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What is Phosphating Agent

 

 

A phosphating agent is a chemical compound used to apply a conversion coating to metal surfaces. This process, known as phosphating or phosphate conversion coating, involves the chemical reaction between the phosphating agent and the metal surface, resulting in the formation of a thin layer of insoluble phosphate crystals.

 

 
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Degreaser;Metal cleaning agent; Antirust agent;Phosphating agent;Silane agent;Cutting solution;Copper blackening agent;Iron rusting agent.

 

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The Role Of Phosphating Agent

The main function of phosphating agent is to form a layer of phosphide on the metal surface. This phosphide can improve the surface hardness and corrosion resistance of the material. Through the treatment of phosphating agent, the appearance quality and service life of the product can also be enhanced, which has the following functions:

  • Improve the hardness and corrosion resistance of metal surfaces to make them more durable.
  • Improve the adhesion of the metal surface, making it more stable during subsequent processing and coating processes.
  • It can prevent oxidation and corrosion, especially for rust-prone metals such as iron and steel.
  • Before electroplating or painting, phosphating treatment can greatly improve the durability and adhesion of the product, thereby enhancing the adhesion and gloss of the coating.

 

Basic Chemistry Behind Phosphating Agent
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Different types of Phosphating Agent processes
Iron phosphating：The result is a light or medium phosphate coat. We use iron phosphate to offer moderate corrosion protection. It also serves as a primer for additional coatings.

Zinc Phosphating: The zinc phosphating process provides a thicker coating than iron phosphating. This results in a better adhesion of paint and enhanced corrosion resistance. The automotive and military industries use this process. They require corrosion protection for their products.

Manganese-phosphating: Manganese-phosphating produces a heavy and durable type of phosphate coat, which has excellent wear resistance. Manufacturers often apply this coating to parts with high wear, such as bearings and gears.

The Step-by-Step Phosphating Procedure
Pretreatment: Cleanse the metal surface thoroughly before applying the phosphate coating. It is necessary to remove oils, grease, and other contaminants to allow the phosphate to adhere correctly to the metal.

Application of the Phosphate Coating：After cleaning the metal, we immerse it in the phosphating solutions. It is essential to carefully control the solution composition, temperature, and immersion time to achieve the desired coating thickness and crystal size.

Post Treatment: After achieving the desired phosphate coating, metal parts are rinsed with water to remove the residual phosphating solutions. Then, the metal parts are dried to prepare them for subsequent finishing processes such as powder coating or painting.

Sealing of the Phosphate layer: Depending on the intended application, the sealant can be either a chromate, a passivation, or a lubricant.

 

 
Benefits Of Phosphating Agent
 
01/

Maximum Hardness–Manganese phosphate is the hardest type of phosphate coating available, providing unbeatable durability.

02/

Increased Corrosion Resistance–Because manganese phosphate is insoluble, it can’t be broken down by water or other liquids.

03/

Improved Lubrication–The crystalline finish absorbs oil and other lubricants, making it ideal for metal parts designed to come in contact with other metal parts, like engines and transmissions. The wear of phosphated parts in friction is dramatically reduced.

04/

Excellent Adhesion–Manganese phosphate provides a crystalline structure that is an effective base for secondary coatings and paint.

 

How To Choose The Different Types Of Phosphating Agent Process
 

Low-temperature phosphating, at room temperature, long processing time, in addition to medium-temperature phosphating has been added to the composition, in order to accelerate the speed of phosphating, but also add fluoride, the advantage of low-temperature work, without heating. The solution is stable mud slag less, but the film corrosion resistance is poor, bonding, heat resistance is also poor, the processing time is long. This phosphate in the production of not much application, spray phosphating when applied.

