Dynacast Surface Finish 101 Webinar Slides PDF

SURFACE FINISH 101
Presented by: Brad Doornbos and Hugh Smith

Hosted by: Taylor Topper
QUESTIONS
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questions and comments using the
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• For more information, please contact

your hostess:
Ttopper@FormTechnologies.com
• Note: Today’s presentation is being

recorded and will be provided in the
next few days.
SURFACE FINISH 101 AGENDA
Discovery
Process Control
Coatings
Questions
DISCOVERY
What needs to be considered when
choosing a finish.
FUNCTION OF PART
• What are you looking to do? • Wear characteristics?

• What is the purpose of the finish coating? • Wear resistance?
• What testing requirements does it need to
pass?
• Does it require a specific thickness?
PRICE CONSIDERATION
• The finish that you specify needs to be in-line • Knowing what options are available
with your requirements
• Advancements in die cast alloys
PROCESS CONTROL
The quality of the substrate is crucial to the
overall success of the project.
SUBSTRATE SURFACE CONDITION
Things that affect the surface condition:

• Surface cleanliness
• Prewash process (die lubricant, buffing)
• Fill rate (air entrapment)
• Quality of substrate
• Secondary surface finish preparation
8
DESIGN CONSIDERATIONS
Parting Lines Fillet & Radii
• Parting line location • Avoid sharp corners

• Design inside corners with fillets
• Design outside corners with radii
• Improves metal flow through reduced
turbulence
9
COATINGS
Overview of most commonly used finishes
ANODIZING
Clear
• Anodizing creates a non-conductive protective

coating
• Good corrosion resistance
• Can be dyed virtually any color or shade. Black,
blue, red, etc.
• Type 2- Sulfuric Anodized Class 1 – Non-dyed,

clear (natural) color.
Black • Type 3- Hard Anodized Class 2 – Dyed, color

must be specified.
• Salt spray test: 190 hours
• Thickness: 0.00005” - 0.0005” (Class 2)
• Cost: $$
11
TRIVALENT CHROMATE
• Does not contain hexavalent chromium which

eliminates chrome reduction in waste treatment.
• RoHS compliant
• Rust resistant
• 150+ hours salt spray
• Cost: $$
• Thickness: less than .000001”
12
CHROMATE WITH ZINC
• Finishes over the Zinc Plate -

Yellow, Clear, Black
• Soft, ductile and decorative
• Clear, Black, Yellow Salt spray 150+
• Excellent paint base.
• Seals are also offered for after

chromates to increase corrosion
resistance
• Thickness: Less than .000001”
• Cost: Clear - $$
13
E-COAT
• E-coat is an electrically-applied paint coating

• Oxidation/Rust resistance
• Cosmetic Finish
• Thickness: Regulated to range between 0.0002”

to 0.001” depending on requirements.
• Cost: $$
Chromium Plating + E-
Coating.
14
BLACK OXIDE
• Uniform black finish

• No Dimensional change
• Will not chip or peal
• Acts as an absorbent to hold oils or wax
• Cost: $
15
POWDER COAT
• Powder coating provides a higher uniformity of

thickness and color consistency than standard wet
paints
• Thickness: 0.004”
• Cost: $$-$$$
16
DECORATIVE CHROME
Bright, Brushed, Satin

• Good wear resistance
• Bright chrome thickness: 0.0015
• Cosmetic applications
• Salt spray – varies depending on thickness of
each layer of plating – up to 1,000 hours salt
spray.
• Design consideration for dimensional changes
should be considered – plating build up will vary
from part to part – part feature to part feature
• Thickness varies depending on part application
• Copper, Nickel, Chrome
• Cost: $$$$
17
BRIGHT NICKEL
• Nickel Plating is a yellowish white, hard reflective

finish used for wear resistance, and solderability
• Cost $$
18
CHEM FILM
• Chem Film is comprised of two types class 1A &

class III
• Class 1A used as a corrosion preventative film, also
as primer for paint which helps in its adhesion.
• Class III used for corrosion protection where low
electrical resistance is required
• Classified as conversion coating

• Cost: $
• Plating thickness is .00001
19
COPPER NICKEL TIN
• Tin plating is normally done to improve

solderability to a variety of base metal
substrates.
• Thickness:0.0011”
• Cost: $$
20
COBALT TIN
• Similar in appearance to chrome yet less

expensive
• Plated with bright nickel, then flashed with cobalt
tin
• Cost: $$$
• Thickness: .001”
21
ELECTROLESS NICKEL
• No electric current required for deposition.

