Pretreatment Systems
General Training Document
Friday 15th June 23
Agenda
◼ Pretreatment Concept and General Sequence
◼ Function of Various Stages
Cleaners
Activation
Conversion Coating
Passivation
◼ Evolution in Multi-Metal Pretreatment
Safety Health and Environmental
Coating Characteristics
Oxsilan® - Mechanism and Properties
Oxsilan® - Various Aspects
◼ Ensure Best Results
2 6/23/2023 Chemetall India - Atul Karpe
Agenda
◼ Pretreatment Concept and General Sequence
◼ Function of Various Stages
Cleaners
Activation
Conversion Coating
Passivation
◼ Evolution in Multi-Metal Pretreatment
Safety Health and Environmental
Coating Characteristics
Oxsilan® - Mechanism and Properties
Oxsilan® - Various Aspects
◼ Ensure Best Results
3 6/23/2023 Chemetall India - Atul Karpe
Pretreatment Concept and General Sequence
Purpose
◼ To Promote Adhesion of Organic Coating
◼ To Improve Corrosion Resistance
–Use of Rust Prevention Oil.
–Conversion Coating + Oiling.
–Conversion Coating + Painting.
–Electroplating.
–Galvanising.
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Pretreatment Concept and General Sequence
Types of Conversion Coatings
◼ Conversion coatings are coatings for metals where, the part
surface is converted into the coating with a chemical or electro-
chemical process.
Chromate Conversion Coatings
Phosphate Conversion Coatings
Thin Film Conversion Coatings
Anodizing
Bluing
……..
……..
5 6/23/2023 Chemetall India - Atul Karpe
Pretreatment Concept and General Sequence
Application of Pretreatment
◼ Paint Bonding Category
Automotive
Auto Ancillary
White Goods
General Engineering
Coil Coating.
◼ Non Paint Bonding Category
Wire Drawing
Tube Drawing
Cold Extrusion and Cold Forging
Cold Heading
Rust Proofing
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Pretreatment Concept and General Sequence
General Process Sequence
◼ Pretreatment Process Sequence in OEM
Zinc- Passivate DIW-
Clean Rinse‘s Activate Phosphate Rinse‘s (optional) Rinse‘s
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Agenda
◼ Pretreatment Concept and General Sequence
◼ Function of Various Stages
Cleaners
Activation
Conversion Coating
Passivation
◼ Evolution in Multi-Metal Pretreatment
Safety Health and Environmental
Coating Characteristics
Oxsilan® - Mechanism and Properties
Oxsilan® - Various Aspects
◼ Ensure Best Results
8 6/23/2023 Chemetall India - Atul Karpe
Functions of Various Stages
Cleaning
◼ To remove all Kinds of Surface Contaminants
(forming oils, lubricants, conversion coatings, salt residue, smut, particles,
corrosion layers and others)
◼ Make the surface wettable by Water
◼ Prepare the surface for following treatment step
(Conversion coating , Painting, storage and others)
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Functions of Various Stages
Parameters for Cleaning Performance
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Functions of Various Stages
Cleaner – Types
◼ Solvent
◼ Emulsion
◼ Neutral
◼ Acidic
◼ Alkaline
Emulsifying
De - Emulsifying
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Functions of Various Stages
De – Emulsifying Cleaning System
◼ This technique helps to prolong lifetime of
degreasing baths on a economic and environmental
sound way.
◼ With Demulsify system + Suparator®, the separated
concentrates contains ~ 95% of oil, where as in UF
concentrates only about 50% of Oil.
◼ This technique helps to reduce Oil concentration in
Cleaning bath, which results in …
Better Cleaning efficiency.
Emulsified Demulsified
Low Foaming tendency. System System
Less Carry over of Oil in following stages.
Save Cost.
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Agenda
◼ Pretreatment Concept and General Sequence
◼ Function of Various Stages
Cleaners
Activation
Conversion Coating
Passivation
◼ Evolution in Multi-Metal Pretreatment
Safety Health and Environmental
Coating Characteristics
Oxsilan® - Mechanism and Properties
Oxsilan® - Various Aspects
◼ Ensure Best Results
14 6/23/2023 Chemetall India - Atul Karpe
Functions of Various Stages
Activation
◼Activation prior to Zinc Phosphate Conversion coating is
essential in order to get compact and uniform coating.
