kushner Electroplating School, upcoming classes and workshops, or would like to know more about Dr. Kushner, please visit his website at www.platingschool.com. He may also be reached by phone at (408) 749-8652, or by email at [email protected].

Your Total Finishing Resource. T: (800) 438-6880 T: (828) 464-1376 F: (828) 464-7094 www.jacksonlea.com

1715 E. Conover Blvd. Conover, NC 28613

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FINISHING TALK

FROM THE FORUM: HEX CHROME ON HARD STEEL Posted on December 3, 2007 In this month’s column, Finishing Talk forum members Overchrome, Labrat, and thechuz discuss problems and solutions surrounding adhesion when chrome plating hard steel. Feel free to add your thoughts to their ongoing discussion by visiting the forums at www.FinishingTalk.com/electroplating and then clicking on the thread entitled “Hex Chrome Hard Steel”. For more ‘From the Forum’ discussions, check out our monthly internet television show, Finishing Talk Live, where hosts Paul Fisher and Paul Skelton bring the boards to life!

www.finishingtalklive.com

Overchrome: I have a project to add a layer of chrome, about 12 mils thick, to a piece of OD round stock. The piece is made from hardened heat treated 1045 steel. My concern is with adhesion. From past experience I know that the harder the piece being plated, the harder to get the chrome to adhere. As of now, I run my tanks around 130 degrees and use a reverse etch of about 30 seconds to 2 minutes to do my plating. This is done in a separate tank that has the same make-up as my plating tank. How hard can stock be before you cannot get it to adhere? Is there a different process that I should use to plate this type of steel? Would using a different chemical to etch help? Labrat: This is normally the process used for hard chrome plating on steel. However, if you have adhesion problems, you could try a more aggressive approach - soak clean (high alkaline) - electroclean (high alkaline) - electrolytic hydrochloric acid prep (reverse current/direct current/reverse current), rinse well, reverse current chrome etch, chrome plate. Another option (if permitted for appearance) is to sandblast after the alkaline cleaning step,

then repeat the entire prep sequence stated above. Hope this helps. Overchrome: I don't have too much trouble doing hard chrome on most steels. Currently, I prep, scotchbrite, naptha wipe, rinse and repeat, reverse etch in chrome, and chrome. I also do a water break test. I found this process works well, except for really hardened steel. I don't think the problem is in the cleaning, I believe it is the etching process. I am going to look into a hydrochloric acid prep process. After sandblasting steel, how much prep do you have to do to it before you can plate over the sandblasted area? Also, what media should be used? Currently, I have the ability to blast with a fine glass bead. Labrat: The glass bead should work. If the glass beads seem to break down before producing a noticeable etch, you may need to use something more aggressive, like aluminum oxide. Make sure the part is thoroughly cleaned before blasting, blast, then reverse current chrome / direct chrome plate. Overchrome: Well, I attempted a test piece using your advice. The only step that I changed right now from my normal process was adding the SANDBLAST. I also Increased the length of the etch time. It is hard to believe that just those little added steps allowed the chrome to adhere. It also turned out a little brighter. I am not sure exactly why the sandblast made such a difference, but it did. Thanks for the advice. I will post back when the other piece comes out. thechuz: If it has been heat treated, you probably have heat -scale on the component, which can make the adhesion poor/ non existent. An HCL pickle can remove this scale most of the time, but there’s potential for hydrogen embrittlement which probably wouldn’t be an issue for that strength of material. A sulphuric etch can help allot for the higher tensile materials, and if there is a significant silicon in the steel (e.g. 300M) a sulphuric/HF etch works a

VOLUME 1, ISSUE 1 treat. Grit blasting usually does the trick on most metals, followed by a good strike. Don’t leave a grit blasted component too long (hours) before plating, as it is a lot more likely to corrode. Grit (sand) and Vapor (wet) blasting are very effective at livening up the surface and removing oxide layers which can make the component passive. Overchrome: Thanks far all the help. The piece I plated came out exactly like I hoped it would. I also found a secondary problem that I think was affecting the process. We rub all our pieces with scotchbrite after the prep, before we plate, and for some reason the tech prepping the piece used the wrong scotchbrite. He used one with aluminum oxide in it. I think this might have been an issue that caused some of the pitting.

