What is Anodizing?

Anodizing is an electrochemical conversion process in existence since the 1930s. Several metals are capable of
being anodized including aluminum, magnesium, titanium, and tantalum. Anodized aluminum is used in many
applications due to its low cost, aesthetic qualities and ideal mechanical properties.
Unlike most protective coatings, anodizing permanently changes the outer structure of the metal. When
aluminum is exposed to air it naturally develops a thin aluminum oxide film that seals the aluminum from
further oxidation. The anodizing process makes the oxidized surface much thicker, up to several thousandths of
an inch thick. The hardness of the anodized aluminum oxide coating rivals that of a diamond, enhancing the
abrasion resistance of the aluminum. The added depth of the oxide layer improves the corrosion resistance of
the aluminum, while making cleaning of the surface easier. The porous nature of particular types of anodizing
makes it possible to dye the aluminum a variety of colors, making it more attractive.

Anodizing typically ranges up to 5 mils thickness. The three most common variations of
aluminum anodizing include chromic (type I), sulfuric (type II) and hard (type III).
Chromic anodizing utilizes a chromic acid electrolyte and yields the thinnest coatings, only 0.02 to 0.1
mils thick (0.5 to 2.5 microns). 50% penetration into the substrate and 50% growth over original
dimensions occurs. Chromic anodizing has the least effect on fatigue strength and is less corrosive, thus
ideal for complex and difficult to rinse parts. Excellent for coating aluminum castings, most chromic
anodized parts are used in military and aerospace applications and are more functional than decorative in
nature.
Sulfuric anodizing is the most common method of anodizing, utilizing sulfuric acid to yield coatings up
to 1 mil (25 microns) thick. 67% penetration into the substrate and 33% growth over original dimensions
occurs. Due to its permeable nature, sulfuric anodizing is excellent for color dyeing and provides a base
for primers, bonding agents and organic coatings. Sulfuric anodizing provides corrosion resistance and
is very durable. Typical applications include architecture, aerospace, manufacturing automotive and
computers.
Hard anodizing (a.k.a. hardcoating) utilizes a higher concentration sulfuric acid electrolyte at a lower
temperature resulting in a tough outer skin with excellent abrasion resistance, corrosion resistance, color
fade resistance, dielectric strength and surface hardness (Rockwell C-Scale up to 70). 50% penetration
into the substrate and 50% growth over original dimensions occurs for a total thickness of 0.5 to 4
mils. Hard anodized metals have heightened surface roughness. Common uses include non-decorative
food packing equipment, photocopier paper rolls, and exterior applications such as building storefronts
and windows.

Aluminum Anodizing process

The aluminum part is hung on stripped aluminum or titanium racks ensuring good electrical
contact. Throughout the anodizing process, parts are affixed and the racks are suspended in a series
of tanks.
1. Aluminum part is dipped in a hot tank containing a soak cleaning agent to remove all
surface dirt.
2. The part is rinsed to avoid contaminating the solution in subsequent tanks.

3. The next tank de-oxidizes the part with an acid solution (chromic, sulfuric, nitric or
phosphoric) removing the thin, non-uniform aluminum oxide surface.
4. Again the part is rinsed to avoid tank contamination.
5. Etching is performed by suspending the part in a tank containing a sodium hydroxide
solution. Etching removes the natural shine of the aluminum and provide a soft, matte,
textured appearance.
6. The part is suspended in the anodizing tank, which contains a diluted acid and water mixture
that is capable of permitting electrical current flow. The type of acid, percent solution and
temperature are all critical parameters and dependent on the desired finish and color. The
negative leg of the electrical circuit is connected to the rack of parts and the positive side of
the circuit is connected to one or more "cathodes" that introduce electricity into the
tank. Quantity and placement of the cathodes varies with the size and shape of the part as
well as the total square footage of aluminum surface to be treated. Surfaces closest to the
cathode will receive a thicker anodic coating. For normal sulfuric anodizing a DC power
source capable of producing up to 24 volts is used, with the voltage held generally between
18 and 24 volts. The amount of current applied to the anodizing tank will vary depending
on the amount of surface to be treated, as a rule between 12 and 16 amps are required for
each square foot of coverage. The electrolyte solution is agitated during the anodizing
process to provide uniform solution temperature. The anodizing tank process, under normal
conditions, takes less than an hour.
7. To add color (dye), the part is dipped in a tank with a diluted, water soluble, organic dye.
Each dye varies in the length of time and temperature for this immersion.
8. The final consideration in the anodizing process is sealing the now dyed outer surface so it
doesn't sunlight bleach or stain. Unsealed, the porous outer surface has a lowered corrosion
resistance. For non-dyed coatings, the anodized aluminum part is put into boiling de-ionized
water for 20 to 30 minutes. This converts the unstructured pores of the aluminum oxide to a
more solid crystalline hydrate form. If the anodized parts are dyed, the sealing process is
performed for 3 to 5 minutes in a tank with a nickel acetate solution.
9. Hard anodizing, depending on the process, uses a mixture of sulfuric and oxalic
acid. Relatively low temperatures are used along with a higher current and a much higher
voltage. The gray oxide layer produced is typically 2 to 3 mils and is very dense, wear and
corrosive resistant.
An alternative to racking is bulk anodizing which is more ideal for anodizing small, irregularly
shaped parts such as rivets, ferrules and medical hubs. Instead of racks, parts are processed in
perforated aluminum, plastic or titanium baskets. Whether you need coil or batch production,
anodizing provides one of the best aluminum finishing options in the industry.
Another alternative is coil anodizing. Coiled aluminum is pre-anodized to lower finishing costs,
save production time, and reduce material handling. Advantages of pre-anodized aluminum can be
applied to most products that are fabricated from sheet or coil stock. Products that are made from
extrusions, castings, rod bar, or plate are limited to piece anodizing processes such as racking or
bulk.
Though most aluminum alloys will build aluminum oxide in an anodizing tank, they tend to
anodize differently. Some alloys are more difficult to anodize while others anodize to slightly

different shades of color. When anodized, various alloys provide different levels of workability
(machining, grinding, polishing), environmental resistance properties, and dimensional stability.
Why Anodize?
Anodizing is a highly effective and desirable means of finishing aluminum. Some of the primary advantages of
anodizing include:

Durability - Most anodized parts experience no wear from handling, installation, usage and
maintenance Adhesion - Anodizing is part of the aluminum for total bonding and unmatched
adhesion.
Color Anodized parts maintain good color stability when exposed to ultraviolet rays, do not
have an applied coating that is subject to chipping or peeling, and have a repeatable coloring
process.
Quality of original finish Parts are not subject to marking from the original anodizing process.
Maintenance - Mild soap-and-water cleaning usually will restore an anodized profile to its
original appearance.
Aesthetics - Anodizing offers a large number of gloss and color alternatives, while allowing the
metallic appearance of the extruded aluminum to show through.
Cost - Anodizing is a very cost-effective value compared to other finishing methods. In
addition to low processing and maintenance costs, durability minimizes replacement costs.
Environment, health and safety - Anodizing is favorable towards current governmental
regulations because it is one of the most environmentally friendly industrial processes and is
typically not harmful to human health. An anodized finish is chemically stable, will not
decompose, is nontoxic, and is heat-resistant to the melting point of aluminum. Since the
anodizing process is a reinforcement of a naturally occurring oxide process, it is non-hazardous
and produces no harmful or dangerous by-products. Chemical baths used in the anodizing
process often are reclaimed, recycled, and reused.
Why measure?
The anodizing process parameters have a significant influence on the properties of the oxide formed. If low
temperatures and acid concentrations are used, it yields a less porous and harder coating. Higher temperatures
and acid content, along with longer immersion times produces softer, more porous coatings. Minor changes to
the alloy itself or any of these parameter can significantly affect the coating.
Through various process controls and measurement techniques, Anodizers are able to monitor, control and
correct the anodized coating application. One of the most critical quality controls for anodizing is
thickness. Thickness of anodizing can be measured non-destructively using an eddy current gage or by
calculating weight per unit area. The simplicity of the eddy current method is not only more efficient than the
calculation method, but also enable the inspector to verify that adequate anodizing occurs across all surfaces of
the part.
Where is the Market?

Anodized products and components are used in thousands of commercial, industrial and consumer
applications:

Building products (curtain walls, roofing systems)

commercial and residential products (vents, awnings, frames, fixtures)

appliances (refrigerators, microwaves, coffee makers)
food preparation equipment (pans, coolers, grills)
home and office furniture (tables, beds, cabinets)
sporting goods (golf carts, boats, camping and fishing equipment)
motor vehicle components (trim, hubcaps, panels, nameplates)
electronics (televisions, photography equipment)
aerospace (satellite panels)

Associations
AAC (Aluminum Anodizers Council)
www.anodizing.org
AEC (Aluminum Extruders Council)
www.aec.org
AAMA (American Architectural Manufacturers Association) www.aamanet.org
The Aluminum Association
www.aluminum.org
Industry Specifications
Military
MIL-A-8625 Anodic Coatings for Aluminum and Aluminum Alloys
MIL-STD-171 - Standard for Finishing and Treating Surfaces

ASTM
B244-97 Standard Test Method for Measurement of Thickness of Anodic Coatings on Aluminum and of Other Nonconductive
Coatings on Nonmagnetic Basis Metals with Eddy-Current Instruments
B487-85 Standard Test Method for Measurement of Metal and Oxide Coating Thickness by Microscopical Examination of a
Cross Section
B137-95 Standard Test Method for Measurement of Coating Mass Per Unit Area on Anodically Coated Aluminum
B136-84 Standard Method for Measurement of Stain Resistance of Anodic Coatings on Aluminum
B457-67 Standard Test Method for Measurement of Impedance of Anodic Coatings on Aluminum
B580-79 Standard Specification for Anodic Oxide Coatings on Aluminum
B680-80 Standard Test Method for Seal Quality of Anodic Coatings on Aluminum by Acid Dissolution
B893-98 Specification for Hard-Coat Anodizing of Magnesium for Engineering Application

SAE International AMS (Aerospace Materials Specifications)

AMS2468 - Hardcoating treatment of aluminum alloys
AMS2469 Hardcoating treatment of aluminum and aluminum alloys
AMS2471 Anodic Treatment of Aluminum Alloys Sulfuric Acid Process, Process-Undyed
AMS2472 Anodic Treatment of Aluminum Alloys Sulfuric Acid Process, Process-Dyed
AMS-A-8625 (copy of MIL-A-8625)

International Standards
ISO7599 Anodizing of aluminium and its alloys; General specifications for anodic oxide coatings on aluminium
ISO8078 Anodic treatment of aluminum alloys Sulfuric acid process, undyed coating
ISO8079 Anodic treatment of aluminum alloys Sulfuric acid process, dyed coating
ISO10074 Specification for hard anodic oxidation coatings on aluminum and its alloys
BS/DIN EN 2101 Specification for chromic acid anodizing of aluminium and wrought aluminium alloys
BS/DIN 2284 Specification for sulfuric acid anodizing of aluminium and wrought aluminium alloys
BS/DIN 2536 Hard anodizing of aluminium alloys
BS/DIN 2808 Anodizing of titanium and titanium alloys
DIN EN 12373-1 Aluminium and aluminium alloys - Anodizing

AAMA
AAMA 2604 - Voluntary Specification, Performance Requirements and Test Procedures for High Performance Organic Coatings
on Aluminum Extrusions and Panels
AAMA 611 - Voluntary Specification for Anodized Architectural Aluminum
AAMA Publication Store: www.aamanet.org/general/2/45/publication-store