Anodize Aluminum Electrical Bus 1

[thorangle]

I would like to know if there is an inexpensive process to anodize 6061-T6 aluminum such that the electrical resistance at the surface is equal to (or less than) the base metal and the surface is protected from atmospheric corrosion?

 

[TVP]

You've just described what anodizing aluminum does-- Aluminum oxide (an extremely poor conductor) forms on the surface during this process. Depending on the exact nature of the bath chemicals and the immersion time, the coating is generally around 2 - 50 micrometers in thickness, with corrosion resistance increasing with increasing thickness. Sealing the anodized layer with a polymer will further improve corrosion resistance and lower the conductivity. You can find some excellent information on anodizing at the following website:

http://www.metalast.com/

 

[thorangle]

TVP
Is there a process that provides GOOD Conductivity as well as corrosion resistance?

 

[BarryMartin]

Check out

http://www.brushplating.com.

Electroplating provides options for anodizing aluminum or applying a metallic coating as a barrier layer. For example, a pore-free nickel layer a few thousandths thick would provide a barrier layer for corrosion and a good long term electrical contact resistance. For even lower contact resistance you could use silver or a combination of nickel and silver.