Analysis and characterization of environmental friendly trivalent chromium passivation of aluminum alloys

As of 21st September 2017, industrial use of hexavalent chromium (Cr(VI)) will, due to its environmental toxicity and carcinogenicity, be restricted by REACH regulations. Saab Aeronautics is therefore shifting anticorrosion surface treatment of aluminum alloys from hexavalent chromium conversion to trivalent chromium (Cr(III)) passivation. The purpose of this thesis is to investigate the characteristics of conversion coatings formed with the passivation chemical SurTec 650V, in order to facilitate transfer to the more environmental friendly alternative. Process parameters, such as pH and immersion time in SurTec 650V passivation baths, have been investigated for passivation of three different aluminum alloys; 2024, 6061 and 7075. The characteristics of the Cr(III) conversion coatings achieved at laboratory scale in the thesis work have been compared with SurTec 650V process in production scale and with Cr(VI) containing Alodine 1200 and Alodine 1500 processes. The impact of varying process parameters have been investigated with goniometry, x-ray photoelectron spectroscopy (XPS), auger electron spectroscopy (AES), scanning electron microscopy (SEM) and transmission electron microscopy (TEM) to analyse characteristics of the conversion coatings. Differences in chemical composition on the surface and in depth profile was detected with XPS and AES, respectively and topology of coatings was found to differ for different aluminium alloys and parameter combinations. With TEM, the thickness of the conversion coating was found to be approximately 30-50 nm, which is thinner than the coatings formed with Cr(VI) passivation. Characteristics of coatings formed with Cr(III) passivation is concluded to be very dependent on parameter variation, especially for alloy 2024. Differences also occur between passivation at laboratory and production scale. Further evaluation of the production scale SurTec 650V process and corrosion testing should be performed, and an elaboration of a process control is required before the shift to an environmental friendly passivation process can be completely successful at Saab