Join in on this conversation and other finishing discussions at www.finishingtalk.com. Maybe your advice, views, or opinions will end up in a future installment of ‘From the Forum’.

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FINISHING TALK

FINE TUNE CLEANING & RINSING - CONTINUED FROM PAGE 1 orifice which traps both cutting oil and metal shavings. Because the parts are subsequently plated, cleanliness is critical. The size and projected volume of the parts make racking impractical, so the parts are processed in both the pretreatment and plating operations in a motorized barrel loaded one-third full. Even with the mechanical action provided by the motorized barrel and a mild alkaline cleaning solution and multiple rinses, the cleaning was unsuccessful. A closer look at the process became necessary when O-rings farther along in the production chain failed to seat correctly on the parts, indicating the continued presence of oil and/or metal shavings. In fact, microscopic evaluation of a sampling of 100 parts showed that 99 had some remaining soil contamination after barrel processing through the alkaline clean and multiple rinsing steps. So, although in theory, rotation would maximize part exposure to cleaning and rinsing agents, the combination wasn't getting the job done. Process engineers explored various alternatives and/or enhancements for the process. These included different cleaning chemistries and electrocleaning, but neither solved the problem. How Ultrasonics Can Help "Ultrasonics are a good option to consider in cleaning scenarios such as these, because of the nature of the cleaning activ-

ity they provide," says Ryne Johnson of Miraclean, who was called in to work on the project. Ultrasonic energy occurs when sound waves are introduced into a liquid such as water. The sound waves create microscopic bubbles during periods of positive pressure, which implode and release a burst of energy during periods of negative pressure. This process is called cavitation, and in conjunction with appropriate chemistry and temperature, the energy undermines and releases soil barriers.

Parts cleaned in rotating barrel in mild alkaline cleaning solution show cutting oil and metal shavings still present on the parts.

One of the most special aspects of ultrasonics is that the imploding bubbles travel wherever the solution goes, allowing cleaning activity even within complex part geometries. In this case, the rotating barrel holding the parts—with its small perforated openings for solution to flow through—had to be considered as well. In a typical parts-cleaning application, ultrasonics are bottom -mounted and the watts of ultrasonics required are determined by the volume of the

tank, the substrate and geometry of the parts, and the nature of the soil. Stainless steel process tanks are indicated, as they encourage reflection of the sound waves throughout the solution, thereby enhancing the ultrasonic action while at the same time withstanding it. When cleaning with ultrasonics, the frequency of the sound waves is matched to the application. For the most part, lower frequencies (20-40 kHz) are safe for most applications and will produce the most intense cavitation energies to remove the most common types of contaminants (oil, grease, metal chips). They are also the most commonly used frequencies. Higher frequencies (68-250 kHz) will produce smaller cavitation bubbles with less intense energies, but more of them. This can be beneficial in the removal of smaller particles and where damage is a concern (polished surfaces, delicate parts, soft substrates). Accomplishing the Retrofit The pretreatment line originally consisted of a series of polyethylene tanks, including a polyethylene cleaning station. Because space was available for a new clean station and polyethylene is not compatible with ultrasonics, Miraclean recommended adding a new stainless steel station to the beginning of the line where the ultrasonic cleaning activity would take place. (In other retrofit scenarios, ultrasonics can be added to existing stainless steel tanks.) Presented with the new tank

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VOLUME 1, ISSUE 1 option, process engineers decided to size the tank to accommodate two motorized barrels, thereby increasing throughput. The new tank is equipped with

Parts now clean after ultrasonics retrofitted on the application (which remained the same otherwise).

