Chemical conversion coating

Chromate conversion.

Clear chemical conversion coating on aluminium and aluminium alloys to MIL-DTL-5541F — Class 1A for maximum corrosion protection, Class 3 for low electrical resistance.

The process

Microns thin. Conductive. Paint-ready.

Chromate conversion (chem film) forms a clear protective coating by chemical reaction with the aluminium surface — no electrolysis, negligible dimensional change, and a surface that stays electrically conductive.

We process Type II clear coatings using SurTec 650 — a trivalent, hexavalent-chromium-free chemistry qualified to MIL-DTL-81706 and listed on QPL-81706. The finish is clear, not the iridescent yellow of older hex-chrome films — applied by immersion after all machining, forming and heat treatment is complete. Parts are cleaned to a water break-free surface before coating; no iron-bearing abrasives ever touch the work.

It's the standard pre-treatment under paint and primer systems, and the standard finish where grounding, bonding or EMI shielding rules out anodising.


CLASSES · MIL-DTL-5541FTYPE II · TRIVALENT
CL 1A

Maximum corrosion protection

For parts painted or unpainted where corrosion resistance is the priority. The standard base for primer and paint systems.

CL 3

Low electrical resistance

A thinner coating for corrosion protection where electrical contact matters — grounding points, bonding surfaces, EMI/RFI shielding.

Quality control

Verified the way the spec demands.

TestMethodAcceptanceFrequency
01Visual inspectionMIL-DTL-5541F §3.5Continuous coating, no powdery or loose areas, voids or flawsEVERY BATCH
02Salt spray corrosionASTM B117 · 168 h · 5% fog≤5 isolated pits per panel, none >0.031 in; ≤15 across 5 panelsMONTHLY · ≤35 DAYS
03Wet tape paint adhesionFED-STD-141 M6301.3 · ASTM D3359 Proc. A24 h immersion · rating 4A or better, no intercoat separationMONTHLY · ≤35 DAYS
04Electrical contact resistanceClass 3 · per contractResistance values as specified by the acquisition activityAS SPECIFIED
05Solution analysisMIL-DTL-5541F §3.8Concentration, pH and temperature within manufacturer rangesWEEKLY

PROCESS CONTROL PANELS · 3 × 10 IN · RUN WITH PRODUCTION HARDWARE THROUGH ALL PRE- AND POST-TREATMENT

Applications

Where chem film is called out.

AIRFRAME & STRUCTURAL PARTSBASE UNDER PRIMER / PAINT
ELECTRONICS ENCLOSURES & CHASSISEMI SHIELDING · CL 3 · FIG. 01
GROUNDING & BONDING SURFACESLOW CONTACT RESISTANCE · CL 3
RF / MICROWAVE HOUSINGSCONDUCTIVE FINISH · CL 3
TIGHT-TOLERANCE MACHINED PARTSNO DIMENSIONAL CHANGE · CL 1A
MARINE & GSE HARDWARECORROSION PROTECTION · CL 1A
TOUCH-UP OF ANODISED ASSEMBLIESREWORK & REPAIR
FIG. 01 · DRONESHIELD ELECTRONICS ENCLOSURE
Good to know

Sequence matters.

Conversion coating is applied after all heat treatment, forming, machining, brazing and welding. Mixed-metal assemblies are masked or processed as detail parts. Envelope to 2600 × 600 × 900 mm.

SPECMIL-DTL-5541F · TYPE II · CL 1A & 3
MATERIALSSURTEC 650 · QPL-81706 · CLEAR
ENVELOPE2600 × 600 × 900 MM
RECORDSCOC · SOLUTION LOGS · TEST PANELS