Minden, NV, United States

METALAST International, Inc.

Minden, NV, United States
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Manavbasi A.,METALAST International, Inc. | Nibhanupudi S.,METALAST International, Inc. | Bodily K.,METALAST International, Inc. | Clarke T.,METALAST International, Inc. | And 2 more authors.
Metal Finishing | Year: 2012

A new environmentally friendly non-chromated chemfilm with different pretreatments was studied as a replacement to conventional hexavalent chromium-based chemfilm technologies for magnesium alloys. Anti-corrosion and paint adhesion properties of conversion-coated sand-cast AZ92A-T6 magnesium alloy were investigated. Open-circuit potential (Eoc), potentiodynamic polarization, neutral salt spray and gravimetric methods were employed to evaluate the corrosion resistance of this novel conversion coating. Surface morphology and the presence of the coating were investigated by scanning electron microscopy (SEM) technique. Tape adhesion and pull-off adhesion studies were performed to characterize the paint adhesion properties. Rework along with the Touch-Up application and turbine-oil immersion studies was performed in order to simulate the depot-level maintenance. The results of corrosion and paint adhesion studies revealed that the new non-chromated conversion coating technology could be a drop-in replacement to the conventional hexavalent chromium-based conversion coatings. © 2012 Elsevier Inc.

Manavbasi A.,METALAST International, Inc. | Nibhanupudi S.,METALAST International, Inc.
National Association for Surface Finishing Annual Conference and Trade Show 2010, SUR/FIN 2010 | Year: 2010

Anodization treatment of magnesium and its alloys is a useful surfacetreating technique for forming protective coatings to improve their anti-corrosion properties, wear resistance and to enhance the adhesion capabilities of the surface. The anodic films formed on magnesium depend on the alloying constituents, anodizing process parameters and the electrolyte composition. To improve corrosion properties of anodic coatings on magnesium, environmentally friendly, new aqueous alkaline electrolytes containing organic compounds, without toxic chromates and/or hazardous fluorides and phosphates, were investigated. Anodic film structure, component and surface morphology were analyzed using X-Ray Diffraction (XRD), Scanning Electron Microscopy (SEM) and Energy Dispersive Spectrometer (EDS). The anti-corrosion properties were investigated by electrochemical techniques. The results showed that the novel organic additive reduced the sparking voltage and provided relatively smoother surface. Additionally, pores became considerably uniform in both size and distribution due to the presence of the organic additive in the anodizing electrolyte. The anodic film produced with the organic additive exhibited the highest corrosion resistance for the AZ31B alloy. Copyright © (2010) by the National Association for Surface Finishing.

Manavbasi A.,METALAST International, Inc. | Estes B.,METALAST International, Inc.
NACE - International Corrosion Conference Series | Year: 2010

Hard-coat (Type III) anodized aluminum alloys have been used by the military, aerospace, automotive, and other industries for applications where superior hardness and wear resistance are required. In recent years there has been a great interest in sealing and dyeing hard-coated aluminum in order to improve the corrosion resistance and appearance of the oxide film. Although hard-coated aluminum has very high wear resistance, it has to be sealed to ensure a desirable level of corrosion resistance. However, conventional industrial seals for hard-coated aluminum cause a dramatic reduction in abrasive wear resistance. A novel room temperature trivalent chromium based seal was found to be an excellent post-treatment for hard-coated aluminum to provide enhanced corrosion resistance without compromising the wear characteristics. In this study, a comparison of post treatments including trivalent chromium based seal, hydrothermal, nickel acetate, sodium dichromate, sodium silicate, nickel fluoride, black dye, black dye and nickel seals was made. The quality of the oxide film was evaluated by microhardness, wear resistance, corrosion resistance, and dielectric strength. The effects and possible mechanisms of the post-treatment processes on the anodic film are discussed. © 2010 by NACE International.

Nibhanupudi S.,METALAST International, Inc. | Manavbasi A.,METALAST International, Inc.
Magnesium Technology | Year: 2011

Magnesium and its alloys have excellent physical and mechanical properties due to their high strength-to-weight ratio and are ideal for various applications in automotive, aerospace and defense sectors. However, Mg alloys are also highly susceptible to corrosion under harsh environments. Owing to this carcinogenicity as well as environmental impact of hexavalent chromium fueled by stringent environmental regulations, an environmentally green alternative to the carcinogenic hexavalent chromium coatings on magnesium is due. In this work, a novel trivalent chromium based conversion coating has been developed to improve the corrosion resistance and paint adhesion properties of Mg alloys. Coating performance characterization has been investigated via hydrogen evolution, weight loss measurement and electrochemical corrosion analysis techniques. Results have shown that the novel environmentally green trivalent chromium based coating on magnesium has indeed performed comparable to hexavalent chromium and thus establishing a viable alternative.

