Phosphates-old
Acid Rinse Aid 93
Dev-Kote 77
Dev-Zinc 720
Iron Phos #2
Non-Chrome Seal Rinse
Phos Black #2
Acid Rinse Aid 93
Operating Conditions:
| Concentration | 0.5 – 2% by volume |
| Time | 15 to 30 seconds |
| Temperature | Ambient – higher temperatures will aid in drying. |
| Control | pH of the final rinse should be maintained around 4 – 5 |
Handling:
This product is an acidic material containing wetting agents. Handle with normal precautions given for any acidic product.
Read Material Safety Data Sheet before using this product.
Dev-Kote 77
The Dev-Kote 77 coating is a superior basis for paint producing a finer finish with less paint usage than regular zinc phosphate. The zinc phosphate coating produced is also an excellent carrier for tube and wire lubricants. At the same time it provides better corrosion protection and “creep” resistance than iron phosphate. Dev-Kote 77 may be used in either spray or immersion processes.
Operating conditions are general guideline, but may vary widely depending upon the individual application.
Operating Make-Up:
| Spray System | Immersion System | |
|---|---|---|
| Time: | 30-90 seconds | 200 – 300 seconds (2-5 minutes) |
| Temperature: | 120 – 150 oF | 140 – 180 oF |
| Spray Pressure: | 8 – 12 psi | —————- |
| Concentration: | 1.5 – 3.0 % Vol. | 3.0 – 5.0%/Vol. |
| Analysis Points: | 8 – 15 pts | 15 – 25 pts |
| Conversion: | 1% Vol. = 5 points total acid | |
Operating Cycle:
| Spray System | Immersion System |
|---|---|
| 1. Soak Clean | 1. Soak Clean |
| 2. Spray Rinse | 2. Water Rinse |
| 3. Dev-Kote 77 | 3. Dev-Kote 77 |
| 4. Spray Rinse | 4. Spray Rinse |
| 5. Neutral Seal | 5. Neutral Seal |
Operating Notes:
Mild steel equipment is satisfactory, except for pump and spray nozzles, where stainless steel is recommended. Use stainless steel whirl-jet type nozzles.
Dev-Kote 77 and additive solutions should be added while circulating pump is operating.
When starting a freshly made up solution of Dev-Kote 77, the solution should be used immediately after the initial heat-up to the operating temperature. The initial iron which dissolves into the bath acts as a stabilizer.
Analysis And Control:
For ease of operation, we have developed a simple operator controllable analysis, which can be performed routinely every 2 – 6 hours depending on workload.
For greater product control, see pages 3 to 8 for additional component analysis procedures along with operating information.
For spray applications, we recommend replenishment by the metering method.
Total Acid Analysis:
Reagents:
- 0.1N Sodium Hydroxide (NaOH)
- Phenolphthalein indicator
Procedure:
- Pipette a 10 ml sample of Dev-Kote 77 bath into a clean 250 ml Erlenmeyer flask.
- Add 50 – 100 mls DI water.
- Add 3-5 drops of phenolphthalein indicator.
- While swirling, titrate with 0.1N Sodium Hydroxide to a pink end-point.
Calculation
- Mls 0.1 N NaOH x 0.194 = % by volume
- Mls 0.1 N NaOH = Total Acid Points (Pointage)
Packaging:
55 GALLON DRUMS (720 LBS. NET)
Concentration Control Method:
The Dev-Kote 77 bath may need to be analyzed regularly for proper chemical concentration (i.e., once every 4 hours for heavy work loads to once every 8 hours for light work loads.) Dev-Kote 77 concentrate is used to maintain the total acid level. 2% by volume = 10 points total acid
The operating concentration of Dev-Kote 77 is dependent upon the ferrous iron content. the following chart gives the recommended total acid level for a determined amount of ferrous iron.
| Ferrous Iron Points | Recommended Total Acid Points |
|---|---|
| 0-1 | 35-40 |
| 1-2 | 35-40 |
| 2-3 | 35-40 |
| 3-4 | 39-42 |
| 4-5 | 42-45 |
| 5-6 | 45-48 |
| 6-7 | 48-51 |
| 7-8 | 51-54 |
| 8-9 | 54-57 |
| 9-10 | 57-60 |
| 10-11 | 60-63 |
| 11-12 | 63-66 |
Operating Conditions:
The above guideline is recommended for operating Dev-Kote 77 baths where the concentrate is metered in. When manual additions are made, use the following formula:
3 X Iron points + 30 = Total acid level
For example: If iron points are found by analysis to be 5.0 iron points, then total acid should be at or adjusted up to 45 points (or 43 to 47). If the acid points are higher than the control level, the phosphate coating will simply be put on faster.