 

Medium-temperature phosphating 50 to 70 ℃, with Ma Zhifu salt, zinc dihydrogen phosphate and oxidizing agents (such as zinc nitrate, manganese nitrate, nickel nitrate) composed of phosphating solution, the film in addition to iron, manganese and other ferrous metals, but also interspersed with zinc, nickel. Film corrosion resistance, bonding and high-temperature phosphate film equivalent, stable solution, film speed, slag less than high-temperature phosphating. This process is applicable to a large area, in addition to the lower requirements for the hardness of the functional phosphate film, phosphating before painting the most applications. The disadvantage is that the composition of high-temperature phosphate is more complex, difficult to adjust.

 

High-temperature phosphate treatment temperature of 90 to 98 ℃, with Ma Zhifu salt and oxidizer (such as manganese nitrate) phosphate solution, phosphate film for iron, manganese, does not contain zinc. Film corrosion resistance, bonding, heat resistance, hardness are relatively high. The disadvantage is the long heating time, energy consumption, the amount of slag. Composition changes quickly, the solution is not stable. Phosphate crystallization coarse, thick film. This process is suitable for functional phosphate film, such as gears, automotive piston rings with friction reduction layer, lubrication phosphate layer between processing processes.

 

The Purpose And Function Of Metal Phosphating Agent

 

Any production and processing work must have a certain purpose to be achieved. For example, the reason why many manufacturers perform phosphating processing on metal workpieces is to improve the practicality and quality of the workpieces with the following application significance of this processing technology, the process in which the workpiece (steel or aluminum or zinc) is immersed in a phosphating solution (a solution based on some acid phosphates) and deposited on the metal surface to form a layer of water-insoluble crystalline phosphate conversion film, which is called Phosphate. Phosphating is a process in which chemical and electrochemical reactions form a phosphate chemical conversion film. The formed phosphate conversion film is called a phosphate film. The purpose of phosphating treatment is to provide protection to the surface of the base metal and prevent the metal from being corroded to a certain extent; it is used as a primer before painting to improve the adhesion and anti-corrosion ability of the paint film layer; it can reduce friction in the metal cold working process Use with lubrication. Metal surface phosphating is widely used in anti-corrosion technology and metal cold deformation processing industry.

Enhance the surface properties of metal workpieces. By phosphating the metal workpiece, the wear resistance, lubricity and other properties of its surface can be effectively enhanced. With this, the workpiece can better maintain stability in applications with excellent surface properties. Surface effect.

Improve the surface processing performance of metal workpieces. Through phosphating processing, the surface coating, heat treatment effect, plating properties and other processing properties of the metal workpiece can be greatly improved, thereby optimizing the subsequent processing of the workpiece and optimizing the subsequent surface processing of the workpiece. Effect.

Optimize the performance of metal workpieces. Phosphating processing can improve the performance of metal props and enhance the surface functionality of metal workpieces. It will inevitably optimize the performance of metal workpieces and make the workpieces present better in applications. Surface effect.

 

Application of phosphating agent

Phosphating agents are widely used in metallurgy, chemical industry, machinery, electronics, aviation, automobiles, electrical appliances and other industries, and the market demand is very large. Here are some common application scenarios:

1

Galvanized iron sheet

Treatment with phosphating agent can form a layer of fine, regular phosphide on the surface of the iron sheet, thereby improving its corrosion resistance and surface gloss, forming galvanized iron sheet.

2

Circuit boards

Phosphating agents are widely used in the surface treatment of circuit boards, which can prevent corrosion and rust on the surface of circuit boards and make them more stable during subsequent processing.

3

Auto parts

Phosphating agent can form a protective layer on the surface of auto parts to prevent corrosion and rust of auto parts.

4

Metal forgings

By surface treatment of metals with phosphating agents, the surface hardness and corrosion resistance of forgings can be improved, thereby enhancing their service life.

 

 

Process Flow Of Phosphating Agent

Pre-degreasing → degreasing → rust removal → water washing → (surface conditioning) → phosphating → water washing → post-phosphating treatment (such as electrophoresis or powder coating);

Main aluminum parts and zinc parts;

The phosphating blackening liquid is used at room temperature, and the phosphating protection is formed in one step. It is also called steel colorant. It is diluted at 1:4-5 before use, soaked at room temperature for about 30 minutes, and finally sealed for protection;

Treatment process: Oil and rust removal - immersion in anti-rust water - phosphating and blackening - drying - closed for protection.

