phosphating and painting

by
p. Jayaraman
r.v. Prakash

Iron Ore
(Iron Oxide)
Iron and
Steel
Casting
Steel and
Ferro
Alloys
Melting
Process

topics
Session one

Corrosion formation
Surface preparation



Session two

Corrosion prevention

- Phosphating
- Nickel plating
- Hard Chrome
Plating
- ENP
- Metallising
- Painting





to prevent

CORROSION
&
ERROSION
Corrosion loss
Corrosion loss calculated app.500 Billions.
In India calculated around 36000 Crores.

[ Direct losses
Replacement of corroded materials, use of
more corrosion resistance materials, use of
coatings and inhibitors.

[ Indirect losses

Shut down
Loss of product
Loss of efficiency
Contamination of product
Over Design



Corrosion Loss
In most of the cases, indirect losses are
substantial part of the corrosion cost.

Sometimes, due to corrosion of critical
part, may result in the loss of human
life which is very serious.
Theory
4 Corrosion may be defined as the dissolution
or oxidation of a metal due to interaction
with the environment.

4 Example:
Rusting of iron
Discolouration or tarnishing of copper


TYPES OF CORROSION
A. Direct Oxidation
B. Atmospheric
Corrosion
C. Electro Chemical
Corrosion
D. Galvanic
Corrosion
E. Bacterial
Corrosion
F. Stress Corrosion
G. Corrosion
resulting from
differential
aeration.
(O2 deficiency)

TYPES OF CORROSION
4 Atmospheric Corrosion:

4 This Corrosion will occur when metal
directly contacts with atmosphere.

4 Electrochemical Corrosion:

4 This Corrosion will occur due difference the
emf valves of steel and contact substance.


TYPES OF CORROSION
4 Stress Corrosion:

4 This Corrosion will occur due to more
stress when two metal directly contacts with
each other.
(e.g. Bolt , screw fitting)


606934 10x8 CS valve
Selection of soil preparation
mechanical

Hand cleaning
Power Tool
cleaning
Flame cleaning
Abrasive
cleaning
chemical

solvent wiping
Degreasing
Pickling
Electrolytic
cleaning


ABRASIVE CLEANING
4 Grits, shots, sand, Garnets are
used in abrasive cleaning.
4 Pressurised abrasive will release
from the nozzle which will come
and hit the surface.
4 This continuous hits will create
anchor profile.
Blasting Standard
SURFACE PREPARATION STANDARDS
S.No. QUALITY NACE SSPC
SIS (ISO
850
1-1)
REMARKS
1
White Metal Blast
Cleaning
No. 1 SP-5 Sa 3
When viewed without magnification, the surface shall be free from
millscale, rust, paint coatings and foreign matter.
2
Near White Blast
Cleaning
No.2 SP-10 Sa2 1/2
When viewed without magnification, the surface shall be free
from millscale, rust, paint coatings and foreign matter,
except for staining as noted below.
Random stainging sall be limited to no more than 5% of
each unit area of surface as defined in section 2.6 and
may consist of light shadows, slight streaks, or rust
stains of mill scale, or stains of previously applied
coating
3
Commercial Blast
Cleaning
No.3 SP-6 Sa 2
When viewed without magnification, the surface shall be free from
visible oil, grease and dirt, and from most of the millscale, rust,
paint coatings and foreign matter. Any residual contamination
shall be firmly adhering.
4 Brush-off Blast Cleaning No. 4 SP-7 Sa 1 Light Blast cleaning
5 Solvent Cleaning SP-1 Cleaning the substrate by solvent
6 Hand Tool Cleaning SP-2 St2 Through hand and power tool cleaning
7 Power Tool Cleaning SP-3 St3 Very through hand and power tool cleaning
9
Mineral and Slag
Abrasives
AB-1
Key Points to Check


4 Nozzle
4 Pressure
4 Moisture free air
4 Temperature of air
Blasting Profile
CORROSION PREVENTION
4 OILING

4 PHOSPHATING

4 ACID PICKLING

4 PLATING

4 PAINTING
PHOSPHATING
Degreasing
Rinse
De-Rusting
Rinse
Refiner/
Pre-dipping
Phosphating
Rinse
Organic
coating
DEGREASING
4 Step-1 :
the degreasing part will attack the oil
surface.
4 Step-2 :
the degreasing part will reduce the
contact angle between the oil and surface.
4 Step-3 :
the oil completely removed from the
surface
DEGREASING

Stage I
Stage II
Stage III
















Degrease chemical
CHECK
Total alkalinity
Free alkalinity
Oil content (emulsified)
Water Rinse





Enough water rinse is required to
remove alkali carry over.

