Statistisk kvalitetsvärdering för optimering av processteg i aluminiumanodisering : Utvärdera avverkning på aluminiumdetaljer i avverkningsbad

Sammanfattning:

The intention with this thesis was to evaluate how much pickling that have been achieved on aluminium details in the pickling bath before the anodization in an anodization process. As there were no earlier studies to use around pickling before anodization, statistical experimental design was chosen as planning tool. Statistical experimental design was used to plan the experiments in an organized way and to evaluate how the pickling process works together with the main effects and the interaction effects. Detailed scientific studies were performed on how aluminium is prepared and how the anodization process works. The studies were performed in reference books. Three different methods were designed. The first method, method 1, was based on a fractional factorial design with four design variables, temperature, sodium hydroxide and aluminium concentrations and the time the details was submerged into the pickling bath. The aluminium details was made from a square profile pipe. There was nine experiments performed in method 1. The measurements on the pickling was performed in two ways, first with a dial indicator where the pickling was compared with a reference surface before and after, and another method also performed with a dial indicator, where the measurements was performed over the edge between the pickled surface and the reference surface. A statistical control calculation was done on the surface smoothness of the square profile pipes. The control showed that the standard deviation was 11 µm. Method 2 was based on a complete factorial design where the design variables was temperature and the time the details was submerged into the pickling bath. All aluminium details were homogenous. There were seven experiments performed in method 2. The measurements on the pickling was performed in two ways, first with a dial indicator where the pickling was compared with a reference surface before and after, and another method also performed with a dial indicator, where the measurements was performed over the edge between the pickled surface and the reference surface. A statistical control calculation was done on the surface smoothness of the homogenous details. The control showed that the standard deviation was 14 µm. Method 3 was designed in a different way than method 1 and 2. In method 3 one experiment was performed and the design variable which was changed was the time when the details was submerged into the pickling bath. The aluminium details had the form of homogenous cubes. The measurements on the pickling was performed by measuring the weight of the details on an analytical scale before and after the pickling, and then calculate the pickling in µm in two different ways. The first way was to use the atomic radius of aluminium and the second way was to use the size of the unit cell of aluminium. The two first methods gave very different results than the third method. The result for method 1 showed very random values with great dispersion which resulted in a non-detectable pickling. The result for method 2 was very similar to the result from method 1, very random values with great dispersion and no pickling was detectable with any confidence. The result from method 3 gave a theoretical calculated result for the pickling, when the aluminium details was submerged in the pickling bath for 1 minute, and based on the atomic radius of aluminium, of 1,52 µm and with the same conditions but using the unit cell of aluminium showed a pickling of 1,62 µm. When the aluminium details were submerged in the pickling bath for 3 minutes, the theoretical calculation with the atomic radius of aluminium gave that the pickling was 4,51 µm and with the same conditions but using the unit cell of aluminium showed a pickling of 4,79 µm.