Finishing Talk Newsletter - August 2008

OCTOBER 2008

VOLUME 1, ISSUE 9

E-COATING & POWDER COATING STRIPPING APPLICATIONS

CONTENTS COVER STORY

1

Stripping e-coat and powder from racks, in-plant

INDUSTRY EVENTS

2

By: Samuel L. Miles, Miles Chemical Solutions

NEWS & NOTES

3

FROM THE FORUM

6

FINISHING SPOTLIGHT

9

THE LAST WORD

15

This article is an overview of the three most common stripping methods used by finishers to clean hooks, racks, and part rejects. The article points out the major benefits and concerns of each method with users of electro-deposition coating (e-coating) and powder coating in mind.

Many methods are available for removing powder coating and ecoating from production hooks, racks, and fixtures. The most beneficial means available can be the same for both coating processes. Before you can fully measure the benefits of chemical stripping, you must first understand the common practices used to clean racks. The finishing industry’s rack cleaning practice has been to use burnoff ovens or abrasive-

Inside This Issue: From the Forum: Anodizing Aluminum; where went (page 6)

wrong?

media blasting to remove e-coat and powder, either by doing it in-plant or by sending the racks out to stripping services. Burn-off ovens Benefits: The burn-off oven method provides adequate results for coating removal. The benefit of the burn-off oven is the coating buildup on the rack can accumulate from 3 mils to more than 50 mils in some cases, and the burn-off oven continues to provide adequate cleaning results. Continued on page 4

Finishing Spotlight:

First Annual Gebhardt Award presented at SMF 2008

(page 9)

Economic Instability can Promote Innovation (p.15)

Page 2

FINISHING TALK

INDUSTRY EVENTS 2008 October 14-16:

October 27-28:

November 5-6:

FutureCoat! 2008

Electroplating Know How Basics

Powder Coating School

Chicago, IL

Dallas-Fort Worth, TX

San Diego, CA

[email protected]

www.platingschool.com

surfacefinishingacademy.com

October 14-27:

October 28-29:

November 7:

NASF Trade Tour - China

Applications of Nanotechnology

N. England Rgnl SF Conference

Beijing-Shanghai, China

Ypsilanti, MI

Hyannis, MA

www.nasf.org

[email protected]

[email protected]

October 15-17:

October 28-30:

November 7:

International Coatings Expo

Chemical Engineering 2008

Metalform Mexico Exposition

Chicago, IL

Birmingham, England

Mexico City, MX

www.coatingstech.org

www.chemeng08.com

www.metalform.com/mexico

October 23:

November 3-4:

ASTM Committee B08 Meeting

Aluminum Finishing Course

West Conshohocken, PA

Chicago, IL

[email protected]

www.nasf.org

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

Page 3

VOLUME 1, ISSUE 9 8

NEWS & NOTES Newport News, VA Andrew George Bachmann, inventor, entrepreneur, and business leader, died on Sept. 15, at the Riverside Regional Hospital in Newport News, Va. He was 68. Founder and Chairman of the Dymax Corporation, Bachmann's adhesive inventions and successful marketing led to the creation and development of products used in the manufacture of medical, electronic, automotive, aerospace, and consumer products. Bachmann's adhesives changed the way many of the items used daily are manufactured, helping companies to become "green" manufacturers while becoming more competitive in the global marketplace.

ers. The firm, a division of Charter Manufacturing Co., Mequon, WI, manufactures engine dipsticks, transaxle retaining rings, valve keys and valve-spring retainers. To further its global reach, in February 2007 Charter Mfg. acquired Valve Train Components Limited, Lichfield, England; and recently opened a manufacturing, warehouse and distribution facility in Wuhu, China. Learn more at charterautomotive.com.

Independence, OH The newly released September 2008 Precision Metalforming Association (PMA) Business Conditions Report indicates metalforming companies expect business conditions to weaken somewhat during the next three months. When asked what the trend in general economic activity will be during this period, metalformers anticipated a slight decline. 53% predict activity will remain unchanged (compared to 52% last month), while 31% forecast a decline in business conditions (up from 28% in August). "Increased economic uncertainty in the credit and financial markets are having an impact on PMA members, giving them less confidence that there will be any rebound in orders and shipments in the fourth quarter," said William Gaskin, PMA president. For a complete copy of the report, please visit www.pma.org/about/ stats/BCreport.

