The proposed project focused on the validation of a TSAA process, including pre- and post-treatment, which is defined by the topic manager, and its implementation in industrial scale. An existing industrial plant, which was be selected by the topic manager, was benchmarked with respect to the number and dimensioning of the components of the plant and its periphery with respect to the technical requirements for the process. The process itself was performed in laboratory- and pilot scale to verify the reproducibility of the process for given aluminium alloy(s) and to characterise and quantify the properties of the surface of specimens after each step of the TSAA process.

Failure mode analyses, such as FTA (failure tree analysis), DRBFM (Design review based on failure mode) and FEMS (Failure modes and effects analysis) will be performed. Knowledge-based analysis of the process and the relevant parameters, such as temperature and filtration, as well as the aforementioned failure mode analysis, will lead to the definition of process sheets and risk assessment plan. Environmental analysis of the process will consider chemicals used – also with respect to REACh compliance -, exhaust fumes (especially in the working area), waste and waste water output. As far as possible, recycling routes for process waters and chemical components will be analysed and suggested. Risk analysis will also include possible health risks in the working area, which can originate from incorrect use of chemicals or waste.

The results of the analysis of environmental and health risks will be included into the process sheets and risk assessment plan. Data and process-relevant knowledge gained during the aforementioned analysis steps will finally lead to elaboration of a manufacturing plan and compilation of a Process procedures and standard manual.