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
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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.
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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 Properties
Oxsilan® - Various Aspects
Ensure Best Results
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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.
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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
19 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
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
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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
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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
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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
