Metal Finishing and Electroplating 2

8/8/2019 Metal Finishing and Electroplating 2

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WhatWeWill Cover Today Introduce the Problem

40 CFR 413 Electroplating

40 CFR 433 Metal Finishing

6 Main or Core Operations Electroplating Electroless Plating

Anodizing

Coatings

Etching and Chemical Milling

Printed Circuit Board Manufacturing

How to determine the Difference Between 433 and 413

Other Metal Categories


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433 or 413,Whats the Problem?

Two Categorical classifications coveringthe same processes.

How do we know.

if it is a categorical discharger (433 or 413);

If so, is it 433 or 413.

Or is it some other category altogether?


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40 CFR 413 - Electroplating Original "surface finisher" regulation promulgated

in 1979 and 1981

Covers 6 main or Core processes

Electroplating

Electroless Plating

Anodizing

Coatings




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40 CFR 433 Metal Finishing

Promulgated in 1984 Most 413 CIUs moved to 433

Covers same 6 main core processes as 413

Electroplating

Electroless Plating Anodizing

Coatings



40 other ancillary metal finishing operations

Cleaning, painting, machining, grinding, polishing, barrelfinishing, burnishing, impact deformation, pressuredeformation, shearing, heat treating, thermal cutting,

welding, brazing, soldering, flame spraying, sand blasting.


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Basics of 433 and 413 Both use various chemical processes to change

the surface ofa piece ofmetal, either adding a

layer or taking a layer off - often referred to inthe business as surface finishing

Some, like plating, very easy to see the surface

change. Some, like iron phosphating, sometimes difficult

to detect with the untrained eye.


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Basic?Electro-

plating

Process

Identify Base Metal

Clean

Acid Descale & Activate

Pre-Plate(If required)

Final Plate

Post Treatments(As Specified)

Rinse

Rinse

Rinse

Rinse

Rinse

Dry & Package

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 2R

Step 3R

Step 4R

Step 5R

Step 6R

For Example: Steel,

Cooper , Brass

For Example:

Degrease, Soak, &

Electroclean

For Example:

Hydrochloric, Sulfuric,

or Fluoboric Acids.

(Some cases Peroxide

Descale or Brite Dip

For Example:

Cadmium, Chromium,

Copper, Gold, Lead,

Nickel. Silver, Solder, &

Tin

For Example:

Chromates, Lacquers,

& Seals

For Example: Box orHot Air Spin Dryers

For Example: Copper,

Sulfamate Nickel, orNickel

If more than one is

specified Repeat Steps

4 & 4R as needed.


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The Big 6


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Core #1 - Electroplating Electroplating is the deposition of a metallic

coating onto the surface of an object by putting anegative charge onto the object and immersing itinto a solution which contains a salt of the metal to

be deposited.


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Core #1 - Electroplating

Before - dull

After - shiny


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Core #2 - Electroless Plating

Electroless plating is plating without the use of

electrical energy- a chemical reduction process

which depends upon the catalytic reduction

process of metal ions in an aqueous solution(containing a chemical reducing agent) and the

subsequent deposition of the metal.

Typical choice for irregularly shaped, highly

detailed part shapes because of completely

uniform deposit thickness and high precision.


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Core #3 - Anodizing Anodizing is the electrochemical process by which

the surface ofa metal part is converted into ametal oxide

Aluminum is the most common metal anodized

1- Aluminum base metal

3- Aluminumox

idelayer (Core #3)

5- Coloring matter

Anodizing


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Core #3 - Anodizing

A cathode is connected

to the negative terminal

of a voltage source and

placed in the the

anodizing solutiontypically made up of

sulfuric acid. A metal

part is connected to the

positive terminal of

the voltage source and also placed in the anodizing solution.When

the circuit is turned on, the oxygen from the water molecules in the

anodizing solution will be liberated and combine with the metal

molecules? ions? on the surface of the part, forming a metal oxide

coating.


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Core #4 - Coating

Any operation that includes:

Chromating,Phosphating,

Metal coloring, and

Passivating


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Core #4a Chromating

Portion of the base metal is converted to a

component of a protective film.