• Uniform plate build up around corners and blind
holes. No high current density areas
• Types of Electroless Nickel
• Low Phos – Primarily used for hardness and wear
properties
• Mid Phos – Most commonly used deposit
• High Phos – Superior corrosion resistance, ductile
finish with excellent adhesion properties
• Cost: $$
22
GOLD PLATING
• Types of Gold Plating:

• Pure Gold – 99.90%, 90 HK25
• Hard Gold – 99.7%, 130-220 HK25
• Electroless Gold – 99.90%, 90 HK25
• Immersion Gold – By substituting nickel as an
undercoat instead of electroless nickel, immersion
is only about 10% more expensive than electroless
nickel alone. It is relatively inexpensive and an
affordable finish.
• Thickness:
• Electroless – 0.000005”
• Bright – 0.000015”
• Pure – 0.000015”
• Cost: $$$
23
SILVER
• Highest thermal and electrical conductivity

of any metal
• Cost: $$
24
NICKEL-FREE COATING
• Decorative finish very similar to chrome plating

• No nickel layer which may cause skin irritation
• Application primarily used with wearable
products which require a decorative finish
• Dynacast Singapore has created 18 variations of
a nickel free option including, Gold, Rose Gold,
Silver, Black and Gray
• Cost: $$$$
25
POLYURETHANE PAINT
• These coatings are very long lasting and are

recommended for exterior use. Can be painted
smooth or textured.
• Cost: $$
26
IMPREGNATION
• Seals porosity - leak free casting
• Cost: $
27
TEFLON
• Teflon is a thermally cured solid film lubricant

• Provides improved torque/tension control
• Salt Spray: 500 hours
• Thickness: 0.0003-0.001”
• Cost: $$-$$$
28
THANK YOU
PLATING AND E-COATING
Cosmetic requirement on a luxury product
Developed plating and e-coating process that achieves a vibrant surface finish on an aluminum casting
30

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SURFACE FINISH 101

Presented by: Brad Doornbos and Hugh Smith

• For more information, please contact

• Note: Today’s presentation is being

• What are you looking to do? • Wear characteristics?

Things that affect the surface condition:

Parting Lines Fillet & Radii

• Parting line location • Avoid sharp corners

• Anodizing creates a non-conductive protective

• Type 2- Sulfuric Anodized Class 1 – Non-dyed,

Black • Type 3- Hard Anodized Class 2 – Dyed, color

• Salt spray test: 190 hours

• Thickness: 0.00005” - 0.0005” (Class 2)

• Does not contain hexavalent chromium which

• Finishes over the Zinc Plate -

• Clear, Black, Yellow Salt spray 150+

• Excellent paint base.

• Seals are also offered for after

• Thickness: Less than .000001”

• E-coat is an electrically-applied paint coating

• Thickness: Regulated to range between 0.0002”

• Uniform black finish

• Powder coating provides a higher uniformity of

Bright, Brushed, Satin

• Nickel Plating is a yellowish white, hard reflective

• Chem Film is comprised of two types class 1A &

• Classified as conversion coating

• Tin plating is normally done to improve

• Similar in appearance to chrome yet less

• No electric current required for deposition.

• Types of Gold Plating:

• Highest thermal and electrical conductivity

• Decorative finish very similar to chrome plating

• These coatings are very long lasting and are

• Seals porosity - leak free casting

• Teflon is a thermally cured solid film lubricant

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