Testing and Development

Testing and development of surface treatments including TiZr pre-treatments and surface coatings

Testing, development and managed control of our aluminium surface treatments and powder coating process are core services at Powdertech Surface Science, both for our ongoing client -based processes and as research work for OEMs.

Investment in advanced equipment and team expertise

We have the capability and expertise to offer a suite of tests and analytical techniques to probe the properties of a given surface for our clients. This is made possible by our investment in sophisticated equipment to evaluate aluminium surface cleanliness and bonding strengths.

Your project will benefit from our knowledge and expertise which is always at the cutting edge through our participation in key research projects within the industry.

We will provide reports, feedback and recommendations to assist product development & process improvement.

All testing, research and development work is done on our site, coordinated by our technical team and overseen by our technical expert ,Dr Nick Welton, who specialises in the science of surfaces and coatings and has been working in the industry for over 25 years.

On-site labs to ensure the highest standards in metal finishing

To measure and control our metal cleaning treatments, TiZr passivation process and powder coating, we have two dedicated surface coating laboratories: our Surface Science Lab and our Quality Control Lab.

Surface Science Laboratory

In our dedicated Surface Science Laboratory we have invested in the latest equipment to accurately measure the exact levels of cleanliness of aluminium (and magnesium) surfaces and quantify the strength of bonded metal joints.

Instron measuring bond strength

We want to be certain that the passivation process we provide is 100% fit for any intended purpose, most especially when it comes to TiZr coating for bonding. We have the capability to optimise our TiZr treatment to meet different specification requirements. This includes ensuring that the bonds achieved following our TiZr conversion coating consistently meet and exceed our customers’ requirements.

We have world leading Instron equipment as part of our testing suite. This is an electromechanical universal testing machine, able to perform a wide range of mechanical tests including tensile, compression, bend, peel, tear, friction, and shear testing. Tests are performed on all the aluminium alloys we work with, from 3xxx series up to 7xxx series, and in all formats, cast, extruded and sheet.

The results of our Instron testing enable us to work with our clients to help them to understand the optimal surface finishing pre-treatment process they need to take their bonding strategies to the next level, and to achieve repeatability going forwards.

The Instron 34TM-50 tests materials in accordance with ASTM, ISO and other industry standards. It has a 50kN load cell and 80mm wide grips, with a thermal chamber capable of reaching 350C.

Instron equipment to test bonding after TiZr — Instron 34TM-50

Surface cleanliness

We use XRF equipment Dyne inks and UV-Fluorescence to measure the level of aluminium surface contaminants and to demonstrate compliance to specifications detailing RFU limits.

Why do we take so much care over this measuring and cleaning prior to powder coating and adhesive bonding?

The simple reason is that surface contaminants, many that can’t even be seen, will impair the performance of any adhesive or coating applied to the metal.

Bond strengths will be unacceptably low, especially in wet environments when surface corrosion can initiate. Battery Electric Vehicles (BEV) are a good example where a high levels of cleanliness in the component structure are vitally important to ensuring the integrity and safety of the battery system.

For powder coating, a poorly cleaned surface can result in coating defects such as fisheyes, inclusions, pinholes and reticulation.

We will always ensure that your metal is clean before any coating is applied.

Dyne inks to test metal cleanliness. — When Dyne level test fluid is applied to the metal surface, the liquid will either form a continuous film on the surface or pull back into small droplets. They quality of the continuous film will determine the suitability of the surface for coating.

Measuring elemental composition

We have XRF (X-ray fluorescence) capability on-site. This handheld device will give us immediate, lab-quality results from which we can determine the next course of action, allowing us to stay on top of our TiZr passivation quality better than ever.

This is a powerful, non-destructive technique for measuring elemental composition from magnesium (Mg) to uranium (U).

XRF equipment to measure elemental composition — Handheld XRF (X-ray fluorescence) equipment to determine the chemical composition of a sample.

Quality Control Laboratory

Daily control and maintenance

The processes and chemicals used in our aluminium surface treatments are measured and tested throughout the day, every day, in our Quality Control Laboratory.

This is to ensure that concentrations, pH levels and cleanliness are optimal and consistent.

Temperatures of the ovens to cure the powder coating are also monitored throughout the day. Coating jobs are preceded by test plates to check the powder coating thickness, gloss level, smoothness, bond strength and colour consistency.