Finishing Talk Newsletter - March 2008

8/14/2019 Finishing Talk Newsletter - March 2008

1/16

Finishing

Spotlight:

Interview w ith Cleaning

expert Dr. John B. Durkee

(page 4)

From the Forum:

Inside This Issue:

Note: The average

worker with 20 x 20

vision can locate a

coating defect 50 mi-crons in size and given

enough time for a thor-

ough visual inspection.

The same worker in-

specting fluorescent

coating by black light

can easily locate a de-

fect 10 microns in size

or smaller even in low

light or during produc-

tion painting opera-tions.

E N E R G Y S A V I N G P A I N T

Abstract

A leading problem withthe use of protective

coatings occurs when

structure life exceeds

coating life and creates

a need for additional

recoating operations to

maintain effective cor-

rosion control.. Protec-

tive Coatings NDT is a

lifetime maintenance

program that has been

developed to provide

consistent corrosion

protection for steel

structures based on the

application and mainte-

nance of one highly

specialized coating sys-

tem.

PC/NDT uses a princi-

pal of non-destructivetesting (NDT) where

fluorescence and black

light illumination are

used to locate surface

defects. By integrating

a defect detection indi-

cator (fluorescence)

into the original coat-

ing formulation, black

light inspections allows

workers to inspect

large or complex sur-

faces in relatively short

period of time and de-

termine exactly where

and when maintenance

is required.

M A R C H 2 0 0 8 V O L U M E 1 , I S S U E 2

Protective Coatings NDT

P R O T E C T I V EC O A T I N G SN D T

1

I N D U S T R Y E V E N T S

2

N E W S & N O T E S

3

F I N I S H I N GS P O T L I G H T

4

F R O M T H EF O R U M

6

T H E L A S TW O R D

1 5

C O N T E N T S

Placement of

Anode B askets

(page 6) Protective

Coatings NDT (page 8)


2/16

Page 2F I N I S H I N G T A L K

March 16-20:

Corrosion 2008

New Orleans, Louisiana

800.797.NACE

[email protected]

http://www.nace.org

March 18-20:

3-Day Spray Finishing

Technology Workshop

Mt. Wachusett Gardner, MA

Ken Hanson at 978-630-9179

[email protected] 18-20:Process Technology ExpoCharlotte Convention CenterCharlotte, NCwww.ptxsouth.com

March 26-28:

Nanotechnology in Coatings

Orlando, FL

www.coatingstech.com

March 31-Apri l 1:

Electroplating Know How Basics

Greenville, SC

[email protected]

www.platingschool.com

April 1-3 :

Metal Form Birmingham

Jefferson Convention Complex

Birmingham, AL

www.metalform.com

April 3-4 :

Electroplating Know How Basics

Cincinnati, OH

[email protected]

www.platingschool.com

April 9-10

Powder Coating School

Denver, CO

surfacefinishingacademy.com

April 21-23 :

Coatings for Plastic Symposium

Chicago, Illinois

(888) 530-6714

www.coatingsforplastics.com

April 21-24 :

NA 2008

I-X Center

Cleveland, OH

www.nashow.com

Have an upcoming event? Tell

us about it at:

www.finishingtalk.com!

I N D U S T R Y E V E N T S 2 0 0 8


3/16

Page 3V O L U M E 1 , I S S U E 1

N E W S & N O T E S

West Haven, CT Enthone Inc.

celebrated the grand opening of its

advanced plating applications labo-

ratory with an open house at-

tended by more than 150 custom-ers, state and local government

officials and company employees.

The laboratory houses multiple

plating lines that enable processing

of functional, decorative and elec-

tronic coatings on parts used in

automotive, plumbing, printed wir-

ing board (PWB) and other appli-

cations. It features dedicated lines

for plating-on-plastics, copper/

nickel/chrome, passivation proc-

esses, surface preparation chemis-try, zinc and zinc alloys, hard

chrome and electroless nickel.

Washington, DC The National

Association for Surface Finishing

(NASF) has named Fred Barnes,

political commentator and co-

founder and executive editor of

The Weekly Standard, the keynote

speaker for the Washington Fo-

rum, April 2224. Barnes is set to

deliver his speech on Wednesday,

April 23, during a special luncheon

at the LEnfant Plaza Hotel. Cur-

rently, Barnes co-hosts (along with

Mort Kondracke) the "Beltway

Boys" on FOX News. He also hosts

the weekly radio show, "Issues in

the News" on Voice of America.