40 kHz of bottom-mounted ultrasonics, proven through testing to be able to penetrate the motorized barrel openings and cavitate throughout the load. The motorized barrel speed was minimized to promote the ultrasonic penetration and enhance

the cleaning action. The tank also is equipped with heat, which encourages ultrasonic activity in a temperature range of 100 to 180ºF (above which heat reduces cavitation pressure and becomes counterproductive to ultrasonic activity). Cleaning time in the new ultrasonic scenario remains the same as before: three minutes per load—now actually three minutes per two loads, thereby doubling production. As before, the cleaning station is followed by immersion in multiple rinses occurring in the original polyethylene tanks. The difference is that a recent microscopic evaluation of parts cleaned in rotating barrels in the new ultrasonic tank found that 99 out of 100 parts were clean and showed no evidence of cutting oil or metal shavings. Subse-

quent processes also now proceed without incident. Ultrasonic Rinsing Takes a Turn Ultrasonics are not always necessary in rinse tanks, but they can be recommended in certain applications where the geometry of the parts or the level of cleanliness required suggests that they would be of value (to meet a clean room or military specification, for example). As with cleaning tank ultrasonics, rinse tank ultrasonics can also be retrofitted into existing applications to improve performance. One such application is a nickel chrome plating line at a major manufacturers, designed to plate a bright finish on parts. Continued on page 12...

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FINISHING TALK

AAC RELEASES NEW TECHNICAL BULLETIN FOR ANODIZING INDUSTRY

A

nodizing professionals now have a new reference to turn to when searching for an answer to the question ‘which is the proper adhesive to bond various materials to anodized aluminum’? The Aluminum Anodizers Council (AAC) has released a new Technical Bulletin: “Guide to Selecting the Proper Adhesive for Anodizing Applications.” The document explains which adhesives are better to use when bonding anodized aluminum to various substrates. The publication, released to AAC members in February, is another in a series of Technical

Bulletins containing valuable reference information about aluminum anodizing. The Technical Bulletin addresses considerations for choosing an adhesive, identifies characteristics of each adhesive, and features a selection guide. The new Technical Bulletin, titled, "Guide to Selecting the Proper Adhesive for Anodizing Applications," as well as the Technical Bulletin Compendium containing the full library of Technical Bulletins published by the Aluminum Anodizers Council over the past 15 years is available for purchase through AAC. The Aluminum Anodizers Coun-

cil is the international trade association of firms engaged in aluminum anodizing and whose mission it is to promote the use of anodized aluminum worldwide through technical interchange, education, marketing and other means to meet the common interests of its members.

For more info, contact the Aluminum Anodizers Council, 1000 N. Rand Road, Suite 214, Wauconda, IL 60084-3102 USA. Telephone: 847/526-2010 Fax: 847/526-3993; [email protected]; www.anodizing.org.

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VOLUME 1, ISSUE 1 GM SPONSORS 2008 BRIGHT MINDS MENTOR PROGRAM

T

he Society of Manufacturing Engineers (SME) announced that General Motors will sponsor its fifth annual Bright Minds Mentor Program. As a part of the program, 50 Orlando School Districts' high school students will participate in the customized program while attending the SME RAPID 2008 Conference & Exposition at Disney's Coronado Springs Resort on May 21, 2008. Since 2003, the SME program's ongoing mission has been to give promising technology-oriented high school students opportunities to learn about additive manufacturing and rapid development technologies from industry-expert mentors.

The Bright Minds Mentor Program originated from SME's Rapid Technologies & Additive Manufacturing Community in 2003 and is led by a distinguished panel of dedicated SME members and volunteers. One of these leaders is General Motors senior researcher, Patrick Spicer. "We see this as a great opportunity to get students interested in technical fields that are crucial to the automotive industry, such as engineering and manufacturing," he said. "That's one of the reasons why we're glad to be a part of this program. General Motors is always looking for talented people with strong backgrounds and expertise in technical areas."

