THE ECONOMICS OF
THE SANFORD PROCESS™
The large
current densities required for most anodize coating processes
create excess oxygen on the surface of the anodized object. This
blocks the pores of the aluminum and builds resistance to the
electrical current. As a result, progressively more voltage has
to be applied in order to maintain adequate current display.
These high voltages generate extreme heat at levels which can
damage the anodized aluminum component. In order to avoid this damage,
the heat has to be removed with energy-intensive chillers.
As
a result of these two factors, energy bills for hardcoating are
substantial. The Sanford Process’s™ unique low voltage
DC + AC hardcoating solves this problem by augmenting the traditional
direct current ("DC") used for electrolysis with an overlay of
alternating current ("AC"). The AC regularly reverses direction,
creating a "windshield wiper" effect that wipes oxygen created
on the "plus" electrode and hydrogen created on the "minus" electrode.
DC current flows easier and tank voltage is reduced drastically.
DC energy consumption is reduced proportionally. Further, the Sanford Process™ can be run at temperatures up to 70 degrees and produce Mil. Spec. quality
hardcoat.
As a result,
users of the Process have the ability:
- to hardcoat
2000 series and all aluminum alloys successfully;
- to uniformly
and successfully hardcoat edges and thin material;
- to achieve
these results with significantly lower energy usage than would
be required for competitive processes;
- to achieve
exceptional hardness in the finish.
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