Barnes appears regularly on FOXs

"Special Report with Brit Hume."

For more information about the

Washington Forum, and an exten-

sive biography on Mr. Barnes,

please visit www.nasf.org.

Charleston, SC Southern Metal

Finishing, an annual metal finish-

ing conference held each year in

historic Charleston, S.C., has an-

nounced that registration is now

open for its Sept. 1416, 2008,

conference and tradeshow. This

years conference will be held at

the majestic Francis Marion Hotel.

The event will feature the Powder

Coating School, taught by the ex-

perts at Tiger Drylac, and 21st

Century Cleaning Technologies,taught by Dr. John B. Durkee,

world-renowned cleaning expert

and Metal Finishing columnist. In

addition, participants are invited to

take part in a variety of events

over the duration of the show. For

more information about the

upcoming conference or to

r e g i s t e r , p l e a s e v i s i t

www.surfacefinishingacademy.com

and click on "Conference."

Nationwide As part of the alli-

ance between NASF and the U.S.

Occupational Safety and Health

Administration, OSHA provides

NASF with information on its com-

pliance assistance resources. The

latest update is a link to a list of

OSHAs new compliance assistance

products that may be helpful for

surface finishing industry opera-

tions, including publications,

eTools, Safety and Health Topics

pages, and success stories with

the appropriate links. A list of

available health and safety compli-

ance assistance tools is availableon the NASF website at

www.nasf.org

Nationwide The National Paint

& Coatings Association (NPCA) and

the Federation of Societies for

Coatings Technology (FSCT) re-

cently signed a Memorandum of

Agreement, which outlines the de-

tails of a prospective merger of the

two organizations. The agreement

describes a "governance merger"that will consolidate the govern-

ance, management and adminis-

trative functions of both groups

under NPCA, while preserving each

organizations separate identities,

operations, functions, and member

services. In short, NPCA and FSCT

will remain as separate organiza-

tions managed through a common

governing structure.


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Page 4

F I N I S H I N G S P O T L I G H T : D R . J O H N B . D U R K E E

ers. Clients which can be identi-fied include the Los AngelesSouth Coast Air Quality Manage-

ment District (SCAQMD), theU.S. Air Force, the U.S. Army,the U.S. Department of Justice,and the U.S. Environmental Pro-tection Agency. I am frequentlyasked to, or do, comment onpending environmental regula-tions.

In 1999, I ceased being part ofand managing an organizationproviding consulting services. I

accepted an assignment whichlasted through 2002 to a singleclient, Flo-Matic, located in Rock-ford, Illinois. At Flo-Matic, wedeveloped technology for clean-ing machinery parts without useof cleaning solvents or deter-gents. This technology is pro-tected by U.S. Patent No.6,368,414. Ultrasonic force wasapplied and controlled for thispurpose. We designed, con-

structed, and sold several ma-chines to local machine shopcustomers. The machines pro-vided dry parts through manage-ment and application of com-pressed air, and efficient wastedisposal through a uniqueevaporator. My assignment withFlo-Matic was terminated in 2002due to lack of funding.

In 2002, I initiated work to com-

plete a selfgenerated challenge.The industrial cleaning industryhas little unbiased science-basedliterature about the foundationsof its technology. Moreover, theindustry had little or no literatureabout management of that tech-nology. Since 2003, I have en-deavored to develop and provide

clean room to metal cleaning ina working machine shop.

In 1993, Du Pont sold this busi-

ness. At this point, I retired fromDu Pont to pursue independentopportunities as a professionalconsultant in industrial cleaning.In 1993, along with several asso-ciates, I formed Creative Enter-priZes with the mission of pro-viding consulting service to bothend-use and supplier firms withtechnology to replace CFC-113and other ozone-depleting

chemicals. Nearly all work on theozone-depletion initiative wasconfidential for a variety of rea-sons. However, it included:cleanliness evaluation and moni-toring, product and process se-lection, market research aboutindustry needs, parts drying, anddrying equipment, managementof hazardous chemicals, ultra-sonic and megasonic cleaningand rinsing, control of particles

via hydrodynamic and othermeans, solvent substitution andselection, and many other af-fairs.

I have taught cleaning scienceby invitation to firms and chairedand/or presented technical pa-pers at conferences and semi-nars such as Clean-Tech, NEP-CON West, APEX, the PhoenixSolvent Substitution Workshops,

the NASA Aerospace Confer-ences on Environmental Affairs,the International Conferences onElimination of CFCs, Interna-tional Symposia on Particles onSurfaces: Detection, Adhesionand Removal, International Sym-posia on Contact Angle, Wet-tability and Adhesion, and oth-

This month, Finishing Talkinterviewed professional consult-

ant, author, and educator incleaning sciences, Dr. John B.

