Surface treatment is the process of altering a material’s surface to enhance corrosion resistance, wear resistance, decoration, or other properties.

Why is Metal surface Finishing very important for metal components

Metal surface treatment benefits both the final product and the user. Generally, high-quality metal surface finishing enhances the aesthetic appeal of the final product and extends its lifespan. As a result, end users can enjoy a more satisfying experience with the product.

The importance of surface treatment for metal components primarily reflects the following aspects:

• Enhanced durability: Surface treatment can significantly improve the lifespan and durability of metal components.
• Enhanced corrosion resistance: This occurs by forming a protective layer that prevents oxidation and corrosion of the metal surface.
• Elimination of surface defects: This involves removing imperfections such as unevenness and scratches, thereby enhancing the overall quality.
• Enhanced coating adhesion: This provides a better foundation for subsequent coatings and paints.
• Improved aesthetic appeal: This enhances the shine and texture of the metal surface,thereby enriching the visual impact of the product.
• Enhanced chemical resistance: This increases the metal surface’s resistance to chemicals.
• Improved conductivity: This enhances the electrical conductivity of the metal where required.
• High strength and wear resistance: This increases the hardness and wear resistance of the surface.

Types of Metal Surface Treatment Processes

There are various types of metal surface treatments, each with its unique advantages. The type of part and the choice of material will determine the surface treatment process you adopt. Below are some common methods of metal surface treatment:

what is brushed aluminum

It is a process that creates fine lines or textures on the aluminium surface through mechanical means,

aimed at improving the appearance and texture of aluminium while enhancing its corrosion resistance.

HOW do i get a smooth finish on aluminum?

• Aluminium Surface Brushing Process: Enhancing Aesthetics and Durability.

Aesthetic effect: Aluminium brushing creates fine, uniform lines on the surface, giving it a refined, attractive look, widely used in decorative components, furniture, and appliances.

Modern aesthetic: The brushed aluminium surface offers a sleek, stylish look, ideal for high-end designs and luxury products.

• Enhanced corrosion resistance

Corrosion resistance: Mechanical processing removes surface oxides and contaminants, creating a denser layer that improves aluminium’s corrosion resistance.

• Improved coating adhesion

Increased surface roughness: Brushing creates a fine particulate structure on the aluminium surface, enhancing adhesion for coatings, paints, and other treatments.

Enhanced coating effectiveness: This improves the adhesion of the coating, making it more secure and preventing flaking, thereby increasing the durability and stability of the coating.

• Removal of surface defects

Flaw elimination: Aluminium brushing removes fine scratches, spots, and imperfections, producing a smoother, more uniform finish.

Improved quality: Eliminating surface defects enhances the overall quality and aesthetic appeal of the product.

• Versatile applications

Multiple uses: Aluminium brushing finds applications in architectural decoration, furniture finishes, appliance panels, automotive interiors, signage, brand displays, and electronic devices, showcasing broad potential.

High flexibility: It suits aluminium products of various shapes and sizes and can be processed according to design requirements.

• Environmentally friendly

Chemical-free: Aluminium brushing is a mechanical process that avoids chemical agents, producing no harmful waste and making it environmentally friendly.

High safety: The process does not produce harmful gases or dust, making it safer for operators and the environment.

Its application fields include：

Architectural decoration: Brushed stainless steel serves as a sleek material for wall coverings and elevator panels, adding a modern, stylish touch to indoor and outdoor spaces.

Furniture finishes: This process enhances durability and provides a polished appearance for tables and cabinets in high-end furniture manufacturing.

Appliance panels: It add elegance and style to kitchen appliances such as refrigerator doors and oven panels, combining aesthetics with functionality.

Automotive aesthetics: Brushed stainless steel enhances car interiors by adding a touch of luxury to dashboards and control panels.

Signage and branding: Its durability and modern appearance make it ideal for unique signs and brand displays, enhancing a professional image.

Retail displays: It enhances retail settings by adding a refined shine to displays, thereby improving the overall shopping experience.

Electronic devices: It offers a durable, stylish surface for smartphones and laptops, enhancing aesthetics and longevity.

Hotel interior design: Used to create sophisticated and modern spaces in hotels, from lobby decorations to room furnishings.