When the iron reaches a level deleterious to the coating, a portion of the bath should be discarded. After discarding, the level is restored with water and the proper ration of total acid to iron points adjusted with Dev-Kote 77.
Analytical Procedure:
Iron Analysis
Reagents:
- 0.2 N Potassium Permanganate
- 50% Sulfuric Acid (1 to 1 by Volume)
Procedure:
- Pipette a 10 ml sample of the phosphate solution into a 250 ml Erlenmeyer flask.
- Add 10 – 15 drops of 50% sulfuric acid
- Titrate sample with 0.2N potassium permanganate until a clear to pink end point.
Calculation
- Mls. 0.2 N Potassium Permanganate = iron points
Free Acid Analysis:
Reagents:
- 0.1 N Sodium Hydroxide
- Bromophenol blue indicator (goes from yellow to blue)
Procedure:
- Pipette a 10 ml sample of the phosphate solution into 250 ml Erlenmeyer flask.
- Add 3-4 drops Bromophenol blue indicator
- Titrate sample with 0.1N sodium hydroxide from a yellow to a blue purple endpoint.
Calculation
- Mls 0.1 N Sodium Hydroxide = Free acid points
Typical Processing Cycle For The Phos And Oil:
| Stage | Operation |
|---|---|
| 1 | Hot alkaline soak clean, 5-10 minutes, 140 – 180 oF |
| 2 | Rinse, overflowing water, 30 seconds, room temperature |
| 3 | Pickle, mineral acid pickle solution, 5-10 minutes, 65 – 115 oF |
| 4 | Rinse, overflowing water, 30 seconds, room temperature |
| 5 | Hot rinse, 30 seconds, 140 – 160 oF |
| 6 | Phosphate, Dev-Kote 77, 30 sec. to 5 min, 165 – 185 oF, (3 x Iron points + 30 = TA) |
| 7 | Rinse, overflowing water, 30 seconds, room temperature. |
| 8 | Neutral Seal |
| 9 | Oil, Deveco water emulsion oil, or oil & wax bath, 30 – 60 seconds, 135 – 145 oF. |
Note: Consult your Deveco sales engineer for further process information assistance.
Equipment:
Operating Information:
It is important that there be good rinsing following any acid dip.
For optimum performance, a bath should be titrated before each shift.
This bath may be used for dip operations when parts are racked or are in baskets.
The immersion time when work is dip coated on hooks or racks is approximately one-third as long as when the work is tumbled to produce the same coating weights.
Barrel operations require barrel rotation of 1-2 rpm in all stages of zinc phosphating for best results and complete coatings.
A coating having a white powdery appearance usually indicates a bath low in free acid, high in pH or that the temperature of the bath has exceeded 200oF.
If the pH of the bath should drop below the 2.5 pH operating limit, the bath may be brought back to the recommended pH by the addition of a neutralizer. An excessive amount of free acid may also be corrected by the addition of a neutralizer to the bath. This is rarely required. Consult Deveco for assistance.
If the coating shows a “blush rust” appearance, it indicates insufficient phosphate coating. This could be due to low bath temperature, a short immersion, high free acid or high iron in the solution.
If oil accumulates in the processing tank (usually as a result of poor cleaning or rinsing), it can best be removed in the morning before turning on the heat. It may be either skimmed or blotted off.
To obtain the highest efficiency, production should be processing practically all the time. That is, when one load of production is taken from the work tank, another should be ready to replace it.
More crystalline coatings will be obtained when 20-40% by volume hydrochloric acid dip is used prior to phosphating. Sulfuric may be used; however, hydrochloric acid is preferred.
Safety Precautions:
Dev-Kote 77 is an acidic material. Avoid contact with skin or clothing. Wear a face shield, apron and rubber gloves when handling material. In case of contact with skin or clothing, wash immediately with large amounts of water. For eyes, flush with clean water for at least 15 minutes and obtain medical attention. Read the Material Safety Data Sheet before using this product.
