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
2 6/23/2023 Properties
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
3 6/23/2023 Properties
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
Clean Rinse‘s Activate DIW-
Phosphate Rinse‘s
(optional) Rinse‘s

7 6/23/2023 Chemetall India - Atul Karpe

Agenda
 Pretreatment Concept and General Sequence

 Function of Various Stages

Cleaners

Activation

Conversio
n Coating

Passivatio
n

 Evolution
in Multi-
Metal
Pretreatme
nt
Safety
Health
and
8 6/23/2023
Environ
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.

13 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

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.

15 6/23/2023 Chemetall India - Atul Karpe

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

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
20 6/23/2023 Chemetall India - Atul Karpe
Properties
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 drawing,
Multimetal cold extrusion, rust proofing.

Steel and Paint bonding (less severe service

2 Iron Phosphate
Multimetal conditions), cold forming.

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

21 6/23/2023 Chemetall India - Atul Karpe

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
Manga
nese
 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
24 6/23/2023 Chemetall India - Atul Karpe
Properties
Functions of Various Stages
Passivation
 To improve corrosion Resistance
 To dissolve excessive secondary crystals
 Toreform 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
26 6/23/2023 Chemetall India - Atul Karpe
Properties
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
27 6/23/2023 Chemetall India - Atul Karpe
Properties
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

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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

31 6/23/2023 Chemetall India - Atul Karpe

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 Si
Passivation Zr Si
C
O O O O O
x
Me Si
Me O Zr
O O O MeOtal O O

32 6/23/2023 Chemetall India - Atul Karpe

Evolution in Multi-Metal Pretreatment
Oxsilan System – Various Aspects
From Zinc Phosphate…….

Zinc- Passivate
Clean Rinse Activate Phosphate Rinse (optional) DIW-Rinse

Safety labelling Energy and water consumption

acc. to GHS Waste water and sludge generation
Process costs
Multi-Metal compatible (more
Aluminium)
Sludge formation
Zn-Ph 3 - 15 g
Toxic heavy metal ions
/ m²
Corrosion protection and paint
Oxsilan® < 0,2 g
/ m² (sludge-free if no adhesion
……to OXSILAN-Technology
CRS/HRS)
Product consumption
Plant invest
Clean OXSILAN® DIW- Rinse
33 6/23/2023 Chemetall India - Atul Karpe Rinse DIW-
Rinse
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

34 6/23/2023
Oxsilan® - Various Aspects
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 Dosing
Process 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.
Parameters substrate)
!

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

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6C41/h2e3m2/e02ta3l India - Atul Karpe