REACH Compliant Hexavalent Chrome Replacement for Corrosion Protection
Lead Research Organisation:
University of Southampton
Department Name: Faculty of Engineering & the Environment
Abstract
Metal corrosion and wear currently costs industry $1.5-2 trillion globally per annum. The basis of many systems to mitigate
these problems utilise compounds containing hexavalent chromium (Cr6+) as used in: chromic acid anodising (CAA);
chemical conversion coatings; primers; paint, and hard chrome plating (EHC). Corrosion and wear are of particular
importance to the aerospace industry where protection requirements are extremely severe. European REACH legislation is
expected to ban the use of Cr6+ containing materials by 2016 due to its carcinogenic properties. This is a critical issue for
the aerospace industry and has been highlighted as a priority in the 2011 National Aerospace Technology Strategy. A
number of attempts have been made to introduce Cr6+ free materials and processes. The solutions have been found not to
be as robust as expected, due in part, to the lack of validated, accelerated testing methods, resulting in unexpected
failures. Individual aerospace companies are developing their own, proprietary solutions. This has caused problems in the
supply chain, which it is finding difficult to support. This bid addresses this situation by bringing together an integrated
aerospace based team from SMEs to academia to identify innovative solutions and develop robust accelerated testing
methods that accurately reproduce severe environmental applications. This will enable the sector to adopt a common
these problems utilise compounds containing hexavalent chromium (Cr6+) as used in: chromic acid anodising (CAA);
chemical conversion coatings; primers; paint, and hard chrome plating (EHC). Corrosion and wear are of particular
importance to the aerospace industry where protection requirements are extremely severe. European REACH legislation is
expected to ban the use of Cr6+ containing materials by 2016 due to its carcinogenic properties. This is a critical issue for
the aerospace industry and has been highlighted as a priority in the 2011 National Aerospace Technology Strategy. A
number of attempts have been made to introduce Cr6+ free materials and processes. The solutions have been found not to
be as robust as expected, due in part, to the lack of validated, accelerated testing methods, resulting in unexpected
failures. Individual aerospace companies are developing their own, proprietary solutions. This has caused problems in the
supply chain, which it is finding difficult to support. This bid addresses this situation by bringing together an integrated
aerospace based team from SMEs to academia to identify innovative solutions and develop robust accelerated testing
methods that accurately reproduce severe environmental applications. This will enable the sector to adopt a common
Planned Impact
This project is capable of delivering impact as it brings together a team including academia, SMEs and OEMs in the
aerospace sector, in a fully integrated, structured, science-based, systems approach to the development of testing methods
and materials processes in an area that has traditionally been developed on an empirical basis. This has not been
attempted before in this area and will result in innovative test methods, materials and processes being developed and a
significant up skilling of the sector. This approach will capture this knowledge in a useable form for the future and makes it
widely available outside of the aerospace sector. In terms of measurable impact, the main beneficiaries from the proposed
study will initially be the consortium OEM's and first tier companies that are within the aerospace sector. As best practice in
terms of testing is disseminated and more widely adopted, then other industries will benefit from the standardised and
reliable corrosion and wear test methodologies generated from this research. Such materials testing protocols will lead to
reductions in materials testing costs and shorter times-to-market for future coatings. The validation of Cr6+ free coatings
will impact upon both the aerospace and, also eventually, other key industrial sectors such as automotive and defence that
also require similar processes. Key benefits to the aerospace sector will be the specification of new coatings for use on
their products. Those who have their own processing facilities will be able to set up the capability to produce the new
coatings. The specialist processing companies, including SMEs, will be able to set up facilities to provide these coatings
and to provide the materials these process will require. A successful project will result in the removal of Cr6+ surface
coatings from the operating environment which will address the environmental concerns and reduce operating costs.