Cuba, MO Paul Fredericks and his company Usona Metal Finishing Co. were indicted on federal charges involving the illegal transportation, storage and discharge of hazardous waste at the company’s Cuba, Mo., plant, U.S. Attorney Catherine Hanaway said Thursday. The indictment alleges that in April 2007, the Usona powder coating plant on Clinton Street ceased operations and that Fredericks, 44, of St. Louis, directed the illegal transportation of drums of hazardous waste to his plant in Cuba. Between April 2007 and April 2008, approximately 100 drums of hazardous waste were illegally stored at the Cuba plant, and in April 2008, Fredericks allegedly directed the illegal discharge of those pollutants into the sanitary sewer drain at the Usona plant in Cuba. If convicted, violations of the Washington, D.C. The U.S. Envi- Resource Conservation & Recovery ronmental Protection Agency (EPA) Act carry a penalty range of two to is issuing a new Stormwater Multi- five years prison and/or fines up to Sector General Permit (MSGP) for an $250,000; and violation of the estimated 4,100 industrial facilities Clean Water Act carries a maximum in 29 different sectors to implement penalty of three years prison and/or site-specific stormwater pollution fines up to $250,000.

Milwaukee, WI Milwaukee Wire Products has been renamed Charter Automotive to reflect its commitment to global automotive custom-

Netherlands DSM Powder Coating Resins recently launched Uralac® Corres – a new technology platform, based on breakthrough innovative polyester resins for corrosion protective coatings. The first product from this line, Uralac® P 7604 is specifically developed for top coat and primer applications and provides exceptional corrosion protection in metal coating. For top coat applications, the unique Uralac® Corres technology offers the possibility to significantly reduce and sometimes completely eliminate chemical pre-treatment steps.Through the reduction of pretreatment chemicals, less process waste is created, resulting in a significant reduction in environmental impact. DSM Powder Coating Resins, the global leader in powder coating resins and part of the Business Group DSM Resins, specializes in innovation, development and manufacture of polyester resins for powder coatings. More information on DSM can be found at www.dsm.com.

prevention plans to protect water quality. Facilities are required to install control measures that meet established technology- and water quality-based effluent limits and must develop a stormwater pollution prevention plan. The new permit offers several improvements from the previous MSGP, including easier to understand discharge requirements; fast and easy electronic filing of Notices of Intent (NOIs) and monitoring reports; web-based tools for locating waterbodies and determining impairment status; and updated monitoring, inspection and corrective action schedules. More information on the MSGP: epa.gov/ npdes/stormwater/msgp

Page 4

FINISHING TALK

STRIPPING APPLICATIONS... (CONT FROM PG 1)

Concerns: Burn-off ovens operate at temperatures up to 1,000°F for durations of 1 to 8 hours. These temperatures and cycles over time can cause stress, brittleness, and metal fatigue on the steel rack substrate. In addition, residual coating ash is left behind on the rack surface after burning and must be removed by pressure water rinse or acid chemical pickle to prevent dirt contamination. The cost of gas (energy) to operate a burn-off oven must also be absorbed by the end user. Abrasive-media blasting Benefits: Abrasive-media blasting is another common method used in the finishing industry to clean e-coat and powder coating deposits from racks. Abrasive-media blasting provides adequate cleaning and coating removal. One of the benefits of rack cleaning with abrasive media is that any rust or oxidation that may be present is removed with the coating, and this is accomplished at ambient, or room, temperature. Concerns: Using abrasive media to clean racks on a regular basis results in loss of metal. This means that over time the racks must be completely replaced. Another concern associated with this method is that the residual blasting media, if

not completely removed from the racks, can create dirt contamination upon subsequent use. In addition, abrasive media is often carried out with the racks and distributed on the plant floors, creating safety concerns. The cost of abrasive-media replacement must be absorbed by the end user.

E-coated and powder-coated rework parts can also be recycled and restored to their original surface quality, and reprocessed through the coating lines in less than an hour. Powder coating racks can also be chemically stripped, as long as the racks have fewer than 10 mils of powder buildup and are cleaned daily.

Chemical stripping solutions

Concerns: Common questions concerning chemical stripping for racks and coating rework involve the proper training and knowledge associated with environmental and operator handling. The latest chemical stripping solutions are more environmentally and operator friendly than those in the past. Powder coating and e-coating sludge must be removed regularly, either by filtration equipment or by decanting on an asrequired basis. The cost of chemical replenishment must be absorbed by the end user.

