Phosphate Coating Processes 347

This coating differs in structure and composition from that produced on

steel and has the characteristics of a fine grained zinc phosphate.
Another popular prepaint treatment is calcium modif ied zinc
phosphate. The coating consists of densely packed granular crystals
showing a high degree of unif ormity that create a surf ace with greatly
increased surf ace area and an intricate void pattern well-suited to provide
a high degree of mechanical lock of the organic coating to the treated
surf ace.
Amorphous Phosphate Coatings on Aluminum Surfaces
Coatings consisting mainly of aluminum and chromium (trivalent)
phosphates with traces of other elements are f ormed on aluminum alloy
surf aces by treating them with acid aqueous solutions containing
phosphorus (pentavalent), chromium (hexavalent) and fluorine. Other
elements may be present in the solutions including boron, silicon,
zirconium, titanium, etc. These coatings are characterized by a degree of
crystallinity too low to be readily detected by electron diffraction or X-
ray techniques. They are accordingly designated as amorphous.
The chemistry of f ormation of these coatings is not entirely
understood. Apparently direct oxidation of the aluminum surf ace by the
hexavalent chromium and hydrogen ion couple in the presence of the
phosphate radical leads to the formatio11 of a trivalent chromium and
aluminum phosphate layer. The role of either the fluoride or complex
fluoride seems to be one of depassivation. Suf fice it to say that very little
fluorine appears i11 the coating produced .
·1e the coatings described may be considered to be typical of
several of the types available, their structure and perf ormance may vary
with the specific chemical composition and operating conditions of the
phosphating solution as well as a variety of other factors, including the
composition of the metal being treated, its physical form and surf ace
history, its degree of cleanliness and surf ace activation, the effectiveness
of rinsing between stages, and the nature of . any seal or other post-
treatment that may be applied. The chemical compositions used to clean,
activate, phospha te, seal or post-treat are usually proprietary prod ucts
and the specific recommendations of the supplier should be f ollowed .
However certain general comments may be beneficial.
Because the metal surf ace being phosphated participates in the
chemical reaction to form the coating, the ease and unif ormity of its
ability to corrode in the reaction plays an important part in proper
coating formation. The chemical and physical nature of the extreme
outer surf ace is much more important than the same properties for the