Download - 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
Etching and Chemical Milling
Printed Circuit Board Manufacturing
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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
Etching and Chemical Milling
Printed Circuit Board Manufacturing
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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How do we know which is which?
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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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
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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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 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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How do we know which is which?
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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How do we know which is which?
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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Other Metals Categories -
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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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 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