RPS6 Iss 9 Phosphate Treatment of Ferrous Parts

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RPS6
Date
December 2009
Issue
9

PHOSPHATE TREATMENT OF
FERROUS PARTS

Approval

J E Marks

E. S. & S. MATERIALS
Referenced specifications

RPS128 RPS367 RPS386 RPS461 RPS661/15 RPS900 CSS117 AMS2480 AMS2481

DEF STAN 03-4 DEF STAN 80-34
This specification replaces Rolls-Royce Derby Engine Division Works Process Specification (WPS)
No.6 and Rolls-Royce Bristol Engine Division Technical Instructions (TN) 1002, 1004 and the
relevant part of 1077 in respect of phosphating bearing cages.
Other definitions - see RPS900
CHANGES: For information only, changes since the last issue are recorded on the last page. You
are advised not to consider these changes in isolation as other requirements of the specification
may be affected by them.

1. SCOPE

1.1 This specification covers the phosphate treatment of ferrous parts for corrosion
prevention. The phosphate coating produced provides a good key for normal low
temperature paints or for the retention of oil base corrosion preventives and with some
proprietary solutions improves the anti-scuffing properties of sliding surfaces.
Phosphating shall not be used as a base for enamels used above 300C.

Note

Where Component Definitions call up phosphating to RPS6 Appendix 2 using
Parkerising GZ, then Clause 2 Parkerising from Appendix 2 shall be used instead.

1.2 This process shall not be used on components made of steel of specified minimum
strength exceeding 1390 MPa or equivalent hardness without the prior written
agreement of the Rolls-Royce Laboratories. The requirements of DEF STAN 03-4
shall be applicable to steels in this category.

1.3 In all areas the conditions for tress relief and de-embrittlement heat treatments shall
be observed.

1.4 The operation and control of this process shall be to the requirements of RPS900.

1.5 Alternative solutions and processes may be used only with written approval from the
Rolls-Royce Laboratories.

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1.6 Where this specification is referenced on the Component Definition:

AMS2480 - Zinc Phosphate Treatment - Paint Base
or
AMS2481 - Manganese Phosphate Treatment - Antichafing

may be used as alternatives to this specification with the written agreement of the
Rolls-Royce Technical Authority.

2. CONDITION OF COMPONENTS

Components for phosphating shall be free from rust and scale.

3. PROCESS EQUIPMENT

Components shall either be placed in a rack, or on a steel hook or wire of suitable
material, ensuring that the components do not touch each other.

4. PROCESS PLANNING

4.1 Dimensions of finished parts shall be those after phosphating and before the
application of a supplementary finish, unless otherwise stated on the Component
Definition.

Some growth in dimensions will occur during phosphating and inclusion of an
allowance in the manufacturing process should be considered.

For example, phosphating using the Parco 30 solution to the requirements of Appendix
1 can produce a surface growth of 0,0025 - 0,007 mm.

4.2 Phosphate coating weight requirements depend upon the purpose for which the
coating is intended. Minimum coating weights are shown in Clause 13.4.

4.3 Where a Component Definition specifies painting of some areas to RPS661/15 and
phosphating in other areas, the processing should be carried out in that sequence.
This is to ensure that there is no phosphate under the enamel.

5. PROCESS CONTROL

5.1 Parts will be processed to work instructions which identify the technical parameters and
sequential requirements of this specification.

5.2 No Specific to Part Data Card Control is required.

5.3 Substantiation

5.3.1 New companies/facilities may be requested to substantiate their process by the

5.3.2 Records will be kept of standards agreed at substantiation for classified parts.

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5.3.3 Any change in method/equipment/materials used on classified parts will be cause for
re-substantiation and source and method change approval.

5.3.4 Periodic substantiation testing may be required of existing approved
companies/facilities as directed by the Rolls-Royce Laboratories.

5.4 Control of Solutions

Unless otherwise stated in the relevant Appendix, solutions shall be analysed and
maintained by suitable additions.