General requirement is 4-7 times
of dilution is required.

De-rusting





4 to remove loose rust (iron oxides )
4 to remove loose carbon particles
CHECK
1. Acidity
2. Iron Content
Water Rinse





Enough water rinse is required to
remove acid carry over.

pH shall be always 7.0.

PRE-DIP / REFINER





4 Pre-dip is a two pack system.
4 One is water softener
4 Another one is activator

PRE-DIP / REFINER





4 Activator:

Activator will create active centers
More active centers will control Coating
thickness and Crystal size

PRE-DIP / REFINER




Activator Function:


Without Activation
With Activation
(No Secondary
Phosphate Observed)
Active Centre
Secondary PO
4
2+


CHECK
No Direct Checking for bath content
pH
Alkalinity
Bath frequency will be changed
based on Coating Weight
Phosphating



4 Zinc phosphate

4 Manganese phosphate

4 Cold Zinc Phosphate




Zinc Phosphate


4 etching:
Phosphoric acid attack on the substrate
4 deposition:
Zinc phosphate deposited on the substrate
4 completion:
Iron Phosphate sludge formation



Mechanism of Phosphate



4 etching / primary reaction:
Fe
2+
+ 2H
3
PO
4
Fe(H
2
PO
4
) + H
2
^

4 deposition / secondary reaction:
Fe(H
2
PO
4
)
2

Fe(HPO
4
) + Fe
2
PO
4
+

4 completion / tertiary reaction:
3FePO
4

Fe
3
(PO
4
)
3
+ H
3
PO
4




CHECK
Total Acidity
Free Acidity
Iron Content
Toner level for Zinc Phosphate
Coating Weight
Sludge Visual Check
Rinses

Rinse 1: D.M Water Rinse to
remove excess
acidity

Rinse 2: D.M Water Rinse







OILING

After D.M. water rinse the
component shall be dipped in
dewatering oil, to remove water
from the component.







Machined Plug
Cold Phosphating






Cold Phosphated Body
7- Tank Hot Phosphating
Hot Zinc Phosphated Component
Mn Phosphate with LoMU
Tectyl-506 oiled component
Hot Zinc Phosphated with RP Oil
PHOSPHATING
DEFECTS
Patchy Coating
Rough Coating



defects counter measure
Patchy Coating

1. After degreasing
water Breaks
should be checked.
2. Iron content in
the bath should be
checked.

Roughness
Coating
1. Bath
Concentration
should be checked.
2. Running time
should be checked.

Inspection

4 Visual Inspection.
4 Coating Colour
4 Coating Weight
4 Coating Thickness
4 Salt Spray test
490-120 Hrs. for Mn Phosphate
472 Hrs. for Zn Phosphate



PAINTING

4 What is meant by paint?
Paint is a homogeneous
mixture of rinse in which
solid particles are blended
PAINT
4 Paint normally contains

Binder
Pigment
Solvent
Additives

4Binder

Binder or resin forms the bulk of the
dried paint film. It gives of its
mechanical and weathering properties.

4Pigment

Pigment is the colored part of the
coating. It is dispersed into fine
particles with the binder.

4 Solvent

Solvents are used to dilute the Binder. There
are normally several solvents in one coatings,
each performing a different task.

4 Additive

Additives are chemicals which when used in
small quantities can improve certain properties
of a wet paint or a cured film.
Type of Paints
Organic
4 Epoxy
4 Phenolic
Epoxy
4 Poly
Urethane
4 Acrylic
Inorganic
4 Silicone
4 Ethyl Zinc
Silicate


COATINGS DEFECTS
APPLICATION
DEFECTS
SAG: (RUNS or CURTAINS)
Cause:
1. Spray gun too close.
2. More thin.

Remedy:
1. Control your speed
and distance of spray.
2. Add require thinner
only.

OVER SPRAY: (DRY SPRAY)

Cause:
1. Spray out side the
pattern.
2. Dry spray.