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Generation Of Phosphating Agent Must Solve Challenges
 
Sludge

This thick, moist substance has been a necessary evil of the phosphating process, costing significant resources and downtime for the cleaning of equipment and tanks. Additionally, the cost to dispose of this sludge can be prohibitive, particularly in the quantities it is produced.

Water Consumption

The current phosphating process requires multiple rinse steps that requires high volumes of water, and also produces a significant amount of wastewater that needs internal pre-treatment before it can be discharged to sewer systems.

High Temperatures

The high temperatures generated by the phosphating process create incredible inefficiencies – requiring costly energy to heat process tanks up to 200°F. The mists and vapors generated by heated tanks are hazardous for employees, requiring removal from the environment using ventilation.

Space

Zinc phosphating is a “production-line” process, requiring a large footprint to complete its cleaning, rinsing, activating, phosphating, a second round of rinsing, and drying steps – plus the addition of ancillary equipment to treat the waste; ductwork for ventilation; hoists to move baskets; and so on.

Color

Zinc phosphating typically has delivered a finished product that has a gray matte finish – requiring interim steps, depending upon the application. For fasteners, this often means dipping the completed part in a colored wax or other topcoats to facilitate the distinction of one part from another; for larger parts, it requires heavy coats of primer or finish preparation prior to painting.

 

Method Of Phosphating Agent
 
 

High temperature phosphating
The phosphating film formed by high-temperature phosphating of manganese series has the best effect, has good corrosion resistance and wear resistance, and is the most widely used in high-temperature phosphating. However, the treatment effect is not good for some high-alloy steels, and it is even difficult to phosphate, such as 25Cr2Ni4WA alloy steel.

 
 

Medium temperature phosphating
The phosphating film layer of zinc calcium medium temperature phosphating has fine crystallization and good corrosion resistance, which has unique advantages over other series of phosphating films.

 
 

Low temperature phosphating
The film formation rate of calcium-based phosphating liquid is slow and usually requires medium and high temperature treatment. Zinc-calcium low-temperature black phosphating adds Mn2+, Ni2+, oxidants, surfactants, blackening agents, etc. to achieve excellent formation performance at low temperatures. Black phosphating film with dense film layer and strong corrosion resistance.

 

 

 

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FAQ
 

Q: Why is phosphating done before painting?

A: Phosphating is a surface preparation method for ferrous metals before coating or painting. It increases corrosion prevention and also helps improve anti-friction properties. In addition, the process precedes powder coating, which involves metal removal.

Q: How are metal protected by phosphating?

A: Phosphating is a chemical method of surface treatment in which a metallic surface reacts with an aqueous phosphate solution. This creates a hardly soluble conversion layer made of metal phosphates. For this purpose, the material is first cleaned with acid and then the phosphate layer is formed.

Q: How long does phosphate coating take?

A: 70–90 °C. At lower temperatures, the coating is characterized by low corrosion resistance. If a phosphate coating is obtained, the optimum phosphating reaction time is 12–15 min.

Q: How does phosphate prevent corrosion?

A: Phosphate: Decreases corrosion by providing cathodic and anodic inhibition. pH: As pH increases, corrosion decreases. Silicates: As silicates increase, corrosion decreases. Temperature: As temperature increases, corrosion increases.

Q: What are the benefits of phosphating?

A: Phosphating is one of the most important and widespread metal surface treatments in precision mechanics. It achieves significant corrosion resistance, improves material durability and facilitates paint adhesion.

Q: Which solution is used for phosphating?

A: I. Zinc phosphating solution.
– Advantages: Zinc phosphating solution is widely used for phosphating metal surfaces and has good corrosion and wear resistance. It can provide good coating adhesion and increase the surface hardness of the workpiece.

