900 Tons/Month Turnkey Micro-Arc Oxidation Production Line for New
Energy Battery Trays
This turnkey micro-arc oxidation (MAO) production line is designed
for manufacturers of new energy vehicle battery trays. The line
covers the complete process chain from pre-treatment through
micro-arc oxidation to post-treatment within a PLC-controlled
automated system.
Micro-arc oxidation is an electrochemical surface treatment process
that generates a ceramic oxide layer on the surface of aluminum,
magnesium, and titanium alloys through micro-zone arc discharge in
an electrolyte. The process uses a weak alkaline electrolyte
without heavy metals, and the resulting ceramic layer is
metallurgically bonded to the substrate, providing corrosion
resistance, electrical insulation, and wear resistance for battery
tray applications.
Technical Specifications
| Parameter | Specification |
|---|
| Applicable Workpieces | Aluminum and magnesium alloy battery trays, battery pack housings,
structural components |
| Operation Mode | PLC-controlled automatic line with recipe management |
| Anodizing Type | Micro-Arc Oxidation (MAO / Plasma Electrolytic Oxidation) |
| Film Thickness | 50-100 μm (configurable based on component requirements) |
| Surface Finish | Matte ceramic layer, uniform grey or dark grey appearance |
| Process Temperature | Electrolyte temperature controlled within 20-40°C |
| Current Density | 1.5-18 A/dm² (adjustable by alloy and part geometry) |
| Production Capacity | 900 tons/month (dependent on surface area per ton and cycle time) |
| Sealing Method | Post-treatment sealing / impregnation (configurable) |
Note: Process parameters are adjustable within these ranges based
on specific alloy composition, workpiece geometry, and target
coating properties. Actual throughput depends on part size, racking
density, and required film thickness. Detailed specifications are
available upon request.
Reference Performance Data
| Property | Typical Range |
|---|
| Microhardness | 400-3,000 HV (depending on substrate and process parameters) |
| Salt Spray Resistance | ≥500 hours for 50 μm coating (battery tray applications) |
| Dielectric Resistance | ≥100 MΩ |
| Porosity | ≤5% (with optimized process control) |
| Coating Bonding | Metallurgical bonding with substrate |
Sources: Published MAO process research and industry technical
bulletins.
Micro-Arc Oxidation Process Flow
The production line follows a sequential multi-stage process:
- Loading
- Degreasing
- Rinsing
- Alkaline Cleaning
- Rinsing
- Acid Neutralization
- Rinsing
- Micro-Arc Oxidation
- Multi-stage Rinsing
- Post-treatment (Sealing/Impregnation)
- Rinsing
- Drying
- Unloading
Each stage is controlled by the central PLC system, with automated
transfer between tanks. Rinse stages incorporate cascading
counter-flow to reduce water consumption. The micro-arc oxidation
stage uses a dedicated pulse power supply with adjustable
frequency, duty cycle, and voltage waveform. Electrolyte
temperature is maintained within the process range by a circulation
and cooling system.
Key Features
- Controlled Film Thickness: The MAO power supply and PLC system regulate voltage, current
density, and oxidation time to achieve target film thickness from 5
μm to 100 μm.
- Automated Process Control: Central PLC system manages hoist movement schedules, immersion
times, power supply parameters, and electrolyte circulation with
real-time data logging.
- Batch Consistency: Automated electrolyte circulation, temperature control, and dosing
systems maintain stable bath composition for consistent results.
- Temperature & Filtration Control: Circulation pump system, plate heat exchanger or chiller, and
filtration units maintain electrolyte temperature within 20-40°C.
- Flexible Surface Finishing: Accommodates different pre-treatment and post-treatment options
based on specific requirements.
- Environmental Compliance: Uses weak alkaline electrolyte without heavy metals, equipped with
wastewater treatment and exhaust gas collection systems.
Production Line Configuration
A typical line layout includes the following major equipment:
- Pre-treatment System: Degreasing tank, alkaline cleaning tank, acid neutralization tank,
multi-stage rinsing tanks
- MAO Power Supply: Dedicated high-voltage pulse power supply with adjustable
parameters
- Oxidation Tank System: Corrosion-resistant tank with cathode system and uniform electric
field design
- Electrolyte Circulation & Cooling System: Circulation pumps, heat exchanger or chiller, filtration units
- Automated Transfer System: Gantry crane or rail-mounted hoist system
- PLC Control Cabinet: Central control with touchscreen HMI, recipe management, and data
logging
- Post-treatment System: Sealing/impregnation equipment, pure water rinsing, and drying
system
- Exhaust & Scrubber System: Fume hoods with exhaust gas treatment
- Wastewater Treatment System: pH adjustment, sedimentation, and filtration for discharge
compliance
The line footprint and tank dimensions are customized based on
maximum workpiece size and required throughput.
Frequently Asked Questions
Q1: What is the difference between micro-arc oxidation and
conventional anodizing?
Micro-arc oxidation operates at higher voltages than conventional
anodizing, generating micro-zone arc discharge on the metal
surface. This produces a ceramic oxide layer that is
metallurgically bonded to the substrate, with higher hardness
(400-3,000 HV compared to 200-400 HV for conventional anodizing)
and improved corrosion resistance. The process uses a weak alkaline
electrolyte without heavy metals.
Q2: What film thickness is suitable for battery trays?
For battery tray applications, typical film thickness ranges from
50 μm to 100 μm to provide enhanced corrosion protection and
electrical insulation. Thinner coatings (5-20 μm) may be suitable
for precision components where dimensional tolerance is a concern.
Q3: What is the typical lead time for line delivery and
installation?
Lead time and installation schedule are confirmed based on project
scope. Equipment manufacturing, shipment, installation, and
commissioning proceed according to the project plan after design
confirmation. (Actual timeline is subject to project scope
confirmation.)
Q4: How is the 900 tons/month capacity calculated?
Capacity is calculated as: Monthly throughput = (Surface area per
rack × Racks per hour × Operating hours) ÷ Average surface area per
ton. Actual throughput depends on part geometry, racking density,
and required film thickness.
Q5: What alloys are supported?
The line supports aluminum alloys (including 6061, 6063, and
die-cast grades) and magnesium alloys (including AZ91D and AM60)
commonly used in battery tray manufacturing.
Q6: Does the line include environmental compliance equipment?
Yes. The line is equipped with wastewater treatment and exhaust gas
collection systems. Micro-arc oxidation uses a weak alkaline
electrolyte without heavy metals, and the specific treatment
configuration is customized based on local environmental
regulations.
Customized Micro-Arc Oxidation Line Solution
Every production scenario differs in workpiece geometry, alloy mix,
and throughput target. We provide customized line layouts and
process solutions based on your specific requirements.
To receive a tailored proposal, please share:
- Workpiece drawings or samples (material, dimensions, surface area)
- Target film thickness and performance requirements
- Required monthly throughput (tons or pieces)
- Available factory space and utilities (power, water, drainage)
Our engineering team will respond with a proposed line layout,
equipment list, and estimated process cycle time.
