Mirrors are a great tool for drivers to see what's going on around them. They are a key safety feature included on all modern automobiles.
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However, mass production vehicles are not tailor made for the end user, thus, some drivers experience blind spots, or areas where they cannot see out of the car. Blind spots can be a great safety hazard depending on the situation and it is therefore encouraged to eliminate them by properly adjusting the mirrors on a vehicle. Unfortunately, mirror adjustments can offer only so much field of vision, and it is sometimes necessary to add an extra mirror to the vehicle to help reduce the occurrence of blind spots.
Broadway Mirrors are a great way to eliminate blind spots and increase vehicle safety while on the road. They are available in various styles, finishes, lengths, and coatings, but all serve the similar purpose of helping the driver see out of the vehicle.
Most OEM (Original Equipment Manufacturer, Stock) mirrors have a length of about 220mm, and are curved around the edges. The small size and curved edge is generally for aesthetic reasons and does not provide optimal vision per the outside of the vehicle. In order to overcome this, Broadway Mirrors come in various Lengths. They are generally, 240mm (=9.45inch), 270mm(=10.63inch), and 300mm(11.81inch).
A note regarding length- size does matter, both in viewing area and physical size. Although the largest mirror is best for being able to see, going too large may interfere with the flip-down sun visor operation. In this case, it is possible to off-set the mounting of the mirror to one side, allowing either the driver, or the passenger to make use of the sun visor, but it is advised to just go with a smaller mirror to not impede any function of the stock equipment.
Length depends on personal preference and vehicle application, and much like clothes.
Broadway Mirrors are all available in either Flat or Convex styles. This refers to the curvature of the reflective element, whether it is flat, or slightly curved.
The Flat mirrors, as the name would suggest, are flat. They offer a linear portrayal of whatever is reflected, and does not distort the image around the edges.
The Convex mirrors are curved, and offer a greater viewing area when compared to the Flat mirrors, but at the expense of image distortion around the edges. The curve of the mirror creates the effect of images looking further away than they actually are, and can cause some issues for those who make use of corrective vision.
As a note, the Convex 240mm shows the same amount as the Flat 300mm. In the case of vehicle safety, being able to see more should out-weigh any other factors, but driver comfort should also be a top priority.
Broadway Mirrors are available with three coatings, Aluminum, Chrome, and Blue. Each has unique properties, advantages, and disadvantages.
Aluminum Coating (Blue Packaging) mirrors have less tint on them when compared to most OEM mirrors, and other Broadway offerings. The presence of less tint allows for more light to enter the mirror, therefore reflecting a brighter image. This is helpful for vehicles which have a tinted rear window, making the darkness difficult to see with their stock mirror.
Chrome Coating (Red Packaging) mirrors have more tint on them when compared to most OEM mirrors, and other Broadway offerings. The increased tint on the mirror allows the reflective element to cut down on glare from the sun and headlights shining in the mirror. This is helpful for vehicles which are lowered and frequently experience glare from headlights in the rear view mirror.
Blue Coating mirrors cut down on glare immensely, while preserving most of the light entering the reflective surface. A similar coating is often found on the mirrors of many German vehicles. This mirror achieves the same glare-reduction of the Chrome and the brightness of the Aluminum through the use of the specially tinted glass surface.
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Most Broadway Mirrors utilize a spring-loaded clip-on mechanism to attach to the stock mirror. The ends of these Clips have rubber pads on them to insure a tight grasp, and to reduce rattling from vibrations. These mirrors will fit on most OEM mirror applications, but it is encouraged to insure fitment due to variance in mirror thickness.
Aluminum coatings are different surface treatments manufacturers and product designers commonly use to protect aluminum alloys from high heat, abrasion, chemical reactions, and humidity. Below are different types of aluminum coatings suitable for your project:
Anodizing is an electrochemical process that enhances abrasion and corrosion resistance in aluminum parts by thickening the natural oxide layer to form a dense film. The aluminum coatings become thicker depending on the time the aluminum spends in the anodizing tank containing electrolytic solution.
More importantly, anodized aluminum offers several desirable benefits, such as dye adhesion, vibrant colors, and better heat dissipation in aluminum machined parts. Below are the different anodizing types:
Clear anodizing is an anodizing finish that doesn't involve using dyes. Clear coating is more forgiving, unlike darker anodized colors, which usually exhibit color inconsistency and disfigurations when installed on-site.
This involves dying the anodic film into any color to achieve a decorative finish after the anodizing process. This dyeing process provides a vibrant finish on the aluminum part. Anodized aluminum absorbs the dye through the pores of the aluminum oxide layer when immersed in a dye bath. It allows you to achieve a range of colors that best fit the requirements of your parts.
Hard, clear anodizing offers greater corrosion and wear resistance in aluminum products. Although it is similar to regular anodizing, its oxide layer is thicker and more durable on an aluminum surface. Hard clear anodizing is commonly used to achieve a clear finish with enhanced durability in aluminum products.
Conversely, hard-dyed anodizing provides a thicker and more robust coating with a wide range of color options added through dyeing. As a result, it helps to enhance the durability of aluminum parts and achieve a specific color for your custom aluminum parts.
Blasting and anodizing are a combination of two processes commonly used to prepare and anodize aluminum parts. The blasting process involves using an abrasive media such as glass beads or sand to remove imperfections or contaminants from the surface of aluminum components.