Read Material Safety Data Sheet before using this product.
Dev-Zinc 720
Dev-Zinc 720 provides excellent corrosion protection on ferrous metal parts by depositing in excess of 2,000 milligrams per square foot of crystalline zinc phosphate. When used with water emulsion oil and oil & wax products, Dev-Zinc 720 can surpass 168 hours salt spray.
Operating Conditions:
| Dev-Zinc 720 | 2 to 6% by volume |
|---|---|
| Temperature | 160 to 175 °F, normal |
| Immersion Time | 10 to 30 minutes |
| Control ranges | Total Acid: 35 to 60 points Free Acid: 5 to 10 points Iron: 1 to 14 points |
| Conversion | 1% by vol. Total Acid = 10 points 1% by weight Iron = 10 points |
| Coating Weight | 2000 to 3500 mg/sq.ft. |
Make-Up And Control:
- Fill clean tank with water.
- Heat to approximately 120°F.
- Add 4% by volume of Dev-Zinc 720 and mix thoroughly.
- Heat to operating temperature 160-175°F, and begin operation.
(Steelwork must be put through the tank immediately after initial heat of a new solution. The initial dissolved iron is needed to stabilize a new phosphating bath.)
The Dev-Zinc 720 bath should be analyzed on a regular schedule for proper chemical concentration (i.e., once every 4 hours for heavy work loads to once every 8 hours for light work loads).
Dev-Zinc 720 concentrate is used to maintain the total acid level.
- 1% by volume = 10 total acid points.
The operating concentration of Dev-Zinc 720 is dependent upon the ferrous iron content. The following chart gives the recommended total acid level for a determined amount of ferrous iron.
Operating Guidelines:
| Ferrous Iron Points | Recommended Total Acid Points |
|---|---|
| 0-1 | 35-40 |
| 1-2 | 35-40 |
| 2-3 | 35-40 |
| 3-4 | 39-42 |
| 4-5 | 42-45 |
| 5-6 | 45-48 |
| 6-7 | 48-51 |
| 7-8 | 51-54 |
| 8-9 | 54-57 |
| 9-10 | 57-60 |
| 10-11 | 60-63 |
| 11-12 | 63-66 |
The above guideline is recommended for operating Dev-Zinc 720 baths where the Dev-Zinc 720 concentrate is metered in.
Iron points vs. TAP (Total Acid Points) relationship is calculated using the following formula:
3 X Iron points + 35 = optimum TAP relationship
For example: If the iron points are found by analysis to be 5.0 iron points, then total acid should be at or adjusted up to 50 points. (3 x 5 + 35). If the acid points are higher than the control level, the phosphate coating will simply be put on faster.
When the iron reaches a level deleterious to the coating, a portion of the bath should be discarded. After discarding, the level is restored with water and the proper ration of total acid to iron points adjusted with Dev-Zinc 720.
Analysis:
Iron Analysis:
Reagents:
- 0.2 N potassium permanganate
- 50% sulfuric acid (1 to 1 by volume).
Procedure:
- Pipette a 10 ml sample of the phosphate solution into the flask.
- Add 10-15 drops of 50% sulfuric acid.
- Titrate sample with 0.2 N Potassium Permanganate until a clear pink end-point.
Calculation
- mls 0.2 N Potassium Permanganate = Iron points.
Total Acid Analysis:
Reagents:
- 0.1 N Sodium Hydroxide.
- Phenolphthalein indicator solution.
Procedure:
- Pipette a 10 ml sample of the phosphate solution into a flask.
- Add 3-4 drops of phenolphthalein indicator solution.
- Titrate the sample with 0.1 N Sodium Hydroxide to a pink end point.
Calculation
- mls 0.1 N Sodium Hydroxide = Free acid points.
