{"id":12780,"date":"2026-09-01T06:08:37","date_gmt":"2026-09-01T06:08:37","guid":{"rendered":"https:\/\/www.alcircle.com\/blog\/?p=12780"},"modified":"2026-09-01T06:08:41","modified_gmt":"2026-09-01T06:08:41","slug":"failure-in-the-surface-attack-of-al99-5-aluminium-alloy-discs-for-the-production-of-non-stick-cookware","status":"publish","type":"post","link":"https:\/\/www.alcircle.com\/blog\/failure-in-the-surface-attack-of-al99-5-aluminium-alloy-discs-for-the-production-of-non-stick-cookware","title":{"rendered":"Failure in the surface attack of Al99.5 aluminium alloy discs for the production of non-stick cookware"},"content":{"rendered":"\n

Abstract<\/strong><\/h2>\n\n\n\n

The chemical composition and microstructure of an aluminium alloy directly influence its mechanical behaviour, formability and resistance to corrosion. When aluminium is exposed to an acidic solution for a short period, surface etching, a form of corrosion, occurs, removing impurities and creating the roughness essential for the adhesion of the non-stick coating.<\/p>\n\n\n\n

Each alloying element can influence this surface attack differently, even when present in small concentrations.<\/p>\n\n\n\n

In this study, the same alloy produced in different industrial plants was evaluated. Depending on the particularities of each unit, a slight variation in the chemical composition was observed, especially in the manganese, copper and iron contents. These differences had a strong impact on the behaviour of the alloy during pickling.<\/p>\n\n\n\n

Introduction<\/strong><\/h2>\n\n\n\n

Aluminium is a lightweight, malleable metal with excellent thermal conductivity characteristics that make it especially suitable for kitchenware, particularly for those seeking practicality in everyday use. Its high conductivity, low cost, lightness, recyclability, mechanical strength and corrosion resistance, along with ease of cleaning and a long service life, make it a material highly valued by the household utensil industry.<\/p>\n\n\n\n

These products can be manufactured using various methods, such as stamping or casting. Some items are made of polished aluminium, while others feature a non-stick coating. In the latter case, the non-stick coating is applied to the disc prior to mechanical forming, which requires creating a rough surface to ensure proper adhesion of the coating.<\/p>\n\n\n\n

Processes used to generate this roughness include sanding, blasting and chemical attack, the latter being gradually replaced due to concerns regarding health, safety and environmental impact.<\/p>\n\n\n\n

Strict control of process variables is essential to ensure the final quality of the utensils and their performance during use.<\/p>\n\n\n\n

Problem description<\/strong><\/h2>\n\n\n\n

The cookware manufacturer used the Al99.5 alloy to produce polished and non-stick coated pots and pans, achieving high levels of efficiency, productivity and quality. For the non-stick cookware, chemical attack was employed to create the surface roughness required for coating adhesion.<\/p>\n\n\n\n

At a certain point, the client began reporting instances of the non-stick coating peeling off. During the process inspection, it was identified that some discs were not achieving the minimum roughness required to ensure proper coating adhesion.<\/p>\n\n\n\n

We had a technical visit to the client\u2019s facility to better understand the manufacturing process and get more data to support the failure analysis. It was observed that the chemical attack procedure involved five stages: The first tank contained an NaOH solution; the second and third contained HCl solutions of varying concentrations; the fourth tank used an HNO\u2083 solution and the final one contained a low-concentration NaOH solution. Following this stage, the non-stick coating was applied, followed by curing and the forming of the pan.<\/p>\n\n\n\n

The client reported that some batches of discs exhibited complete surface attack, others only partial attack and some showed no surface attack at all. Representative samples from the three batches were collected for laboratory analysis.<\/p>\n\n\n\n

Instability in the chemical attack process had been requiring frequent adjustments to bath concentrations, resulting in higher reagent consumption and, consequently, increased operating costs.<\/p>\n\n\n\n

Characterisation of the problem<\/strong><\/h2>\n\n\n\n

SEM\/EDS analysis revealed a significant difference in surface roughness among the three evaluated batches. On the other hand, optical microscopy did not reveal any discontinuities that could be associated with the origin of the defect.<\/p>\n\n\n\n

The determinations of chemical composition and mechanical properties yielded results consistent with the values \u200b\u200bspecified in the standard for the Al99.5 alloy in the O temper.<\/p>\n\n\n\n