Remedy:
1. Control your spray
pattern.
2. Use correct quantity
and quality thinner.

BLISTER:
Cause
Oil, moisture or
salt
contaminated
surface.
Remedy
Contamination
free surface shall
be used for
painting.

MUDCRACK:
Cause
1. surface finish.
2. High dft

Remedy
1. 40-65 m-
Anchor Profile.
2. Apply only
required DFT
FIELD DEFECTS
Abrasion Damage:
Cause:
Physical damage by
abrasion.
Impact
Remedy:
Impact and abrasion
damage shall be avoided.
Name plate like thing to
be fixed without
damaging the paint film.
Peeling of Paint from Substrate:
Cause:
Improper white metal
surface finish.
White metal
Contamination.
Remedy:
Proper Surface
preparation.
Contamination free white
metal.
PIN POINT RUSTING:
Cause:
More sharp edges.
surface finish.
Pin hole in paint
surface.
Remedy:
Proper Surface
preparation.
Defect free top coat
surface.
INSTRUMENTS
Testing Type
4 Ford Cups F1, F2,
F3 and B4 to check
the viscosity.
4 More viscous only
stable in transit.
4 Thinner should be
added for
application.

Surface Tension Liquid
4 Place a drop on
object.
4 If it spreads (water
breaks) low ST
4 No water breaks
surface tension ok
DRYING TIME RECORDER
4 Place the
instrument on Wet
painted object
4 The needle slowly
and freely rotates.
4 If paint surface
dried the rotation
got stop.
4 The running time
will give drying
time.
Hardness of the Dry film Surface
4 Pencil H series
4 Draw the line with
H pencil
4 No Pencil mark
means hardness of
the film is more
than the pencil.
Colour Comparison

4 Multi angle
comparison
4 Good for Metallic
Parts
4 Flip, Flap and Face
comparison
Adhesion cutter
4 Class A, B, C, D
4 No peel off is AIL
standard.
4 Normal Paint
adhesion check will
be in mesh type.
4 Zinc Silicates
adhesion check will
be X type
Blasting Standard
SURFACE PREPARATION STANDARDS
S.No. QUALITY NACE SSPC
SIS
(ISO
850
1-1)
REMARKS
1
White Metal Blast
Cleaning
No. 1 SP-5 Sa 3
When viewed without magnification, the surface shall be free from
mill scale, rust, paint coatings and foreign matter.
2 Near White Blast Cleaning No.2 SP-10 Sa2 1/2
When viewed without magnification, the surface shall be free from
mill scale, rust, paint coatings and foreign matter, except for
staining as noted below.
Random stainging sall be limited to no more than 5% of each
unit area of surface as defined in section 2.6 and may consist of
light shadows, slight streaks, or rust stains of mill scale, or
stains of previously applied coating
3
Commercial Blast
Cleaning
No.3 SP-6 Sa 2
When viewed without magnification, the surface shall be free from
visible oil, grease and dirt, and from most of the mill scale, rust,
paint coatings and foreign matter. Any residual contamination
shall be firmly adhering.
4 Brush-off Blast Cleaning No. 4 SP-7 Sa 1 Light Blast cleaning
5 Solvent Cleaning SP-1 Cleaning the substrate by solvent
6 Hand Tool Cleaning SP-2 St2 Through hand and power tool cleaning
7 Power Tool Cleaning SP-3 St3 Very through hand and power tool cleaning
9
Mineral and Slag
Abrasives
AB-1
Chloride test kit
Chloride test kit
Dew Point Meter
DFT Meter
Salt Spray Chamber
Schematic Diagram of SS
Surface Profile Gauge
Non Contact Thermometer
4 IR principle
4 Just hit the object
with IR
4 Digital display will
give the
temperature
4 Distance should be
with respect to the
model
Wet Film Gauge
4 Place the comb
perpendicular on
the Wet Paint
Surface for few
seconds
4 The wet film
thickness is biggest
teeth contact
Powder Coat WET FILM Gauge
DFT meter with differ Probe
DFT STD FOILS
4 Standard DFT
gauge foils
4 Used for
calibrations only
Pull off machine
Holiday Detector

4 Holidays will be
found out easily.
4 Holiday is mild gap
in the film
continuity
4 Working based on
conductivity
principle.

Metal Detector



4 Holiday reverse
principle almost.


4 Thank You