Description

This specification establishes the materials and procedure for the formation of an insoluble mildly protective iron phosphate coating on ferrous surfaces, having an iridescent blue to bluish brown color. This process will produce coatings in accordance with TT-C-490 TYPE II American specification. The thickness of the coating is over 35 mgr/ft2

Application

Iron phosphate coatings are applied to steel surfaces in order to protect them from corrosion but mainly are applied as a base for better paint adhesion (wet or electrostatic).

1st stage : Degreasing - phosphatizing Product: PHOSPHAT - F Concentration: 5 - 6 % by immersion Temperature: 50 - 60 oC.

Contact time: 5 - 7 min by immersion

2nd stage : Rinsing

Clean overflowing cool water for 1-2 minutes. Dump & refill daily.

3rd stage : Passivation

If the water of the rinsing stage is hard it is preferable to use deionized water or perform the passivation stage which increase the anti-corrosion protection of the metal.

Product: HIB

Concentration: 2 o/oo by immersion or spray. Temperature: 50 - 60 oC.

Contact time: 30 sec.

In some cases the second or the third step may be omitted.

General Information

The tanks or the spray equipment could be made from stainless or mild steel. Depending on the production the PHOSPHAT - F solution must  be changed every month.

The solution of the passivation stage must be changed every 2 - 4 days. If the second step is omitted the HIB solution should be changed daily.

Description

PHOSPHAT is liquid containing a high concentration of liquid solvent type detergents and mild acidic chemical phosphating compounds. PHOSPHAT is a heavy duty cleaner and iron phosphating compound for use in dip tanks. The primary advantage of PHOSPHAT is its superior cleaning ability, PHOSPHAT provides a more uniform and consistent iridescent phosphate conversion coating on steel and zinc surfaces, and also assures excellent post rush inhibition.

PHOSPHAT-SUPER is used in DIP TANK APPLICATION and PHOSPHAT- SUPER-SPRAY is a low foaming product used in spray application.

Applicable Government Specification

Meets TT-C-490, Type II Requirement for Iron Phosphate Coatings.

Advantages

          PHOSPHAT provides the following product features :

1. COMBINES CLEANING AND PHOSPHATING IN ONE STEP, to reduce operational costs.
2. PROVIDES EXCELLENT CLEANING, normally superior to powdered cleaner/iron phosphate compounds.
3. ASSURES LONG TANK LIFE and AMORPHOUS PHOSPHATE COATING for optimum paint adhesion.

How to use PHOSPHAT

 DIP TANK APPLICATION                           SPRAY APPLICATION

1. CLEAN/PHOSPHATE

PHOSPHAT-SUPER at 5-6 % at                       PHOSPHAT-SUPER-SPRAY at 1,5-3 %

40-60 ^oC for about 5 minutes or.                      at 20-60 ^oC for about 2 minutes.

10-15% at room temperature for

10 minutes.

2. RINSE

 Clean overflowing cool water                         Clean overflowing cool water for

 for 1-2 minutes. Dump & refill                         1-2 minutes. Dump & refill

 daily.                                                            daily.

3. INHIBITIVE RINSE

   HIB or HIBI SEAL-NC, 2 ^o/oo                   HIB or HIBI SEAL-NC , 2 ^o/oo

   at 20-80 ^oC for 1 minute.                           at 20-80 ^oC for 1 minute.

Dump and recharge weekly.                         Dump and recharge weekly.

Description

PHOSPHAT is liquid containing a high concentration of liquid solvent type detergents and mild acidic chemical phosphating compounds. PHOSPHAT is a heavy duty cleaner and iron phosphating compound for use in dip tanks. The primary advantage of PHOSPHAT is its superior cleaning ability, PHOSPHAT provides a more uniform and consistent iridescent phosphate conversion coating on steel and zinc surfaces, and also assures excellent post rush inhibition.

PHOSPHAT-SUPER is used in DIP TANK APPLICATION and PHOSPHAT- SUPER-SPRAY is a low foaming product used in spray application.

Applicable Government Specification

Meets TT-C-490, Type II Requirement for Iron Phosphate Coatings.

Advantages

PHOSPHAT provides the following product features :

1. COMBINES CLEANING AND PHOSPHATING IN ONE STEP, to reduce operational costs.
2. PROVIDES EXCELLENT CLEANING, normally superior to powdered cleaner/iron phosphate compounds.
3. ASSURES LONG TANK LIFE and AMORPHOUS PHOSPHATE COATING for optimum paint adhesion.