1- Aluminumbase metal

2- Chromate

coating-core #4

4- Lacquer

coating

Film is composed of:

Base metalHexavalent chrome

Active inorganic or

organic compounds


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Core #4a Chromating

Before Chromating

(shiny)

After Chromating

(dull)


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Core #4b - Phosphating

Immersion of steel, iron, or zinc plated steel inphosphoric acid to add a coating to the surface sothat paint or some other substance will stick to themetal

Zinc phosphating new layer is easy to see, shiny,but not as shiny as electroplating

Iron phosphating new layer is more difficult to

see. Iron phosphated surface looks like it has agrayish scaly layer on it look closely!

Some, especially line workers, will call ironphosphating cleaning just cleaning up thepart prior to painting!


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Core #4b - Phosphating

Iron Phosphating


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Core #4c - Metal Coloring

Chemical method of converting the metalsurface into an oxide or similar metallic

compound to produce a decorative film.


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Core #4d - Passivating Process of forming a protective film on

metals by immersion on an acid

solution

Nitric acid

Nitric acid with sodium dichromate


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Core #5 - Etching and

Chemical Milling


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Core #5 - Etching and

Chemical Milling Etching is the controlled removal of metal

by dissolving it with chemical reagents or

etchants to produce a specific design

configuration.

Chemical milling is the same process except

the rates and depths of metal removal aremuch greater in chemical milling.


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Core #6 - Printed Circuit

Board Manufacturing


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Core #6 - Printed Circuit

Board Manufacturing Formation of circuit pattern of conductive metal

(usually copper) on nonconductive board materialssuch as plastic or glass. Employs cores # 1, 2,

and 5 in sequence.

Five basic Steps

Cleaning + surface preparation

Catalyst + electroless plating (#2)

Pattern printing + masking

Electroplating (copper) (#1)

Etching (#5)


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What aboutall the

rinsing and

cleaning?

Identify Base Metal

Clean

Acid Descale & Activate

Pre-Plate(If required)

Final Plate

Post Treatments(As Specified)

Rinse

Rinse

Rinse

Rinse

Rinse

Dry & Package

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 2R

Step 3R

Step 4R

Step 5R

Step 6R

For Example: Steel,

Cooper , Brass

For Example:

Degrease, Soak, &

Electroclean

For Example:

Hydrochloric, Sulfuric,

or Fluoboric Acids.

(Some cases Peroxide

Descale or Brite Dip

For Example:

Cadmium, Chromium,

Copper, Gold, Lead,

Nickel. Silver, Solder, &

Tin

For Example:

Chromates, Lacquers,

& Seals

For Example: Box orHot Air Spin Dryers

For Example: Copper,

Sulfamate Nickel, orNickel

If more than one is

specified Repeat Steps

4 & 4R as needed.


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Cleaning Ancillary #7

Only action is to remove dirt, oil, etc. from thetop of the surface of the metal.

Does not change the character of the actual

metal surface or the color of the metal itself Will only look different because dirt layer is

gone

Often confused with phoshating (#4b)Usually a 5 stage process: alkaline cleaning,

rinse, phosphate, rinse, and sealerorchromating or something


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Rinsing

Generally rinsing is required after each (core or

ancillary) process step.

Removes chemicals from the previous process step

that are lingering on the surface of the part, thuspreventing cross-contamination of process tanks.

Rinse tanks are generally discharged continuously

or in batches to the WWTF.

Rinse water is considered part of the operation

for the purposes ofdeciding whether an IU

discharges from an operation


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Multi-Stage Countercurrent

Flow Rinse

Drain

Work Flow

Water Flow


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Two Stage Rinse Tank

Hand Dunking


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Two Stage Rinse

Power Assisted Dunking


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How do we know which is which?

Information needed both in the terms the IU uses, and inregular words you understand

what they make

raw materials and how they are used in themanufacturing process

other materials used in manufacturing

how they make it - process flow chart (physical andchemical processes), which steps generate wastewater,and can you see a difference in the surface between anyprocess steps?