6. STRESS RELIEF

6.1 After final machining and before phosphating, steel components, shall be degreased to
RPS128 or RPS461 and stress relieved as indicated below:

Tensile Strength
Or hardness
Stress Relief
Heat Treatment
Less than 1000 Mn/m
2

Or 302 HB or 310 HV
Not required
1000 MN/m
2
or 302 HB or
310 HV up to and
including 1390 MN/m
2
or
408HB or 432 HV
*1 hour minimum
at 190C - 210C

*Note 1

The heat treatment period shall commence when the components have reached the
specified temperature.

Note 2

Where components are manufactured from a material of a tensile strength and/or
hardness range which covers both the above conditions eg 930 to 1080 MN/m
2

(268 to 321 HB) the components shall be stress relieved in accordance with the
requirements of the higher value.

6.2 Components which are tempered at less than 200C shall be referred to the

7. SURFACE PREPARATION

7.1 Parts with areas painted to RPS661/15 shall only be degreased to RPS128 prior to
phosphating.

7.2 All other components shall be degreased to RPS128 or RPS461 and unless otherwise
stated on the relevant Component Definition or operation planning sheet, may be
abrasive blasted with 120/220 mesh aluminium oxide grit to RPS386 on all surfaces
which require to be phosphated. Care must be taken to protect fine limit dimensions,
threads, blind holes and internal passages during abrasive blasting.

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8. DEGREASING

Components shall be degreased in accordance with RPS128 or RPS461.

9. MASKING

9.1 Where possible, parts shall be phosphated all over.

9.2 In cases where masking is required a medium such as approved masking media, or
any alternative approved by the Rolls-Royce Laboratories shall be applied.

Note

The maskant must be removed after the phosphate treatment.

10. PHOSPHATE TREATMENT

10.1 Parts shall be immersed in one of the solutions detailed in Appendix 1 or 2 with the
following exceptions:

(a) Parts which require an anti-scuffing surface (eg gears) shall be immersed in one
of the solutions in Appendix 3.

(b) Bearing cages shall be immersed in the solution to Appendix 5.

The relevant appendix shall be specified on the detail Component Definition or
operation planning sheet.

10.2 Parts shall be suspended in the phosphating solution, care being taken to avoid parts
entering the sediment layer, particularly with the Parkerising solutions. Hollow parts
and those containing cavities or crevices shall be arranged so that air-locks or gas
entrapment cannot occur.

10.3 On conclusion of the phosphate treatment, parts shall be washed in clean cold running
water. The rinse water shall be free from chloride ion in excess of 0,5 g/l.

10.4 Unless the components are to be given a chromate wash to Clause 11, they shall be
dried of from immersion in hot water (80C minimum). If necessary, complex
components shall be force fried in an oven or a stream of oil free hot air. Acidity of the
hot water shall never be allowed to exceed that corresponding to 0,75 ml of 0.1 N
sodium hydroxide solution per 50 ml of rinse water.

11. CHROMATE WASH

11.1 After washing in cold water to clause 10.3 all parts, except those granodised in
Appendix 5, shall be immersed in a boiling solution of 3% w/v potassium dichromate for
30 minutes.

11.2 parts shall be remove from the potassium dichromate solution then washed and dried
to Clause 10.3 and 10.4.

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1.3 As an alternative to Clause 11.1 parts may be rinsed in any of the following solutions:

(a) 15-50 gm chromic acid per 100 litres of water or

(b) 15-50 gm alkali metal chromate per 100 litres of water or

(c) 15-50 gm alkali metal dichromate per 100 litres of water or

(d) 15-50 gm 1:1 ratio chromic:phosphoric acids per 100 litres of water

The above solutions are operated at room temperature and no rinsing is required after
treatment.

12. DE-EMBRITTLEMENT

12.1 Phosphated components shall be given a de-embrittlement treatment if required, as
soon as possible and not later than 16 hours after phosphating.

