Conversion coatings

Phosphate coatings
• Treatment of Fe, Steel, GI steel sheet, Al with dil.
Solution of phosphoric acid & other chemicals
• After chemical reacts surface of metal is
converted to
– an integral,
– mildly protective layer of insoluble crystalline
phosphate
• Weight , crystalline structure & extent of
penetration of coating in base can be controlled
– Cleaning method before treatment
– Use of activating rinses containing Ti , compounds
– Method of applying solution
– Temperature, concentration, duration of treatment
– Modification of composition of phosphate bath
 Types of Phosphate coatings
• Zinc phosphate coating

• Iron phosphate coating

• Manganese phosphate coating

 Process steps
• Cleaning
– Chemical or Mechanical, Caustic= 8 – 10%,
phosphate 4 – 5 %,soda ash 3 – 5, detergent 8 - 10
• Rinsing
– Water 70 to 80 C, immersion / spray (70 – 140 kPa)
• Phosphate
• Rinsing
• Chromic acid rinsing
• Immersion – Zn, Fe, Mn
• For racked parts, small parts
• Springs, washers, clips, screws,
• Pump bodies with inaccessible areas
• Heavier coatings
• Spray- Zn, Fe
• Panels for household applications
• Mass production
• Lighter coatings
• Faster rate of coating
 Rinsing
• Rinsing in water to remove chemicals
• Otherwise cause corrosion of parts or
blistering of film
• Chromic acid rinsing- applied to enhance
corrosion resistance
 Equipments for immersion
• Tanks,
• Temperature and solution level controllers
• Overflow and drainage system
• Vapor exhaust system
• Material handling devices
 Temperature
• Operating Temperature 30 -100 C
• Low temperature – thin coating , non
existence
• High temperature – coating builds up
excessively
• Nonadherent, powdery surface
• Sludge and scale produced
 Zinc phosphate coating
• Wide range of weights & crystal characteristics
ranging from heavy films with coarse crystals to
ultrathin microcrystalline deposits
• Color from light to gray
• Coatings are darker
– as % C of underlying substrate increases,
– Fe content of coating increases,
– heavy metal ions are incorporated in phosphate
solution
 Application
• Immersion
– 1.61 to 43 gsm
• Spray
– 1.08 to 10.8 gsm
• Combination of both
 Applications
• Base for paint , Steel, GI, Al stamping for
automobiles, house hold applicatons
• Aid in cold forming
• Tube drawing and wire drawing
– Increases wear resistance
– Rust proofing
 Iron phosphate coating
• Alkali metal phosphate solution
• pH 4 to 5
• Fine crystals
• Amorphous coating consisting of iron oxides
• Phosphate salt – 12 to 15%, phophoric acid- 3
to 4%, Molybdate accelerator – 0.25 to 0.5 %,
detergent - 8 to 10%,
• Base for subsequent films of paint
• Excellent adherence
• Good resistance to flaking
• Corrosion resistance less than zinc
• Operating temperature – 25 to 65 ⁰ C
 Manganese phosphate coating