Durkee, PhD., P.E. Having

served as an experienced chemi-

cal and engineering professional

for more than 25 years, in addi-

tion to innumerable accomplish-

ments, awards, and publications,

Dr. Durkee has become an in-

dustry leader in his field. In this

interview we discuss how he got

to where he is today, currentand future issues that effect the

industrial cleaning sector, Dr.

Durkees most recent publication

and his upcoming workshop.

FTalk: How long have you beenworking in the critical, precision,and industrial cleaning sector,and what got you interested inthis industry?

JD: In 1989, I was assigned byDu Pont and Conoco to developequipment and chemistry forcleaning technology to replaceCFC-113 ("Freon") as a corebusiness. My work involved ex-tensive contact with end-usecustomers to learn of their needsand preferences, as well as part-ner firms who produced equip-ment for use with Du Pont's pro-prietary cleaning chemicals. A

significant portion of my timewas spent in understanding com-petitive patent art, as well asthat owned by Du Pont, so that aproprietary basis for commer-cialization could be found. Thiswork involved cleaning opera-tions from critical cleaning in a

F I N I S H I N G T A L K


5/16


T: (800) 438-6880

T: (828) 464-1376

F: (828) 464 -7094

www.jacksonlea.com

Your Total Finishing Resource.

1715 E. Conover Blvd. Conover, NC 28613

that literature through lastingresources: books, magazine col-umns, training courses, and oc-casional papers.

In 2004, I started a self-fundedand managed project to inventand develop replacement clean-ing technology for users doing,or wanting to do, solvent clean-ing. The approach, long layingfallow, is to use binaryazeotropes to replace single sol-vents. I have developed, withthe University of Massachusetts(Lowell) Toxic Use ReductionInstitute, basic data teachingand showing how this technology

works. I have recently filed anapplication for comprehensiveU.S. patent covering a broad-based new approach to solventcleaning which involves newprocess technology and newcleaning formulations. This workis ongoing with more tests beingconducted.

FTalk: What is the most com-mon question, concern, or prob-

lem that arises from the compa-nies and individuals who requestyour consulting services?

JD: Question: Tell me in twentyfive words or less how thisworks, and dont cost me anymoney in doing so!

Concern: Im whipsawed be-tween increased demand forquality and consistency by mycustomers, and increased need

to make quantum-sized (major)reductions in cost by manage-ments need to preserve jobs inthe U.S. I want something bet-ter, but I cant spend any moneyto get it; if I knew what it was.Summary = frustration.

Problem: Finishing work is be-

ing driven by environmentalregulations which are out of mycontrol, whose details are socomplex I need a specialist, andwhose cost appears unjustified.Im a good citizen. I dont pol-

lute. I dont violate laws. I wantto protect the environment. Buthow do I deal with environ-mental regulators who can seeonly one side of my situation?

FTalk: What is the biggesttrend, from your perspective,that is going on right now in theindustrial cleaning sector?JD: TODAY: Getting toxic metals(Chromium, Lead, Cadmium,etc.) out of wastes.

TOMORROW: EPA has regulatedsince 1970 on the basis of massamount of emissions of specificchemicals. Their decisions werefairly easy to understand. Nowthat pollution has generally beenreduced by ~80% or so, EPA isstarting to regulate based on risk

to human life. Future decisionswill be harder to understand andaccept because the basis for riskdetermination is not consistent,well-proven, or well-known.

FTalk: In addition to consulting,you are also known for your vari-ous publications most recentlybeing Management of IndustrialCleaning Technology and Proc-esses, published by Elsevier,2006, (ISBN 0-0804-48887). Inyour opinion, who would benefitthe most from the informationand insight you present in thisbook, and what are some of themajor themes you touch upon?

JD: Firms and persons trying tomanage cleaning better usingexisting technology and notspending substantial new invest-ment for quality, safety, and en-vironmental improvements. Per-sons seeking to understand thefundamentals of technology,

Continued on page 12 .


