DIRECTIONS

IS 2-11-2013

LOTUS LIGHTWEIGHT STRUCTURES WELLINGBOROUGH

IS 2-11-2013

SYWELL ROAD, PARK FARM INDUSTRIAL ESTATE, WELLINGBOROUGH, NORTHAMPTONSHIRE, NN8 6XD

TELEPHONE +44 (0) 1953 674477

IS 2-11-2013

ANODISING FACILITY

LLS operates its own high quality structural anodising plant from a 5,000 m2 facility in Wellingborough. The facility is capable of anodising 400,000 m2 per annum and also acts as a logistics co-ordination hub for key customers.

Structural aluminium anodising line producing up to 5 flight bars per hour capable of surface treating cast, sheet and extruded alloys. This is currently one of only a few facilities commercially available within the UK and Europe that is capable of anodising parts to the required high standard for structural bonding.

• Clear (sulphuric) anodising from AA5 to AA25 thicknesses• Hydrothermically sealed• BS EN 7599:2010• E0 (degreasing and deoxidation) pretreatment• E6 (pickling) pretreatment• Black anodising from AA10 to AA25

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WHY ANODISING?

On exposure to air, aluminium will immediately form a stable oxide layer. This natural oxide film is, however, very thin, approximately 1/100th of a micron, is easily damaged and provides little corrosion resistance under normal atmospheric conditions.

Anodising is the controlled formation of an oxide coating on the surface of components made, primarily, from aluminium and its alloys. The anodic coating is produced by passing an electric current through a dilute sulphuric acid solution, hydrogen is released at the cathode (the negative side of the cell) and oxygen is formed at the anode forming aluminium oxide. The thickness, density, hardness and colour of the coating can be varied depending on the solution and the processing conditions.

By modifying the processing conditions and electrolytes, a wide range of properties and coatings can be achieved, making anodising an ideal surface engineering technique for a wide range of applications.

 

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SULPHURIC ANODISING

The most common form of anodising is sulphuric acid anodising. An anodic film thickness of up to 25 microns can be produced, depending on the grade of alloy and end use of the components. The lower range of thickness is ideal for decorative finishes. Anodic films with a thickness above 15 microns are used for increased durability and external applications, where corrosion resistance and wear are the main criteria.

Pre-treatment Since the anodic film is clear, the original surface is visible after anodising. It is important then to correctly use the wide range of pre-treatments available. Lotus can provide E0 (degreasing and deoxidation) and E6 (pickling) pretreatments.

Post-treatmentAn anodic film has a very fine columnar pore structure. Firstly, the film must be correctly sealed in order to ensure good corrosion resistance, sealing is achieved by immersion of the workpiece in de-ionized water held just below boiling point.

Secondly this structure makes it possible prior to sealing, for the anodic film to absorb dyes and pigments into its pores thereby producing a range of coloured finishes. Lotus can provide black dyed anodised components.

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BENEFITS OF ANODISING

Corrosion resisitance Anodising protects aluminium against most forms of corrosion. This resistance will increase with film thickness. If the product is to be exposed to a harsh chemical environment it is advised to discuss the specific chemical conditions with our engineering team. Lotus can provide a coating of 5 to 25 microns (AA5 to AA25).

Heat reflectivity and emissionThicker anodic films of 10 microns or more are good heat emitters or absorbers having an emissivity exceeding 70%. The thermal conductivity of the anodic coating is about ⅟10 that of the aluminium. But it has been found that anodic coatings of 10 microns and over produce an excellent heat dissipating surface where the maximum rate of radiant heat transfer is required. An example of this is on heavy duty electronic heat sinks.

Wear resistance The anodic film is much harder than the base aluminium and therefore can confer a high degree of abrasion resistance to the anodised component.

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STRUCTURAL ANODISING

• BS EO ISO 7599 structural anodising• Components up to 1.5 x 4 x 0.6 metres in size

• Plating thickness of 5 (AA5) to 25 (AA25) microns• Black anodising from 10 (AA10) to 25 (AA25) microns

Structural aluminium anodising line producing up to 5 flight bars per hour capable of surface treating cast, sheet and extruded alloys. This is currently one of only a few facilities commercially available within the UK and Europe that is capable of anodising parts to the high standards required for structural bonding.

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ADVANCED DATA MANAGEMENT SYSTEM

A key benefit of our service is our data management system (DMS).

It is a modular package which allows process control, data monitoring, process alarming and plant fault diagnostics, which has also been extended to provide advanced features such as work history logs, production reports and maintenance schedules.

• Networking also allows the DMS to provide multiple terminals for access to live and historical information, both locally and remotely.

• With an integrated part library system, the operator is only required to enter the component part number, batch number and quantity which is all achieved by bar code scanning, thereby reducing any keying errors.

• Multiple part types are jigged together with the system automatically checking for compatibility between them. The unique anodising profiles are then automatically obtained when the part number is entered.

• An overview of the plant and processing parameters are provided in real time and dynamically displayed.

• The DMS continuously records information about the activity of the plant.

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COMPREHENSIVE DATA LOG OF EVERY COMPONENT

Combined with the DMS, work history logs enable complete part traceability with recall by part/batch number of each load processed.

While the work is being processed through the plant, the system records processing information, including details of actual immersion times to the second and process parameters together with any alarms affecting that particular load.

In addition, process parameters on each stage can be displayed in graphical format.

• Most anodising specifications suggest the required quality systems only

• LLS anodising specification details all chemistry, time and temperature controls. E.G. hot seal, we have seven controlled/measured variables; minimum solution temperature and turbidity, maximum conductivity and total suspended solids minimum/maximum immersion times, seal additive concentrations and pH

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PLANT QUALITY SYSTEMS

Every part is quality assured at several stages. This includes full traceability of the parts from material receipt to shipping. All parts are receipted and Odette labels are applied at receipt of goods.

The parts to be loaded onto the system are then scanned to process and given a unique works order. The part information is subsequently scanned onto the LLS MRP system and also into the plant process operating system which hard codes the relevant anodising program and designates a unique flight bar number. Each flightbar contains a number of extruded test samples for adhesive bonding certification:

• The anodised coupons are adhesively bonded and tensile tested using an in-house Instron tensile test machine. Each bond durability test consists of a ultimate failure load and the energy released at peak load

• Off line chemistry certifications are performed daily in our plant laboratory and we also have a highly accurate Hach Lange DR2800 spectrophotometer to measure the concentration of the additive, the Total Suspended Solids and Turbidity of the seal

• All chemistry values are electronically recorded and SPC charts are produced daily to track progress and identify long term drift

• LLS is one of only a handful of companies worldwide capable of producing to such a high specification (exceeds Qualanod), pertaining to the requirements for structural bonding applications

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LOTUS LIGHTWEIGHT STRUCTURES WORCESTER

LLS can also provide a range of services from its Worcester facility with Wellingborough being the Tier 1 or Tier 2 supplier.

LLS Worcester is part of Group Lotus and is closely linked with both Lotus Cars and Lotus Engineering.

LLs can provide combined engineering services and component supply.

• Aluminium structures• Aluminium bonding • Aluminium welding• Weight saving engineering

DIRECTIONS

IS 2-11-2013

SYWELL ROAD, PARK FARM INDUSTRIAL ESTATE, WELLINGBOROUGH, NORTHAMPTONSHIRE, NN8 6XD

TELEPHONE +44 (0) 1953 674477