Benefits: A chemical stripping process can be done in-plant at considerably less expense than the burn-off and the abrasivemedia blasting methods, which require higher equipment, energy, and media costs than chemical stripping requires. Chemical stripping operates at moderate temperatures, usually 150°F to 200°F, which keeps energy costs down. Chemical stripping also leaves the original surface of the racks intact and very clean after a freshwater rinse. Chemically stripping e-coating from parts is also easy and quick because of the low film build created during the first pass through the e-coat tank. First-pass film build is usually about 1 mil. As a result, strip time is normally 20 to 30 minutes. In less than an hour, the racks are ready to be returned to the coating line.

Samuel L. Miles, owner Miles Chemical Solutions, LLC Kissimmee, FL 248-765-9946. For further information on chemical stripping, visit: www.mileschemicalsolutions.com

Page 5

VOLUME 1, ISSUE 9 FIRE DAMAGES BELTON NICKEL PLATING PLANT Belton, SC — On September 25th an early morning fire broke out in the Belton, SC based B & B Plating plant, part of the Belton Standpipe Industrial Park. The fire is expected to sideline about 30 workers in a plant that uses high-voltage electricity to coat metal with nickel. Jim McGee, owner of the facility, said he was notified of the fire around 4 a.m. - two hours after the plant's second, nine-hour shift had closed the plant. Belton Fire Chief Alan Sims said Thursday afternoon that the fire was accidental, caused by overheated chemicals in a vat. McGee, noting that roof panels and wiring were destroyed, but the building was saved from other damage by Belton City

Firefighters, said damage to the interior of the metal building is “considerable.” Though at least one of the two production lines is likely up and running again by this point, employees on the other line could be out of work for about two weeks. “Nickel has to be heated to 140 degrees,” McGee said. “It appears to have gotten too hot and shorted out a 208-volt power line.”

dled the cleanup of sulphuric acid. McGee said the acid, used in the electroplating process, spilled and Hepaco workers were attempting to neutralize it before it became mixed with storm water runoff. An official with the South Carolina Department of Health and Environmental Control was monitoring the cleanup.

Many of the workers in the facility have been affected, and as many as 10 are involved in cleanup operations. Later that afternoon, crews from the Charlotte-based Hepaco, wearing protective clothing, han-

Cleaning Crew member, being sprayed down with decontamination solution.

Page 6

FINISHING TALK

F R O M T H E F O R U M : ANODIZING ALUMINUM; WHERE WENT WRONG? Posted on February 16, 2007 October is all about cruising through the countryside, watching the leaves change. What better way to do that than from a motorcycle? Unfortunately, Hard Color is having a hard time anodizing the clutch on his Yamaha, but has received some expert advice forum members Zurv, Labrat, Ryan Cook, DustinGebhardt, Smittys800, and John Hu. Feel free to add your thoughts to their ongoing discussion by visiting the forums at www.finishingtalk.com/community and choosing the “Anodizing” forum. For more ‘From the Forum’ discussions, check out our internet television show, Finishing Talk Live, where hosts Paul Fisher and Paul Skelton bring the boards to life!

www.finishingtalklive.com Hard Color Where am I going wrong, guys? I am trying to anodize the clutch lever on my Yamaha motorcycle, but it will not take color and I don’t know if it even took any anodizing. I am using the battery charger method, if you are familiar with it. These were my steps: 1. rinsed part in muratic acid to ensure perfectly clean. 2. used 14ga alum wire to hang part in a solution of 3. 50% premixed battery acid, 50% water 4. which should have given me about a 20% sulfuric acid solution. 5. had lead for neg in solution and attached battery charger to lead 6. attached positive to aluminum rod that the part was hanging off of

8. my bushing in the part dissolved quickly (ok b/c old bent lever used for test) 9. left on for 20 min until neg stopped bubbling and 10. the charger showed zero current was being drawn 11. took part out and rinsed in cold water 12. dipped in Rit black dye for 15 min 13. rinsed off in water, and it looked just like I started! Do you guys have any ideas of where I went wrong, or of where I could look for a better process? I would really like to figure this out, it is driving me nuts. Some teenagers are doing this and I can’t even get it...:confused: Hard Color