6/16


F R O M T H E F O R U M : P L A C E M E N T O F A N O D E B A S K E T S I N T A N K

In this months column, Finishing Talk forum mem-bers Toyota111, DustinGebhardt, and Skelton

discuss issues relating to the proper placement ofanode baskets in an anodizing tank. Feel free toadd your thoughts to their ongoing discussion byvisiting the forums at www.FinishingTalk.com/general-discussion and then clicking on the threadentitled Placement of Anode Baskets in Tank. Formore From the Forum discussions, check out ourmonthly internet television show, Finishing TalkLive, where hosts Paul Fisher and Paul Skeltonbring the boards to life!

www.finishingtalklive.com

Toyota111:

Hi, I'm new to this and could use some help. I amplating zinc onto pot metal holley carburetors andwondering if anyone could tell me about the for-mula for calculating the amount of zinc anode tobe used, and placement of the anodes in the tank.

Also, any clearances between the anode and thepiece to be plated. I have a 22" x 21" x 19" deeptank with a penguin agitation pump. Any helpwould be greatly appreciated. Thanks.

Skelton:

Welcome to the wonderful world of metal finish-ing.....welcome to finishingtalk.com too! Why, mayI ask, are you zinc plating a carburetor? I am no'Cooter' from Hazzard county, but I believe yourcarb may be zinc alloy - if not an aluminum alloyand not pot metal. Correct me if I am wrong,maybe you are just using the slang term "potmetal"???Regardless, all three base metals have similar char-

acteristics in that you just do not plate any of thesewithout the proper pre-cleaning and pre-plateprocess; i.e. a copper strikebut that's anothertopic (focus Skelton).

As for you question regarding anode baskets, I amgoing to assume you may have 2" diameter SHGzinc ball anodes in titanium baskets, which ofcourse will not require much anode surface area

due to the size of your tank and the assumedmaximum current of your rectifier - again, relativeto the size of your tank, I am guessing maybe 100

amps or less? Which relates to approx. 5 sq.ft. ofanode surface area at 20 asf or approx. 60 - 2"dia. zinc balls in 2 - 6 anode baskets (dependingon style of basket) As for placement, 2 - anodebars on each side of the tank (parallel) with 1 - 3anode baskets on each anode bar, with plenty ofdistance from anode to cathode...and you will beready to plate your holley carburetor. Woo hoo!I hope this helps, good luck.

Toyota111:

Thanks for getting back to me, I have a 200 amp

lamda rectifier. Im using zinc slabs about 8" x 2.5"x 1" thick. The carbs. are zinc alloy. From yourmessage, I have to run the anode baskets whichare 12" x 12" x 3" along the two sides of the tank,not on all four sides. If so, thats good because Ihave anode bars running parallel on two sides builtinto the tank. I am assuming the pump will keepthe bath agitated enough that anodes are not re-quired on all 4 sides of the tank. Like I said, this is

just a hobby I'm getting into and any help or ad-vice you can give me would be GREATLY appreci-

ated. If you ever want to learn how to run a trackexcavator let me know, thats what I can do. AndI'm told I'm not to shabby at it. Thanks.

DustinGebhardt:

Why are you trying to plate zinc on to a zinc alloy?R e g a r d i n g t h e a n o d e p l a c e m e n t :The anode placement helps determine the "line ofsight" for the deposition of the zinc metal ontoyour carb. If you use two anodes, you will build upmore zinc on the sides facing the anodes. Now,you can help offset that by increasing the spacing

between the anodes and your part. This will makethe deposit more uniform, but it will never be asuniform as using anodes on all sides of your part.Increasing the solution flow will also help preventburns in the high-current-density areas of the part.It won't help with deposit uniformity. As long asyou have a good amount of flow across the entirepart (coupled with enough wetter) you shouldn'thave to worry about burning the part unless you

Posted on February 16, 2008


7/16


really crank up the current.

Ideally, you'll have anodes on all sides of your parti f you wan t max imum un i fo rm i ty .

As for the amount of anode surface area that youneed, I'll make some assumptions.

First, I'll assume that you are using an acid electro-lyte. You will want the same amount of anode sur-face area as your part surface area AT THE MINI-MUM. Most people have 1.5-2x the anode surfacearea than the part surface area. You will have tocalculate the surface area of your carb and usethat number to determine how much anode sur-face area you need. Does this help, or am I on thewrong track?

Toyota111:

Ok, yes you are very helpful; youre the pro. Ill tryit!! Thanks for your help.

Join in on this conversation and other finishing

discussions at www.finishingtalk.com. Maybe your

advice, views, or opinions will end up in a future

installment of From the Forum.


