document : V7.00.

00

released : 13-01-1986 SURLON K.E. issue : 03 page : 1 of 8

revised : 09-03-1998 copyright : 804252 / 682959

ANODIC INTEGRATED HARDCOATING FOR ALUMINIUM

1.0. SCOPE

This specification covers the requirements for electrolytic formed Surlon K.E.
hardcoatings on aluminium and aluminium alloys for industrial applications.
This results in a continuous, lubricating plastic-ceramic surface of which the
Surlon particles become an integral part.

2.0. CLASSIFICATION

Surlon K.E. coatings for aluminium and aluminium alloys shall be of the following
types.

Abrasion Release Coating thick

Type Lubricity
Resistance properties ness

V 7.00.47 Excellent good good 30 – 70 µm

V 7.12.14 very good very good very good 30 – 70 µm

V 7.18.22 Moderate excellent excellent 15 – 30 µm

V 7.20.00 Aluminium castings Surlon KE impregnated

Tabel 1

3.0. GENERAL

3.1. The Surlon K.E. process produces a harder-than-steel surface on aluminium.

Taber abrasion tests have shown that Surlon K.E. has greater abrasion resistance
than case hardened steel or hard chrome plate.
Wear tests have shown that regardless of what metal is used against it, Surlon
K.E. resists wear under the most rigorous conditions (See page 8).

3.2. The Surlon K.E. process provides a permanent, dry lubricating surface and
provides an unusual degree of lubricity combined with hardness. By leveling off
the surface asperity with the Surlon, surface tension is drastically reduced and
lubricity greatly increased.

Surface Treatment Nederland B.V., Maasbracht, Nederland

Surface Treatment Belgium N.V., Turnhout, België
document : V7.00.00

released : 13-01-1986 SURLON K.E. issue : 03 page : 2 of 8

revised : 09-03-1998 copyright : 804252 / 682959

3.3. The Surlon K.E. process protects against corrosion.

The interlocking structure of K.E. and aluminium oxide provides an effective
corrosion resisting seal that is responsible for the excellent behavior of Surlon in
salt spray and other corrosive environment tests.

3.4. Corrosion resistance.

Surlon K.E. finishing shows greatly improved corrosion resistance over
conventional hard anodizing.
Surlon K.E. is resistant to most common chemicals.

3.5. Weather resistance.

Tests of K.E. samples exposed to practically all climatic conditions confirm its
weather-resistant properties. Resistance to extreme heat and to ultraviolet light is
excellent. This process is a permanently lubricated coating for aluminium parts,
which is superior to that of standard anodizing; more resistant to corrosion,
erosion and abrasion; and has far superior dielectric properties.

3.6. The Surlon K.E. process yields excellent dielectric properties and strength. The
Surlon K.E. process converts the surface to one with excellent dielectric
characteristics, without affecting the high conductivity of the parent metal.

3.7. The Surlon K.E. process becomes an integral part of the parent metal. Since
Surlon is really the surface of the metal converted to a ceramic and then
interlocked with K.E. it cannot peel or strip.
And because it is harder than casehardened steel, it cannot be nicked, scratched
or flaked by ordinary means.

3.8. Color of the Surlon coating.

The color of this coating will vary depending on the alloy and treatment
requirement and thickness of the coating applied.

3.9. Thickness of the Surlon coating.

The recommended thickness of Surlon K.E. for most applications ranges is
between 30 µm and 100 µm.
Thickness including growth shall be as specified. If maximum thickness is to be
controlled, it shall be as specified on the design drawing.

Surface Treatment Nederland B.V., Maasbracht, Nederland

Surface Treatment Belgium N.V., Turnhout, België
document : V7.00.00

released : 13-01-1986 SURLON K.E. issue : 03 page : 3 of 8

revised : 09-03-1998 copyright : 804252 / 682959

3.10. Dimensional growth.

Surlon K.E. finishing produces a dimensional growth that can be controlled during
processing. The following are growth values for various thickness of Surlon.

Coating thickness in µm
Alloy type 30 40 50 60
Dimensional growth approx.
Wrought aluminium
AA 6061 (AlMgSi1) 27 36 45 55
AA 2024 (AlCuMg2) 24 32 40 48
AA 7075 (AlZnMgCu1,5) 24 32 40 48
Aluminium Silicon Magnesium casting
alloys
235 (AlSi5Mg) 26 34 43 51
236 (AlSi7Mg) 23 31 39 47
341 (AlMg8) 23 30 37 45
Tabel 2

To allow for this processing growth, parts should be dimensioned under size
proportionately. Surlon finishing within the limits of processing growth can bring
worn parts or those rejected because they are below the required dimensions to
the desired tolerances.