12.2 Prior to de-embrittlement treatment it must be ensured that all traces of masking have
been removed and that the components are in a clean condition.

12.3 De-embrittlement shall be carried out as directed below:

Tensile Strength or Hardness De-embrittlement
Heat Treatment
Less than 1000 MN/m
2

or 302 HB or 310 HV
Not required
1000 MN/m
2
or 302 HB
or 310 HV up to and
including 1390 MN/m
2

or 408 HB or 432 HV
*1 hour minimum
at 190C - 210C

*Note 1

The heat treatment period shall commence when the components have reached the
specified temperature.

Note 2

Where components are manufactured from a material of a tensile strength and/or
hardness range which covers both the above conditions eg 930 to 1080 MN/m
2

(286 to 321 HB) the components shall be de-embrittled in accordance with the
requirements of the higher value.

12.4 Components which are tempered at less than 200C shall be referred to the

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13. INSPECTION

13.1 The phosphate coating shall be uniform and matt in appearance. There shall be no
untreated patches or flaky and uneven deposits in the treated surfaces. Phosphate
coatings showing minor variations in colour or surface texture, due to previous surface
treatments, heat treatment or degrees of cold work shall be acceptable provided they
meet all other requirements.

13.2 Any superficial powdery deposits on the surface shall be removed by light brushing or
by a method which shall not cause damage to or contaminate the main coating.

13.3 The coating shall be free from such residues of the phosphating solution as may
initiate deterioration of the supplementary finish or premature corrosion.

13.4 Except for granodising a coating weight check shall be carried out on new solutions to
the following requirements, when determined as described in Appendix 6. To maintain
the minimum required coating weight, checks will be carried out throughout the life of
the solution at the discretion of the Rolls-Royce Laboratories.

Purpose of Coating Appendix Coating Weight (g/m
2
)
Corrosion 1 Minimum 7.5
Prevention 2 Minimum 4.5
Anti-Scuff 3 Minimum 7.5
Granodising of Bearing Cages 5 No requirement.
See Appendix 5
for bath control.

14. CORROSION PREVENTION

14.1 All parts which are not to be painted shall be dipped in lanolin protective PX-1 or
corrosion preventive oil PX-4 (DEF STAN 80-34), or Rolls-Royce approved RPS367
protective oils, unless an unsealed phosphate coating is specified.

14.2 Where parts are required to be painted and the interval between phosphating and
painting exceeds 16 hours, the phosphated parts shall be kept under conditions which
preclude contamination or condensation of moisture on the surface eg closed
polythene bags containing VPI paper to CSS117.

15. REWORK OF COMPONENTS

15.1 Components may be stripped and re-phosphated once so long as there is no evidence
of attack or other deleterious effect.

15.2 Components exhibiting any such damage or require rework more than once must be
referred to the Rolls-Royce Laboratories who will determine acceptability, whether
further rework may be permissible and whether concession procedure is required for
the components.

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15.3 Components which require to be stripped of phosphate coatings may be treated
chemically to the requirements of Appendix 4 or dry abrasive blasted with alumina to
RPS386.

16. CORROSION PROTECTION

It should be noted that most metallic surfaces are susceptible to corrosion,
particularly after operations which leave the metal dry and exposed to atmospheric
conditions. It is, therefore, of the utmost importance that the protection requirements
of RPS367 shall be considered in relation to the planning and/or manufacture of
metallic parts at all stages. The foregoing instruction is not necessarily satisfied by
the provisions of any specific clause which may appear elsewhere in this
specification.

17. HEALTH, SAFETY AND THE ENVIRONMENT

There is statutory obligation to provide and maintain safe working environments and
process operations. Further information on the requirements and responsibilities is
provided in RPS900.