Then, you can anodize the prepped aluminum surface to achieve the desired coating. This anodizing process forms a smooth, high-quality oxide layer on the aluminum surface.
Powder coating is a surface treatment that provides shiny, long-lasting colors with excellent resistance to ultraviolet rays in various metals. You must clean and prep the aluminum parts, then spray the powder coat with an electrostatic gun to apply the dry paint powder on the metal surface. Then, you must bake the powder-coated aluminum parts to melt and cure the coating to achieve a uniform finish.
Al H111 Conversion Coating Cowder CoatingPowder coatings are not as hard and long-lasting as anodized aluminum. However, powder coatings provide an excellent appearance and corrosion resistance. Unlike liquid painting, the powder coating technique is non-toxic since it lacks solvents comprising volatile organic compounds (VOCs).
Chemical conversion coating or alodine finish is an inexpensive alternative to anodizing. Chromate chemical conversion is suitable for improving the passivating oxide layer on the aluminum parts' surface. It provides excellent corrosion resistance and an aesthetically appealing exterior.
Moreover, chemical conversion coatings provide high electrical conductivity in aluminum machined parts in applications that require high electrical conductivity. However, alodine solution has low environmental sustainability compared to other finishes.
Chromate plating is widely embraced in consumer goods and manufacturing industries. It uses an electrolytic process to form a protective aluminum layer and bright luster on the surface of the aluminum part by submerging it in an electrolytic bath. Chrome plating is especially suitable for decorative purposes or enhancing the preferred properties of machine parts.
Below are the two types of chrome plating that offer the preferred surface finish for metals:
Hard chrome plating, or industrial or engineered chrome, involves immersing a metal part in a chromic acid solution. It is usually thicker than the decorative type and ideal for various industrial applications that require great strength, wear, and corrosion resistance.
Hard chrome provides a durable thickness that reduces friction between machine parts, improving components' durability and performance. More importantly, industrial chrome ensures machine components' extended lifespan and reduces downtime and maintenance expense risks.
Decorative chrome plating improves the aesthetic appeal of aluminum parts with its thin layer of chromium asides protecting the base material from corrosion and wear. This chrome plating doesn't offer the same durability levels as the hard chrome plating.
However, it is easy to clean, provides some corrosion and wear resistance, and improves your metals' aesthetic appeal. Its typical applications include kitchen utensils, car parts, and tools.
Polyvinylidene fluoride (PVDF) coating is a typical resin-based aluminum coating entrenched with color pigment particles. They are best applied on aluminum machined components in a factory setting and provide an extensive range of matte-finish colors. These coatings offer extreme hardness and high insolubility, allowing them to protect metal substrates from corrosion.
PVDF coatings ensure your metal surfaces exhibit excellent resistance to fading, chemicals, and corrosive substances. Hence, these aluminum coatings are ideal for exterior applications such as aluminum wall cladding. More importantly, you do not need an oven to cure PVDF coatings, and these coatings do not contain toxic VOCs like liquid painting.
Teflon or PTFE coating is excellent for different applications ranging from automotive, electronics, pharmaceutical, aerospace, optical devices, and cookware. Teflon coating has a high molecular weight, which makes it resistant to water.
Product engineers often choose this coating because of its long list of benefits, including outstanding electricity insulation, ultraviolet ray resistance, doesn't absorb water, and can withstand extreme temperatures.
Its high chemical resistance property makes it a well-suited coating for aluminum components in the medical industry. It is suitable for coating tubes, pipes, and vessels. Similarly, its low-friction co-efficient property makes it an ideal aluminum coating in automotive and industrial applications.
The electrophoretic coating or E-coat process involves submerging the aluminum product in a bath of coating material and using an electric current to apply the coating on the surface. It provides your product with good resistance to corrosion and chemicals.
This aluminum coating type is straightforward and inexpensive, making it a popular choice in industries like the automotive industry. This coating solution allows you to combine other coatings to enhance its performance further.
It would help to know that the aluminum part protection that these processes offer often varies from bright and mirror-like to rough or patterned. Therefore, it is advisable to understand these surface finishes to determine the one that best enhances your products. It would help to choose a finish that meets your application's quality standards and ensures the aluminum part fits and functions well.
The aluminum metal's versatility makes it compatible with an extensive list of applications, including automotive, aerospace, marine, defense and military, and consumer products. However, it is crucial to consider environmental factors when choosing aluminum coatings for your project, especially if your product is meant for outdoor use.
It would help to consider environmental factors that can affect aluminum parts in the long run, such as humidity, temperature, sunlight, ultraviolet rays, etc., when choosing a finish for aluminum machined parts for outdoor applications. Choose a finish that ensures the extended life span of aluminum machined parts even when exposed to environmental factors.
Nevertheless, ensure that the chosen aluminum coating fits your budget without sacrificing quality. More so, your budget should guide your choice of a finish while having quality in mind because choosing a costly finish may increase the product's machining cost.
Aluminum coating is fundamental to your custom aluminum parts because it helps to elevate these products from 'basic' to 'superior.' Besides, partnering with an aluminum finishing expert is crucial in achieving the best results when producing aluminum parts. Therefore, you must understand these finishes to choose the ideal one for your products and intended application.
AT-Machining offers expert aluminum finishing at the best prices that fit within your budget. Our team of expert product designers, engineers, and quality control experts ensures your aluminum parts get the right finish that meets the intended application's demand. Contact us today to elevate your project to the desired quality standard. Upload your CAD file now for an instant quote!
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