Typical Processing Cycle For Phos And Oil:
| Stage | Operation | ||
|---|---|---|---|
| 1. | Hot alkaline soak clean, | 5-10 minutes, | 140-180°F. |
| 2. | Rinse, overflowing water, | 30 seconds | room temp. |
| 3. | Pickle, mineral acid | 5-10 minutes, | 65-115°F. |
| 4. | Rinse, overflowing water, | 30 seconds, | room temp |
| 5. | Hot rinse, | 30 seconds, | 140-160°F. |
| 6. | Dev-Zinc 720, | 10-20 minutes, | 165-185°F, |
| 7. | Rinse, overflowing water, | 30 seconds, | room temp. |
| 8. | Seal rinse, | 30-60 seconds | 140°F. |
| 9. | Oil, water emulsion oil, or oil & wax bath, | 30-60 seconds, | 135-140°F. |
Note:
Consult your So Clean Solutions sales engineer for further process information or assistance.
Equipment:
Trouble Shooting:
It is important that there be good rinsing following any acid dip.
For optimum performance, a bath should be titrated before each shift.
This bath may be used for dip operations when parts are racked or are in baskets.
The immersion time when work is dip-coated on hooks or racks is approximately one-third as long as when the work is tumbled to produce the same coating weights.
Barrel operations require barrel rotation of 1-2 rpm in all stages of Zinc phosphating for best results and complete coatings.
A coating having a white powdery appearance usually indicates a bath low in free acid, high in pH or that the temperature of the bath has exceeded 200°F.
If the pH of the bath should drop below the 2.5 pH-operating limit, the bath may be brought back to the recommended pH by the addition of a neutralizer. An excessive amount of free acid may also be corrected by the addition of a neutralizer to the bath. This is rarely required. Consult So Clean Solutions for assistance.
If the coating shows a “blush rust” appearance, it indicates insufficient phosphate coating. This could be due to a low bath temperature, a short immersion, high free acid or high iron in the solution.
On hardened parts, the coating will appear darker and have a much finer grain than on cold-rolled and low-carbon parts. So Clean Solutions can provide special additives to produce darker phosphate deposits on all steel work. Consult So Clean Solutions for assistance if darker deposits are required.
When the bath takes too long to heat up and isn’t holding temperature, it indicates normally that the coils need cleaning.
While sludge is not a problem, it is recommended to pump out the bath into a storage tank at least monthly to remove any iron parts and sludge that might have accumulated.
If a fresh, new phosphate that is heated to the operating temperature and left idle, then the bath may become inoperative. To bring back the bath to operating condition, add 1.5 lbs. of urea per 100 gallons of solution to change the nitrites which formed in the unused bath back into nitrates. (Always use a fresh bath after the initial heat up, and avoid this possible start-up problem.)
The average build-up on a surface treated with Dev-Zinc 720 process is about 0.0002” to 0.0004” (0.2 – 0.4 mil). To obtain a dense, fine-grained coating on some articles where close tolerance is essential, it may be necessary to change the cleaning procedure to include a sand tumble or a hand wiping operation.
To obtain the highest efficiency, production should be processing practically all the time. That is, when one load of production is taken from the tank, another should be ready to replace it.
If oil accumulates in the processing tank (usually as a result of poor cleaning or rinsing), it can best be removed in the morning before turning on the heat. It may be either skimmed or blotted off.
Caution:
Dev-Zinc 720 is an acidic material. Avoid contact with skin and clothing. Wear a face shield, apron, and rubber gloves when handling this material. In case of contact with skin or clothing, wash immediately with large amounts of water. For eyes, flush with clean water for at least 15 minutes and obtain medical attention.
Read the Material Safety Data Sheet before using this product.
At So Clean Solutions We Strive To Create Better, Safer And Cost Effective Cleaners For All Types Of Manufacturing.
Iron Phos #2
An amorphous iron phosphate coating is produced that will be gray to blue iridescent in color and have coating thickness of from 40 to 80 mg/sq foot.
Iron Phos #2 is generally used in pressure spray washing machines, but can also be used in simple dip operations. Selected wetting agents provide added cleaning strength.
Iron Phos #2 is a mildly acidic, clear liquid concentrate that mixes readily in water and is completely safe for workers to handle. Fast acting surfactants speed cleaning of the metal surface and provide for a uniform coating finish.
Equipment:
Operating Conditions:
Iron Phos #2 is designed for use in three-stage pressure spray washing machines and for best results should be used in this manner:
| Iron Phos #2 | 2 to 6% by volume in water |
| Operating temperature | 140 to 160 oF. |
| Time | 30 seconds to 3 minutes. |
| pH | 4.8 – 5.5. |
The second stage is a cold water rinse. The third stage is a brief rinse in a seal rinse solution. Parts should be dried immediately following the third stage by conventional methods.
