FORMCOAT 9 chemicals are formulated to impart dense crystalline zinc phosphate coatings on steel surfaces. Lower surface micro finishes on FORMCOAT 9 treated parts may be obtained after forming operations due to the dense crystalline structure. It is used primarily to facilitate the cold forming of metal, when used in conjunction with an immersion lubricant. Treatment with FORMCOAT 9 will impart multiple reactive lubricants when used in conjunction with FORMLUBE 1,FORMLUBE 7 or FORMLUBE 47, providing a broader melting point range than standard zinc phosphate coatings.
• The process tank should be constructed from stainless steel or an acid and oxidizer resistant
composite material that will withstand the temperature ranges required. Use of mild steel will result in shortened equipment life due to chemical attack.
• Heat transfer surfaces should be constructed of 316 stainless steel, or an acid and oxidizer
resistant high temperature composite, if steam or heat transfer fluid type heat exchangers are used.
• Piping and pumps may be constructed of stainless steel, mild steel, or an appropriate composite material. Use of mild steel will result in shortened equipment life.
Fill the tank to the three quarter level with water and add 40 gallons (490 LBS) of FORMCOAT 9A chemical for each 1,000 gallons of working solution required. With water bring the tank to the operational level and heat to the required temperature, typically 160°CF. Once the optimum temperature is determined, it should be maintained within ±5°CF. A processing bath built up according to these recommendations will result in 20 points of Total Acid, or what is referred to as a 20 point bath. Cleaned parts are placed in this solution at approximately 160°CF for 3 to 5 minutes to produce a uniform coating.
The treatment process for FORMCOAT 9 is generally as follows:
1. Cleaning with a FREICLEAN series cleaner
2. Hot water rinse
4. Cold water spray rinse
5. Cold water rinse
6. Hot water preheat
7. FORMCOAT 9
8. Cold water rinse
9. Hot NEUTRALIZER rinse
10. FORMLUBE soap or polymer series lubricant
To maintain the bath’s performance it should be regularly tested and adjusted to within operating parameters. Normal processing time with FORMCOAT 9 is 3 to 10 minutes. Processing parameters can vary widely based on individual processes and performance requirements. Typical operating parameters are listed below. Your Freiborne representative will help develop the proper operating parameters for your specific needs.
Insoluble phosphate sludge will be generated as a natural byproduct of the FORMCOAT 9 reaction with the steel. This sludge must be periodically removed to prevent it from depositing on the surface of the steel being coated, as it is abrasive in nature and therefore very detrimental to forming operation.
Maintaining the temperature of the rinse prior to FORMCOAT 9 as close to the temperature of the FORMCOAT 9 as possible will reduce both chemical consumption and sludge generation.
Testing and control of a FORMCOAT 9 bath is based on Total Acid and Total Acid/Free Acid ratio (TA/FA Ratio) according to the following table.
Total Acid: Using a 10ml volumetric pipette, transfer a 10ml sample of the FORMCOAT 9 into a clean 250ml Erlenmeyer flask (adding up to 50ml of DI water to the flask may aid in viewing the endpoint). Add 5 drops of Indicating Solution #3 (Phenolphthalein) and titrate with Testing Solution #11 (0.1 N NaOH) to a slight pink endpoint. Record the buret reading as the Total Acid.
To maintain the solution concentration FORMCOAT 9B is used for normal replenishing. An addition of 1.5 gallons (18 LBS) of FORMCOAT 9B per 1000 gallons of working solution will increase the concentration by 1.0 points.
To compensate for loss of concentration due to mechanical loss, such as sludge clean-out, leaks, etc. the FORMCOAT 9A material should be used. Here, an addition of 2 gallons (25 LBS) of FORMCOAT 9A per 1000 gallons of working solution will raise the concentration by 1.0 points.
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