This year's Bright Minds Mentor Program will kick off with an overview by industry consultant and analyst Terry Wohlers of Wohlers Associates, Inc. Over the course of the day, these students will attend conference sessions, tour exhibits featuring computer-aided drawing demonstrations, and learn Rapid Technology's influence on dental and medical applications as well as aerospace industry advancements. Several of the top prototyping equipment manufacturers also will loan equipment and provide materials to the schools for the next school year. For more information on Bright Minds, please visit www.sme.org/ brightminds. For details on SME or the RAPID show, please visit www.sme.org/rapid.

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FINISHING TALK

F I N E T U N E C L E A N I N G & R I N S I N G , CONT FROM PAGE 9... The plating line consists of pretreatment, plate, and nine post-plating rinses, all heated and equipped with air spiders to promote solution movement. To eliminate unacceptable spotting, the last two rinse tanks are high quality DI water. The final rinse is followed by a recirculating hot air dry. Because the parts are now a finished product, they then move on to inspection and packaging. Identifying the Problem The problem that led to the ultrasonic retrofit in this case was a spot that mysteriously began appearing after the drying operation. Orange to brown in color (indicating that it was errant hexavalent chromium plating solution), the spot was miniscule in size but very obvious on the otherwise bright finish. It occurred near a cavity, but was not visible during any of the nine rinses or until after the hot air dry, when it was discovered by product inspectors. A nuisance cosmetic imperfection, the spot then required hand-cleaning by the inspection team, which was time and energy consuming. Continued on next page...

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VOLUME 1, ISSUE 1

Evaluating Ultrasonics The spot was traced back to imperfect rinsing despite the quantity of rinses, the air agitation and heat in the rinses and the DI water. Process engineers determined that the dry cycle was wicking the errant chrome out from the cavity. Miraclean was called in to test ultrasonics in the rinse cycle. In a testimony to the power of imploding bubbles, 25 kHz ultrasonics tested as too powerful for the application, when the frequency microscopically opened a gateway in the cavity, affecting fit in the final part. The slightly less aggressive 40 kHz effectively removed the spot in testing without affecting part fit. Retrofitting the Ultrasonics There were two challenges to retrofitting ultrasonics on this production line. The first was that the nine rinse stations were all constructed of polypropylene, which while an economical choice in the world of multiple rinses, would not support ultr asonic a ctivity. (Ultrasonic energy is absorbed by polypropylene, therefore losing some of the ultrasonic effectiveness, and ultrasonics will undermine the welds in a polypropylene tank causing tank failure.) Miraclean designed a stainless steel tank insert for the third to the last rinse station on the line (the last tap water rinse). Sized to fit into the existing tank, the

insert is outfitted with electric heat, a junction box for the heat and the ultrasonics, and a remote, cooled NEMA enclosure to house the ultrasonic generators and provide a central disconnect.

Schematic steel

of

stainless

insert/rinse

tank

ultrasonic retrofit.

The second challenge on this retrofit was that the parts are rack mounted for plating on plastisol coated racks. Even here, the plastisol will absorb some of the ultrasonic energy, potentially minimizing its effectiveness. Plus the critical surfaces of the part face a side, not the bottom, of the tank in this application. Therefore, to maximize ultrasonic exposure to critical part surfaces, the immersible ultrasonic "cans" also are rack mounted and cover a side wall in this application. Rinse tank times remain the same as before the addition of ultrasonics (23 seconds of immersion per rinse). The result

of adding ultrasonics to one rinse station in this process line is that the spotting problem that used to affect almost every part has been eliminated, thereby saving time and money. Variety of Sizes and Configurations Ultrasonics come in a variety of sizes and configurations. They are available as diaphragmmounted in a dedicated stainless steel tank that has been sized to meet particular requirements, or as immersible stainless steel cans in a variety of sizes to be retrofitted into existing stainless steel tanks. As we've seen, they can even be retrofitted into polypropylene tanks by thinking outside the box (or inside the tank) and employing a stainless steel insert. Ultrasonics in the right frequency for the job and at the appropriate watt density, can make a big and immediate impact on the success of a cleaning, pretreatment, or rinsing project. The potential for retrofitting ultrasonics means that you don't have to wait for a whole new process line to reap the rewards. ~ Written by Cheryl Larkin of Miraclean® Ultrasonic Cleaning Systems based in Ashville, NY.