8/16


P R O T E C T I V E C O A T I N G S N D T - S U B M I T T E D B Y J A M E S D E A R D O R F F

is based on a program of sched-uled inspections to determinewhen a component has reacheda predetermined unacceptablecondition. At this point, repairsor replacements are performedto prevent a more costly failurefrom occurring. The identifica-tion of wear stressors, by rootcause analysis, can aid facilityowners in improving the effec-tiveness of future maintenanceoperations through designchanges or modifications.

Saving Comparison

- 0% Reactive

- 25% to 35% Preventive

- 45% to 55% Predictive

- 60% to 80% RCM with rootcause analysis,

Protective Coatings NDT

Protective Coatings NDT re-

moves the cost, production, and

technical barriers that prevent

the coating industry from usingPredictive or Reliability Centered

Maintenance programs. PC/NDT

is based on the formulation of

coatings to fluoresce at a specific

wavelength (365nm) in the elec-

tro-magnetic energy spectrum.

When fluorescent coatings ap-

plied in alternating layers with

non-reactive (NR) surfaces or

standard NR coatings, black light

produces an Enhanced Visual

Signature (EVS) that dramatically

increases a workers ability to lo-

cate, define, and repair coating.

PC/NDT is the only quality con-

trol process that has an inspec-

tion speed comparable to the

application rate of modern spray

equipment. Line of sight inspec-

When fossil fuels are converted

into energy they produce carbon

dioxide a green house gas. Each

year, 6.1 billion metric tons ofgreenhouse gases are added to

the atmosphere. Greenhouse

gases causes global warming,

severe climate changes, rising

sea levels, and diminished land

usage patterns. Experts generally

agree that no combination of al-

ternative technologies will re-

place the worlds dependence on

fossil fuels in the near future.

Corrosion is a terrible waste ofenergy and costs the UnitedStates economy over $500 billionper year. This represents 6 per-cent of the Gross Domestic Prod-uct (GDP) valued at $8.79 trillion.Using a simple comparison, theannual cost of corrosion equalsthe cost of 5 billion barrels of oil.

Advanced Maintenance Tech-n o l o g i e s ( B a c k g r o u n d )In the early 1960s, the crashrate for jet aircraft was alarminghigh. In an attempt to reducecrash numbers American Airlinessenior management with the ap-proval of the Federal Aviation Agency (FFA) began intensiveengineering studies on in-serviceaircraft. The studies proved thatthe major assumption that everycomponent in first generation jetaircraft had a specific lifetimeof reliable service after whichhad to be repaired or replaced inorder to prevent catastrophic fail-ures proved to be wrong in virtu-ally every specific case. Many ofthe discoveries made by the air-line revolutionized the mainte-nance discipline for industrial as-sets. This has been the basis fora new generation of highly effi-

cient maintenance programsknown as: Reliability CenteredMaintenance (RCM).

Currently, industry recognizesfour major maintenance classifi-cations.

-Reactive

-Preventive

-Predictive

-Reliability Centered Maintenance(RCM)

Reactive Maintenance is wherean asset is allowed to operate to

failure before repairs or replace-ments are performed. It is esti-mated that 55% of all industrialrepairs are based on reactivemaintenance.

Preventive Maintenance is whererepairs or replacements arescheduled at predetermined timeintervals. Work is based on per-formance estimates and opera-tional histories. It is estimated

that 31 % of all industrial repairsare based on preventive mainte-nance.

Predictive Maintenance is wheremaintenance is scheduled basedon current asset condition. Pre-dictive maintenance relies on theprecise evaluation to detect mi-nor changes in operational per-formance. Repairs or replace-ments are planned before a major performance changes occur.

It is estimated that 12 percent ofall industrial repairs are based onpredictive maintenance.

Reliability Centered Maintenance(RCM). This maintenance con-cept utilizes preventive and pre-dictive maintenance techniqueswith root cause analysis. RCM


9/16


tions can be performance as fast

as the hand can more a black

light and as fast as the human

eye can follow.

The following explains the proce-

dure for black light inspections:

Fluorescent Primer EVS:

Film coverage defects are locatedby the dark shade of bare metalshowing through voids in thefluorescent primer.

Finish Coat NR Applied OverFluorescent Primer EVS:

Defects are located by the glowof the fluorescent primer shin-ning through voids in the NR fin-

ish coat. Note, this combinationis the most visible of the NDT /EVS inspection process.

Complete System making maxi-mum use of NDT / EVS technol-ogy:

-Fluorescent Stripe Coat EVS

-Primer Coat NR

-Fluorescent Intermediate CoatEVS

-Finish Coat NR

PC / NDT Maintenance Op-eration

When coatings are inspected fordamage to plan for maintenancerepairs, defects are located bythe fluorescence of the basedcoats showing through faults inthe non-fluorescent finish coat.

