Chemical Conversion Coating in Electronics: Corrosion Protection

Chemical conversion coating has become a standard practice in electronics manufacturing due to its exceptional ability to protect metal parts, panels and enclosures from corrosion while maintaining electrical conductivity.

Also known as chem film, it is a chemical treatment applied to aluminum and its alloys to protect the surface from corrosion by applying a layer of chromate. It forms a thin, protective layer on the metal, preventing oxidation and acting as a safeguard against environmental damage.

This protective layer provides several benefits, including corrosion resistance, durability and stable electrical conductivity.

Corrosion Resistance

Corrosion is one of the leading causes of failure in electronic systems. Therefore, protective coatings are an important step within the production process. And that’s where chemical conversion coating plays a vital role by creating a robust, reliable barrier that extends the life of components.

It offers corrosion resistance for electronic components, thereby making them more reliable in high-moisture and tough environments. It also supports lightweight designs, boosts reliability in aerospace systems and works great as a durable base for extra coatings like paint or powdercoat finishes.

Aluminum parts with chem Film and bare metal finishes

Benefits of Chemical Conversion Coating

With chemical conversion coatings serving as an efficient barrier against corrosion, here’s how they benefit electronics:

Durability

Corrosion weakens components over time, ultimately reducing performance and appearance. Chemical conversion coating creates a durable barrier to protect parts from humidity and chemical exposure.

Maintains Precision via Thin & Lightweight Coating

Electronics often require tight tolerances between components to ensure smooth assembly and operation. Because it’s ultra-thin, chem film ensures corrosion protection without affecting the dimensional accuracy of parts.

Resists Extreme Conditions

Many electronic devices operate in harsh environments, such as outdoor weather or industrial manufacturing plants. Chem film protects components against a wide range of corrosive agents, from saltwater in marine environments to industrial pollutants.

Environment Friendly and Industry Compliant

At ProtoSpace Mfg, we use Chemeon TCP-HF® which is an environmentally friendly trivalent chromium formulation. It is free of toxic and dangerous hexavalent chromium.

Chemeon TCP-HF® conforms to a wide variety of environmental and workplace safety regulations, such as RoHS, WEEE, ELV, REACH and the OSHA PEL. Additionally, we qualify our process to pass the requirements of MIL-DTL-5541F Type 2 Class 1A & 3, and -81706B.

While some coatings create an insulating barrier, Class 3 chem film maintains electrical conductivity, making it ideal for electronic enclosures, circuit board housings and grounding applications.

Non-Reflective & Aesthetic Finish

Electronics often need a uniform, non-reflective surface and chem film offers a smooth, matte finish that reduces glare and improves appearance without affecting performance.

Cost-Effective Over Time

Chemical conversion coating prevents premature component failure, therefore reducing the need for costly repairs, replacements, or downtime.

Chemical Conversion Coating at ProtoSpace Mfg

Through our High Velocity Mass Customization (HVMC) capabilities, we can apply chemical conversion coating on CNC machined and sheet metal parts, panels and enclosures in-house in just one day. Furthermore, we can custom-manufacture fully finished parts within 3-4 days.

While we can process aluminum parts, panels and enclosures that have been manufactured in our own facilities, we are also happy to work with aluminum parts that have been fabricated or machined elsewhere, so long as they meet our dimension constraints.

So, what are these dimension constraints? We can handle aluminum parts with maximum dimensions of 43.5″ x 34″ x 30″ (1104.9mm x 863.6mm x 762mm).

Conclusion

Ultimately, choosing the right surface treatment comes down to your design needs. However, if you’re working with electronic enclosures and precision components, chemical conversion coating is a great choice. It offers the ideal mix of protection, conductivity and practicality.

Got a design ready? Get a quote with us today!

If you have any questions, just reach out to your ProtoSpace Mfg Account Manager – they’ll be happy to help!