(update) Okay, I just found a different "how to" online that says that I need 3 parts water to 1 part battery acid to get 20%. A different source said 50/50, and even another said 2 parts battery acid to 1 part water! Ahh, my head!

edit: Wikipedia says battery acid is 33.5%, battery acid (used in lead-acid batteries) (pH 0.5). That means a 1/1 ratio of water/battery acid should have been right on. Hmm...at least I am learning. This is a fun new challenge for me. Zurv Haha, yeah... you will find that. Hopefully one of the many experts that visit our forums will be able to help your with you problem. Hard Color Okay guys, I decided to go with LCD anodizing per the caswell instructions. I ordered up their dyes and got a CC/CV power source off eBay. When everything gets here, I will try again with that method.

7. turned charger on and the lead ground bubbles

Labrat

a lot

Most dyes are sensitive to temperature and pH.

VOLUME 1, ISSUE 9 Check to make sure these 2 components are within the recommended ranges per the technical data sheets that should have been included with the dyes. Also, you said you clean with muriatic acid. This will remove metallic contamination from the surface (oxides, etc.), but not organics like soils, fingerprints, etc. You’ll need to pre-clean in a detergent based cleaner to remove these contaminants. Make sure the cleaner is not caustic based, or it will etch or dissolve the aluminum. You may also want to include a deoxidizer prep to remove any smut that could be present on the surface. 50% nitric acid works well. There are also proprietary deoxidizers on the market. Welcome to the forum! Hard Color Muratic acid attacks aluminum the same as it does other metals, correct? So, shouldn’t muratic acid work as an etcher also? Ryan Cook Let’s do this… Go to the kitchen. Get out the big old bottle of dish detergent - Dawn, Joy, etc…all have a great deal of surfactants and emulsifiers in them that will rid your not so pristine clutch handle of any dirt, oil, or grease. If you can heat the solution, great! Heat at 130 degrees, and soak it for 10-15 minutes, agitating the part occasionally. Next, rinse the part really well, and prepare to anodize it. The concentration of the bath should be about a 15% sulfuric acid solution, at around 70 degrees. Lead cathode will work, but make sure your cathode is at least 2 times the size of your part. Anodize the part at 16 volts for about 45 minutes and you should achieve a thickness of at least .7 mils. Rinse the part thoroughly, as any acid left in the anodic pores will ruin the dying process you are about to perform. DO NOT TOUCH THE PART WITH YOUR HANDS AFTER ANODIZING!! (not yet, anyways.) Your dye tank should be at a generic PH of 5.5 at 130 degrees (each dye is different, tech data sheets are great to find parameters). Dye the part for at least 10 minutes, longer for lower temperatures. Finally, you will need a boiling pot of Distilled/Deionized water; submerge your freshly dyed/rinsed-off handle in the boiling DI water for a

Page 7

minimum of 30 minutes (this is the poor boy’s style of sealing the anodized coating; crude, but effective.) Voila - you should have a good, black, anodized part. Post your findings here and feel free to contact me at [email protected] Smittys800 Sounds like you did not have a good connection to the part. John Hu Your problem seems to me to lie in not having control of anodizing temperature. Anodizing is a competitive process. Electric current makes the anodizing thickness grow, while electrolyte consumes the layer of anodizing. As during anodizing, lots of heat is released, and it will make the solution temperature go up quickly if no chilling system is there and higher temperature in the solution consumes the anodizing layer more quickly. If the speed of consuming is faster than that of growing, there will be no anodizing layer. DustinGebhardt If you have a conductivity tester, you can test for the presence of a non-conductive layer (i.e. the anodized aluminum oxide layer). I've seen them at Harbor Freight for about $10. It looks like an ice pick with a light in the handle and a wire lead with an alligator clip attached. To make sure that the part is clean before anodizing, do a water break test. Remove the part from your rinse after the acid and see if the water beads up or breaks. On a clean part, the water should sheet perfectly. If there is any debris or oils, the water will break or bead up (just like a freshly waxed car). Make sure that your anodizing acid is cold. When you mix up the acid and water, you will generate heat and the bath will be too hot to use for anodizing. 70F is generally considered the optimum temp for anodizing. As the temperature increases, the anodizing layer starts to be consumed during the process. At a high enough temp, the oxide is dissolved at fast as it is formed. An aquarium chiller can help keep the temps down for those of us on a budget. Just be aware that the acid can and will eat up the internals of the aquarium chiller unless Continued on page 13...