Fluorescence

More than 3,000 natural and man-made substances can transforminvisible energy into longer visi-ble wavelengths that producefluorescence. These substancesreact because they composed ofeasily excitable molecules. Whenexposed to black light this en-

ergy, in the form of photons,causes one or more electrons tobe kicked up into a higher en-ergy state. These electrons areextremely unstable and will even-tually lose this excess energy and

return to their original state.This release of excess energy iswhat we see as fluorescence.

Black Light

Black Light also known as WoodsLight, Blue Light, or Long Waveultraviolet, is a form of Electro-magnetic energy that occurs justbelow the visible end of the visi-ble light spectrum. This low en-ergy wavelength covers the

range between 320 and 400 na-nometers (NM). Unlike ordinarylight bulbs that create light bymoving electricity through a fila-ment wire, black light is pro-duced by sending electricitythrough a tube filled with an inertgas (such as argon)) and a smallamount of mercury. An electricspark passed across an electrodemakes the mercury atoms movea high velocity. As they slowdown they release excess energyin the form of Black Light UV-A.

Solid State Black Light

In the past, a major problemwith black light inspections is theinability to produce a noticeablefluorescent response in normallight. This problem has beenvirtually eliminated with the in-

troduction of new, solid state,black light inspection lamps.These new lights make use oftransistorized power supplies andstate-of-the-art bulb design forincreased power and intensity.

Advantages

-Produces 10 times the powerand intensity found in conven-tional lights

-Produces a minimum of 40,000

uW/ cm at one meter

-Light Weight

-Cool to the touch

Solid State Black Lights provide atremendous advantage over tra-ditional models due to their in-creased power and inspectionrange. Coverage defects 4 to 8feet from the black light focuspoint will begin to fluoresce whenscanned by solid state lamps.This saves time and inspectioncosts for large surface areas.

Continued on next page...


10/16


Black Light Laser Sight

The solid state black lights havea range of 50 to 100 feet. At this

distance it is difficult for workersto determine exactly where theblack light energy is focused.(black light is invisible until itcomes into contact with a fluo-rescent material). The lasersight attachment is fitted directlyto the light and allows workers toperform accurate, long rangeinspections of surfaces.

Primary Corrosion Sites

Virtually all man made structurescontain areas that are commonlyknown as primary corrosion sites.These points include welds, joints, corners, edges, nuts,bolts, rivets, fasteners, cracks,cervices, or anywhere there is asharp change in surface contour.The use of a fluorescent stripecoat can perform a dual functionfor reducing premature failure forprimary corrosion sites. For

welds, cracks, and crevices blacklight insures complete wetting ofvoids. For joints corners, oredges black light shows wherecoatings have cured away from asharp edge and require additionalfilm thickness.

Two-Component Mixing

Many applications specify two-component coatings due to in-

creased chemical resistance anddurability. To insure that per-formance standards are achievedit is important that the part A(base) is completely blended withthe part B (activator). By addingfluorescence to part B and mixingwith part A until a solid EVS isachieved complete blending is

P R O T E C T I V E C O A T I N G S N D T - C O N T I N U E D

insured. Note incompleteblending produces a candy caneeffect under black light.

Training

PC/NDT provides a valuabletraining tool for new workerslearning basic application tech-niques. In addition, EVS allowsexperienced applicators to makereal time adjustments for speci-fication changes, varied struc-

tural designs, or new coating for-mulations.

One of the most effective train-ing programs would involve ap-plying fluorescent coatings in atotal black light working environ-ment. Under true black light illu-mination there are only two major shade variations, black formetal surfaces or standard coat-ing and the particular shade forfluorescent coatings.

Advantages

The two major advantages forProtective Coatings NDT are thevirtual elimination of catastrophiccoating failure and crisis condi-tion recoating.

Additional advantages include:

-Return On Investment (ROI) 10fold (based on rising energycosts).

-Increased equipment and struc-ture life

-Reduced corrosion related re-pairs, downtime and early re-placement costs

-Improved performance and op-erational readiness

-Improved worker safety andmoral

-Reduced wastes and disposal

costs-Reduced VOCs and negativeenvironmental impact

-Improved remanufacturing andrecycling potential

-Lean Engineering, A reducedneed to over-design products toresist corrosion.