Q: What is the temperature of phosphating process?

A: Phosphating is a rather energy-consuming process, since the operating temperatures of phosphating solutions traditionally used in industry reach 55-90°C. The use of such temperatures leads to increased energy consumption and sludge formation, also a need to change and clean the heating elements.

Q: What is the salt spray test for phosphating?

A: Salt spray test measures the ability of various types of coatings to withstand in a corrosive-cum-humid atmosphere. As paint pretreatment coating, the phosphate coating is expected to improve the adhesion of the paint coating and prevents the spreading of underfilm corrosion.

Q: What is the phosphating process of metal?

A: Phosphating is a corrosion prevention method applied to carbon steel, low-alloy steel, and cast iron as a pretreatment before coating or painting. It converts a steel surface to iron phosphate, which most people use with another corrosion protective method.

Q: What is the total acid and free acid in phosphating?

A: The total acid concentration should be 0.48 to 0.8 g/L (3 to 5 points), according to titration with 0.1N NaOH and phenol phthalein indicator. The free acid should range from 0.03 to 0.08 g/L (0.2 to 0.5 points) titrated against brom cresol green.

Q: What is surface activation in phosphating?

A: Surface Activation chemicals activate the metal to obtain fine crystalline structure during phosphate coating which will increase corrosion resistance and adhesion properties. Crystalline structure less than 10 Microns always preferable.

Q: How do you test for free acid in phosphating?

A: RE: free acid test
The remaining free acid concentration can be determined by a simple titration to pH 4.5 using 1 [N NaOH solution. Total acidity is determined by titrating to pH 9.5. Alternatively, each phosphating bath has an optimum pH range, and the pH can be measured directly.

Q: What are the benefits of phosphating?

A: Phosphating is one of the most important and widespread metal surface treatments in precision mechanics. It achieves significant corrosion resistance, improves material durability and facilitates paint adhesion.

Q: What is the difference between phosphating and Parkerizing?

A: Parkerizing is usually considered to be an improved zinc or manganese phosphating process, and not to be an improved iron phosphating process, although some use the term parkerizing as a generic term for applying phosphating (or phosphatizing) coatings that does include the iron phosphating process.

Q: What temperature should I apply zinc phosphating?

A: For good reaction and deposition of the phosphate coating, zinc phosphate should be applied at 130°F (55°C) or higher. Many efforts have been made to apply it at cooler temperatures, but the amount of zinc in the deposited coating drops dramatically when the temperature is lowered.

Q: What is the process of zinc phosphating?

A: The zinc phosphating process relies on a chemical reaction that occurs on the metal substrate when the process solution comes in contact with the metal. This process creates a crystallization, resulting in a protective layer of insoluble zinc that prevents rust.

Q: What are the steps of the phosphating process?

A: Patented and Phosphated High Carbon Wire
Pickling, in several stages, with sulphuric acid or hydrochloric acid.
Water rinse, for example with two dip tanks and a spray rinse.
  • Activation.
  • Phosphating.
  • Water rinse.
  • Post treatment.
  • Drying.

Q: What is the condition of phosphating?

A: Phosphating (or phosphate coating) is part of a group of conversion coatings and describes a process whereby an insoluble adherent phosphate coating is formed on a surface (normally of iron, steel, galvanized steel or aluminium) by immersion in an acidic solution of iron, zinc or manganese phosphate.

Q: How does phosphate prevent corrosion?

A: Phosphate: Decreases corrosion by providing cathodic and anodic inhibition. pH: As pH increases, corrosion decreases. Silicates: As silicates increase, corrosion decreases. Temperature: As temperature increases, corrosion increases.

Q: What is the purpose of phosphating?

A: Phosphating is a surface preparation method for ferrous metals before coating or painting. It increases corrosion prevention and also helps improve anti-friction properties. In addition, the process precedes powder coating, which involves metal removal.

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