◼Titanium Phosphate based Activation chemicals are used
as conventional activators.
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Functions of Various Stages
Activation - Function
◼ Activation acts as nucleus for uniform, compact crystal growth by….
Controlling Crystal Size
Reducing Inter crystalline gaps.
Controlling Coating Weight.
Conversion Coating without Conversion Coating with
Activation Treatment – Activation Treatment –
Crystal Size – 10 µm Crystal Size – 1 µm
◼ Which results ultimate improvement in corrosion resistance property.
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Functions of Various Stages
Activation – New Generation
◼ Extended Bath Life Less Waste Water
◼ Reduced minimum phosphate time higher process robustness
◼ Low temperature process Energy Saving
◼ Aluminum: Less Sludge Less maintenance and disposal
◼ No limitation in Aluminum throughput More Flexibility
◼ More compact coating better corrosion resistance
◼ Low chemical consumption Cost Saving
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Functions of Various Stages
Activation – New Generation
Field experience on difficult to treat CRS substrate
90 sec. 120 sec. 180 sec.
Traditional
Zinc Phosphate
Gardo®Flex
Improvement in minimum phosphating time and crystal structure
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Agenda
◼ Pretreatment Concept and General Sequence
◼ Function of Various Stages
Cleaners
Activation
Conversion Coating
Passivation
◼ Evolution in Multi-Metal Pretreatment
Safety Health and Environmental
Coating Characteristics
Oxsilan® - Mechanism and Properties
Oxsilan® - Various Aspects
◼ Ensure Best Results
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Functions of Various Stages
Conversion Coating – Phosphate / Chromates
◼ Phosphating / Chromatings are more commonly used Chemical Conversion Coatings.
◼ Types of Conversion Coatings
Sr.
Type Substrate Application
No.
Paint bonding, corrosion resistance (severe
Steel and
1 Zinc Phosphate service conditions) wire drawing, tube
Multimetal drawing, cold extrusion, rust proofing.
Steel and Paint bonding (less severe service
2 Iron Phosphate conditions), cold forming.
Multimetal
Lubrication, oil retention, corrosion proofing
3. Manganese Phosphate Steel of moving metal parts
4. Chromate / Zr / Ti Al, Zn, Mg Paint Bonding, Corrosion resistance.
5. Thin Film Coatings Multimetal Paint bonding, corrosion resistance
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Functions of Various Stages
Conversion Coating – Zinc Phosphate
◼ Tri cation phosphate is used as conversion coating in Automotive and Auto Ancillary,
and it consists of three cations namely…
Zinc
Nickel
Manganese
◼ Advantages of Tri cation Zinc Phosphate….
Complete Coverage
High ASR – give maximum corrosion protection.
Optimum Crystal morphology.
High bath Stability.
Suitable for all types of Organic Coatings.
22 6/23/2023 Chemetall India - Atul Karpe
Agenda
◼ Pretreatment Concept and General Sequence
◼ Function of Various Stages
Cleaners
Activation
Conversion Coating
Passivation
◼ Evolution in Multi-Metal Pretreatment
Safety Health and Environmental
Coating Characteristics
Oxsilan® - Mechanism and Properties
Oxsilan® - Various Aspects
◼ Ensure Best Results
24 6/23/2023 Chemetall India - Atul Karpe
Functions of Various Stages
Passivation
◼ To improve corrosion Resistance
◼ To dissolve excessive secondary crystals
◼ To reform defective phosphate coating (Blue coating) caused by
inconsistent treatment conditions
◼ To improve wet adhesion of alloy galvanized surface.