How to use PHOSPHAT

 DIP TANK APPLICATION                           SPRAY APPLICATION

1. CLEAN/PHOSPHATE

PHOSPHAT-SUPER at 5-6 % at                       PHOSPHAT-SUPER-SPRAY at 1,5-3 %

40-60 ^oC for about 5 minutes or.                      at 20-60 ^oC for about 2 minutes.

10-15% at room temperature for

10 minutes.

2. RINSE

Clean overflowing cool water                         Clean overflowing cool water for

for 1-2 minutes. Dump & refill                         1-2 minutes. Dump & refill

daily.                                                            daily.

3. INHIBITIVE RINSE

HIB or HIBI SEAL-NC, 2 ^o/oo                   HIB or HIBI SEAL-NC , 2 ^o/oo

at 20-80 ^oC for 1 minute.                           at 20-80 ^oC for 1 minute.

Dump and recharge weekly.                         Dump and recharge weekly.

Description

SUPER KLEEN is a greenish liquid that contains a high concentration of liquid solvent type detergents and acidic chemical phosphating compounds.

Usage

SUPER KLEEN is a heavy duty cleaner and iron phosphating compound used in dip tanks.  The primary advantage of SUPER KLEEN is its superior cleaning ability as compared with powdered iron phosphating cleaning compounds.  Because of its superior cleaning ability, SUPER KLEEN provides a more uniform and consistent iridescent phosphate conversion coating on steel and zinc surfaces, and also assures excellent post rush inhibition.

SUPER KLEEN is used for contemporaneous degreasing, de-rusting and phosphating of ferrous and galvanized parts before painting. Can also be used for cleaning aluminum and cast aluminum alloys.

Applicable Government Specifications

Meets TT-C-490, Type II Requirement for Iron Phosphate Coatings.

Advantages

          SUPER KLEEN provides the following product features:

• COMBINES CLEANING AND PHOSPHATING IN ONE STEP, to reduce operational costs.
• PROVIDES EXCELLENT CLEANING, normally superior to powdered cleaner/iron phosphate compounds.
• ASSURES LONG TANK LIFE and AMORPHOUS PHOSPHATE COATING for optimum paint adhesion.

Usage

SUPER KLEEN is applied at room temperature by dipping and is diluted in water in a ratio of 1:5 up to 1:10.  The immersion time is 10-20 minutes. Finally, rinse parts with water preferably hot.

SUPER KLEEN can be used as received for removing rust from ferrous parts.

Note

All tanks containing SUPER KLEEN should be composed of stainless steel or PVC.

The rinse water must be changed frequently.

Description

PHOSPHAT Z-101 is an emerald green liquid concentrate of mildly acidic metal phosphates that already contain the necessary catalysts and crystal refining toners required to produce optimum corrosion protection and appearance of the surface finish.

Advantages

• Provides microcrystalline zinc phosphate coatings that are extremely fine and compact.
• Paint adhesion is improved due to refined crystalline matrix of coating.
• Cost of paint is reduced since the extremely fine-grained phosphate coating allows greater coverage.
• Corrosion protection is increased because of improved paint bond.
• Appearance of paint finish is improved because of smoother microcrystalline finish.
• Saves in operational costs, because of compactness of microcrystalline coating tends to restrict formation of excessively heavy coatings.
• Simplifies process control because of built-in catalysts and toners.

Application

PHOSPHAT Z-101 is a chemical concentrate that is specifically formulated to provide smooth, compact, microcrystalline zinc phosphate coatings to steel, zinc and cadmium surfaces. PHOSPHAT Z-101 coatings provide increased protection from corrosion as well as improved paint adhesion. Because of the compact coating, paint consumption is vastly reduced, and improved luster is obtained.

PHOSPHAT Z-101 conforms to U.S. Military Specification MIL-P-16232, Type Z and TT-C-490, Type I.

Usage:

Precleaning – Prior to phosphating, parts must be free of all grease, rust, soil, and loose scale. Cleaned parts must be water-break-free after rinsing with clean cold water.

Phosphating – The PHOSPHAT Z-101 is used diluted with water as follows:

For spray application: 2-3% at a temperature of 140-180°F for 1-2 minutes. For dipping: 8-10% at a temperature of 140-180°F for 5-10 minutes.

The bath should be tested and adjusted to operational limits

Rinse: The phosphating parts are to be immediately rinsed in cold or lukewarm clean, overflowing water bath, for not less than 60 seconds.

Inhibitive Rinse – HIB is a non-chromate rinse aid that may be used to replace chromic acid type rinse inhibitors. For best results a clean, fresh water rinse should follow the HIB rinse. This can be done by adding HIB to the rinse immediately, following the phosphate bath and use clean, hot water in the final rinse.

