Integrated Electrolytic Chrome Stripping/Recycling Technology without Hexavalent Chromium Formation

ABSTRACT: The proposed technology addresses the need to eliminate the environmental and safety hazard associated with hexavalent chromium generated during conventional electrolytic chrome stripping. Faraday proposes to demonstrate and develop an integrated electrolytic FARADAYIC(R) Chrome Stripping/Recycling closed loop process, to directly recover the"stripped"chromium metal from the electrolyte and return the electrolyte to the stripping process. FARADAYIC(R) Stripping will be a drop-in replacement for the current process, requiring only a change in rectification and a change in electrolyte to favor the generation of non-toxic trivalent chromium. Phase I will demonstrate removal of chrome from high strength steel substrates while eliminating or minimizing hexavalent chromium to below OSHA PELs, and assess the economic, safety and technical viability of the technology. We will downselect to a range of electrolytes and waveform parameters, and tune the stripping process to ensure no adverse effects on the steel surface finish. We will begin development of a transition plan for future implementation at Air Force maintenance facilities. Phase II will design and build a pilot-scale facility to strip specific parts, perform compatibility testing for functional performance metrics, integrate the FARADAYIC(R) Recycling component of the technology and develop electrolyte maintenance protocols for a zero-discharge process. BENEFIT: The anticipated result of this SBIR program is the demonstration, development and deployment of the FARADAYIC(R) Chrome Stripping/Recycling technology for rapid removal of chrome from landing gear parts and other aircraft components, while maintaining the functional requirements of those parts, and eliminating or reducing hexavalent chromium formation to below OSHA PELs. This process is scalable, will use current equipment, and will result in significant cost reductions through elimination of expensive air scrubbers and reduced waste treatment and protective equipment costs, as well as avoiding liability associated with hexavalent chromium. The United States chrome plating market has been valued at $3.2 billion, and is very much application driven, as well as driven by technological developments and the need for processes to comply with stringent environmental and workplace safety concerns. Faraday"s approach centers on developing a drop-in replacement using a robust electrolyte and controlling the stripping process through use of sophisticated waveforms engineered to remove the chrome coating while controlling formation of the dissolved chromium ion species. Hexavalent chrome coatings are commonly applied to hydraulic cylinders and rods, crankshafts, printing plates/rolls, pistons, molds, and cutting tools. The potential market extends far beyond landing gear, the focus of the proposed program.