BLOCKING BY
CHROMIUM /
ZIRCONIUM
BASE METAL
PHOSPHATE CRYSTAL
INTERCRYSTALLINE FISSURES
SEALING OF PHOSPHATE COATING TO IMPROVE CORROSION RESISTANCE
25 6/23/2023 Chemetall India - Atul Karpe
Agenda
◼ Pretreatment Concept and General Sequence
◼ Function of Various Stages
Cleaners
Activation
Conversion Coating
Passivation
◼ Evolution in Multi-Metal Pretreatment
Safety Health and Environmental
Coating Characteristics
Oxsilan® - Mechanism and Properties
Oxsilan® - Various Aspects
◼ Ensure Best Results
26 6/23/2023 Chemetall India - Atul Karpe
Agenda
◼ Pretreatment Concept and General Sequence
◼ Function of Various Stages
Cleaners
Activation
Conversion Coating
Passivation
◼ Evolution in Multi-Metal Pretreatment
Safety Health and Environmental
Coating Characteristics
Oxsilan® - Mechanism and Properties
Oxsilan® - Various Aspects
◼ Ensure Best Results
27 6/23/2023 Chemetall India - Atul Karpe
Evolution in Multi-Metal Pretreatment
Safety Health and Environment
Safety labelling acc. to GHS
Chrome-VI Chrome-III Tri-cation Iron
Zn-Ph Phosphate
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Customer Needs……..
…in a continuously changing environment
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Evolution in Multi-Metal Pretreatment
*R&D project
Development towards efficiency and ecology
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Evolution in Multi-Metal Pretreatment
Coating Characteristics
Further layer Further Layer Further Layer
Further Layer
E-Coat E-Coat E-Coat
Substrate Substrate Substrate Substrate
Thickness 1 – 2 µm Thickness 0,8 – 1,5 µm Thickness 0,1 – 0,25 µm Thickness 10 – 15 µm
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Evolution in Multi-Metal Pretreatment
Oxsilan® - Mechanism and Properties
◼ Passivation ◼ Chemical Anchor
⚫ Reduced reactivity of metal surface ⚫ Reactive / polar groups
⚫ Less reaction with water and oxygen to better bonding of the paint
◼ Dense Stable Film ◼ Morphology
⚫ Reduced permeation ⚫ Amorphous surface
of water and oxygen for better anchoring of the paint
Chemical Anchor
Dense Stable Film for Paint Chemical Anchor
and Morphology
OH
Si N Paint Adhesion
H2 O O
C
Passivation Zr Si Si
C
O O O O O O
x
Me Me Zr Si
O O O Metal
O O O O
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Evolution in Multi-Metal Pretreatment
Oxsilan System – Various Aspects
From Zinc Phosphate…….
Zinc- Passivate
Clean Rinse Activate Phosphate Rinse DIW-Rinse
(optional)
Safety labelling Energy and water consumption
acc. to GHS Waste water and sludge generation
Process costs
Multi-Metal compatible (more Aluminium)
Toxic heavy metal ions
Sludge formation
Zn-Ph 3 - 15 g / m² Corrosion protection and paint adhesion
Oxsilan® < 0,2 g / m²
(sludge-free if no CRS/HRS)
Product consumption
……to OXSILAN-Technology Plant invest
Clean Rinse DIW-Rinse OXSILAN® DIW- Rinse
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Agenda
◼ Pretreatment Concept and General Sequence
◼ Function of Various Stages
Cleaners
Activation
Conversion Coating
Passivation
◼ Evolution in Multi-Metal Pretreatment
Safety Health and Environmental
Coating Characteristics
Oxsilan® - Mechanism and Properties
Oxsilan® - Various Aspects
◼ Ensure Best Results
34 6/23/2023 Chemetall India - Atul Karpe
Ensure Best Results
Suitable Cleaner - wettability / pH /
Contaminants / optimum
concentrations
Chemical Activation – pH / Aging / Water Quality
Parameters Conversion Stage – all Key Parameters Zn / Ni /
Mn / NO2 / pH / Conductivity /
Zr / Si / F / Cu ……
Conditioning of Rinses / Control on Microorganism
Optimum Circulation / Spray Pattern / Filtration System.
Plant Maintenance / transfer time / Nozzle orientation
Process Dosing Equipment / Pressure / Temperature
Parameter Bath Level / Functioning of Cascading System etc……
…..A Good Equipment Design ….
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Ensure Best Results
Other
Influences
Chemical (e.g. substrate) !
Parameters
Optimal Performance
Coating meets all
Weight* Specification
Process
Parameter
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Evolution in Multi-Metal Pretreatment
Low Temp
Low Temp Aluminium
Alumunium Ecology
Low Temp
Ecology 2 in 1
Established Aluminium
standard
*R&D project
Development towards efficiency and ecology
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Chemetall India - Atul Karpe
6/23/2023
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