H.A.L (BC) DOC.NO.

: HSP(AS)01
A/C DIVISION CHROMIC ACID ANODISING ISSUE :H
Q.C. DEPT. PAGE : 1 of 10
DATE : 10.10.2005

HINDUSTAN SPECIAL PROCESS

ON

CHROMIC ACID ANODISING(CAA)

FOR

A320/321 SUB CONTRACT PROGRAMME

Revised By : Checked By : Approved By :

J.VEDALIN SAMUEL S.A.RAZACK Y.N.KHADGI

Engineer Chief Manager Addl. General Manager
Works Test Laboratory Quality Engineering Quality Control

HINDUSTAN SPECIAL PROCESS

Intellectual property of Aircraft Division, HAL, Bangalore. Not to be copied or distributed. For
an official copy, write to Quality Department.
H.A.L (BC) DOC.NO. : HSP(AS)01
A/C DIVISION CHROMIC ACID ANODISING ISSUE :H
Q.C. DEPT. PAGE : 2 of 10
DATE : 10.10.2005

1.0 CONTENTS :

- COVER PAGE

1.0 CONTENTS

2.0 RECORD OF CHANGES

3.0 PURPOSE

4.0 SCOPE

5.0 REFERENCE DOCUMENTS

6.0 EQUIPMENT AND MATERIALS

7.0 REQUIREMENTS

8.0 PROCEDURE

9.0 QUALITY CONTROL

10.0 REWORK PROCEDURE

- ANNEXURES

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an official copy, write to Quality Department.
H.A.L (BC) DOC.NO. : HSP(AS)01
A/C DIVISION CHROMIC ACID ANODISING ISSUE :H
Q.C. DEPT. PAGE : 3 of 10
DATE : 10.10.2005

2.0 RECORD OF CHANGES :

2.1 Brief Details of Change :

Issue Date Page Brief Details of Changes

Nil July 89 All First Issue

A OCT 89 All Updated to indicate revised

Coating thickness

B JULY 91 2 Time duration in CAA revised

B JULY 91 4 Change in signatory for revision

B 15.05.93 1 Reference Documents included and

Building Number included

C 15.05.93 2 Tank sequence changed.Alkaline

cleaner specified as DC-AL.Cold water
swill after pickling deleted.

C 15.05.93 3 Time requirement of water break test

specified.

C 15.05.93 4 Change in signatory.

D 10.06.93 All Updated

E 01.07.93 6&7 Tank numbers reidentified with new

numbers and bath control reference
column introduced.

F 10.02.95 6 DC-AL is replaced by MC-AL Solution

in Tank No.H-2

G 14.10.2000 All Format change, paragraphs

Renumbered. Periodic review.
5 Para 3.0 added.
6, 7 Flow Chart Corrected.
MC-replaced by DC-Al

HINDUSTAN SPECIAL PROCESS

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an official copy, write to Quality Department.
H.A.L (BC) DOC.NO. : HSP(AS)01
A/C DIVISION CHROMIC ACID ANODISING ISSUE :H
Q.C. DEPT. PAGE : 4 of 10
DATE : 10.10.2005

Issue Date Page Brief Details of Changes

H 10.10.2005 5 Para 6.0 deleted

6,7 Para 7.6, 7.7, 7.8 & 7.9 added.
Amendment G1 & G2 amalgamated
Paragraphs renumbered

HINDUSTAN SPECIAL PROCESS

Intellectual property of Aircraft Division, HAL, Bangalore. Not to be copied or distributed. For
an official copy, write to Quality Department.
H.A.L (BC) DOC.NO. : HSP(AS)01
A/C DIVISION CHROMIC ACID ANODISING ISSUE :H
Q.C. DEPT. PAGE : 5 of 10
DATE : 10.10.2005

3.0 PURPOSE :

3.1 To establish the procedure to the followed for Chromic Acid Anodizing of
aluminium alloys of Airbus components.

4.0 SCOPE :

4.1 The special process specification details the procedure and process parameters to
be followed for chromic acid anodising of Aluminium alloy 2000 and 7000 series
of Airbus components. This specification is drawn to cover the special/additional
requirements. This document is applicable only for Airbus components processed in
Aircraft Division.