-Reduced energy demands forcorrosion prevention mainte-

nance programs.Maintenance Personal

The savings produced by PC/NDT would allow facility ownersto hire full time coating engineersto monitor and schedule mainte-nance operations based on blacklight evaluations.

Safety

As with any high energy illumina-tion source, safety precautionsshould be followed. Black light(UV-A) requires no protectiveclothing but, it is recommendedthat uv blocking eye ware beworn during black light qualitycontrol inspections. These spec-tacles make coating defects eas-ier to see by increasing fluores-cent contrast. They also, protect

Maxima 3500 Black Light (Spectroline)


11/16


eyes from repeated uv exposure.

Note, in 2007 no major airlineaccidents were reported in theUnited States.

References:

Corrosion Costs and PreventiveStrategies in the United States

2002, US Federal Highway Ad-ministration Highway researchCenter.

The Coating Consumer: Under-standing Initial and Long-TermPainting Costs.

Dec 1993, Gordon Brevoot, TheJournal of Protective Coatingsand Linings.

Performance of Coating SystemsUsing Numerical Life Predictions

July 1998, Neil P. Adamson, Jour-nal of Protective Coatings andLinings.

Economics of a Total Mainte-nance Coating Program.

August 1994, Materials and Per-formance an Offical NACE Publi-cation.

Black Light Measurement forNDT

Copyright @ 1983 The AmericanSociety for Nondestructive Test-ing

Shedding Light On UV TestEquipment

Sept 1992, Quality Progress,By: Les Davis

External Links,http://en.wikipedia.org/wiki/Reliability Centered Maintenance(RCM).

Published Articles

Nov 1992, Industrial Finishing

Technology Update:, Black-LightEarly-Warning Coating-Defect

Detection

Dec 1992, Journal of ProtectiveCoatings & Linings, Volume 9,Number 12

Innovative Practice, IndustrialCoating System Simplifies In-spection.

August 1994 Materials and Per-formance an official NACE publi-cation

Focus on Industry, Black LightReactive Coating Eases Flaw De-tection.

March 1994, Pipeline Digest

Quality Control, Savings in NewCoating System.

Nov / Dec 1995, PWC, Paintingand Wall Covering Contractor,

Industrial Products,Black Light


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F I N I S H I N G S P O T L I G H T , C O N T F R O M P A G E 5 . . .

medical and environmental hazards, and organiza-tional management applied to cleaning work. Thechapter themes are: (1) how the unit operations ofcleaning, rinsing, and drying work, (2) environ-

mental regulations and trends from a global pointof view, (3) hazard management and recognition,(4) process control using simple and powerful tech-niques well-known in other industries, (5) evalua-tion of cleanliness quality, (6) specific equipmentguidance, and (7) special topics such as particleremoval and how to purchase new equipment.There are two appendices, one of which providesspecific instruction on use of spreadsheets to man-age cleanliness based on statistical principles.

FTalk: What kind of impact do you think current

environmental and global issues will have on partscleaning?JD: They are everything! Globalization is drivingprices that customers are willing to pay down bylarge increments. Differentiation between devel-oped and developing countries in international en-vironmental regulation generates contempt for the

former and a cost advantage for the latter.

FTalk: You will be teaching a workshop on clean-ing technology later this year at the annual South-

ern Metal Finishing Conference in Charleston, SC.Who will benefit from taking this course, and whatshould they expect to learn during the class?JD: The course includes most of the materialsmentioned above in Management of IndustrialCleaning Technology and Processes. But thecourse material is tailored for those doing aqueouscleaning in the finishing industries. If you read, orshould read, Metal Finishing Magazine, you shouldattend this course.

Ftalk: Will you be giving presentations or speak-

ing at any other locations this year?

JD:Yes. I will be speaking at both the Sixth Inter-national Symposium on Contact Angle,Wettabilityand Adhesion; and the Eleventh InternationalSymposium on Particles on Surfaces: Detection,Adhesion and Removal. Both will be held July 16 -18 (2008) at the University of Maine, Orono,Maine. My workshop, 21st Century Cleaning Tech-nology, may also be presented in locations otherthan Charleston; these locations are still being de-termined, and will be announced at a later date.

FTalk: Do you have plans for another publicationin the near future?JD: I am completing preparation of forthcomingbookSolvent Cleaning for the 21st Century, alsoto be published by Elsevier, in 2009. I writemonthly columns in Metal Finishing Magazine,Controlled Environments Magazine, and Gal-vanotechnik Magazine; and contribute occasionallyto ProcessCleaning Magazine. ~FT~

For more information about Dr. Durkee, he can be

reached directly phone at (830)-238-7610 or by e

-mail at [email protected]. Visit his

website at www.precisioncleaning.com.