Page 8

FINISHING TALK

A DAY IN THE LIFE OF A NEW METAL FINISHING SALESMAN

By: Matt Greenway, Finishing Market

I

started my new job as a salesman of new and used metal finishing equipment only two months ago – but I graduated from the University of North Carolina at Chapel Hill with a German Language degree in 2005. What have I been doing with myself since graduation, one might ask? I asked myself the same question. I was working as a bartender, and it was time for something new. After quitting my dead end job and taking a short vacation, I was offered an opportunity to work for my cousin (by marriage, not by blood) at his warehouse in my hometown in the foothills of NC. I packed up and left Hillsborough, NC, and allowed my living situation to regress ever so slightly (i.e. moved back in with the parents). For the record, I am currently house hunting. But I digress.

So, I jumped headfirst into my new job. Imagine my surprise when, on my second day at the warehouse, I was asked to prepare a rectifier for shipment. My first question, of course, was: "What's a rectifier?" And my second set of questions were, "Where is it?” and “Can you point it out to me?" I couldn't believe they trusted me to maneuver that beast of machinery around the floor with only one day of forklift training under my belt. Fortunately, I accomplished the mission with no broken bones - or rectifiers.

Fast forward two months… I have taken an Introduction to Plating course, and I have the certificate to prove it. I’m thinking I will frame it and hang it beside my diploma. Today, I got up at 5:30am and toured three plating companies. I finally got to see those beastly rectifiers turned on and working. Wow, what a site! I was amazed, not only by the functioning rectifiers, but by the total picture. Robotics moving the racks, experienced forklift drivers going 30mph (in reverse…uphill), the product coming out of the final rinse, etc... What a day in the life of a new metal finishing salesman!

Matt is a next generation metal finishing professional in training. He currently works for Finishing Market, one of the world’s largest resellers of used metal finishing equipment. Visit them online at www.finishingmarket.com.

Page 9

VOLUME 1, ISSUE 9 FINISHING SPOTLIGHT:

T

he 2008 Southern Metal Finishing Conference, September 14-16 in Charleston, SC, ended on a jovial note, with an awards ceremony and luncheon the final day of the show. There were many prizes to be handed out - from golf and scavenger hunt awards (I-pod shuffles!), and a special award presented to Travis Stirewalt of Tiger Drylac in recognition of 5 years of excellence and service through powder coating instruction. Once the awards were handed out, Paul Fisher, Executive Director of the Surface Finishing Academy - a sponsor of the conference - and publisher of Finishing Talk, announced from the podium that a new award was to be presented on behalf of Finishing Talk. Mr. Dustin Gebhardt of Charlotte, NC is the recipient of the first ever Gebhardt Award for Outstanding Contribution to the Surface Finishing Community. As one of Finishing Talk’s most avid forum contributors, it was only fitting that he receive recognition for the seemingly endless advice, tips, and assistance he has provided forum members since the inception of the web site almost two years ago. This honor will continue to be bestowed in subsequent years upon Finishing Talk community

1ST ANNUAL GEBHARDT AWARD

members who give of themselves through their time and expertise to benefit others in the surface finishing community. Dustin, a native of San Diego, CA, “somehow managed to survive” high school and street racing his Datsun 280ZX, while pursuing his passion and feeding his curiosity through Chemistry. After attending UCSD on a full academic scholarship, he graduated in 2001 with his BS in Biochemistry/Chemistry. Not wanting to be cooped up all day in a research lab like his friends, many of which went on to work in the pharmaceutical and medical industries , Gebhardt wound up as a Lab Tech for a plating company in Vista, CA. “I had been working there for a year or two when I was introduced to A Brite Company. With their extensive support and mentoring, I gained much of my foundation on plating.” During this time, Dustin also finished his CEF coursework, becoming a Certified Electro Finisher. He gradually became more involved in the daily polishing, plating, powder coating, and wastewater treatment operations that his company performed. Dustin’s next job was at a small factory in Tijuana, MX. But

Dustin Gebhardt—recipient (and namesake) of the 2008 Gebhardt Award.

when that company started having financial problems, he approached his friends at A Brite for a job recommendation—and ended up with a job! Dustin spent the next two years working for A Brite out of Yuma, AZ, covering the Southwest US and Northwest Mexico regions. During this time, he gained additional knowledge and experience with a variety of finishing processes. However, with 4 kids, and a wife at home, traveling daily started to become a strain on him and his family, so he sought a more stable position. This brought him to his current job as Value Stream Engineer (Plating EngiContinued on next page...

