Volume 05 - Surface Engineering Part 8 pptx

Table 2 Compositions and physical properties of lead-base babbittsCompressive yield point ab Ultimate compressive strength ac Hardness, HB d Composition, % Complete liquefaction Proper

•

•

•

High-Temperature Galvanizing.

d V

dV

•

•

•

•

•

Exposed Matte Surfaces.

Cleaning and Surface Preparation.

General Surface Conditions After Galvanizing.

Table 8 Guide for visual inspection of galvanized surfaces

rejection?

Choice of Paint.

Table 9 Comparative characteristics of paints and paint films used on hot dip galvanized steel

Numbers of paints in Table 5 Paint (film)

characteristics

Zinc Handbook: Properties, Processing, and Use in Design,

Table 1 Compositions and physical properties of tin-base babbitts

Compressive yield point (a)(b) Ultimate compressive

strength (a)(c)

Hardness, HB (d) Composition, %

Complete liquefaction

Proper pouring temperature

At 100

°C (212 °F)

Table 2 Compositions and physical properties of lead-base babbitts

Compressive yield point (a)(b) Ultimate compressive

strength (a)(c)

Hardness, HB (d) Composition, %

Complete liquefaction

Proper pouring temperature

°F)

At 100

°C (212

°F)

Metals Handbook

Manual of Bearing Failures and Repair in Power Plant Rotating Equipment,

Degreasing.

Pickling of steel,

Abrasive blast cleaning

Sodium chloride

Hydrochloric acid (a)

Water Solution

Table 5 Centrifugal casting speeds for tin-base babbitt bearings

Inside diameter of bearing shell

Centrifugal casting speed, rev/min

Coating weight Accelerator Surface treated

g/m 2 oz/ft 2 × 10 -3

Plat Surf Finish.,

Table 2 Accelerators used in phosphate coating processes

Optimum operating conditions Effective

Prod Finish.,

Phosphate Coatings as a Base for Paint

Table 3 Low-carbon sheet steel components spray phosphate coated for paint finishing

Area Part

m 2 ft 2

Production, pieces/h

Zinc phosphate (a)

Iron phosphate

Corrosion Protection

Phosphate Coating as an Aid in Forming Steel

•

•

•

•

Table 4 Applications of zinc phosphate dip spray coating to facilitate cold forming

m 2 ft 2 g/m 2 oz/ft 2 × 10

-2

Production, pieces/h

Sequence

of operations

Wear Resistance

Table 5 Parts immersion coated with manganese phosphate for wear resistance

time, min

Supplementary coatings

Steels

Concentration Component

g/L lb/gal × 10 -2

Cast Irons

μ

Prod Finish.,

CAB Curr Aware Bull (200),

Die Cast Manage.,

μ μ

Rinsing after Cleaning

Phosphating Methods

Table 6 Operating temperature ranges for phosphating solutions in phosphating applications

Operating temperature Phosphate coating method Metal

treated

Reason for treatment

Rinsing after Phosphating

Chromic Acid Rinsing

Plat Surf Finish.,

Total acid value N

Iron Removal.

Total acid value N

Table 7 Monitoring requirements for quality control of phosphate coating production

Hourly

Twice per shift

Once per shift

Operating temperature Solution

No.

Cycle time, min

N V V

Zinc Phosphating Solutions.

Manganese Phosphating Solutions.

Service life, yr Process

Low-carbon steel

Type 316 stainless steel (a)

Tank accessories,

Tank Design.

Cleaning equipment

Phosphating equipment

Level control

mm in °C °F Water Liquid Oil

Table 11 Sequence of operations in automatic spray application of zinc phosphate to automobile or truck small parts

Temperature Pressure

Time, s

kPa psi

N

N

Table 12 Sequence of spraying operations in iron phosphating of panels, brackets, and other parts for household appliances

Concentration Temperature Operation Solution

Time, s

Table 13 Sequence and details of operations for an automatic manganese phosphating indexing line

Temperature Operation

Time, min

N

Mortar Shell Casings.

Operating temperature Solution

No.

Solution Composition

Cycle time, min

μ μ

Operating temperature Solution

No.

Cycle time, min

°C °F

Time,s

μ

Requirement Value

Table 15 Energy demands of a system producing fine-grain immersion zinc phosphate coatings Operating temperature Heat-up energy Temperature maintenance energy Total energy required per day

°C °F kJ Btu kJ/h Btu/h kJ Btu

• Excellent

• Satisfactory

Phosphating and Metal Pre-Treatment,

Table 16 Process parameters for selected phosphate coatings

Operating conditions

Coating weight

Time Temperature Time Temperature

Rustproofing applications

Antifriction applications

Wire drawing applications

Tube and wire drawing applications

Tube drawing lubricant applications

Cold extrusion applications

Cold-forming aluminum applications

Galvanized steel applications

Chromate/phosphate for aluminum applications

Rustproofing applications

Antifriction applications

Wire drawing applications

Tube and wire drawing applications

Tube drawing applications

Cold extrusion applications

Cold-forming aluminum applications

Galvanized steel applications

Chromate/phosphate for aluminum applications

Phosphating and Metal Treatment,

Table 17 Industrial standards and process specifications for phosphating of metals in selected Western countries

original adoption

or last revision

Description

Country Standard Section Date of

original adoption

or last revision

Description

Country Standard Section Date of

original adoption

or last revision

Description

Country Standard Section Date of

original adoption

or last revision

Description

Country Standard Section Date of

original adoption

or last revision

Description

The Phosphating of Metals,

•

•

•

Electroplating Engineering Handbook, Practical Electroplating Handbook,

U.S Regulations (Ref 12)

Table 18 Effluent limits for phosphate coating processes per U.S Code of Federal Regulations

Electroplating (40 CFR 413) Metal finishing (40 CFR 433)

Component

mg/L lb/gal × 10 -5 mg/L lb/gal × 10 -5 mg/L lb/gal × 10 -5 mg/L lb/gal × 10 -5

Contaminant Concentration limit (6.0 < pH <9.5), ppm

Solid and Liquid Waste Disposal

categorical characteristic

a b

c

Table 19 Treatment options for sludges generated by prepaint lines

Equipment Selection and Operation (Ref 17).