Aluminium anodising

This electrochemical process helps to create a durable, decorative, and corrosion-resistant anodised surface. Manufacturers immerse the metal in an acidic electrolyte bath and then pass an electric current through the medium to complete the surface treatment. Aluminium acts as the anode, while the anodising tank houses the cathode.

Anodising is an electrochemical process that both protects aluminium components from wear and corrosion and improves their appearance.

Let’s break down the basic steps involved in anodising parts:

• Connect the components to the anode.
• Immerse the components in an acidic electrolyte solution.
• Attach the cathode to the metal electrode in the solution.
• Positive ions react with negative O2 ions, resulting in a porous surface.
• This will form a layer of aluminium oxide on the components.
• Use corrosion inhibitors or colour dyes to achieve aesthetic effects.
• Seal the nanopores.

In this process, oxygen ions from the electrolyte combine with aluminium atoms to form an anodised layer on the surface. Thus, anodising is a controlled oxidation process for metal substrates. Anodising primarily treats aluminium parts but also works effectively on non-ferrous metals like magnesium and titanium.

Its advantages include

Strong corrosion resistance: The dense, well-structured oxide film effectively prevents corrosion and oxidation, enhancing the aluminium’s corrosion resistance.

Enhanced hardness: Anodising significantly increases the aluminium surface hardness to 150-300 HV, improving wear and scratch resistance.

Good aesthetic appeal: The anodising process allows for various colour dyeing treatments, enhancing the aluminium surface’s decorative qualities to meet diverse design requirements.

Insulation properties: The anodised film has excellent insulation performance, making it suitable for applications in the electronics and electrical fields where insulation protection is required.

Enhanced adhesion: The surface roughness of aluminium increases after anodising, facilitating better coating adhesion and improving the durability and stability of the coating.

Good permeability: The anodised film forms pores and fine cracks on the surface, allowing better penetration of dyes, which enhances the durability and colour stability of the dyed layer.

Lightweight design: Aluminium is inherently lightweight, and after anodising, it not only retains its lightweight characteristics but also gains enhanced durability, making it suitable for fields requiring lightweight design.

Metal Bead Blasting

Applying various polishing and metal finishing techniques prior to anodising allows us to enhance and expand our surface finishing services beyond the standard sulphuric acid anodising.

Bead Blasting is the process of using compressed air to apply fine glass beads at high pressure to remove deposits from various metal surfaces without damaging the surface.

• Preparatory work

1.1 Selection of abrasive

Select the appropriate abrasive based on the metal material and the intended purpose of the treatment. Common abrasives include:

• Sand particles: Suitable for cleaning and roughening most metal surfaces.
• Glass beads: Used for more delicate treatment, they do not excessively damage the metal surface.

• Steel shot: Steel shot has high projection capability, creating deep pits and grind marks during sandblasting, making it ideal for applications requiring strong abrasive impact.

• Aluminium oxide: Suitable for the treatment of harder metal surfaces.

1.2 Equipment preparation

• Sandblasting machine: Primarily consists of a pressure tank, spray gun, and compressed air system.
• Protective equipment: Sandblasting generates considerable dust and splatter, so operators should wear protective clothing, masks, gloves, and other safety gear.

1.3 Workpiece preparation

• Cleaning: Ensure that the metal surface is free from grease, dust, and other contaminants.
• Masking: Protect areas that do not require sandblasting by masking them to prevent damage.

• Sandblasting process.

2.1 Adjusting sandblasting parameters

• Air pressure: Select the appropriate air pressure based on the workpiece material and abrasive, typically ranging between 60-120 PSI.
• Sandblasting distance and angle: The spray gun’s distance and angle relative to the workpiece affect the sandblasting effect. A distance of 6-12 inches and a spray angle of 45-90 degrees are generally recommended.

2.2 Sandblasting operation

• Start the equipment: Activate the compressed air system to ensure the sandblasting machine operates properly.
• Uniform spraying: Operate the spray gun to apply the abrasive evenly to the metal surface, ensuring all areas are treated. Avoid lingering in one spot to prevent surface indentations.

2.3 Inspection and adjustment

• Inspect the surface: Regularly check the treatment effect on the metal surface and adjust the sandblasting parameters as needed.
• Re-treatment: For areas that are more difficult to process, it may be necessary to sandblast multiple times.