Page 10

FINISHING TALK

F I N I S H I N G S P O T L I G H T , CONTINUED...

neer) for Danaher Tool Group in Gastonia, NC. “We left Arizona wearing shorts and sandals with a temperature in the 70’s, and arrived in Charlotte to a light snow storm. Talk about a change in scenery.” Gebhardt says that he first learned about Finishing Talk through Paul Fisher, whom he met for the first time at the Los Angeles Powder Coating School (sponsored by the Surface Finishing Academy) while he was still working for A Brite. “When I moved to NC, I realized he was just down the road, and we met up several times. He mentioned his ideas for an

online forum and I signed up when it went live. The rest, as they say, is history.” In addition to a successful career in metal finishing, Dustin enjoys spending time with his family - 5 year old twin boys, 3 years old and 1 year old daughters, and his beautiful wife. As far as pets go, they are down to two dogs and a large freshwater fish tank. Dustin spends his free time on “tinkering in the garage”, working on his car, woodworking, computers, fish-keeping, camping, and on role-playing games.

“But all of those take a back seat to hanging out with the kids, where I am a coach for the boys’ flag-football team and unofficial cheerleader for my daughter’s gymnastics class. First and foremost, I am a family man.” Dustin hopes to stay in the metal finishing industry for a long time. He aspires to acquire the skills and knowledge possessed by the “gurus” that he’s met along the way, including Bruce Anderson, Scott Dunigan, Bob Kosier, Larry Farnsworth, and Dianne Patterson.

Page 11

VOLUME 1, ISSUE 9 NEW PARTNERSHIP SPANS THE OCEAN

T

wo capital equipment suppliers are announcing a partnership that will provide industrial facilities a single source solution for their dryer, oven, and air pollution control needs. Anguil Environmental Systems, Inc., a United States based oxidizer manufacturer, and Spooner Industries, a convection dryer supplier located in the United Kingdom have partnered to better serve each of their respective markets and regions. After working together on multiple turnkey projects, the two companies have decided to make their partnership official. Anguil Regenerative Thermal Oxidizers (RTOs), as well as Direct-Fired, Catalytic and Thermal Recuperative oxidizers are used for the destruction of Volatile Organic Compounds (VOCs), Hazardous Air Pollutants (HAPs), NOX and odorous air emissions often generated from the drying and curing equipment manufactured by Spooner. By combining the complimentary product lines, customers and prospects can get a complete turnkey solution for their industrial drying, curing, coating and air pollution control needs. In addition, the Anguil Heat and Energy Recovery products can be applied on

these industrial systems to reduce operating costs and energy consumption. Under the new agreement, Spooner Industries will fabricate and install the Anguil oxidizer designs on air pollution control applications throughout Europe. They will work exclusively together for the supply of oxidizers for European converting, coating and printing operations. The systems will incorporate the established, proven designs of Anguil Environmental and the quality, dependable fabrication of Spooner Industries. Spooner’s new 60,000 square foot facility will be the primary manufacturing location for Anguil oxidizer systems going into Eastern and Western Europe. The local UK fabrication capability will allow Anguil to serve the European region without expensive transportation costs. In the United States and North America, existing Spooner customers will now have the assurance of working with a dryer company that has local air pollution control and energy recovery capabilities. Anguil’s extensive service capabilities will also be utilized in America for Spooner customers with emergency or long-term service needs. In addition, Anguil cus-

tomers with dryer and coating systems will have the experience of Spooner’s technologies through Anguil. Both Spooner and Anguil are long standing companies with excellent reputations, having been in business since 1932 and 1978, respectively. “We are extremely excited about this new partnership” says Gene Anguil, CEO of Anguil “Not only are our product offerings complimentary but our firms have a similar philosophy and focus with custom engineered industrial systems”. Steve Newell, Sales & Marketing Director at Spooner Industries agrees “This partnership with Anguil fits extremely well with Spooner in terms of technology, markets and culture. The disciplines involved with these units are very similar to our core competence” For more information, contact Kevin Summ of Anguil Environmental Systems Inc. www.anguil.com at (800) 4880230 or Steve Newell of Spooner Industries Ltd www.spooner.co.uk at +44 (0) 1943 609505