18. REFERENCED SPECIFICATIONS

RPS128 CLEANING AND DEGREASING USING HALOGENATED
HYDROCARBON SOLVENTS

RPS367 CORROSION PROTECTION OF COMPONENTS DURING
MANUFACTURE AND STORAGE

RPS386 ABRASIVE BLASTING

RPS461 CLEANING AND DEGREASING USING AQUEOUS MEDIA

RPS661/15 HIGH HEAT RESISTING ALUMINIUM STOVING ENAMEL TO
MSRR9029

RPS900 TECHNICAL CONTROL OF MANUFACTURING PROCESSES

CSS117 PACKAGING PAPER IMPREGNATED WITH VAPOUR PHASE
INHIBITOR

AMS2480 PHOSPHATE TREATMENT PAINT BASE

AMS2481 PHOSPHATE TREATMENT ANTICHAFING

DEF STAN 03-4 The Pre-Treatment and Protection of Steel Items of Maximum
Tensile Strength Exceeding 1450 MPa

DEF STAN 80-34 Corrosion Preventive, Oil, Thin Film Joint Service Designation:
PX-4

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APPENDIX 1

The following solutions produce manganese and/or iron phosphate coatings having a coating
weight of not less than 7,5 g/m
2
.

1. WALTERISATION MC BATH

Composition

An aqueous solution of 4% v/v PHO.MC solution. The water shall be heated to 60C
before adding the PHO.MC solution.

Operation

The solution shall be operated at 92C - 96C. The components shall be immersed in
the solution for 15 - 30 minutes.

Control

For the phosphating of active ferrous materials such as mild steel the solution may be
operated at a total acid pointage of 20 - 25 and a minimum total to free acid pointage
ratio 5:1. For less active ferrous materials such as 0.5% molybdenum - boron steel
(Fortiweld) the solution shall be operated at a total acid pointage of 28 - 30 and the
ratio to free acid will be 8:1. This latter solution composition may also be used for
active ferrous materials.

2. PARCO 30

Composition

An aqueous solution containing 6 litres Parco 30 added to every 100 litres of water.
The water shall be heated to 65C - 77C before adding the Parco 30.

Operation

The solution shall be operated at a minimum temperature of 96C.

Parts shall be immersed in the solution for 45 minutes or for the time taken for gassing
to cease whichever is the shorter.

Control

The solutions shall be maintained to the manufactures recommendations.

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APPENDIX 2

The following solutions produce a zinc phosphate and other metal phosphate coatings having,
in the case of Bonderising, a coating weight of not less than 1,6 g/m
2
and in the case of
Parkerising, a coating weight of not less than 4,3 g/m
2
. They were previously in TN1002.

1. BONDERISING

Composition

An aqueous solution of 75 kg, or 53.2 litres, of Bonderite D (IMU), made up to
1000 litres with demineralised water. Tap water may be used at the discretion of the
Rolls-Royce Laboratories where the tap water is of adequate quality such that the
integrity of the mixture is not affected.

Operation

The solution shall be operated at 82C - 88C and components shall be immersed in
the solution for 5 to 10 minutes.

Control

The solution shall be maintained according to the manufacturers instructions.

2. PARKERISING

Composition

As detailed in Clause 1 above.

Operation

The solution shall be operated at 82C - 88C and components shall be immersed in
the solution for approximately 30 minutes.

Control

The solution shall be maintained according to the manufacturers instructions.

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APPENDIX 3

The following solutions produce manganese and/or iron phosphate coatings having a coating
weight of not less than 7,5 g/m
2
and were previously in TN1004. These solutions are primarily
used to produce a coating for anti-scuffing purposes eg on gears.

1. GRANODINE 101

Composition

An aqueous solution of Granodine 101 5% v/v. The water should preferably be
demineralised.

Note

Before use the bath must be aged by the addition of 1 kg degreased steel wool per
450 litres of solution.

Operation

The solution shall be operated at 98C to 100C. The degreased parts shall be wiped
with methylated spirits, and immersed in a pre-heat tank of water at 95C minimum.
When the parts have reached the temperature of the pre-heat water, they shall be
transferred without delay to the Granodine solution and immersed for a minimum
period of 20 minutes or until the gassing ceases.

