Bright etching is an advanced surface treatment technology for aluminum alloys. It involves a significant transformation of the acid etching process, incorporating a sand-surface polishing tank and a smooth-light polishing tank to achieve bright finishing on acid-etched materials. This innovative method not only preserves the advantages of traditional acid etching—such as strong grain formation, rapid sand development, low aluminum consumption, and complete removal of acid residue—but also addresses long-standing issues like surface darkening and contamination in coloring and electrophoresis tanks.
This breakthrough technology has been recognized internationally and has led to two national invention patents. It represents a major advancement over conventional methods such as alkali etching, acid etching, and low-temperature polishing. Bright etching can produce both flat light and sand-blasted materials, as well as a new type of bright matte finish. The technology has already been adopted by large aluminum processing companies like Guangdong Xingfa Group, signaling its potential to significantly impact China's aluminum industry.
Since its introduction in 2000, acid etching has gained popularity due to its efficiency and cost-effectiveness. However, it has always struggled with the issue of darkened surfaces, which affects product quality and leads to contamination in downstream processes. Many manufacturers have tried to address this by adding alkaline pits and neutralization tanks, but these solutions are only partial and do not fully resolve the problem. Acid etching ash remains stubborn, often leading to dust accumulation in coloring and electrophoresis tanks, which causes defects like electrostriction shrinkage.
Bright etching solves this global challenge by completely removing acid ash while maintaining the desired texture and brightness. It also enhances the surface quality of sand-blasted materials, eliminating grain and ash, resulting in a fine, uniform finish. Additionally, it integrates degreasing, film removal, brightening, and ash removal into one process, replacing the need for separate low-temperature polishing tanks. This three-in-one approach improves efficiency and reduces aluminum consumption.
The bright etching process consists of four key stages: deoiling and dewaxing, brightening and etching, sand-surface polishing, and flat polishing. Each stage plays a critical role in achieving the final high-quality finish. The deoiling tank removes oils, wax, and natural oxide layers, while the brightening etching tank enhances the surface brightness and prepares it for further processing. The sand-surface polishing tank eliminates acid ash and refines the texture, and the flat polishing tank increases brightness and ensures a consistent metallic luster.
One of the unique features of this technology is the concept of "flat light polishing," which helps reduce light loss during anodizing. By fixing the brightness before oxidation, the process maintains a higher level of gloss and minimizes defects. Another innovation is the "sand-surface polishing" technique, which effectively removes acid ash and achieves a smooth, polished finish without excessive aluminum use.
The technical process involves several steps: deoiling and dewaxing, washing, brightening etching, sand-surface polishing, additional rinsing, flat polishing, final washing, and oxidation. Each step is carefully controlled to ensure optimal results. For example, the deoiling tank not only cleans the material but also prepares it for subsequent treatments. The brightening etching tank improves the surface quality, making it easier to polish and reducing the need for extended processing times.
The research behind bright acid etching was driven by the need to overcome limitations in existing technologies. Studies showed that tri-acid polishing produced the brightest finish, but it was costly and inefficient. Alkaline etching retained the metal color but lacked polishing ability, while acid etching resulted in dark surfaces and poor quality. Based on these findings, researchers developed three key innovations: bright etching, leveling and brightening technology, and low-temperature semi-polishing.
The bright etching solution is a specialized additive that enhances the performance of standard acid etchants. It improves the removal of mechanical textures, increases brightness, and stabilizes the pH of the bath. It can be added directly to existing tanks without requiring equipment changes, making it a practical and cost-effective upgrade.
In terms of bath management, the solution typically contains 200 kg/m of acid etching agent and 100 kg/m of ammonium fluoride. The working temperature is maintained between 35°C and 45°C, with processing times ranging from 3 to 12 minutes. Additives such as etching agents (10 kg/ton) and ammonium hydrogen fluoride (40 kg/ton) are used to enhance performance. The fluoride ion concentration should be between 45–60 g/L, and the pH should be around 3.0–3.5.
Overall, bright etching represents a significant leap forward in aluminum surface treatment. It combines efficiency, quality, and environmental benefits, positioning China’s aluminum industry for greater competitiveness on the global stage.
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Key benefits of high PPE plant lights include:
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