Page 12

FINISHING TALK

A 21ST CENTURY CLEANING PERSPECTIVE

L

earn and teach: Those were my two goals in presenting my course about cleaning technology (21st Century Cleaning) at the fifth annual Southern Metal Finishing Conference, held September 15 and 16 in Charleston, SC. The class included a crosssection of suppliers and end users, with points of view provided by a military organization, environmental staff, industry sales personnel, and operating management. As so often happens in these experiences, I learned a lot from my students. I want to share some of that because it speaks to what the cleaning sector of the metal finishing industry believes we need now. In lively group discussions, the following opinions were voiced. While spoken by others, these specific opinions are consistent with my general view of our sector. 1. Information is Key -- and we don't have it. The level of distrust of supplier claims has risen, reminding me of the bitter maelstrom during the CFC phaseout of the 1990’s. Users want, and apparently value cleaning science (knowing how things work); competent training of some staff (so work is done right and consistently); correct and limited commercial claims (so management expectations are fulfilled); and a belief that there is a commercially-sound future for some metal finishing operations, so they can continue to

feed their families. 2. Energy prices are driving change, whether or not the technology is available to support cleaning work with reduced energy costs. Users want to clean with water and detergents at room temperature – not 100, not 120, not 140, or 160̊F. They don't want to heat the cleaning bath and then cool the parts. The technology doesn't exist to do what's wanted, at least at the same level of cleaning quality that they currently enjoy (or hate). We don't have detergents to do that, and allow efficient separation of the soil from them. 3. Floor space is driving change. Users want to skip the rinsing step because it requires a second tank and its associated utilities. The product they seek is a "no-rinse" cleaner. Claims for its existence precede its actual commercial arrival. One knowledgeable, experienced student was adamant about this. 4. Users want to do aqueous cleaning because they believe it removes concern about environmental, safety, and health (ESH) issues from their already thick list of worries. But they dislike it because of its high cost and complexity of operation. Rising energy prices have exacerbated this situation. 5. Users are intrigued by and attracted to use of cleaning solvents, chiefly n-propyl bromide. Remembered simplicity

BY: DR. JOHN B. DURKEE

and lower energy costs of solvent cleaning spur this inquiry. Because change from aqueous to solvent cleaning hasn't significantly happened, misapplications lead to misinformation, which is misdirected by competitive suppliers. Of the many topics covered, this one had the participants' highest level of interest. Dr. Durkee is an Industry leader and professional consultant in developing and implementing new technology in the critical, precision, and industrial cleaning sectors, as well as an Educator in cleaning science. He is the author of several industrial cleaning textbooks, including his most recent

Management of Industrial Cleaning Technologies & Processes. He is also a frequent contributor to Metal Finishing Magazine.

John B. Durkee, PhD, PE Consultant in Industrial Cleaning POB 847 Hunt, TX 78024 (830)-238-7610 [email protected] www.precisioncleaning.com

Page 13

VOLUME 1, ISSUE 9 F R O M T H E FO R U M , CONTINUED FROM PAGE 6... they can withstand the acid. Heating the dye can speed the penetration of the dye into the pores of the oxide layer. There is a limit, of course, but around 130-140 is pretty common. Your power supply may be undersized for the part. I'd imagine that the shift lever is no more than 0.25 square feet of surface area, which needs about 3-4 amps of constant current. Hard Color Why can I not repeat the process? I had great success anodizing a single piece of ali 1 inch sq. at 175 ma for 1 hour, rinsed and rinsed again, soaked in dye for 30 minutes, boiled for 45...beautiful

BUT WHY CAN I NOT REPEAT THE PROCESS? I tried the above process with the same bit of metal, this time only filed the anodizing away to reveal virgin material, and increased the size of the lead…but nothing happens. The metal only turns grey after boiling. I tried the same process with other bits of metal, used a different power supply, checked temperature, distance of anode and cathode, and polarity. I even "over cleaned” the work with ultrasonic - most bubbles at the lead, and still no joy. I notice there is a bit of crystallization at the acid waterline with the metal. I am using 2 liters of acid and fresh de-ionized water every time to rinse. Acid is the

same; battery acid cut 50/50 wit DI water. I store acid in a clear plastic container, outdoors, behind my shed from direct sunlight. I have also noticed that the acid color is now clear instead of that very light yellow when first mixed. Do I need to change the acid, dye after every job...this is extremely frustrating. Please help.