This research will work towards the aim of the elimination of Cr6+ by 2016, as currently proposed under REACH. The
proposed project represents an opportunity for the UK aerospace industry to become leaders in the area of Cr6+
replacement through the development and demonstration of an innovative common testing programme and materials and
process. This research will be underpinned by a science-based understanding at leading universities and acentralised
materials data management architecture. This research will also lead to the potential for development of alternative Cr6+
processes in the partner universities by understanding the failure mechanisms of existing candidates.
aerospace sector, in a fully integrated, structured, science-based, systems approach to the development of testing methods
and materials processes in an area that has traditionally been developed on an empirical basis. This has not been
attempted before in this area and will result in innovative test methods, materials and processes being developed and a
significant up skilling of the sector. This approach will capture this knowledge in a useable form for the future and makes it
widely available outside of the aerospace sector. In terms of measurable impact, the main beneficiaries from the proposed
study will initially be the consortium OEM's and first tier companies that are within the aerospace sector. As best practice in
terms of testing is disseminated and more widely adopted, then other industries will benefit from the standardised and
reliable corrosion and wear test methodologies generated from this research. Such materials testing protocols will lead to
reductions in materials testing costs and shorter times-to-market for future coatings. The validation of Cr6+ free coatings
will impact upon both the aerospace and, also eventually, other key industrial sectors such as automotive and defence that
also require similar processes. Key benefits to the aerospace sector will be the specification of new coatings for use on
their products. Those who have their own processing facilities will be able to set up the capability to produce the new
coatings. The specialist processing companies, including SMEs, will be able to set up facilities to provide these coatings
and to provide the materials these process will require. A successful project will result in the removal of Cr6+ surface
coatings from the operating environment which will address the environmental concerns and reduce operating costs.
This research will work towards the aim of the elimination of Cr6+ by 2016, as currently proposed under REACH. The
proposed project represents an opportunity for the UK aerospace industry to become leaders in the area of Cr6+
replacement through the development and demonstration of an innovative common testing programme and materials and
process. This research will be underpinned by a science-based understanding at leading universities and acentralised
materials data management architecture. This research will also lead to the potential for development of alternative Cr6+
processes in the partner universities by understanding the failure mechanisms of existing candidates.
| Description | We are looking for optimum coating candidates to replace hexavalent chrome in aerospace industry. Our role is to provide forensic analysis of high number of coatings and their downselection. This phase has achieved and selected solutions are now being tested by industrial partners. Knowledge acquired during the project directly led to consultancy work from one of the project partners (10k in 2015, 51k in 2016, and 77k in 2017) and 1 fully funded PhD student by industrial partner. It should be stressed here that total award was just 58K. |
| Exploitation Route | Replacement of hexavalent chrome is required by EU legislation (REACh). It will affect many industrials areas, particularly aerospace sector, which traditionally veru strong in the UK. Solutions found in this project could be then used by other industries facing similar problem. |
| Sectors | Aerospace, Defence and Marine,Construction,Energy,Environment,Manufacturing, including Industrial Biotechology |
| Description | Thsi project was part of a large TSB/EPSRC project. Our role is to provide forensic testing of potential alternatives of harmful hexavalent chrome. Our finding so far helped down-select promising candidates and show issues related with their adhesion and wear testing. All results have been uploaded to Granta database and can be accessed by wide industrial and research community.The results are used now by industrial partners of the project. Thanks to testing methodology developed in the frame of the project, University of Southampton received over 90k GBP in 2015-2018 as a consultancy for industrial project partners. |
| First Year Of Impact | 2014 |
| Sector | Aerospace, Defence and Marine,Manufacturing, including Industrial Biotechology |
| Impact Types | Economic |
| Description | HardAlt: New generation of protective coatings alternative to hard chrome |
| Amount | € 395,000 (EUR) |
| Funding ID | 606110 |
| Organisation | European Commission |
| Department | Seventh Framework Programme (FP7) |
| Sector | Public |
| Country | European Union (EU) |
| Start | 12/2013 |
| End | 11/2016 |
| Description | Functional Coatings For Industry I, II, and III |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Professional Practitioners |
| Results and Impact | I organized seminar Functional Coatings for Industry focused on major issues in the field, such as environmental and legislative pressure (REACh) and energy efficiency. Audience (45 companies, 80 participants) was quite positive and several new proposals and contacts started there. The project was first introduced here to the public (2012), then the workplan was shown (2013) and final results presented (2015). I personally started collaboration with leading motorsport company and with John Crane (collaborative project). I met as well representant of Surface Engineering Association there and I invited SEA to FP7 project, which was funded in 2013. |
| Year(s) Of Engagement Activity | 2012,2013,2015 |
| URL | https://db.tt/sX9xGuG6 |