Exploring the root cause<\/strong><\/h2>\n\n\n\n

Following the initial analyses, a multidisciplinary group was formed to identify the root cause of the problem, comprising two process engineers, three chemical analysts and a metallographic analyst. The Ishikawa diagram was used to guide the investigation, serving as the basis for defining actions related to the possible origins of the defect.<\/p>\n\n\n\n

The aluminium manufacturer operated three industrial plants. So, Plant 1 was equipped with refining and reduction (smelter) processes, as well as remelting facilities for producing ingots destined for rolling. Plant 2 also featured reduction and remelting processes. Plant 3, meanwhile, was equipped with recycling, remelting and hot and cold rolling units, in addition to annealing furnaces.<\/p>\n\n\n\n

Plants 1 and 2 produced only commercially pure alloys: Al99.5, Al99.6, Al99.0Cu, and Al99.0. Plant 3, in turn, manufactured a wider range of alloys, including Al99.5, Al99.0Cu, Al99.6, Al99.0, AlMn1Cu, AlMn1Mg1, AlMg2.5 and AlMg4.5Mn0.7.<\/p>\n\n\n\n

When correlating the batches subject to claims with their respective production units, the following pattern was observed: Plant 3 showed the best performance, Plant 2 an intermediate result and Plant 1 the worst performance.<\/p>\n\n\n\n

Given this scenario, it was decided to replicate the chemical attack process used by the client at the Plant 3 laboratory facilities. Consequently, it was established that all material produced using this alloy had to undergo laboratory testing before being shipped to the client.<\/p>\n\n\n\n

An initial comparative assessment of the chemical composition of the Al99.5 alloy produced at the three facilities, considering only two decimal places, revealed no significant differences between the batches. However, a more detailed analysis extending to five decimal places made it possible to identify variations in manganese, copper and iron content. This finding prompted further laboratory testing, which confirmed that the alloy produced at Plant 3 contained higher concentrations of these elements, resulting in superior performance during the chemical attack process. Plant 2 showed slightly lower values, reflecting intermediate performance. In contrast, the alloy from Plant 1 contained negligible levels of manganese and copper, as well as significantly lower iron content, explaining its reduced chemical attack efficiency.<\/p>\n\n\n\n

Alloy<\/strong><\/td>Si<\/td>Fe<\/td>Cu<\/td>Mn<\/td>Mg<\/td>Zn<\/td>Ti<\/td><\/tr>
Al99.5<\/strong><\/td>0.25<\/td>0.40<\/td>0.05<\/td>0.05<\/td>0.05<\/td>0.05<\/td>0.03<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

Table 1:  The chemical composition limits specified by the Aluminium Association (wt%).<\/em><\/p>\n\n\n\n

Corrective actions: Elimination of rejections<\/strong><\/h2>\n\n\n\n

To enhance the performance of the Al99.5 alloy during chemical attack, minimum levels were established for manganese, copper and iron, ensuring the formation of the roughness required for proper adhesion of the non-stick coating.<\/p>\n\n\n\n

Conclusion<\/strong><\/h2>\n\n\n\n

This study provided a deeper understanding of the effects of manganese, copper and iron, even at very low concentrations, on surface corrosion during chemical attack. Small variations in the levels of these elements can lead to significant differences in final roughness and, consequently, directly impact the adhesion of the non-stick coating.<\/p>\n","protected":false},"excerpt":{"rendered":"

Abstract The chemical composition and microstructure of an aluminium alloy directly influence its mechanical behaviour, formability and resistance to corrosion. When aluminium is exposed to an acidic solution for a short period, surface etching, a form of corrosion, occurs, removing impurities and creating the roughness essential for the adhesion of the non-stick coating. Each alloying […]<\/p>\n","protected":false},"author":111,"featured_media":12781,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[378],"tags":[866,865,460],"class_list":{"0":"post-12780","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-downstream-aluminium","8":"tag-acid-etching","9":"tag-aluminium-alloy-disc","10":"tag-failure-analysis"},"yoast_head":"\nAl99.5 Aluminium Alloy Disc Failure: Root Cause Study<\/title>\n<meta name=\"description\" content=\"Al99.5 aluminium alloy disc failure linked to Mn, Cu and Fe variations affecting surface attack, roughness and coating adhesion.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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