3.11. The Surlon K.E. process suitable aluminium alloys.

Aluminium and its alloys that contain less than 50% copper and that do not
contain excessive zinc are most suitable for the Surlon K.E. finish.
These may be either wrought or cast. Certain die cast alloys do not reach the
ultimate hardness if their silicon content is extremely high.

3.12. Electrical properties.

The Surlon has mechanical strength and chemical and thermal resistance
combined with outstanding electrical properties as an insulator. The K.E. has no
water absorption, and resistivity values remain unchanged even after prolonged
soaking in water. Resistivity values were taken at 100 percent relative humidity.

Surface Treatment Nederland B.V., Maasbracht, Nederland

Surface Treatment Belgium N.V., Turnhout, België
document : V7.00.00

released : 13-01-1986 SURLON K.E. issue : 03 page : 4 of 8

revised : 09-03-1998 copyright : 804252 / 682959

3.13. Electrical conductivity.

SURLON is a non-conductor, acts as an insulator, and it will withstand a range of
600 to 2.000 volts, depending upon its thickness. Standard anodizing films break
down at about 300 volts.

3.14. Mechanical surface preparation.

Any mechanical surface preparation required on the surface to be converted shall
be as specified on the applicable engineering drawing.

3.15. Chemical surface preparation.

Remove all dirt, grease, oil, welding, flux, scale and other surface impurities that
may contaminate the electrolyte and result in poor surface.

3.16. Masking.
Assemblies containing metals other than aluminium alloys shall be disassembled
or masked. Chemical surface preparation shall be followed immediately by the
conversion process.

4.0. QUALITY AND PROCESSING

4.1. Quality.
The coating shall be continuous, smooth, adherent, uniform in thickness and
appearance and shall be free from powdery areas, discontinuities such as breaks
and scratches and other detrimental defects, except that porosity, roughness and
other irregularities common to die castings and not detrimental to the function of
the part shall not be cause for rejection of die cast parts. The size and number of
contact marks shall be minimal, consistent with good practice.

4.2. Lubricity.
The lubricity of the coated surface shall be evidenced by the exhibition of
hydrophobic characteristics when tested as follows:
Thoroughly wash the surface to be tested with trichloroethylene. With the test
surface in a horizontal plane, facing up, rinse it thoroughly with distilled water.
Upon completion of rinsing examine the condition of the water remaining on the
test surface. If the water is in the form of droplets (beaded) the surface has a
hydrophobic character. If the water forms a continuous film, the surface does not
exhibit hydrophobic characteristics.

4.3. Abrasion Resistance.

The coating shall withstand 10.000 cycles at 1000 grams, 70 RPM with CS 17
calibrase wheel on a Taber Abraser in conformance with Mil 8625.
Requirement: 40 mgs. max. weight loss (not applicable to die-castings).

Surface Treatment Nederland B.V., Maasbracht, Nederland

Surface Treatment Belgium N.V., Turnhout, België
document : V7.00.00

released : 13-01-1986 SURLON K.E. issue : 03 page : 5 of 8

revised : 09-03-1998 copyright : 804252 / 682959

5.0. REQUIREMENTS

5.1. Materials.
The materials used shall be such as to produce coatings that meet the
requirements of this specification.

5.2. Basis metal.

The basis metal shall be sufficiently free from surface defects, caused by
machining, cutting, scratching, polishing, buffing, roughening, bending,
stretching, deforming, rolling, sandblasting, vaporblasting, etching, and
inclusions, which will be detrimental to the functional use of the coating. It shall
be subjected to such cleaning, etching procedures as are necessary to yield
coatings meeting all requirements of this specification.

5.3. General.
Unless otherwise specified in the contract, order or applicable drawing, parts and
assemblies shall be treated after all heat treatment, machining, welding, forming,
and perforating have been completed.
Surlon parts which contain non-aluminium materials such as steel, brass or
organic substances, which would be attacked by chemical or would prevent the
uniform formation of the Surlon K.E. on the aluminium surfaces or cause attack
of the aluminium alloy, shall not be treated as assemblies, unless the non-
aluminium surfaces are masked or electrically insulated in a manner which
produces satisfactory Surlon parts.
Parts shall be so handled during all pretreatment that mechanical damage or
contamination will be avoided. Soiled parts shall be cleaned with such materials,
which will remove the soil without damaging the part or coatings. Parts shall be
free of all foreign substances, oxides and soils, such as greases, oil, paint and
welding flux. Parts shall have oxide and other interfering film removed by the use
of proper cleaning procedures so as to be cleaned and have water break free
surfaces.
Unless otherwise specified in the contract, order or applicable drawing, Surlon
coatings shall not be applied to assemblies, which will entrap the electrolyte in
joints or recesses. Surlon coatings shall not be used for assemblies where the
electrolyte cannot be removed. When authorized by the contract, order or
applicable drawings, edges shall be masked to prevent electrolyte entry.
Spot welded assemblies are examples of assemblies requiring edge masking.
Residual electrolytes will engender corrosion of aluminium. Where coating of
assemblies is not authorized, parts of assemblies shall be coated before
assembling.