Manavbasi A.,METALAST International, Inc.
National Association for Surface Finishing Annual Conference and Trade Show 2012, SUR/FIN 2012 | Year: 2012

A novel hexavalent chromate-free conversion coating was developed to improve anti-corrosion and adhesive-bonding characteristics of the magnesium alloys and zinc-nickel (Zn-Ni) plated steel substrates. The corrosion behavior of the coated and uncoated alloys was investigated by Neutral Salt Fog (NSF) and Electrochemical Corrosion tests. Surface wettability of the pretreated substrates was investigated by static contact angle measurements. Wet-tape adhesion tests verified that there is a strong adhesion between the primer and the chem film treated substrates. The morphology and composition of coated surfaces were investigated by Optical Microscopy (OM), Scanning Electron Microscopy (SEM) and Energy Dispersive X-Ray Spectroscopy (EDX) methods. This trivalent chromium based surface treatment is potential hex-chromate conversion coating replacement for magnesium alloys and Zn-Ni plated steel.

Manavbasi A.,METALAST International, Inc. | Bodily K.,METALAST International, Inc. | Clarke T.,METALAST International, Inc. | Johnson K.,METALAST International, Inc. | Estes B.,METALAST International, Inc.
Metal Finishing | Year: 2013

Corrosion resistance of anodized aluminum sealed with conventional and a new sealant was tested against the alkaline, acid and neutral chloride salt solutions. The results show that the conventional water based sealants have good acid and Neutral Salt Fog resistance; however, they do not possess the necessary alkaline corrosion resistance to be used for decorative and automotive exterior applications. A new anodic coating sealant was developed to provide the necessary alkaline corrosion resistance along with the acid and neutral salt attack resistance. Acid Dissolution Test (ADT) Rating, Alkaline Corrosion Resistance, Neutral Salt Fog, Heat Resistance and Alkaline Car Wash Detergent tests were done in accordance with General Motors Spec GMW 14665. Results revealed that this novel sealant is significantly capable of meeting the rigorous GMW 14665 specification and can be used for sealing the anodic coatings used in automotive exterior applications. © 2013 Elsevier Inc.

Agency: Department of Defense | Branch: Air Force | Program: SBIR | Phase: Phase II | Award Amount: 749.86K | Year: 2010

The objective of this Air Force SBIR Phase II proposal is to optimize and develop an environmentally friendly replacement for the carcinogenic hexavalent chromium based conversion coatings on AMS 4434 Magnesium and Zinc-Nickel plated AISI 4130 and 4340 steel substrates. The proposed research is a continuation to the successful studies conducted during the Phase I stage of establishing the feasibility of a new trivalent chromium based conversion coating for the aforementioned alloys. The proposed conversion coating is a formulation of trivalent chromium, zirconium and an organic inhibitor in proportions found to offer effective corrosion protection and paint adhesion properties. Design and optimization of an efficient surface activation with the effective pretreatment of the surface for the deposition of reliable conversion coating shall be investigated. Corrosion resistance, coating adherence, multi-layer coating systems, simulated depot-level maintenance procedures including stripping/rework and their effects on the fatigue and corrosion resistance shall be investigated. The end result of the proposed research would be a complete environmentally green Trivalent Chromium based Conversion Coating process and product system as a performance and cost effective replacement for the carcinogenic Hexavalent Chromium Conversion Coatings on AMS 4434 Magnesium and Zinc-Nickel plated AISI 4130 and 4340 steel parts. BENEFIT: Magnesium alloys are used in military applications as helicopter gearbox casings, transmission casings, inline skates and some other high strength-low weight required applications. Kruger flaps, reverse thrust manifolds and control wheels found on many commercial aircrafts such as Boeing 727, 737 are sand-cast out of AZ92A alloy. The longest living aircraft B-52 Stratofortress brake calipers are manufactured out of AZ92A-T6. In spite of its high strength-to-weight ratio, magnesium alloys suffer from high corrosion rate coupled with complicated and expensive pretreatment routines. However, looking at the increasing trend of magnesium alloy usage in Military, Aerospace, Automotive sectors, METALAST believes a breakthrough in developing a successful replacement of hexvalent coatings would find widespread usage and demand. Cadmium plating of steel is another carcinogenic corrosion inhibition system restricted in many military applications. Zn-Ni plating, as a sacrificial layer, was found to be a suitable and economical alternative for various steel applications including fasteners, bolts and rivets. In the wake of recent EPA, OSHA and DoD directives for the replacement or limitation of the typical hexavalent conversion coating, there is a huge demand and need for an environmentally green yet potentially effective conversion coating system. Existing alternatives haven’t been either economical or potentially superior. METALAST International has often understood this need and demand from metal finishing industry. Hence, METALAST envisions the need and plans to utilize this opportunity through SBIR to develop an efficient replacement. Developing an environmentally green conversion coating will not only negate the health hazards but also increase the lifetime of both magnesium and Zn-Ni plated steel parts, the parts adjoined, subsequently reducing the high maintenance costs.

METALAST International, Inc. | Date: 2012-04-17

Chemicals for use in metal treatment to prevent corrosion, consisting of cleaners, etchers, deoxidizers, dyes, electrolytic colors, sealants, electro polishers, anodizing additives, surfactants, acidifiers, basifiers, anodizing accelerators, fume suppressants, and anti foaming agents. Computer hardware systems comprising central processing units, computer monitors, computer input devices, namely, computer touch screens and keyboards, and computer interface controllers; computer software for controlling and monitoring metal treatment processes, storing data related to metal treatment, and for creating process verification reports.

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