Do you have something to add? Log on to the Finishing Talk forums today to join in on this discussion – or start a discussion of your own!

www.finishingtalk.com

Page 14

FINISHING TALK

San Diego, CA………. November 5-6

Page 15

THE LAST WORD ECONOMIC INSTABILITY CAN PROMOTE INNOVATION By: Anna Levitsky, Editor

T

he past few weeks have been marked by a steadily increasing economic turmoil - with financial institutions lined up and falling like dominos, echoing down the corridors of Wall St. But it isn't just banks, credit card companies, and other lending institutions that are feeling the crunch; every individual, organization, or business that relies on these institutions (which is basically everyone) is being either directly or indirectly affected by the crisis. While it's tempting to let the media's constant economic updates and premonitions of disaster enshroud you with despair, it is not necessarily the only way of approaching the issue. Historically (and philosophically), times of crisis or upheaval - anything that blatantly resembles an uncomfortable change - are not simply defined by their obvious jolt to the status quo, but by their ability to transform and create. Think about it: when the American Colonists first decided to challenge the authority and rule of the British Empire, the ensuing revolution was by no means a pleasant response, but it was in fact a change; one that would later lead to the creation of one of the most longstanding, thoroughly composed, and well known governing documents that the world has ever seen - the United States Constitution. (The reason I use this as an example of a transcending result of tumultuous times, in addition to its analogous pertinence, is because this past September 17th marked the 221st anniversary of the U.S. Constitution.) Then as now, the people of America faced a changing economy and way of

life, and they chose to build something from the ashes. Today, as we face mass lay-offs, falling property values, an increasing gap where the middle class once reigned, and other harbingers of economic recession, we too are challenged to either fall behind with the rest of the country, or use innovation to regain a semblance of stability; and who knows, maybe even prosperity? What can we do, as employees and business owners alike to combat high energy costs, rising raw material prices, a shrinking dollar value, and financial insecurity? The answer lies in community and collaboration. These two concepts are pivotal to Finishing Talk's business ideology, and for good reason. When times are tough, recentralization occurs en masse in communities and industry alike. People will pool their resources, knowledge, and skills with everyone else, because they end up gaining stability through contribution to the whole. People will also cut down on superfluous expenses (which, unfortunately, often results in downsizing in industrial situations), leaving them with only the bare necessities. This phenomenon is occurring all over the country right now, and in all sectors. Businesses are laying off employees by the thousands, and people are cutting excessive expenditures from their family budgets. But the upside of this seemingly negative trend is the first 'C' I mentioned - the resurgence of community. This is a subject we have covered in several past issues, and it appears to have been well-timed in light of current events. But the title of this article suggests

a discussion on Innovation, and so far I have digressed. The most effective way to break out of a failing system, in my opinion, is to create your own. This is the essence of innovative thinking. If all around you people are struggling, and they are all trying to stay afloat using the same old, worn out, and ineffective methods, it is up to you to come up with a new and novel solution. To get you started, here are a few areas which you might want to collaborate on with some coworkers to come up with solutions to kick start your business during these trying times: * Reevaluate and consider adding or removing steps in your business processes. * Combine steps for better efficiency * Find ways to conserve energy in the office, factory, or warehouse * Determine which materials can be reused to cut down on expenses * Simplify your products

These are just a few challenges to get your creative juices flowing. Here is another challenge: branch out to your comrades in the industry, and learn from each other. Our online forums have become a great resource for constructive and professional feedback on finishing related questions and more, posed by industry members across the country and around the globe. Have a problem that you can't quite figure out on your own? Visit www.finishingtalk.com and click on "Community". See how others are handling current economic conditions, get inspired, and let the innovation begin!

PRST/STD US Postage Paid Rutherfordton, NC Permit # 154

PO Box 349 Rutherfordton, NC 28139

October 2008 Anna Levitsky, Editor Phone: 704-995-2263 [email protected]

www.FinishingTalk.com

Please deliver this informative newsletter to the following valued Finishing Talk reader: