SBIR-STTR Award

Individual racking of parts during anodization processes is time consuming and inefficient. The objective of this proposed effort is to develop a process that can anodize large number of small parts, fabricated from aluminum alloys, using a non-racking approach while maintaining high surface quality to meet military standards. Two fixture design concepts, batch process and a non-racking fixture, are proposed. In the batch fixture design, ballasts made of porous metal foam are employed to eliminate surface defects due to contacting aluminum parts. The non-racking fixture utilizes highly porous metal foam as the electrical contact to allow maximum electrolyte diffusion, and minimize contact marks. Fixtures are attached to a vibrating axel for maximum agitation, and pulse anodizing methods are applied to achieve better surface finish quality. TRI/Austin will be teaming with two companies to assist in the development of anodizing fixtures and processes. Analytical tests will be conducted to evaluate the anodic film properties including visual appearance, film thickness, Rockwell hardness, abrasion, and corrosion resistance. The results of this research will be an efficient bulk anodizing process that is capable of high volume yield and outstanding surface finish quality.

Keywords:
Small Parts, Vibratory Fixture, Non-Racking Process, Porous Metal Foam, Pulse Anodizing, Anodic Film Quality., Aluminum Anodizing,

Anodizing is the most common surface treatment of aluminum. The natural oxide layer formed provides excellent corrosion and wear resistance. Anodizing processes have relied heavily on the inefficient process of individual racking of the parts. Alternate techniques have been developed but surface problems such as burning cause high scrap rates. A new process for anodizing large quantities of small arms parts for Marine Corps military applications was demonstrated during Phase I. The process produced small arms parts having equivalent hardness, abrasion resistance, and corrosion resistance compared to conventionally anodized parts. This technique will meet an immediate demand for improved high volume processing without the need for individual racking, while maintaining the high surface quality to meet military standards. Phase II will build upon the Phase I work to produce prototype hardware for pilot-scale anodizing of small aluminum parts. The anodizing process will be optimized and process parameters developed that cover anodizing requirements for a wide range of parts. Anodized parts will be tested and their performance will be compared to the performance and reliability of parts obtained with state-of-the-art anodizing processes. The objectives of Phase II include process development, testing, specification compliance, and transition of the process to MCLB facilities.

Keywords:
Small Arms, Small Arms, Aluminum, Racking, Parts, Bulk Process, Anodizing