• Color dark gray

• For ferrous parts – bearings, gears, I/C engine
parts to prevent galling
• Applied by immersion
• Coating weight = 5.61 to 33 gsm
• Temperature = 90 - 95⁰ C
 Applications
• Corrosion protection
– Physical barrier
– Depends upon uniformity of coating coverage
– Thickness, density, crystal size and final seal
 Helps in forming steel
• Acts as lubricant
– Reduces friction
– Increases speed of drawing operation
– Reduces power consumption
– Increases life of tools and dies
– Drawing seamless steel tubes
 Inspection
• Visual inspection
• coating continuity
• Adhesion
• Crystalline structure
• Coating weight
 Anodizing
• Conversion coating of the surface of Al and its
alloys to porous aluminum oxide
• Different electrolytes
• Varying concentration, composition
• Temperature
• Voltage
• Current
 Purpose of anodizing
• Increase
– Corrosion resistance
– Abrasion resistance
– Paint adhesion
• Improve
– Decorative appearnce
– Lubricity
– Adhesive bonding
• Provide
– Unique decorative colors
– Electrical insulation
– Permit subsequent painting
 Anodizing
• Producing decorative and protective films on
articles of Al & its alloys
• Article is anode
• Cathode- SS, Pt
 Anodizing process
• Chromic process – electrolyte is chromic acid
• Sulfuric process – electrolyte is sulfuric acid
• Hard anodizing process – electrolyte is sulfuric
acid (with or without additive)
 Surface preparation
• Vapor degreasing
• Solvent cleaning
• Alkaline soak cleaning
 Chromic acid process
• Less corrosive than sulfuric
• Preferred for riveted or welded parts where it
is difficult to remove all anodizing solution
• 3-10 wt.% of chromic acid and balance water
• pH between 0.5 to 1.0
• Concentration of chloride is less than 0.02% &
sulfate less than 0.05%
• Total chromic acid content is less than 10 %
• Voltage is controlled from 0 to 40 V
• Voltage is regulated to produce current density
more than 1 A/ft2
• Anodizing time 30 to 40 min
• At the end of cycle current is gradually reduced
to zero
• Parts quickly removed , rinsed and sealed
• Minimum coating weight before sealing – 200
mg/ft2
 Sulfuric Acid process
• Conc. 12 to 20 wt.%
• Voltage is adjusted to obtain current density
of 9 to 15 A/ft2
• Not for assemblies that contain joints/recess
that could entrap electrolyte
• Bath temperature 20- 25⁰C
 Hard Anodizing
• Difference in operating temperature (0- 10)⁰C
• Sulfuric acid – 30-50 g/L
• Additive agents - Oxalic acid 3 -5 g/L
• Voltage – 40 to 60 V
• Current density – 25 to 36 A/ft2
• Produces heavier coating
• Time – 1 min/ µm of coating
 Equipment and process control
• Chromic acid bath
– Low carbon steel tank with glass lining
– Provision of heating (32- 35)⁰C
– Agitation facility
– Exhaust facility
 Sulfuric acid bath
• Low carbon steel tank with lining of plasticized PVC
& coated on the outside with corrosion resistant
synthetic rubber paint
• Provision of heating (20- 30)⁰C
• Agitation facility
• Exhaust facility
 Hard anodizing
• Low carbon steel tank with lining of plasticized PVC
& coated on the outside with corrosion resistant
synthetic rubber paint
• Provision of heating (0- 10)⁰C
• Agitation facility
• Exhaust facility
 Color anodizing
• Impregnation of pores
• Organic
• Inorganic coloring material
 Evaluation
• Coating thickness
• Abrasion resistance
• Effectiveness of sealing – SO2 method
comprises exposure of the anodic coating for
24 hr to attack by moist air containing 0.5 to 2
vol.% of SO2. Coating that are incompletely or
poorly sealed develop a white bloom
 Other Metals and alloys
• Mg anodizing – Optical components, heat
sinks in electronic applications
• Ti anodizing – To improve wear , corrosion for
dental, medical applications
• Zinc anodizing – For optimum corrosion
resistance
 Chromate conversion coating
• Aqueous solution of chromic acid,
• chromium salt such as sodium or potassium
chromate /dichromate
• Hydrofluoric acid/ salt
• Phosphoric acid or mineral acid
• Chemical attack causes dissolution of some
surface and formation of protective surface
containing complex chromium compounds
• Increases corrosion resistance
• Better in marine and humid atmosphere
• Decorative purpose
• Fluoride containing chromate bath increases
thickness by 30 times
• Chromium content increases by 4 times
• Green treatment
• Gold treatment
• Green treatment
– Mixture of chromic, phosphoric and HF acid
– Coating 5 – 10 mg/ft2 (color less ) to 500 mg/ft2
( green)
– Sludging due to precipitation of Na3AlF6 &
Na2K2AlF2
• Gold treatment
– Chromic acid, fluoride ion source
– Coating weight 5 – 80 mg/ft2 from light color to
golden
– Corrosion resistance can be enhanced by adding
ferricynide
 Applications
• Al parts
– Aircraft/ aerospace structural parts
– Heat exchangers
– Window, door frame
For Mg, Cd, Zn
Hexavalent Cr is toxic