For immersion applications, if parts are heavily coated with soils, rust inhibitors or lubricants, then precleaning of the work should be performed to insure proper phosphating and to prevent against contamination of the iron phosphating solution.
Make Up Of The Operating Solution
| Iron Phos #2 | 4 to 6% by volume of in water |
| Operating temperature | 160 to 180 oF. |
| Time of immersion | 2 to 5 minutes with agitation of the work or solution |
| pH | 4.8 – 5.5. |
After treating, follow with conventional cold water rinse, then seal rinse and dry
Maintenance And Control:
During operating, the pH and concentration of the treating solution should be maintained through periodic additions of Iron Phos #2. Maintain the pH of the solution between 4.8 and 5.5. The concentration can be checked by simple titration:
- Add a 30 ml sample of Iron Phos #2 solution into a 250 ml beaker.
- Add 3 to 4 drops of phenolphthalein indicator.
- Titrate with 1.0N sodium hydroxide to a pink end point.
Calculation:
mls 1.0 N Sodium hydroxide x 1.1 = % by vol. Iron Phos #2.
Concentration By Test Kit
- Add 3 mls of solution to be tested to empty dropper bottle, use a small graduated syringe.
- Add 2 drops of phenolphthalein indicator.
- Add 1.0N sodium hydroxide dropwise until permanent pink color change. Swirl bottle gently between each drop addition.
- Use the number of drops of 1.0N sodium hydroxide to determine the concentration on the chart below.
| drops of 1.0 n sodium hydroxide | % Of Iron Phos #2 |
|---|---|
| 3 | 1 |
| 5 | 2 |
| 7 | 3 |
| 9 | 4 |
| 11 | 5 |
| 14 | 6 |
Read Material Safety Data Sheet before using this product.
Non Chrome Seal Rinse
Operating Conditions:
| Concentration | 1-4% by volume |
| Time | 30 seconds – 1 minute |
| Temperature | 60 –190 oF. |
| Control | pH: 10.5 – 11.5 |
Make-Up Procedure:
- Mild steel tank should be filled with water.
- Add 2% Non-chrome seal rinse.
- Mix solution with paddle.
- Raise temperature to operating range.
- Check pH and maintain at 10.5 – 11.5
Concentration Control Method:
- Maintain pH at 10.5 – 11.5
- Pump tank and recharge on regular basis, once every 2 – 4 weeks is normal.
Handling
This product is a strong alkaline material containing sequestering agents. Handle with extreme caution.
Read Material Safety Data Sheet before using this product.
Phos Black #2
Operating Conditions:
Phos Black #2 is a conditioning solution for incorporation into conventional zinc phosphate immersion systems to produce a matte black phosphate coating on steel parts.
Phos Black #2 is operated at ambient temperature, requires no accelerator and maintained by a minimum of chemical control.
Equipment:
Phos Black #2 tanks should be constructed of fiberglass or rubber, PVC or Koroseal lined.
Make-Up:
Solution of Phos Black #2 is prepared as follows:
| Water | 87% by volume |
| Phos Black # 2 | 13% by volume |
Phos Black #2 is designed for use in rack, basket, or barrel immersion systems. To avoid marking parts, while processing in barrel or basket, revolve the equipment very slowly, about 1 rpm.
Process Operation:
- Alkaline soak clean to remove oil and grease.
- Cold water rinse to remove all traces of alkali cleaner.
- Acid dip (25-50% hydrochloric acid) if necessary to remove rust or scale.
- Warm water rinse
- Phos Black #2 immersion time of 15 seconds to 3 minutes
- Cold water rinse
- Zinc Phosphate dip
- Cold water rinse
Control:
Once the bath is ready for use, record total acid and maintain at this operating level with additions of Phos Black #2.
- Pipette 2 mls sample into a 100 ml beaker
- Add 50 mls distilled water
- Add 3-5 drops of phenolphthalein indicator
- Titrate with 0.1N sodium hydroxide
- Maintain total acid at new solution level
If the work is not black enough, add 0.25% by volume increments of Phos Black #2 until the desired color is obtained – 1 quart per 100 gallons of zinc phosphate dip solution.
Read the Material Safety Data Sheet before using this product.