FORMCOAT 22 is an immersion zinc phosphate coating process for use in the cold forming industry. FORMCOAT 22 is used primarily to facilitate cold forming when used in conjunction with a FORMLUBE lubricant, or wire drawing when used in conjunction with a FORMATE series drawing compound.
Single chemical zinc phosphate application for lubricant retention used for cold forming of ferrous metals.
• 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 55.5 gallons (688 LBS) of FORMCOAT 22A for each 1,000 gallons of working solution required. Mix, top up to the working level with water and heat to the
operating temperature range of 160o F to 200o F. Temperatures above 175°F will increase the effic iency of the bath and generate less sludge. Just before any work is processed, add 10 oz. (220 mL) of Freidox 2 or 20 oz. (500 mL) of a 20% solution of Freidox 1 per 1,000 gallons and mix.
The treatment process for FORMCOAT 22 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 22
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 22 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 22 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 22 as close to the temperature of the FORMCOAT 22 as possible will reduce both chemical consumption and sludge generation.
If the FORMCOAT 22 phosphating solution is continually heated when not in used excess free acid will be generated resulting in a low TA/FA ratio. To avoid this situation the tank temperature should be lowered during long periods of inactivity.
Testing and control of a FORMCOAT 22 bath is based on Total Acid and Total Acid/Free Acid ratio (TA/FA Ratio) according to the following table.
Total Acid: Using a 5ml volumetric pipette, transfer a 5ml sample of the FORMCOAT 22 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.
Free Acid: Using a 5ml volumetric pipette, transfer a 5ml sample of the FORMCOAT 22 into a clean 250ml Erlenmeyer flask (adding up to 50ml of DI water to the flask may aid in viewing the
endpoint). Add 5-10 drops of Indicating Solution #11 (Bromophenol Blue) and titrate with Testing Solution #11 (0.1 N NaOH) to a blue-green endpoint (absence of yellow). Record the buret reading as the Free Acid.
TA/FA Ratio: Divide the total acid reading by the free acid reading to obtain the TA/FA ratio
An addition of 32 lbs. (2.58 gallons) of FORMCOAT 22 per 1000 gallons of solution will raise the Total Acid 1.0 point. The TA/FA Ratio should remain stable as long as operating temperature is maintained and no
pickling acid is dragged into phosphating tank.
FREIDOX TESTING: (recommended after bath is idle for more than 4 hours or if the bath exhibits an abnormal color)
Dip a strip of Indicator Paper 17 into the working solution. If it turns pink FREIDOX must be added, as above, until a fresh piece of paper does not change color. If it should turn pink the bath is on the “iron
side” and further work should not be processed until sufficient “Freidox” is added to kick out the iron from the solution. This can be done using the same quantities, in increments, as with a new bath.
Extrusion, Metal Working
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