Anodizing is one of the major surface-finishing processes for aluminium. Manufacturers rate this method highly for its effectiveness in enhancing corrosion resistance, appearance, and mechanical properties of the material. But as you consider using anodizing for aluminium, you might be interested in knowing about the cost of anodizing aluminium.
The electrochemical method involves the formation of an oxide layer on aluminium. Machinery and consumables are involved. The process also consumes electricity, so cost is a big element.
Based on these process fundamentals, the cost of anodizing aluminium depends on factors such as the size of the coating, the type of coating, and the size of the material.
This article delves into one recurring question “What is the cost of anodizing aluminium?” Join us as we answer this question and tell you how our aluminium surface finishing services could transform your business.
The Anodizing Aluminium Process
The anodizing process for aluminium creates an oxide layer on the surface of China anodized aluminium sheet and other products. This layer protects the metal underneath from tear and wear and enhances material aesthetics.
Here are the steps of anodizing aluminium at Prolean Tech in brief:
Surface Cleaning
Surface cleaning
The first step in the anodizing aluminum process is surface cleaning, which is crucial for a strong bond between the surface and the anodized layer. Special cleaning agents remove dirt and grease from the metal surface.
Pre-treatment
Surface imperfections
This step aims to remove any imperfections on the aluminium surface. When pre-treatment is complete, the material should have a smooth and clean surface.
How exactly do you achieve these results? Through etching and brightening. For etching, a sodium hydroxide solution is applied on the metal surface to eliminate imperfections. Brightening chemically produces a smooth surface on the metal. Nitric acid is an effective chemical for this process.
Anodizing
Aluminum anodization tank
The next step is anodization. At this stage, we immerse aluminium in a tank containing an electrolyte solution and pass an electric current through it. As the aluminium surface gets oxidized, anodic oxide forms. This oxide improves the metal’s corrosion resistance. You can adjust the thickness of this layer by controlling the time and current.
Coloring
Different colours of aluminum are possible with anodization
Once the aluminium surface is anodized, it becomes easier to apply paint of whatever color you wish. The two leading techniques of coloring the China anodized aluminium sheet and other surfaces are dyeing and electro-coloring.
Dyeing is an excellent way to fill the pores resulting from the electrochemical process. These pores naturally absorb dies and colors. Since the dye thickness is usually thick (about 50 microns), the surface treatment can be very durable.
Electro-coloring will help you achieve darker colors on the anodized aluminium surface. The main materials for this anodizing aluminium process are inorganic metallic salts. Some colors you can achieve with this technique are brown, black, and grey.
Sealing
Finally, quality aluminium die-casting services take anodized aluminium through a sealing step. This step enhances the material’s corrosion resistance and prevents water entry. The process types are cold method, hot method, and a blend of the two methods.
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Types of anodizing to note as you consider the cost of anodizing aluminum
If you compare electroplating and anodizing for metal finishing, the mechanisms and intentions of the processes differ. The main difference is that anodizing increases the thickness of the oxide layer while electroplating coats a metal surface with another metal.
Aluminium anodizing can be categorized as below:
- Chromic Acid Anodizing (Type I)
- Sulfuric Acid Anodizing (Type II)
- Hard Anodizing (Type III)
Chromic Acid Anodizing (Type I)
This method produces the oxide layer using chromic acid. The resulting oxide layer is about 20-100 microinches thick. It is a non-conductive film, but it can support a dielectric process.
An anodized car rim
Since this type of anodizing rarely affects the part dimensions, you may want to use it on parts with tight tolerances. The China anodized aluminium sheet used in sensitive automotive and other sensitive industries can be anodized using the Type I method.
There is a twist to this though, because chromic acid has carcinogenic properties. Manufacturers that use this technique are required to have effective wastewater treatment processes that get rid of the toxic byproducts.
Sulfuric Acid Anodizing (Type II)
Golden-coloured metal parts after anodization
This sulfuric acid-based anodizing method is the most prevalent. You may wonder why this technology is so popular. Well, it is mostly because of the resulting layer’s capability to absorb dyes and pigments, and the layer being thicker – maintains significant dielectric properties.
Apply type II anodizing if you want your aluminium parts to be harder and more corrosion-resistant. This method applies to components in the military, architecture, electronics, and many other areas.
Hard Anodizing (Type III)
Aluminum metal parts after type III anodizing
In the third category of the types of anodizing aluminium, more intense conditions are introduced to Type II. In other words, the sulfuric acid electrolyte is still applicable.
What changes compared to the other types of anodizing aluminum? The temperature can be lowered, voltage increased, and current density increased. As you can guess, the manufacturer would be interested in creating a thicker aluminium oxide layer. There would also be a need for larger pores on the anodized aluminium surface.
What are the factors affecting anodized aluminium cost?
The cost of anodizing aluminium parts or components depends on several main elements. We will discuss these factors briefly next.
Size of the component
The size of the component affects the cost of anodizing aluminium. Larger parts have larger surface areas and are more costly to anodize. In the same way, more parts require more labor and other resources for successful anodization.
Small anodized aluminum parts
Type of anodizing method
The three types of anodizing aluminum we have highlighted above have different capabilities and applications. For instance, type III forms a thicker layer of aluminium oxide than type II does. This alone means that you will need more power to execute type III.
