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Towards Cr(VI)-free anodization of aluminum alloys for aerospace adhesive bonding applications: A review

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Abstract

For more than six decades, chromic acid anodizing (CAA) has been the central process in the surface pre-treatment of aluminum for adhesively bonded aircraft structures. Unfortunately, this electrolyte contains hexavalent chromium (Cr(VI)), a compound known for its toxicity and carcinogenic properties. To comply with the new strict international regulations, the Cr(VI)-era will soon have to come to an end. Anodizing aluminum in acid electrolytes produces a self-ordered porous oxide layer. Although different acids can be used to create this type of structure, the excellent adhesion and corrosion resistance that is currently achieved by the complete Cr(VI)-based process is not easily matched. This paper provides a critical overview and appraisal of proposed alternatives to CAA, including combinations of multiple anodizing steps, preand post anodizing treatments. The work is presented in terms of the modifications to the oxide properties, such as morphological features (e.g., pore size, barrier layer thickness) and surface chemistry, in order to evaluate the link between fundamental principles of adhesion and bond performance.

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Authors and Affiliations

  1. Materials innovation institute (M2i), 2628 XG, Delft, The Netherlands

    Shoshan T. Abrahami

  2. Department of Materials Science and Engineering, Delft University of Technology, 2628 CD, Delft, The Netherlands

    Shoshan T. Abrahami, Herman Terryn & Johannes M. C. Mol

  3. Fokker Aerostructures BV, 3351 LB, Papendrecht, The Netherlands

    John M. M. de Kok

  4. Department of Materials and Chemistry, Research Group Electrochemical and Surface Engineering (SURF), Vrije Universiteit Brussel, 1050, Brussels, Belgium

    Herman Terryn

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Since 2006, Johannes M.C. (Arjan) Mol is an Associate Professor of ‘Corrosion Technology and Electrochemistry’ at the Materials Science and Engineering Department of Delft University of Technology (NL). After finishing his MSc in Aerospace Engineering in 1996, he obtained his PhD at Delft University of Technology (TUD) in 2000 on “The effect of microstructural inhomogeneities on filiform corrosion of aluminium alloys”. In the period of 2000–2006 he was project and team leader at the Dutch Institute of Applied Scientific Research TNO in the research area of lifetime performance of materials. Nowadays Arjan Mol leads various fundamental (PhD and post-doc) projects focused on local corrosion mechanisms, interfacial (de)adhesion of organic coatings, surface treatments and the development and evaluation of coating systems, including self-healing anti-corrosive coatings, utilizing advanced micro- and macro electrochemical and surface analysis techniques. He has published over 110 Web of Science listed papers in international peer refereed scientific journals, 13 book chapters, 1 book as co-editor and over 85 international conference proceeding papers. Arjan Mol is Working party Chairman of ‘Physico-chemical methods for Corrosion Research” and currently, as from 2017, he is Vice-president of the European Corrosion Federation EFC (www.efcweb.org) after serving EFC as Chairman of the Scientific and Technology Advisory Committee in the period of 2014–2016.

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Abrahami, S.T., de Kok, J.M.M., Terryn, H. et al. Towards Cr(VI)-free anodization of aluminum alloys for aerospace adhesive bonding applications: A review. Front. Chem. Sci. Eng. 11, 465–482 (2017). https://doi.org/10.1007/s11705-017-1641-3

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