PT Process General Training Document

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
6/23/2023 Chemetall India - Atul Karpe

2
Agenda
Cleaners
Activation
Conversion Coating
Passivation

6/23/2023 Chemetall India - Atul Karpe

3
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.
6/23/2023 Chemetall India - Atul

4
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
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

6
General Process Sequence
 Pretreatment Process Sequence in OEM
Zinc-
Phosphate Rinse‘s Passivate (optional)
DIW-
Clean Rinse‘s Activate Rinse‘s

7
Agenda

Cleaners
Activation
Conversion Coating
Passivation

Oxsilan® - Mechanism and Properties Oxsilan® -
Various Aspects

8
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)

9
Parameters for Cleaning Performance

1
Cleaner – Types
 Solvent
 Emulsion
 Neutral
 Acidic
 Alkaline
Emulsifying
De - Emulsifying

1
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.
Low Foaming tendency. Emulsified Demulsified
System System
Less Carry over of Oil in following stages.
Save Cost.

1
Agenda

Cleaners
Activation
Conversion Coating
Passivation

Various Aspects

1
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.

1
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.

1
Activation – New
 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

1
Activation – New
Field experience on difficult to treat CRS substrate

90 sec. 120 sec. 180 sec.
Traditional Zinc Phosphate
Gardo®Flex
structure
1
Agenda

Cleaners
Activation
Conversion Coating
Passivation


2
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 drawing,
Multimetal cold extrusion, rust proofing.
Steel and Paint bonding (less severe service

2 Iron Phosphate conditions), cold forming.
Multimetal
Lubrication, oil retention, corrosion proofing of
3. Manganese Phosphate Steel moving metal parts
4. Chromate / Zr / Ti Al, Zn, Mg Paint Bonding, Corrosion resistance.
5. Thin Film Coatings Multimetal Paint bonding, corrosion resistance

2
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.

2
Agenda

Cleaners
Activation
Conversion Coating
Passivation


2
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

2
SEALING OF PHOSPHATE COATING TO IMPROVE CORROSION RESISTANCE

2
Agenda

Cleaners
Activation
Conversion Coating
Passivation



2
Agenda

Cleaners
Activation
Conversion Coating
Passivation



2
Evolution in Multi-Metal Pretreatment
Safety Health and Environment
Safety labelling acc. to GHS
Chrome-VI Chrome-III Tri-cation Iron

Zn-Ph Phosphate

2
Customer Needs……..
…in a continuously changing environment

3
*R&D project
3 6/23/2023 Chemetall India - Atul

Further layer Further Layer Further Layer

Further Layer
E-Coat E-Coat
Substrate E-Coat Substrate
Substrate Substrate
Thickness 1 – 2 µm
Thickness 0,8 – 1,5 µm Thickness 0,1 – 0,25 µm Thickness 10 – 15 µm

3
 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 for Paint Chemical Anchor
Film and Morphology
OH
Si N Paint Adhesion
H2 O O
Passivation C Si Si
Zr C
O O O O O
x O
Me Me Zr Si
O O O MeOtal O O O

3
Oxsilan System – Various Aspects
From Zinc Phosphate…….
Zinc- Passivate
Clean Rinse Activate Phosphate Rinse DIW-Rinse
(optional)
Safety labelling acc. to GHS
Sludge formation
Zn-Ph 3 - 15 g /
m²
Oxsilan® < 0,2 g /
……to OXSILAN-Technology
Energy and water costs
consumption Multi-Metal compatible (more Aluminium)
Safety
Waste water
labelling Toxic heavy metal ions
and sludge Corrosion protection and paint adhesion
generation Product consumption
Process
Plant invest
Clean Rinse DIW-Rinse OXSILAN® DIW- Rinse

33 6/23/2023 Chemetall India - Atul Karpe
Agenda

Cleaners
Activation
Conversion Coating
Passivation

Various Aspects

3
Ensure Best
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 ….

3
Ensure Best
Other
Influences
Chemical (e.g. substrate) !
Parameters
Optimal
Performance
Coating
meets all
Weight*
Specification
Process
Parameter

3
Evolution in Multi-Metal
Low Temp
Low Temp Aluminium
Alumunium Ecology
Low Temp
Ecology 2 in 1
Established Aluminium
standard
*R&D project
40 6/23/2023 Chemetall India - Atul Karpe

C641/h2e3m/2e0t2a3ll India - Atul Karpe

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Pretreatment Systems

General Training Document

Friday 15th June 23

 Evolution in Multi-Metal Pretreatment

6/23/2023 Chemetall India - Atul Karpe

 Evolution in Multi-Metal Pretreatment

6/23/2023 Chemetall India - Atul Karpe

 To Promote Adhesion of Organic Coating

–Use of Rust Prevention Oil.

6/23/2023 Chemetall India - Atul

6/23/2023 Chemetall India - Atul

 Non Paint Bonding Category

6/23/2023 Chemetall India - Atul

 Pretreatment Process Sequence in OEM

6/23/2023 Chemetall India - Atul

 Function of Various Stages

 Evolution in Multi-Metal Pretreatment

6/23/2023 Chemetall India - Atul

 To remove all Kinds of Surface Contaminants

corrosion layers and others)

 Make the surface wettable by Water

 Prepare the surface for following treatment step

6/23/2023 Chemetall India - Atul

6/23/2023 Chemetall India - Atul

6/23/2023 Chemetall India - Atul

6/23/2023 Chemetall India - Atul

 Function of Various Stages

 Evolution in Multi-Metal Pretreatment

6/23/2023 Chemetall India - Atul

Activation prior to Zinc Phosphate Conversion coating is

Titanium Phosphate based Activation chemicals are used as

6/23/2023 Chemetall India - Atul

Controlling Crystal Size

Reducing Inter crystalline gaps.

Controlling Coating Weight.

Conversion Coating without Conversion Coating with

Crystal Size – 10 µm Crystal Size – 1 µm

 Which results ultimate improvement in corrosion resistance property.

6/23/2023 Chemetall India - Atul

 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

6/23/2023 Chemetall India - Atul

Field experience on difficult to treat CRS substrate

Traditional Zinc Phosphate

 Function of Various Stages

 Evolution in Multi-Metal Pretreatment

6/23/2023 Chemetall India - Atul

 Types of Conversion Coatings

Paint bonding, corrosion resistance (severe

Steel and Paint bonding (less severe service

4. Chromate / Zr / Ti Al, Zn, Mg Paint Bonding, Corrosion resistance.

5. Thin Film Coatings Multimetal Paint bonding, corrosion resistance

6/23/2023 Chemetall India - Atul

 Advantages of Tri cation Zinc Phosphate….

High ASR – give maximum corrosion protection.

Optimum Crystal morphology.

High bath Stability.

Suitable for all types of Organic Coatings.