Of these methods, type I is the most affordable because it uses less power and its resources are more available.
What is the anodization color?
The specific color of the anodized aluminium can determine the cost of anodizing aluminium. That’s because producing different colors requires different inputs in terms of processes and materials.
Note that there are standard colors, which are largely cost-effective. Special hues are associated with higher anodized aluminium costs. They might require specialized processes and timelines.
Bracketing Specifics
Bracketing is central to smooth workflow during the anodizing process. Various options are available, including blot racks and clamp racks.
Manufacturers usually opt for the most cost-effective bracketing method. However, you can specify a bracketing type. Specifying this requirement may mean a slower process, which can easily increase the cost of anodizing aluminium.
Supplementary Anodizing Services
Additional services on China anodized aluminium sheet products are sometimes necessary to make the product more appealing or functional. This often comes at a higher anodized aluminium cost.
How much does anodizing aluminium cost?
There are several ways to estimate the cost of anodizing aluminium. The most straightforward one is the use of online calculators. These tools can ask for minimal information, the surface area to be anodized included.
If you want to be more practical, you can estimate the cost of anodizing aluminium manually. Use this simple formula:
Anodized aluminium cost = (SA×M×T)+L+AF
SA is the surface area of the aluminium to be anodized,
M is the cost factor for the aluminium given per area,
T is the thickness factor for the film,
L is the labor cost, and
AF is any additional cost
On cost estimates, the most basic form of anodized aluminum costs $0.50 per square inch. If you opt for the more advanced method (Type III), the process can cost as much as $1.50 per square inch.
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Tips for cost-effective aluminium anodization
As you undertake an aluminium anodization project, the ultimate goal would be to find a balance between excellent results and process cost efficiency. Use the following tips to make your project successful.
Select the right anodization method.
The cost of anodizing aluminium and the functionality of an anodized aluminium component depends on the process used. By understanding the unique elements of each of the three methods, you can make an informed choice and enjoy the benefits of hard anodized aluminium.
What is the best grade of aluminium for anodizing?
Anodizing works differently depending on the aluminium grade. You will most likely need to provide extra surface treatment and pay more cost of anodizing aluminium if you are anodizing the 2000 series because this type of aluminium alloy does not anodize easily. The 1100 aluminium grade is the easiest to anodize, but alloys such as 6063 and 6061 are also easy to anodize.
A 6063 aluminum bar
When choosing an aluminium alloy for anodizing, the quality of the surface is a good consideration. For instance, the 5000 alloys would be the best choice for dyeing because their surfaces absorb dye excellently.
Consider the design of the component.
Even as you look at the surface quality, the design of the material being anodized is also crucial. Some designs are simply more challenging to anodize effectively. Am talking about sharp edges, deep recesses, and such features. Any feature that can potentially affect power flow during the process can hamper quality.
A complex aluminum component
How prepared is the aluminium surface?
However good the aluminium surface is, it is still important to ensure it does not have elements that could affect anodization results. Remove dust, oils, and any other debris or dirt from the surface. Contaminants can affect the anodization process and lead to poor results.
Check the tank parameters.
Effective aluminium anodization depends on how well you control the parameters in the anodization tank. Always ensure there is the right current density. The tank should also remain clean for spotless aluminium anodized results and lower cost of anodizing aluminium.
Hire the best anodizing aluminium providers.
Working with experienced aluminium anodization professionals helps get quality results. Check if the company can produce the service type you are looking for. Do they have the capability to deliver the coating color or thickness to your preference?
On timelines, you also want to ensure the anodized aluminium provider can fulfill your orders. What is their usual lead time? Can they respond to a rush order?
A stock of aluminum rectangular tubes
Most importantly, inquire about the cost of anodizing aluminium. Upfront pricing is preferable because it can help you make the decision fast. The best provider will avoid hidden charges because these can twist the project budget unfavorably for the client. It is always welcome to work with a client that helps with cost-saving alternatives.
Why work with ProleanTech?
Quality aluminum anodizing services at ProleanTech
At Prolean Tech, we provide exceptional aluminium surface finishing services backed by precision, expertise, and cost-efficiency. Our color options range from clear to gold and coating thicknesses from 1.8 μm to 25 μm.
Whether you are looking for custom anodized aluminium surface finishes or the most balanced combination of quality and affordable cost of anodizing aluminium, we are always there to deliver.
Are you ready to get aluminium machining services from the experts? Call Prolean Tech today.
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FAQs
How to tell if aluminium is anodized?
Experts suggest various methods of determining if aluminium is anodized. The first approach is visual inspection for hardness, layer thickness, electrical insulation, and surface roughness. Several physical tests can help in these checks.
What is the 720 rule for anodizing?
The 720 rule for anodizing helps predict how long anodizing aluminium will take. The formula for the rule is as shown below:
720 (Amps * minutes / ft^2 * mil) = current density x time / thickness
A different format for the same formula is:
Time (minutes) = 720 * thickness / current density
How long does it take to anodize aluminium?
The aluminium anodization process timeline can range from a few minutes to several hours. If the layer is thin and the anodizing process simple, the process can last a mere 20-30 minutes. As you would expect, Type III anodizing is usually the most lengthy process. It can last about 2 hours.
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