VALIDATETSAA

Validate of TSAA coating technology. Development of procedures and standards manual. Technical and economical study

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 Obiettivo del progetto (Objective)

'The proposed project will focus on the validation of a TSAA process, including pre- and post-treatment, which is defined by the topic manager, and its implementation in industrial scale. An existing industrial plant, which will be selected by the topic manager, will be benchmarked with respect to the number and dimensioning of the components of the plant and its periphery with respect to the technical requirements for the process. The process itself will be performed in laboratory- and pilot scale to verify the reproducibility of the process for given aluminium alloy(s) and to characterize and quantify the properties of the surface of specimens after each step of the TSAA process. Failure mode analyses, such as FTA (failure tree analysis), DRBFM (Design review based on failure mode) and FEMS (Failure modes and effects analysis) will be performed. Knowledge-based analysis of the process and the relevant parameters, such as temperature and filtration, as well as the aforementioned failure mode analysis, will lead to the definition of process sheets and risk assessment plan. Environmental analysis of the process will consider chemicals used – also with respect to REACh compliance -, exhaust fumes (especially in the working area), waste and waste water output. As far as possible, recycling routs for process waters and chemical components will be analysed and suggested. Risk analysis will also include possible health risks in the working area, which can origin by incorrect use of chemicals or waste. The results of the analysis of environmental and health risks will be included into the process sheets and risk assessment plan. Data and process-relevant knowledge gained during the aforementioned analysis steps will finally lead to elaboration of a manufacturing plan and compilation of a Process procedures and standard manual.'

Introduzione (Teaser)

Hexavalent chromium use has now been highly restricted and in some cases banned given its proven hazards and known carcinogenic activity. Researchers have developed a corrosion protection process for the aerospace industry that does not rely on its use.

Descrizione progetto (Article)

Surface finishing is critical to the stability and performance of numerous metals in a variety of applications. Electroplating using hexavalent chromium has been the treatment of choice for parts in harsh environments, but the aerospace industry must now find an eco-friendly alternative.

Europe has led the way both in restricting use to protect health and the environment and in finding alternatives to support the competitiveness of its industries. The EU supported the project VALIDATETSAA (Validate of TSAA coating technology. Development of procedures and standards manual. Technical and economical study) to strengthen the position of the promising alternative tartaric sulphuric acid anodising (TSAA) for aluminium alloys in the aircraft industry.

In TSAA, tartaric acid is added to sulphuric acid anodising baths, generating a porous film that protects against corrosion resistance. Scientists set out to validate on an industrial scale a novel TSAA process, including pre- and post-treatment of aluminium.

Scientists developed pre-treatment procedures for inspection and cleaning of parts before anodising. Process parameters including time, temperature, bath concentrations and electrical parameters for anodisation (electrochemical conversion to form the porous oxide coating) were then optimised. Post-treatment consisted of hot-water sealing, a critical last step closing the porous aluminium oxide layer after anodising.

In addition to the technical requirements, researchers also conducted economic, safety and risk analyses. The team evaluated chemical usage in light of compliance with the European Commission's Regulation on Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH). It also considered exhaust fumes (especially in the working area), waste and wastewater output. Recycling routes for wastewater and chemicals were also suggested. Risk analysis focused on occupational health risks.

Failure tree analysis, design review based on failure mode, and a failure modes and effects analysis were performed as well. These enabled identification of potential failure modes and the importance of each.

The detailed manufacturing plan and manual of process procedures and standards delivered at close will enable increased use of lightweight aluminium alloys in harsh environments without the use of harsh chemicals. This will enhance the competitiveness of EU aerospace manufacturers and environmental and occupational health and safety.