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PROJECT TITLE: Development of Fluoride-Free Chemical Pickling for Superior Etching Efficiency and Surface Quality

Surface treatments such as Ti/Zr conversion coatings or A951 pretreatment are commonly applied to automotive 5XXX and 6XXX aluminum sheets to enhance adhesion and corrosion resistance. Prior to surface treatment, acid pickling is an essential process step for removing surface oxides and microstructural inhomogeneities, thereby creating a clean and uniform surface for subsequent pretreatment deposition. Fluoride-assisted pickling solutions are widely used in continuous surface treatment lines for automotive aluminum sheet production because of their high etching efficiency and robust process performance. However, hydrofluoric acid (HF) poses significant health and safety risks, as exposure can cause severe deep-tissue injury and systemic toxicity. To improve operational safety, a fluoride-free pickling solution capable of delivering etching performance and surface quality comparable to conventional fluoride-containing systems needs to be developed. A deeper understanding of the effects of pickling chemistry and novel additives on aluminum surface microstructure, as well as on the subsequent pretreatment process, is critical for optimizing pickling conditions and improving overall process robustness.

The role of the intern will be:

• Conduct literature review on environmentally friendly fluoride-free pickling solutions and additives;
• Design and execute DOE studies to evaluate the effects of pickling chemistry and additives on etching performance;
• Perform surface characterization such as SEM/XPS analysis to assess pickling-induced surface modification;
• Evaluate the impact of pickling on subsequent pretreatment deposition and bonding performance.

Competencies & technical & soft skills requirement:

• Pursuing a Bachelor's degree in Chemical Engineering, Chemistry, Materials Science and Engineering, Corrosion Science, or a related field; candidates pursuing a Master's or PhD degree are preferred.
• Demonstrated eagerness to learn and develop new laboratory and materials characterization skills.
• Experience handling hazardous chemicals and working in a laboratory environment.
• Solid understanding of laboratory safety practices and procedures is a must.
• Strong aptitude for operating laboratory equipment and conducting sample preparation, chemical test, and characterization (e.g., microscopy and related techniques).
• Ability to learn effectively from mentors and collaborate with team members.
• Strong analytical, problem-solving, and communication skills are highly desirable.