Modified phosphate coatings applied to steel by cold method

The deposition of phosphate coatings occurs on the surface of the product when it is immersed in a solution containing phosphoric acid. The formation of a film on the metal surface occurs during the deposition of insoluble two- and three-substituted phosphates of iron, manganese, and zinc from a solution. To speed up the process and conduct phosphating at low temperatures, nitrates, nitrites, and fluorides of active metals are introduced into the solution. Organic compounds, such as glucose, glycerin, Trilon A, and Trilon B, are buffer additives to maintain the pH of phosphating solutions in the range of 2.6-3.2. It was found that 10-15 minutes at a process temperature of 20-25 °C are sufficient for the formation of a protective phosphate coating from solutions containing modifiers. The content of zinc phosphates in the modified phosphate coatings is increased. Additives in cold phosphating solutions have a positive effect on the quality and protective properties of the resulting phosphate films. Modified phosphate coatings obtained by the cold method have a fine-crystalline structure, a smooth surface and low porosity.

Defining-Measuring-Analysing-Improving-Controlling (DMAIC): Process and Improve Stability in Carbon Steel Industry

Phosphating is most common method for surface treatment and finishing of ferrous and nonferrous metal. It has excellent corrosion resistance, wear resistance, adhesion and lubricating properties besides its economic values and speed of application. Steel is one of the cheapest materials used in various industries and it requires corrosion resistance therapy. This study aims to provide possible solution to the rusty issue on carbon steel product by improving coating stability using Defining–Measuring–Analysing–Improving–Controlling (DMAIC) method. The result proposed that zinc phosphate coating material has to replace current iron phosphate coating due to the former is more corrosion time resistant than that of the latter.

Evaluation of Corrosion Behavior and In Vitro of Strontium-Doped Calcium Phosphate Coating on Magnesium

This study investigated the biocompatibility of strontium-doped calcium phosphate (Sr-CaP) coatings on pure magnesium (Mg) surfaces for bone applications. Sr-CaP coated specimens were obtained by chemical immersion method on biodegradable magnesium. In this study, Sr-CaP coated magnesium was obtained by immersing pure magnesium in a solution containing Sr-CaP at 80 °C for 3 h. The corrosion resistance and biocompatibility of magnesium according to the content of Sr-CaP coated on the magnesium surface were evaluated. As a result, the corrosion resistance of Sr-CaP coated magnesium was improved compared to pure magnesium. In addition, it was confirmed that the biocompatibility of the group containing Sr was increased. Thus, the Ca-SrP coating with a reduced degradation and improved biocompatibility could be used in Mg-based orthopedic implant applications.

Corrosion performance and morphological analysis of activated zinc phosphate coating formed on steel surface

Purpose The purpose of this paper is to study the effect of different concentrations of pretreatment solution of copper acetate (1, 5 and 10 g/L) on the deposition, growth and protection ability of zinc phosphate coating. Design/methodology/approach Zinc phosphate coatings were deposited on steel surface by immersion method. Scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) were used to study the morphological evolution and chemical analysis of formed coatings. The electrochemical performance of the coatings was evaluated via potentiodynamic polarization curves, electrochemical impedance spectroscopy (EIS) and immersion test in an aerated 3.5% NaCl solution. Findings The results showed that the activation treatment accelerated the deposition of the phosphate coating and improved its surface coverage. A higher phosphate coating weight (7.35 g/m2) and more compact structure was obtained with pretreatment solution of 1 g/L copper acetate. Electrochemical results revealed that the protection ability of the phosphated substrates was markedly enhanced after the pretreatment, and the best corrosion protection was obtained with a concentration of 1 g/L copper acetate solution. The corrosion current density of phosphated substrate was reduced by 64.9% after activation treatment with 1 g/L copper acetate solution. Originality/value In this investigation, dense, stable and compact zinc phosphate layers with improved corrosion resistance were formed on a carbon steel surface after activation pretreatment with copper acetate solution prior to a phosphating step.

Effect of substrate surface roughness on the wear of molybdenum disulphate coated rolling contact bearings

The objective of the present experimental work is to investigate the influence of subsurface roughness on the friction and wear performance of high-temperature ball bearing. Bearings, which are used in high-temperature applications, are affected by several operating conditions. Some factors under high-temperature conditions such as short grease life, thin-film thickness at low speed, and insufficient internal clearance can drastically reduce bearing service life due to an increase in surface friction. For this reason, rolling contact bearings are coated with molybdenum disulfide. Before the molybdenum disulfide (MoS2) coating, phosphatization is applied to the bearings. Because the phosphate layer is micro-porous, it assures that molybdenum disulfide is entrapped in the interstitials between the phosphates. Also, phosphate coating provides a much larger surface area for the lubricant to attach to. In this study, several process steps, sandblasting, manganese phosphate coating, molybdenum disulfide coating, friction moment testing, wear testing, wear depth measurement, SEM, and XRD analyses were carried out. Wear tests and friction moment tests were applied to the rings of bearings of varied raceway roughness. This process ultimately provides molybdenum disulfide coated bearings optimum raceway roughness parameters for good wear resistance and optimum boundary lubrication.