5.0 REFERENCE DOCUMENTS:

5.1 Current issues of following documents are applicable.

A/DET 0072 - Anodising of Aluminium Alloys

NFX 41-002 - Salt spray test

NFA 91-408 - Sealing Test

NFA 91-410 - Coat continuity check

IGC.04.74.100 - Follow-up of protection of light

alloys by anodising treatment

IGC.04.23.100 - Measuring of coat thickness

IGC.04.24.100 - Corrosion resistance test

IGC 04.74.106 - Chromic acid anodising of Al. Alloys

HII 34 - Frequency of Sampling and Bath

Solution control

6.0 EQUIPMENT & MATERIALS:

6.1 The anodising line of Honey-comb shop Building No.599 of Aircraft Division
shall be used for the subject process. The time data logger and Digital programmer
for automatic control of process cycle shall be made use of.

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A/C DIVISION CHROMIC ACID ANODISING ISSUE :H
Q.C. DEPT. PAGE : 6 of 10
DATE : 10.10.2005

6.2 The plating tank shall be made of welded mild steel. The tank serves as cathode.
The bus bar made out of commercial copper serves as anode. The chromic acid
used for the preparation of electrolyte is of the following purity.
____________________________________________________________________
Chemical Specification Purity Maximum impurities
(Min.) Level

Chromium IS 330 98.5% Water insoluble=0.15%

trioxide Electro Plating SO4"= 0.20%
grade) Cl' = 0.05%

7.0 REQUIREMENTS :

7.1 Racks and Jigs shall be made of pure aluminium. In case of aluminium alloys are
used, the aluminium content of jig material shall not be less than that of the
components. Electrical contact must be firm through out the treatment.

7.2 Racking shall be such that there will be no entrapment of air during anodising.

7.3 Clean cotton gloves shall be used to handle the components.

7.4 Maintenance in co-ordination with Shop shall monitor the baths free from
suspended Impurities.

7.5 Shop shall ensure current calibration of voltmeters, Ammeters, thermometers and Deleted: Shop shall ensure current
calibration of voltmeters, Ammeters,
bath composition are upto date. Any bath corrections shall be duly signed by shop thermometers and bath composition are
supervisor. upto date. Any bath corrections shall be
duly signed by shop supervisor.¶

7.6 Parts shall be processed from one step to the next without allowing the parts to dry. Deleted: The anodised components
shall be moved to painting unit
immediately so as to complete the
7.7 Water break free surfaces shall be ensured after precleaning. A continuous water painting with in 16 hours.
film spread over the components surface for atleast 30 seconds is satisfactory. This Deleted: 9
test is to be done immediately after the removal of part from power spray wash. If
water film breaks cleaning cycle shall be repeated.

7.8 The anodised components shall be moved to painting unit immediately so as to

complete the painting with in 16 hours.

7.9 Wet parts shall be handled with clean latest rubber gloves and dry parts with clean
cotton gloves.

HINDUSTAN SPECIAL PROCESS

Intellectual property of Aircraft Division, HAL, Bangalore. Not to be copied or distributed. For
an official copy, write to Quality Department.
H.A.L (BC) DOC.NO. : HSP(AS)01
A/C DIVISION CHROMIC ACID ANODISING ISSUE :H
Q.C. DEPT. PAGE : 7 of 10
DATE : 10.10.2005

8.0 PROCEDURE :

8.1 The procedure to be followed is given in the form of a flow chart along with the
parameters for each operation. The process duration and voltage shall be monitored
and recorded by time data logger. The extended anodising cycle as per Annexure
A shall be programmed with the digital programmer.

FLOW CHART

Operation Tank Bath Composition Duration Temp. Remarks

No. In Min. Deg.C
VAPOUR H1 Trichloroethhylene BS 2-3 Less than
DEGREASE 580 type – 2 or IS 245 or equal
type – 2 to 91
ALKALINE H2 Proprietary DC-AL 5-10 50-60
CLEAN Metal cleaner of Delta
chemicals 50 – 100
gms/litre (Silicate free)
WATER WASH H3 Demineralised water 2-3 Ambient
POWER SPRAY
SULPHO H5 Sulphuric Acid : 3-5* 50-65
CHROME 15%(v/v) Chromic
PICKLE Acid : 5 % (W/v)
WATER WASH H6 Demineralised water 2-3 Ambient
POWER SPRAY
WATER BREAK - - - - Examine for
TEST Continuity
of water
film.
ANODISE H8 Total Chromic Acid 40 40+/-2 ** Electrical
50-60 g/l Free Chromic cycle : 19.5
Acid 30-50 g/l. to 20V
WATER WASH H9 Demineralised water 2-3 Ambient
POWER SPRAY
Cold Swill H 10 Demineralised water 2-3 Ambient
SEALING(only if H 13 K2Cr207=25-35 mgs/l 40-45 95-98
applicable. Refer
Process)
DRY - Still air 120-180 Ambient

* Cumulative not more than 15 minutes.