• Post-Processing

3.1 Cleaning

• Remove residual abrasives: Use compressed air or a brush to clean any remaining abrasives from the metal surface.
• Surface inspection: Ensure that the sandblasting effect is uniform, with no residual rust or oxides.

3.2 Subsequent treatment

• Coating or painting: Carry out coating or painting processes as needed. The surface roughness from sandblasting enhances coating adhesion.
• Rust prevention treatment: For rust-prone metal surfaces, apply rust prevention treatment immediately after sandblasting to prevent oxidation.

Its advantages:

• Efficient cleaning: Sandblasting can quickly remove rust, scale, and other contaminants from metal surfaces, yielding significant results.
• Surface roughening: Sandblasting creates uniform surface roughness that enhances adhesion for subsequent coatings, improving bonding strength and durability.
• High flexibility: The sandblasting process is suitable for various shapes and sizes of metal components, offering broad adaptability.
• Good environmental friendliness: Modern sandblasting equipment often includes dust recovery systems, minimising environmental pollution and safeguarding operators’ health.

Aluminum Silk Screening

Aluminium silk screening services involve applying paint and design elements to metal sheets. This process uses fine polyester mesh and a rubber squeegee to print onto specially designed metal parts.

Aluminium silk screening is a meticulous process that, while seemingly straightforward, requires precise technique and discipline. Steps 1 to 6 outline the screen creation process, and Steps 7 to 10 detail the ink application.

1. The client provides the artwork files.
2. Conco uses DMAX UV opaque dyes to print the artwork onto transfer film (Ryonet’s Econofilm).
3. Select the screen according to the size and place the liquid emulsion onto the screen in a light-safe environment, similar to a darkroom.
4. Then place the screen in an oven to cure the emulsion onto the screen.
5. Activate the exposure unit to use vacuum sealing and ultraviolet light to transfer the artwork film onto the screen.
6. The screen is ready for printing.
7. The screen is positioned above the workpiece, leaving a small gap between the material and the screen to ensure proper rebound.
8. Apply ink to the screen and then wipe the screen with a squeegee.
9. The ink is pushed onto the material through the negative.
10. Remove the screen and allow the finished piece to dry.

Its advantages:

• Lightweight: Aluminium wire is significantly lighter than many metals, such as steel and copper, making it ideal for applications that require low weight and high strength.
• Good conductivity: Aluminium is an excellent conductor, making aluminium wire commonly used in electrical wires and cables for effective energy transmission.
• Ease of processing: Aluminium wire is easy to shape and process, allowing it to be manufactured into various thicknesses and forms through drawing and rolling, meeting diverse application needs.
• Recyclability: Aluminium wire is a renewable resource with excellent recyclability, helping to reduce resource consumption and environmental impact through recycling and reuse.
• Excellent thermal conductivity: Aluminium’s good thermal conductivity makes it ideal for applications requiring rapid heat dissipation, such as heat sinks for electronic devices.

Metal Powder Coating

Metal powder coating services offer high-quality, durable surface treatment for metal components. We provide industrial and commercial powder coating for various industries and applications. Our solvent-free powder coatings produce zero volatile organic compounds.

Choosing metal powder coatings has numerous advantages compared to other industrial coatings:

• Easy to operate: The powder coating equipment and processes are relatively straightforward, with a low learning curve for operators, making them easy to implement and manage.
• Good coating uniformity: The powder particles can evenly cover the entire surface, creating a smooth and uniform coating without drips or runs.

Metal powder is the future of coatings; it is better for the environment and safer for employees. This adds a green dimension to every project without compromising on quality, and is commonly used in:

• Windows and door frames: provide corrosion resistance and weather resistance, extending their lifespan. Available in a variety of colours and textures, enhancing aesthetics.
• Frames: used as supporting structures in construction and industrial applications. They provide a protective layer to prevent rust and corrosion.
• Aluminium flashing: used for the decoration and protection of building roofs and walls. It provides a durable protective coating that is resistant to UV rays and harsh weather conditions.
• Wall cladding: applied for the decoration and protection of both interior and exterior walls of buildings. It provides a durable surface that is easy to clean and maintain.
• Shutters: offer protection against corrosion and aging. Available in a variety of colours to enhance decorative appeal.