Surface Treatment Nederland B.V., Maasbracht, Nederland

Surface Treatment Belgium N.V., Turnhout, België
document : V7.00.00

released : 13-01-1986 SURLON K.E. issue : 03 page : 6 of 8

revised : 09-03-1998 copyright : 804252 / 682959

5.4. Thickness.
Thickness of Surlon coatings shall be as specified in the contract, order, or
applicable drawing.
If a definite thickness is not specified in the contract, order or applicable drawing,
the nominal thickness of the coating shall be 45 – 55 µm. Unless otherwise
specified, the thickness of the coating shall not vary by more than plus or minus
ten percent. Unless otherwise specified in the contract, order or applicable
drawing, Surlon coatings shall not be applied to aluminium alloys with a nominal
copper content in excess of 5 percent or nominal silicon content in excess of 7
percent.
Alloys with a higher nominal silicon content than 7 percent may be coated
subject to approval of the procuring activity provided data is submitted by the
supplier which shows that such coatings are equivalent to those obtained on
alloys of lower silicon contents.

6.0. QUALITY ASSURANCE PROVISIONS

6.1. Responsibility for inspection.

Unless otherwise specified in the contract or purchase order, the supplier is
responsible for the performance of all inspection requirements as specified herein.
Except as otherwise specified, the supplier may utilize his own facilities or any
commercial laboratory acceptable to the Government.

6.2. Quality conformance tests.

The quality conformance inspection shall consist of an examination for the
acceptability of the quality control methods used by the supplier and an
examination and testing of the quality conformance samples as specified.

6.3. Control.
The supplier should maintain a permanent record of the history of each
processing bath, showing all additions of chemicals to the bath, the results of all
analysis performed and the quantity of parts of each kind treated in the bath.

6.4. Process control.

The equipment, procedures and operations employed by the supplier shall be
capable of producing high quality coatings on aluminium and aluminium alloys as
specified in this document. Upon request of the procurement body the supplier
shall demonstrate such capability.

Surface Treatment Nederland B.V., Maasbracht, Nederland

Surface Treatment Belgium N.V., Turnhout, België
document : V7.00.00

released : 13-01-1986 SURLON K.E. issue : 03 page : 7 of 8

revised : 09-03-1998 copyright : 804252 / 682959

6.5. Frequency of tests.

The tests for process control shall be made once each month or more frequently
if required by the Government. In all cases, the results or tests made to
determine conformance of coatings on aluminium and aluminium alloys to the
requirements of this specification for definite contracts or purchase orders are
acceptable as evidence of the properties being obtained with the equipment and
procedures employed.

6.6. Corrosion resistance.

When processed parts are such that they may be conveniently adapted for the
corrosion resistant test, the actual parts may be selected for test in accordance
with A.S.T.M. in lieu of separate test panels prepared in accordance with B 117
of sheet samples. The selected items of specimen test panels shall be tested for
corrosion resistance in accordance with the method specified in A.S.T.M.

6.7. Method.
Specimens shall be washed in distilled or deionized water, dried with a soft cloth
and then subjected to a 5 percent salt spray test in accordance with Method 811
of Fed. Test Method Std. No. 151 or A.S.T.M. B 117, Method of Salt Spray
(Fog) Testing, except that the significant surface shall be inclined approximately
6 degrees from the vertical.
After exposure, specimens shall be examined and compared with unexposed
specimens for the effects of corrosion.

Surface Treatment Nederland B.V., Maasbracht, Nederland

Surface Treatment Belgium N.V., Turnhout, België
document : V7.00.00

released : 13-01-1986 SURLON K.E. issue : 03 page : 8 of 8

revised : 09-03-1998 copyright : 804252 / 682959

DIAGRAM ABRASION RESISTANCE

AL 99 ALZnMgCu1,5 ST 37

5
Weight decrease in mg.

Case hardened steel

Hard chrome
plate
2

Hardcoat

1 Surlon K.E.

0
0 1 2 3 4 5 6 7 8 9 10
Abrasion cycli (x100)

Surface Treatment Nederland B.V., Maasbracht, Nederland

Surface Treatment Belgium N.V., Turnhout, België