HIB is used 2-3 o/oo in hot water to provide post rust inhibition. Maintain the pH of HIB at pH of 3.0 – 4.0 by additions of small amounts of phosphoric acid. Drain tank and recharge daily.

If a chromate type inhibitive rinse is required because of government restrictions use HIBI SEAL-NC 2-5 o/oo in hot water (140-160ºF) and adjust the pH of the solution to pH 3.0-4.0 by the addition of small amounts of phosphoric acid. Drain tank and recharge daily.

Acceleration of Baths :

Excellent zinc phosphate coatings are normally provided by ACCEL baths when operated within the recommended control range. Should lower temperatures or shorter contact time be unavoidable, the bath can be accelerated by ACCEL to encourage heavier, more corrosion resistant coatings. ACCEL is used by dissolving 1-2 lbs. in 10 gallons of water, and slowly running the solution into the PHOSPHAT Z-101 bath during production use.

Other Applications:

PHOSPHAT Z-101 coatings can also be oiled or impregnated with corrosion inhibitors to provide additional corrosion protection.

The dark gray matte finish provided by PHOSPHAT Z-101 is attractive, and this coating can be used for a decorative finish.

Equipment:

TANK: Heavy gauge, mild steel or stainless.

PUMP: Stainless steel.

HEATING: Stainless steel steam coils, internal gas tubes or gas burners.

DRYING: Hot chamber, warm air blast.

Description

Usage

Dip phosphating of iron and steel where heavy coating are required, suitable for impregnation with oils, or other lubricants, for friction resistance, and to assist in “break in” of bearing surfaces. Phosphat – M is particularly suited to production of such coating on high carbon and hard alloy steels.

GOVERNMENT SPECIFICATIONS APPLICABLE

Phosphat – M conforms to the following specifications:

MIL – P – 16232 B, Type M, Classes 1,2,3,4

MIL – P 50002, Type I, Composition B

Application

Preparation of Steel Surface: Surfaces may be cleaned by abrasive blasting prior to the use of Phosphat – M, except for those cases where blasting may be deemed detrimental by the contracting officer, or is waived for other reasons by proper authority. In any event, the metal surface must be subjected to such non – detrimental cleaning and conditioning procedures as are necessary to insure satisfactory phosphating.

When alkaline cleaners are to be used, we recommend our product KEM-2B at a concentration of 4 to 6 oz / gallon and a temperature of 160 – 190˚F. Cleaning must be such that no water break is observed when parts are held under running water. Parts must be thoroughly rinsed in clean water after each liquid cleaning or conditioning operation. Water rinses must be kept pure by steady overflow into weir troughs. Rinse tanks are to be dumped and refilled daily.

Where rust and /or scale are to be removed by chemical means, we recommend our product ATAROL a phosphoric acid type conditioner, otherwise sandblasting is recommended.

Phosphating: The phosphating bath is made up by addition of 9 to 11 gallons Phosphat – M to each 100 gallons clean water. To shorten break-in period, add several pads of steel wool for each 100 gallons bath; this break-in substance is to be used at the start only. Stir, and then heat to operating temperature range.

Immerse the clean parts in the bath at 200-210˚F. for a sufficient length of time to produce the coating required by the specifications. Ordinarily this will be for not less than 10 minutes, or more than 30 minutes.

Water is to be replaced as it evaporates from the bath. Most of sludge should be removed from tank at one week to ten-day periods. The bath need be discarded seldom, if ever, provided it is properly cared for and closely as provided below.

Water Rinse After Phosphating: The phosphating parts are to be immediately rinsed in cold or lukewarm clean, overflowing water bath, for not less than 60 seconds.

Final Chemical Rinse: As a final processing step immediately before dry-off, the parts are rinsed for not less than 30 or more than 60 seconds in a bath made up with our product HIB, 2- 3 ^o/oo in water and used at temperature 140 – 180 ˚F. This rinse must be carefully maintained and controlled according to the Phosphat standard chromic rinse control instructions, copy attached.

If a non chromate type inhibitive rinse is required because of government restrictions,use HIBI SEAL-NC(non-chromate). The parts are rinsed for not less than 30 or more than 60 seconds in a bath made up with our product HIBI SEAL- NC, 2-5 ^o/oo in water and used at temperature (140-180˚F).

Description

PHOSPHAT-SOLVE is a liquid product that contains solvents and creates a phosphate coating on metallic surfaces, which provides good adhesion of the paint and increased protection against corrosion to the metal.