This article was reprinted courtesy of Products Finishing Magazine.

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FINISHING TALK

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THE LAST WORD

T H E F U T U R E O F F I N I S H I N G - A LOOK AT THE REPORT BY THE NMFRC

F

eeling a little shaky about the finishing industry these days? Unsure of what the not-so -booming U.S. economy has in store for you? Then the National Metal Finishing Resource Center just might have some of the answers (and predictions) that you need. In January of this year, the NMFRC released the product of a collaboration between several well known industry professionals, entitled “The Future of Finishing”. Self-described as written for anyone who “has a stake in the Surface Finishing industry”, this thorough report is suitable for business owners, employees of job shop or captive surface finishing operations, suppliers and customers, environmental regulators and the general public. It is a far reaching resource that I would suggest taking the time to at least scan through, as it is packed full of useful facts and detailed explanations of current and future trends affecting the surface finishing industry. Focusing on three areas important to today’s industry – economics, environmental regulations, and technology – the report attempts to both educate the reader on the basics of each trend, as well as explore the likely course of events that could manifest within the industry in response to each one. A set of two ‘potential futures’ for the industry is presented early on: one in which newly introduced technologies would require a skilled coater to function properly, and another where plating technology evolves into

a fully automated, ‘no skills necessary’ process. Since there are few new technologies boasting the reliance on skilled operators, it appears that the latter future may be the one we are heading for; the only question is, how long until plating systems can effectively run themselves? Economics Unfortunately, this is not the most popular buzzword floating around the country at present. The U.S. is currently struggling amidst the ruins of a declining manufacturing base, competing against an unprecedented number of global competitors, wallowing in its trade deficit, and simultaneously ignoring scientific research. With all this negative pressure on the economy as a whole, it’s no wonder that the finishing industry is in such a bind; in addition to the above, finishers nationwide are attempting to compete with impossibly low prices from Asia, stringent product and materials regulations from the European Union, and an endless patchwork of process regulation from the EPA and similar government entities. Environment Which brings me to my next topic. In addition to the run of the mill environmental concerns that any surface finisher can no doubt relay from memory (and the report also does a terrific job of giving a concise overview of existing regulations for those of you who cannot), there is a pretty detailed discussion concerning two fairly recent environmental concerns that will effect finishers in years to come.

The most notorious, of course, would be Global Warming, resulting in a rise in energy costs and potentially slower economic growth. The other, lesser known (but quickly becoming a household name), is the ‘life-cycle method’. This method is a way of manufacturing that takes into consideration the environmental burdens of producing based on the energy and materials used, and wastes created by the process. Technology Insofar as this trend is concerned, the authors of the report provide the reader with a comprehensive analysis of the way that finishers are likely to optimize existing technologies, and develop and implement new technology. These include improving conventional surface finishing processes in order to “reduce chemical usage, worker exposure risk, and waste generation” while maintaining a quality finish and productivity, and the switch from “current immersion chemistry solutions to alternative metal deposition technologies” (such as HVOF or PVD). This article only scratches the surface of the wealth of information meticulously condensed into the report. The insights it offers into current and future trends is definitely worth a glance (or a good, long stare ). You can download it directly (and for free) at the NMFRC’s homepage: www.nmfrc.org.

Take a look, and tell us what you think at finishingtalk.com!

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Rutherfordton, NC 28139 April 2008 Anna Levitsky, Editor Phone: 704-995-2263 [email protected]

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