HINDUSTAN SPECIAL PROCESS

Intellectual property of Aircraft Division, HAL, Bangalore. Not to be copied or distributed. For
an official copy, write to Quality Department.
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A/C DIVISION CHROMIC ACID ANODISING ISSUE :H
Q.C. DEPT. PAGE : 8 of 10
DATE : 10.10.2005

9.0 QUALITY CONTROL :

9.1 The Quality Control Department shall ensure the following checks.

9.2 Bath Control: Bath shall be controlled and the frequency of check shall be as per
HII 34. The results shall be recorded on charts.

9.3 Inspection :

9.3.1 Visual inspection to be performed on 100%. The protective anodic coating must
be continuous, smooth, uniform in colour, free from scratched areas, signs of
corrosion and powdery finish.

9.3.2 Thickness of Anodic Film : This measurement shall be made as follows:

i) 100% on Class-1 part.

ii) 10% on Class-2 and Class-3 parts.

The thickness requirement for 2024 and 7175 alloys shall be in between 2 and 4
microns. The thickness shall be recorded as per IGC.04.23.100.

9.4 Periodic Test :

Check on Test Specimens sealed in K2Cr2O7 solution.

9.4.1 The total specimen shall be as below :

Dimension (in mm) 125 x 80 x 1-4

Surface finish Ra <1 Micron
Material Specification 2024 T3 unclad as rolled condition and
7175 T3 machined.
Tests Frequency

Coat thickness
Sealing quality One test specimen each once in two weeks
Coat continuity
Corrosion resistance One test specimen each once in two weeks

9.4.2 Anodic coat thickness shall be 2 to 4 Microns average value. Test shall be done as
per IGC.04.23.100.

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A/C DIVISION CHROMIC ACID ANODISING ISSUE :H
Q.C. DEPT. PAGE : 9 of 10
DATE : 10.10.2005

9.4.3 Sealing Quality : Test shall be as per NFA 91-408. Sealing is acceptable if dye
does not remain on the surface of the test specimen. A very faint colour stain is
permissible.

9.4.4 Coat Continuity : Test shall be as per NFA 91-410. A maximum of one black spot
per Sq.Cm is permitted and the diameter of the black spot shall not exceed 1 mm.

9.4.5 Corrosion Resistance : Perform a test using 5% sodium chloride spray test for 500
Hours as per NFX 41-002. After completion of test, no signs of corrosion shall be
detected away from the edges of the test specimen.

10.0 REWORK PROCEDURE :

10.1 In the event of defects to rework of the parts involved strip in the following solution.
2 times stripping and 3 times anodising is permitted.

10.1.1 Stripping Solution :

Building No.31-1

Solution Bath Temp. Tank No. Duration

Concentration Deg. C
____________________________________________________________________

H3PO4 35 ml/l Near ST-9 Sufficient time to

(Sp.Gr. 1.75) boiling remove anodic film
CrO3 20 g/l
__________________________________________________________________________

HINDUSTAN SPECIAL PROCESS

Intellectual property of Aircraft Division, HAL, Bangalore. Not to be copied or distributed. For
an official copy, write to Quality Department.
H.A.L (BC) DOC.NO. : HSP(AS)01
A/C DIVISION CHROMIC ACID ANODISING ISSUE :H
Q.C. DEPT. PAGE : 10 of 10
DATE : 10.10.2005

ANNEXURE-A

EXTENDED ANODISING CYCLE

ANODISE TO THE REQUIRED THICKNESS USING VOLTAGE AND TIME

SETTINGS AS SPECIFIED IN THE GRAPH

i) RAISE THE VOLTAGE FROM 0 - 20 V IN FIRST 5 MINUTES

ii) HOLD AT 20 V FOR 35 MINUTES

iii) REDUCE THE VOLTAGE TO ZERO OVER A PERIOD OF ONE MINUTE.

HINDUSTAN SPECIAL PROCESS

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an official copy, write to Quality Department.