1. Metal Finishing 101 Part 1. Metal Finishing and Electroplating August 22, 2005

2. What We Will 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

3. 433 or 413, What’s the Problem? Two Categorical classifications covering the 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?

4. 40 CFR 413 - Electroplating Original "surface finisher" regulation promulgated in 1979 and 1981 Covers 6 main or “Core” processes –Electroplating –Electroless Plating –Anodizing –Coatings –Etching and Chemical Milling –Printed Circuit Board Manufacturing

5. 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 –Etching and Chemical Milling –Printed Circuit Board Manufacturing 40 other ancillary metal finishing operations –Cleaning, painting, machining, grinding, polishing, barrel finishing, burnishing, impact deformation, pressure deformation, shearing, heat treating, thermal cutting, welding, brazing, soldering, flame spraying, sand blasting….

6. Basics of 433 and 413 Both use various chemical processes to change the surface of a piece of metal, either adding a layer or taking a layer off - often referred to in the 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.

7. Basic? Electro- plating Process

8. The Big 6

9. Core #1 - Electroplating Electroplating is the deposition of a metallic coating onto the surface of an object by putting a negative charge onto the object and immersing it into a solution which contains a salt of the metal to be deposited.

10. Core #1 - Electroplating Before - dull After - shiny

11. 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.

12. Core #3 - Anodizing Anodizing is the electrochemical process by which the surface of a metal part is converted into a metal oxide Aluminum is the most common metal anodized 1- Aluminum base metal 3- Aluminum oxide layer (Core #3) 5- Coloring matter Anodizing

13. Core #3 - Anodizing A cathode is connected to the negative terminal of a voltage source and placed in the the anodizing solution typically 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.

14. Core #4 - Coating Any operation that includes: –Chromating, –Phosphating, –Metal coloring, and –Passivating

15. Core #4a – Chromating Portion of the base metal is converted to a component of a protective film. 1- Aluminum base metal 2- Chromate coating-core #4 4- Lacquer coating Film is composed of: –Base metal –Hexavalent chrome –Active inorganic or organic compounds

16. Core #4a – Chromating Before Chromating (shiny) After Chromating (dull)

17. Core #4b - Phosphating Immersion of steel, iron, or zinc plated steel in phosphoric acid to add a coating to the surface so that paint or some other substance will stick to the metal 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 a grayish scaly layer on it – look closely! –Some, especially line workers, will call iron phosphating “cleaning” – “just cleaning up the part prior to painting!”

18. Core #4b - Phosphating Iron Phosphating

19. Core #4c - Metal Coloring Chemical method of converting the metal surface into an oxide or similar metallic compound to produce a decorative film.

20. Core #4d - Passivating Process of forming a protective film on metals by immersion on an acid solution –Nitric acid –Nitric acid with sodium dichromate

21. Core #5 - Etching and Chemical Milling

22. 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 are much greater in chemical milling.

23. Core #6 - Printed Circuit Board Manufacturing

24. Formation of circuit pattern of conductive metal (usually copper) on nonconductive board materials such 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)

25. What about all the rinsing and cleaning?

26. Cleaning – Ancillary #7 Only action is to remove dirt, oil, etc. from the top 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 sealer or chromating or something

27. 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, thus preventing 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 of deciding whether an IU discharges from an operation

28. Multi-Stage Countercurrent Flow Rinse Drain Work Flow Water Flow

29. Two Stage Rinse Tank – Hand Dunking

30. Two Stage Rinse – Power Assisted Dunking

31. How do we know which is which? Information needed – both in the terms the IU uses, and in regular words you understand –what they make –raw materials and how they are used in the manufacturing process –other materials used in manufacturing –how they make it - process flow chart (physical and chemical processes), which steps generate wastewater, and can you see a difference in the surface between any process steps? More

32. 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, base metals, plating materials)

33. How do we know which is which? 433 – applies to SIUS who PERFORM one of the 6 “core” processes –AND discharge from any of the 6 “core” OR 40 “ancillary” –All process effluent is 433 413 - only applies to SIUs who began operation before September 1982 AND ARE EITHER –A Job Shop – Own <50% metal (annual area basis) worked on OR –An Independent Circuit Board Manufacturer – make circuit boards principally for sale to other companies

34. How do we know which is which? Are any of the main “core” 6 performed? Not 433 or 413No Began operation before 9/1/82 + no significant production changes since Yes 433.17 (new source) Yes Independent Circuit Board Manufacturer No413 No433.16 (existing source) Yes Discharge from any of the 46? NoNot 433 or 413 Own <50 % (area) of materials processed No Yes413

35. How do we know which is which? see 40 CFR 433.10(c)(2) and 433.1(c) and (d) and 40 CFR 413.01(a) 433/413 Verification Form available from DWQ - SIU fills out to determine which one applies Guidance Manual for Electroplating and Metal Finishing Pretreatment Standards, EPA, February 1984. EPA-440/1-84/091g Ask your friendly PERCS Staff

36. How do we know which is which? Development Document 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

37. How do we know which is which? Comp Guide, Appendix 3-D –categories, subparts, pretreatment regulated parameters, new source dates Comp Guide, Appendix 3-F –EPA contacts for categories Ask your friendly PERCS Staff

38. 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 metal piece that starts and ends with coil, uncoiled to do surface 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 of the part before they plate it?

39. 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

40. 433/413 Metal Shape Changing drilling threads Pressure/impact Deformation? welding Punching holes

41. Other Metals Categories - Major Shape Changing Casting = melt metal, pour into cast, allow metal to solidify in new shape Rolling = reduce diameter by passing metal between lubricated rollers (metal hot or cold) Drawing = pulling metal thru a die to make diameter thinner or change shape Extruding = use pressure to force metal to flow thru die Forging = use pressure to change shape, with or without dies. Usually on heated metal.

42. Other Metals Categories - Major Shape Changing Extrusion and drawing turned plug of aluminum into the fire extinguisher can – 40 CFR 467 – Aluminum Forming. –Note hole from pressure testing (433/413 ancillary #45) LP gas regulator – casting (464) Tungsten carbide drill bit – powder forming (471)

43. Other Metals Categories - 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 perform casting, drawing, etc., and then do “surface finishing” (6 basic/40 ancillary ), the surface finishing 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)

44. 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

45. 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 #: 919-733-5083 email: firstname.lastname@ncmail.net

46. DWQ Pretreatment Website Homepage: http://h2o.enr.state.nc.us/Pretreat/index.html Categorical items on Permit Writing Page

47. Thanks to… Burrell Brock, City of Raleigh Chris Hord, Surtronics,Inc Dana Folley, PERCS Unit Thank You!

48. Now What? Inspecting a Metal Finishing/Plating Facility –by Dawn Padgett