For information about his upcoming workshop

hosted by the International Surface Finishing

Academy, visit www.surfacefinishingacademy.com.


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Page 15

G R E E N I N G Y O U R S U P P L Y C H A I N B Y : A N N A L E V I T S K Y , E D I T O R

Across the U.S. and around theglobe, large companies are taking itupon themselves to shrink their

environmental footprint a dra-matic and important step towards acleaner, and more environmentallysound future. Realizing that its notjust regulations that are forcing thechange but an equally worrisomerise in energy costs and quality is-sues manufacturers are takingmatters into their own hands. Andthey are starting with their suppli-ers.

According to a recent survey ofsupply chain professionals carried

out for eyefortransports GreenTransportation and Logistics Re-port, green issues are rated by94% of executives as a businesspriority. This is occurring in re-sponse to the high demand bylarge manufacturers corporategiants such as Wal-Mart who areleading the way by revaluating andreorganizing their current supplychain (which is responsible for 92%of the retailers environmental im-pact) - to be more environmentallyfriendly.

Ship SmartThe number one energy culprit inindustry is transportation and logis-tics making up a whopping 75%of a companys carbon impact. Bymaking efficient shipping decisions,such as planning a shipping routethat will transport the most prod-ucts with the least wasted energyand money, companies can reducetheir carbon footprint and save

money.Look at the Big PictureThe concept of Green Supply ChainManagement taking into accountthe entire life cycle of a productand the culmination of its environ-mental impact is something thatis taking hold in industry right now.Due to demands from consumers,government, and advocacy groups,

ity and to rank opportunity areas byvalue. It can also be accomplishedby identifying the root causes ofwastes by constructing cause-and-

effect diagrams or by continuallyasking why certain problems orprocedures exist.

3. Calculate Benefits: Next is thecalculation of costs and benefits ofvarious options. You can conductquantitative evaluations, which relyon empirical Data (for example, theInternal Rate of Return (IRR) andEconomic Order Quantity calcula-tions are two methods). Anotherapproach is through qualitativeevaluation, based on observation

and judgment.4. Decide, Implement, andMonitor:After completing the firstthree steps, the last step to takeinto consideration involves makinga decision, implementing thechanges, and monitoring progress.Without these things, your man-agement plan will either fallthrough or never even begin. It willbe, essentially, unsustainable which is exactly what you are trying

to move away from.It will take time and patience to getyour supply chain where you wantit to be. There are steps that canbe taken to make the transforma-tion to a greener management sys-tem, and as long as you are willingto do the research, communicateyour goals, and keep track of yourprogress, you will be on your wayto sustainability. It wont hurt thatyou will probably increase productquality, boost consumer confidence

and respect for your company,maybe even get some governmentor private organization recognitionfor your effort, and of course, savemoney. Not to mention the planetwill thank you.

Visit our forums at finishingtalk.comfor more information about GreenSupply Chain Management!

many companies are now evaluat-ing the environmental impact of aproduct, from birth to death. Thiscycle encompasses the products

design, the sourcing and selectionof material, the way in which it ismanufactured, purchase by theconsumer, maintenance of theproduct, and finally its disposal, istaken into account.

Get to Know Your Suppliers According to the EPAs Lean andGreen Supply Chain Guide (Jan.2000), direct interaction with sup-ply chain partners can enable acompany to reduce total inventorylevels, decrease product obsoles-

cence, lower transaction costs, re-act more quickly to changes in themarket, and respond morepromptly to customer requests.Many companies have begun toreduce their supplier base down toonly a few key suppliers, and implementing lean manufacturingmethods.

Get StartedThe Lean and Green Supply Chainguide suggests a four step program

to making your supply chain moreefficient:

1. Identify Costs: Review materi-als management practices to iden-tify areas and activities that incursignificant environmental costs. Forexample, the electroplating industrytends to spend resources on largestorage and waste treatment areaswithin a facility. Therefore, storagecosts would be an ideal place tostart. Two common approaches toidentifying sources of environ-

mental costs are materials trackingand EH&S performance reviews.

2. Determine Opportunities:Which identified areas provide thegreatest opportunity for improve-ment? This can be accomplished byimplementing Pareto diagrams andother bar charts to display environ-mental costs by supply chain activ-

T H E L A S T W O R D


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