Application

PHOSPHAT-SOLVE is used for the removal of oil, grease etc. Lightly phosphates surfaces and deems them suitable for painting. It has great cleaning abilities, it is fast and easy to use and does not require expensive operational costs.

Usage

PHOSPHAT-SOLVE is used as is by sponge, cloth, dipping or spray. The objects are left to dry and afterwards are ready to be painted.

Note:

PHOSPHAT-SOLVE is offered in 2 types. PHOSPHAT-SOLVE-S, which is used by dipping and PHOSPHAT-SOLVE-Q, which is fast evaporating and applied by sponge or spray.

Description

KEM BLACK is an alkaline product in powder form which produces a durable, gleaming or matt, black or bluish finish on iron and steel parts for decorative effect and corrosion resistance.

The finish produced by KEM BLACK neither increases or decreases the dimensions of the treated metals. The finish actually forms a part of the metal itself.

KEM BLACK meets the requirements of MIL-C-13924, CLASS 1.

Process Instructions: 

1o Stage: DEGREASING

            Product                       : KEM-2B or PH CLEANER-2-PLUS

            Concentration             : 5-10%

            Temperature                : 70-80 ℃

            Immersion Time          : 5-10 minutes

2o Stage: RINSE

            Thoroughly rinse in clean overflowing water, preferably warm. A cascade rinse tank proving two rinses is advised at this stage.

3o Stage: BLACK OXIDE

            Product                       : KEM BLACK

            Concentration             : 1200 grams per liter water

            Temperature                : 143 + 2 ℃

            Immersion Time          : 15-30 minutes (depending on desired results)

4o Stage: RINSE

Use stage 2

5o Stage: SEALING

            Product                       : HIB

            Concentration             : 0,2 % (2 grams per liter water)

            Temperature                : Ambient

            Immersion Time          : 2 minutes       

6o Stage: PRESERVE

            Immerse parts in WATER DISPLACER (water-displacing rust preventive)

Gneral Information:

Charging the tank

Carefully add the KEM BLACK powder to the cold water under constant agitation or stirring to insure dissolving. When  KEM BLACK has been mixed and dissolved, heat the tank until 143 ℃ is reached.

Strict maintenance of the temperature is imperative.

Once a  KEM BLACK solution has been prepared it is wise to remember two important facts:

1. Adding KEM BLACK salts will automatically increase the boiling point.
2. Adding water will automatically decrese the boilin point.

KEM BLACK solution should be maintained warm or hot at all times. If solution is allowed to cool too much, the salts will precipitate out to form a hard cake. Then when the tank is reheated uneven heating will occur and the salts will “burn”. Parts processed in “burnt” salts may not produce a satisfactory black finish.

If the tank is used only a portion of the day, maintain sufficient heating during idle hours to prevent solidification of the solution (70-90 ℃).

KEM BLACK solution remains effective if it used properly and only replacing dragout losses is necessary.

Control of the solution:

Maintain the boiling point of the solution at  143 + 2 ℃. If the solution boils at a lower temperature than 143 ℃, add KEM BLACK until the boiling point is established at 143 ℃. If the solution boils at an upper temperature thant 143 ℃, add water until the boiling point is established at that point.

Protection of the solution:

Do not use or immerse incompatible or reactive metals, such as aluminum, brass, copper, bronze or tin, cadmium and zinc plated parts. The solution will be poisoned and it will become unusable.

Description

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Description

HIB & HIBI SEAL – NC

INHIBITIVE SEAL RINSE AIDS FOR PHOSPHATE COATINGS

Purpose

INHIBITIVE SEAL RINSES are required after iron, zinc, or manganese phasphating processes to assure maximum corrosion resistance and paint adhesion of the phosphate coatings. Since inhibitors are usually affective at very low concentrations will provide the optimum surface passivation required for these phosphate coatings.

 Description

Use conditions

Concentration and pH control

Since it is imperative that these final rinses be as clean as possible, these final inhibitive seal rinse solutions should be made up fresh each day. After charging the inhibitive rinse aid to the fresh water, adjust the pH of the solutions using phosphoric acid when necessary to lower the pH. To extend the effectiveness of these inhibitive rinse solutions for prolonged daily operations, just add 0,5 – 1 KG per tone of rinse aid during each additional 8 hour shift and readjust the pH when necessary.

Selecting the proper inhibitive rinse aid

All two of the above Inhibitive Rinse Aids are affective for use with either iron, zinc, or manganese phosphate coatings. Chromate inhibitors generally provide the best post rust inhibition, and should be used whenever chromates can be tolerated.

HIBI SEAL – NC has the distinct advantage of being non - chromated, which is important when waste disposal problems are encountered.