Factors to Consider When Choosing Metal Surface Treatment Processes

• Base Metal

Not all metal surface treatment technologies are suitable for every type of metal. For instance, anodising is particularly well-suited for aluminium and other non-ferrous metals. Therefore, it is essential to consider the type of metal used in the manufacturing of the components before selecting a metal surface treatment process.

Some metals have a relatively soft texture, so strong abrasives should not be used to avoid damaging their surface. On the other hand, effective techniques must be applied to hard or tough materials to achieve the desired results.

• Budget

You may have found the perfect surface treatment technique for your metal products, but is it within your budget? Budget management is a key consideration when working with Conco. We understand that the financial pressures of each project may vary, which is why Conco offers one-on-one sales consultant services specifically designed to help you plan and control costs.

Your budget is a determining factor in the metal surface treatment process you select. You should opt for a process that falls within your budget while also delivering high-quality results. By communicating with our sales consultants, you can receive comprehensive budgeting advice, including how to optimise costs without compromising on quality and efficiency. Whether it’s large-scale production or small-batch orders, our aim is to provide the most cost-effective solutions, ensuring your project runs smoothly within budget.

• Delivery Speed

Different metal surface treatment methods have varying completion times; therefore, you must consider the time required to deliver the project. Analyse the metal surface treatment options and consider their processing times. Conco is committed to providing customers with flexible and efficient logistics solutions. We support various international trade agreements:

• Tariff concessions: Reductions or eliminations of import tariffs between signatory countries, making goods more competitive in the market.
• Quota restrictions: Reducing or eliminating import quotas to allow for greater circulation of goods and services between signatory countries.
• Trade dispute resolution mechanisms: Establishing mechanisms to resolve trade disputes to ensure a fair and transparent trading environment.
• Intellectual property protection: Ensuring that signatory countries protect each other’s intellectual property, including patents, trademarks, and copyrights.
• Investment protection: Safeguarding the rights of foreign investors to ensure a stable and transparent investment environment.
• Technical barriers to trade (TBT): Coordinating technical standards and conformity assessment procedures to reduce trade obstacles arising from differing technical standards.
• Sanitary and phytosanitary measures (SPS): Coordinating standards and measures among countries regarding sanitary and phytosanitary issues to ensure food safety and the health of plants and animals.

The agreements mentioned above promote the development of global trade by reducing trade barriers, protecting investors’ rights, and simplifying customs procedures. We can offer various shipping methods tailored to the specific needs of our customers, including sea and air freight. From the production line to the final destination, Conco strictly controls production and shipping timelines to ensure that each step proceeds as planned.

If you require rapid delivery of your project, you will need to adopt a metal surface treatment process with a very short processing time. Additionally, we offer comprehensive logistics tracking services, providing real-time updates that allow customers to accurately and swiftly monitor the status of their goods. This transparent tracking process not only reduces waiting times but also significantly minimises potential issues during transportation.

Through these measures, Conco ensures that every customer receives the highest quality products within their budget and can receive their goods on time, thereby gaining a competitive advantage in a fiercely contested market.

• Applications

The application of the product and the environment to which it is exposed will also influence your choice. Protective surface treatments should be selected for parts subjected to high-intensity applications. These protective metal surface treatments will provide durability to the components and prevent premature damage. On the other hand, for components that do not need to be exposed to high-intensity environments, you may opt for aesthetically pleasing surface treatments.

Conclusion

These metal surface treatment methods are widely used across various industries and applications. Depending on the properties of the material and the requirements of use, an appropriate metal surface treatment method can be selected to achieve the desired effect. High-quality surface treatment is crucial for the production of metal parts.

Conco Machining boasts a modern, large-scale facility equipped with the latest machinery and technology. This enables us to handle projects of all sizes while ensuring efficient production and timely delivery. This not only benefits the end user but also provides multiple advantages for manufacturers. However, if the correct methods are not applied, both manufacturers and end users may be adversely affected in the long run.

We are committed to building long-term partnerships with our clients, understanding their needs, and providing customised solutions, with customer satisfaction being our top priority. With the continuous advancement of industrial technology, it is believed that metal surface treatment processes will play an increasingly important role in future developments.