More


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Information needed (continued)

What operations do they use to change the shape of

metal pieces (see Determining Metals CIUs-Part 2)

Applicable SIC codes

Operation start-up date

Last time production changed (new tanks, basemetals, plating materials)


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433 applies to SIUS who PERFORM one of the 6core processes

AND discharge from any of the 6 core OR 40ancillary

All process effluent is 433

413 - only applies to SIUs who began operation beforeSeptember 1982 AND ARE EITHER

A Job Shop Own


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Are any of the main

core 6 performed? Not 433 or 413No

Began operation before

9/1/82 + no significant

production changes since

Yes

Yes 433.17 (new source)

Yes

Independent Circuit

Board ManufacturerNo 413

No 433.16 (existing source)

YesDischarge from

any of the 46?No Not 433 or 413

Own


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see 40 CFR 433.10(c)(2) and 433.1(c) and (d)and 40 CFR 413.01(a)

433/413 Verification Form available fromDWQ - SIU fills out to determine which oneapplies

Guidance Manual for Electroplating andMetal Finishing Pretreatment Standards,EPA, February 1984. EPA-440/1-84/091g

Ask your friendly PERCS Staff


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DevelopmentDocument for Effluent Limitations

Guidelines and Standards for the .

Metal Finishing Point Source Category, EPA,

June 1993. EPA-440/1-82/091

Electroplaters Point Source Category, EPA,

August 1979. EPA 440/1-79/003

Ask your friendly PERCS Staff


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Comp Guide, Appendix 3-D

categories, subparts, pretreatment regulatedparameters, new source dates

Comp Guide, Appendix 3-F

EPA contacts for categories

Ask yourfriendly PERCSStaff


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Distinguishing Metal CIUs Part 2

Not everyone who performs 6 Core is 433 or 413.

40 CFR 465 - Coil Coating

Coil coaters perform one of 6 basic on metalpiece that starts and ends with coil, uncoiled to dosurface finishing

465 also includes can making - do coating

40 CFR 466 - Porcelain Enameling

perform one of 6 basic on porcelain

What about the SIU who "forms" the basic shape ofthe part before they plate it?


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433/413 Metal Shape Changing

413/433s change shape of metal piece in

relatively minor way

drilling and/or threading holes making bends, holes, dents, etc. by

impact deformation Dana says ka-boom!

pressure deformation slow, steady force

Grinding, machining, or cutting off areas


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433/413 Metal Shape Changing

drilling threads

Pressure/impact

Deformation? welding

Punching holes


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Other Metals Categories -

Major Shape Changing Casting = melt metal, pour into cast, allow metal

to solidify in new shape

Rolling = reduce diameter by passing metalbetween lubricated rollers (metal hot or cold)

Drawing = pulling metal thru a die to makediameter thinner or change shape

Extruding = use pressure to force metal to flowthru die

Forging = use pressure to change shape, with orwithout dies. Usually on heated metal.


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Major Shape Changing

Extrusion and drawingturned plug of aluminum intothe fire extinguisher can 40

CFR 467 AluminumForming.

Note hole from pressuretesting (433/413 ancillary #45)

LP gas regulator casting(464)

Tungsten carbide drill bit powder forming (471)


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Major Shape Changing Where does 413/433 pressure deformation end

and other metals categories forging begin?

Cladding (471) versus brazing (433/413)

for some Other Metals Categories, when performcasting, drawing, etc., and then do surfacefinishing (6 basic/40 ancillary), the surfacefinishing wastes are not covered by 413 or 433,

but are covered by the casting, drawing, etc.,regulation

40 CFR 433.10(b) and 40 CFR 413.(b)


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Other Metals Categories

420-Iron and Steel

421-Nonferrous metals manufacturing

424-Ferroalloy Manufacturing 461-Battery

464-Metal Molding and Casting

465-Coil coating

467-Aluminum Forming

468-Copper Forming

471-Nonferrous Metals Forming and

Metal Powders


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DWQ Pretreatment Contacts

Jeff Poupart, Supervisor ext. 527

Dana Folley, A - F Towns- ext. 523

Jon Risgaard, G - M Towns- ext. 580

Deborah Gore, N - X Towns- ext. 593

Daryl Merritt, Y-Z Towns- ext. 554

Phone #: 919-733-5083email: [email protected]


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DWQPr

etr

eatmentW

ebsite

Homepage:

http://h2o.enr.state.nc.us/Pretreat/index.html

Categorical items on PermitWriting Page


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Thanks to Burrell Brock, City of Raleigh

Chris Hord, Surtronics,Inc

Dana Folley, PERCS Unit

Thank You!


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NowW

hat?

Inspecting a Metal Finishing/Plating

Facility

by Dawn Padgett

Documents

Metal Finishing and Electroplating 2