Control

The solution shall be maintained to the manufacturers recommendations.

2. PARKER GMA PROCESS

Composition

An aqueous solution prepared from 100 kg of Parco LA and 8 kg of Parco GA per
1000 litres of working solution. The water should preferably be demineralised.

Operation

The process treatment consists of immersing the components in the Parco GMA
solution at 85C to 90C for a period of 15 to 30 minutes to convert the metal surface
to a uniform coating.

Control

The solutions shall be maintained to the manufacturers recommendations.

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3. PARCO LUBRITE 8

Composition

An aqueous solution of 100 kg (75 litres) of Parco Lubrite 8A and 31 kg (25 litres) of
Parco Lubrite 8B per 1000 litres of solution. The water should be preferable
demineralised.

Note

Before use the bath must be aged by the addition of 2 kg of degreased steel wool or
scrap iron per 1000 litres of solution.

Operation

The solution shall be operated at 95C to 98C. Parts shall be immersed in the
solution for approximately 10 - 25 minutes, ie until cessation of gassing.

Control


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APPENDIX 4

STRIPPING OF PHOSPHATE COATINGS

Solution A

Composition

This is an aqueous solution containing:

Hydrochloric Acid (HCl) 158 g/l

Inhibitor Armohib 28 2.5 ml/l

Operation

The solution is operated at room temperature.

Control

The solution shall be replaced when it is no longer effective.

Note

Due to the difficulty of removing traces of deposition antimony, and the potentially serious effect
of such deposits upon the substrate material together with the potential for cross-contamination,
it is essential that inhibitors containing antimony salts shall not be used in associated with any
of the solutions covered by this specification.

Solution B

Chromium Trioxide (Chromic Acid) 80 - 120 g/l

Operation

The solution is operated at 90C - 95C. Immerse the parts until the phosphate coating has
dissolved.

Control

The solution shall be analysed and maintained by additions of chromic acid.

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APPENDIX 5

GRANODISING OF STEEL BEARING CAGES

This appendix replaces the method specified in TN1077

GRANODINE (GRADE 101)

Composition

An aqueous solution of 1 part by volume of Granodine (Grade 101) to 9 parts by volume of
water. The water should preferably be demineralised.

Determine the strength of the solution and adjust to 10% v/v if necessary (see control below).

Operation

The solution shall be operated at boiling point.

Parts shall be immersed in the solution for 5 to 10 minutes.

Parts shall be visually examined without washing. The phosphate coating be uniform dark grey
all over. If necessary the parts shall be repositioned and re-immersed in the solution for a
further 5 to 10 minutes.

Control


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APPENDIX 6

METHOD FOR DETERMINATION OF PHOSPHATE COATING WEIGHT

Note

The coating weight shall be determined on a sample part or on a test piece of similar material
as the parts treated, after phosphating, washing and drying and before any heat treatment and
sealing.

Stripping Solution

Composition
Chromium Trioxide 100 g/l (nominal)

Procedure

A convenient surface area for the determination of coating weight is 100 cm
2
. Weigh the part
or test piece and immerse in an un-used sample of the chromic acid solution, maintained at
90C - 95C, until the phosphate coating has dissolved (usually 5 - 10 minutes is sufficient).
Remove from the solution and thoroughly wash in clean water until all traces of treatment
solution have been removed. Wipe off any non-adherent matter with a wet swab of cotton
wool. Dry thoroughly and re-weigh.

Calculation

Weight of phosphate coating (g/m
2
) W/A

Where W = Loss in weight of part in grammes
A = Surface area in square metres

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CHANGES FROM PREVIOUS ISSUE

Appendix 7 moved to Clauses 16 and 17

All the Suppliers addresses have been deleted from the specification.

PAGE 1 Referenced Specifications AMS2480 AMS2481 added.

PAGE 2 Clause 1.6 added.

PAGE 7 Clause 18 added.

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