Table 20 Limits and treatments of contaminants from a phosphating system Containment Direct discharge, Publicly owned treatment

ppm works, ppm

Chemical pH range

Acidity is

Chromium.

Table 21 Effluent levels for phosphate coating process discharges in the Federal Republic of Germany

Temperature (a) Suspended

solids (a)

Chemical oxygen demand (a)

Composition, mg/L(lb/gal × 10 -5 ) (a) Discharge

type

pH value

mL/L mL/gal mg/L lb/gal

× 10 -3

Toxicity

to finishes

as a dilution factor

(GF ) (a) Saponifiable oils and fats Hydrocarbons Cd Cr

(b)

Discharge into watercourse (c)

Discharge into main drainage systems

The Phosphating of Metals,

Prod Finish., The Phosphating of Metals,

The Phosphating of Metals,

Prod Finish.,

Prod Finish.,

Phosphating and Metal Treatment,

Met Finish., Prod Finish.,

The Phosphating of Metals,

The Phosphating of Metals,

Table 1 Common uses of chromate conversion coatings

Chemical polish

Metal coloring

Remarks

The Surface Treatment and Finishing of Aluminum and Its Alloys,

Metal Finishing Guidebook and Directory Issue '92,

o

Metal Finishing,

Progress in Organic Coatings,

Surf Interface Anal.,

o

Metal Finishing Guidebook and Directory Issue '92,

Metal Finishing,

Surf Interface Anal.,

NATO ASI Series, Series C,

J Radioanal Nucl Chem Lett.,

Electrochim Acta,

Corros Sci., Met Technol N.Y.,

Surf Interface Anal.,

Proc National Electrochemical Society Meeting,

•

Surf Interface Anal.,

Aluminum: Properties and Physical Metallurgy,

Corros Sci.,

Federal Register,

Federal Register

Federal Register

Metal Finishing,

Handbook on the Toxicology of Metals,

Hazardous Chemicals Desk Reference, Sax's Dangerous Properties of Industrial Materials,

Patty's Industrial Hygiene and Toxicology,

Plating and Surface Finishing,

Metal Finishing, Plating and Surface Finishing, Plating and Surface Finishing, Chemical Engineering,

Plating and Surface Finishing,

Metal Finishing, Metal Finishing,

Metal Finishing,

Rare Earth Metals.

o

Manganese-based treatments for aluminum and aluminum alloys

Trivalent Cobalt.

Corrosion Inhibitors,

Corros Sci.,

J Electroanal Chem., Corros Sci.,

Metal Finishing,

Metals Forum, Materials Forum, Microstructural Sci.,

Corrosion (NACE), Electrochim Acta, Mater Sci Forum,

Appl Surf Sci., Corros Sci.,

Proceedings of the Symposium on Environmental Degradation of Ion and Laser Beam Treated Surfaces,

Metal Alkoxides, Chem Rev.,

High Temperature Corrosion, Corrosion (Houston),

Thin Solid Films,

Thin Solid Films,

Oil

Water

Grease and petrolatum

Waxes

Thixotropic materials

Hot-melt dry films,

Solvent-cutback dry films,

Table 1 Characteristics and applications of rust-preventive materials covered by military specifications

Specification

number

Specification title Description Intended use

Specification

number

Specification title Description Intended use

μ

Specification

number

Specification title Description Intended use

μμ

μ

μ

Specification

number

Specification title Description Intended use

Specification

number

Specification title Description Intended use

Table 2 Properties of rust-preventive materials covered by military specifications

Coverage (b) Specification

number

Minimum melting point (MP)

or flash point (FP),

Viscosity (c) Penetration

Coverage Specification

number

Minimum melting point (MP)

or flash point (FP),

Coverage Specification

number

Minimum melting point (MP)

or flash point (FP),

Coverage Specification

number

Minimum melting point (MP)

or flash point (FP),

•

•

•

•

Finished machined parts and spare parts,

Tools.

Chemical reactions

Table 3 Duration of protection afforded by rust-preventive compounds

Duration of protection, method Type of

compound

Indoor Shed Outdoor

storage storage storage

The viscosity and specific gravity,

The flow characteristics

Film Characteristic.

Table 1 Properties and applications of coating resins

available

Drying method

Favorable characteristics

Unfavorable characteristics

Table 2 Organic coatings selected for corrosion resistance in various environments

High humidity

High temperature

Table 3 Paints selected for resistance to mechanical or chemical action Action Paint

μ

Cleaning

Power brushing

Grinding,

Abrasive blast cleaning

Emulsion cleaning, solvent cleaning, and vapor degreasing

Alkaline cleaning

Acid cleaning

Pickling

Steam cleaning

phosphating phosphating

Equipment for Air Atomized Spray Painting

Table 5 Equipment requirements for conventional spray painting of two production parts

Procedure or

equipment

Shell for fire extinguisher (a)

Enclosure panel (b)

Production requirements

Equipment requirements

Equipment for Electrostatic Spray Painting