Frank Alkanes India Pvt Ltd

FRANK PHOS FM-2

INTRODUCTION :
Frank Phos FM-2 is a chemical intended for an accelerated hot dip process giving a heavy Manganese Iron Phosphate coating on iron and steel.

BENEFITS :

FRANK PHOS FM-2 provided the following important benefits :

PROTECTION AGAINST WEAR:

FRANK PHOS FM-2 forms an inert crystalline coating which protects against wear on moving parts; It eliminates metal to metal contact, maintains lubrication and reduces tearing and scuffing during Running it.

PROTECTION AGAINST RUSTING:
FRANK PHOS FM-2 also gives outstanding protection against corrosion, and when stained and oiled will often protect the article from rusting throughout its normal life.

CAN BE STAINED, OILED OR PAINTED
FRANK PHOS FM-2 provides an excellent foundation for oils, stains or matt paints and prevents rust under the protective film, should the film become damaged.

FILM BUILD UP
FRANK PHOS FM-2 coatings give only about 5-10 microns build.

ECONOMICAL PROCESS
FRANK PHOS FM-2 gives excellent protection against wear and rusting at an extremely low cost.

EASY OPERATION
FRANK PHOS FM-2 is easy to operate and is controlled by simple tests requiring no chemical knowledge. No fumes or odours are given off.
APPROVALS
FRANK PHOS FM-2 meets WPN/GEN/ 3:1965 as a Class 1 accelerated process and meets the requirements of IS:3618:1966 Class A1.

USES
FRANK PHOS FM-2 is ideal for use on moving parts such as pistons rings, gears and cam shafts, to give maximum protection against wear, particularly during running in. It forms a coating integral with the metal and when oiled and used as a bearing surface, it holds the oil between the moving parts, thereby maintaining lubrication and bearing the burden of the first wear.
In use, the coating quickly becomes very smooth so that friction is reduced and tearing and scuffing of the metal is eliminated. Thus the FRANK PHOS FM-2 coating protects the metal, prevents seizure, fretting corrosion and excessive wear and consequently greatly increases the life of the moving part. FRANK PHOS FM-2 can also be used to protect against corrosion and is particularly suitable for casting, tools , nuts bolts, service equipment and similar parts, which can be stained and oiled but not readily painted.

OPERATING SUMMARY ( GUIDANCE ONLY)
Bath Temperature : 95°C - 100°C
Immersion Time : 3-20 minutes
Coating weight : 10.0 – 43.0 gm/sq.m.
Bath Concentration : 3-10 % FRANK PHOS FM-2 by volume.
Bath Points : 20 for a 3% bath to 60 for a 10% bath
Acid Ratio : 13 – 16
Ferrous Iron Titration : 7.2 ml max.

PROCESS
PRECLEANING
Remove all grease by degreasing with Emulsion Cleaners ( using Frank sol & Frank Additive X) FRANK MOVES or solvent wiping. Rinse where necessary.
Remove any medium to heavy rust and scale by acid pickling or preferably, by grit blasting; fine grit blasting can be used to remove heat treatment scale from precision parts. Alternatively, immersing in FRANK DINES and rinsing can remove medium rust. The FRANK PHOS FM-2 process will remove very light rust satisfactorily.
The type of cleaning used determines the crystal size of the phosphate coating. A fine crystal structure gives the best wear prevention and corrosion resistance.

TYPE OF CLEANING	ETCH & CRYSTAL SIZE	RINSING BEFORE FRANK PHOS FM-2
FRANK MOVES/ FRNK SOL / FRANK ADDITIVE X ACID PICKLING/ FRANKDINES	MEDIUM TO LARGE MEDIUM TO LARGE	TWO RINSES ATLEAST ONE RINSE

NOTES
1. After cleaning, an extra rinse in near boiling water may be used to heat the work almost to the temperature of the FRANK PHOS FM-2 bath and thus accelerate the start of the Phosphating. After rinsing, dry as much as possible if a fine grained coating is required.
2.Apply FRANK RUST TECH FBL -2 to any areas of the work where a phosphate coating is not required.

PHOSPHATE COATING
Immerse in the FRANK PHOS FM-2 bath at 90-100°C. The optimum temperature range is normally 95-100°C.The coating time varies from 3 minutes to 20 minutes, depending on the surface condition of the work being treated, the pre cleaning method used and the bath concentration.
In general the finer coatings obtained at the shorter immersion times and higher bath concentration are better for wear prevention . Higher points are not normally necessary if the coating is required solely for protection against corrosion.

The coating is not complete until gassing ceases.
NOTE :
When treating springs, the bath points must not be more than 30

RINSING
FOR WEAR PREVENTION
A single hot water rinse is normally sufficient but if increased corrosion resistance is required, the work can be given an additional FRANK BOND rinse.

DRYING AND SEALING
FOR WEAR RESISTANCE
Either dry and apply Dewatering oil or dip the phosphated parts in 2-5% emulsion of soluble cutting oil in water at 65-93° C. Immediately after rinsing. This reduces staining on cast iron caused by trace of moisture and is preferable where work cannot be dried rapidly.

FOR CORROSION  RESISITANCE

Dry, if necessary using  an oven or compressed air, and paint, stain or oil as soon as possible. Heavy gauge steel parts often contain sufficient latent heat to dry the surface and no extra heat is needed. Small parts can be dried on a hot plate or in a heated centrifuge.

If the work is to be dipped in de-watering oil, drying is unnecessary.

BATH MAKE – UP AND OPERATION

CHEMICALS REQUIRED

The process requires FRANK PHOS FM-2 for Manganese Phosphting and FRANK BOND in the final rinse.

MAKE – UP

1. Partially fill the tank with water and add FRANK PHOS FM-2. Normally baths are made up with 3-5 litres

of FRANK PHOS FM-2 per 100 litres of bath, but if a finer coating is required, e.g. for wear prevention , a

stronger bath containing up to  8-10 litres of FRANK PHOS FM-2 per 100 litres of bath may be preferable.

2. Fill the bath up to its operating level with water and stir the solution thoroughly.

3. Heat the bath to about 70°C. and add a few kilos of degreased steel wool or scrap metal. After an hour,

when the gassing has ceased, remove the metal and titrate for the Iron-build up. Repeat this operation of

ageing” until the ferrous iron titration is 4 .0 ml. Remove the metal and heat the bath to its operating

temperature. The bath is now ready for use.

BATH CONTROL

Restore the working level of the bath regularly with tap water to make good evaporation and drag-out losses. Check FRANK PHOS  FM-2 concentration and ferrous iron titration twice daily as described below and the acid ratio periodically if required. Before testing adjust the FRANK PHOS FM-2 bath to its normal working level with tap water, stir and check that the bath is at its working temperature.

FRANK PHOS FM-2 CONCENTRATION

This can be measured either by a simple test using a measuring cylinder or more accurately by titration. The titration method must be used if the acid ratio of the bath is to be checked.

CYLINDER METHOD

1.Fill the measuring cylinder up to 20 ml, with bath solution.

2.Add a few drops of phenolphthalein indicator solution.

3.Add a small amount of 0.5N Sodium hydroxide. This gives a pink colour, which disappears on shaking.

4.Continue adding small amounts of 0.5N sodium hydroxide and shaking until a permanent pink colour

   is  obtained.

5.Read the level of the liquid in the measuring cylinder ; for each division below the required level add

   375 ml. of FRANK PHOS FM-2.

BATH CONCENTRATION	CORRECT LEVEL
3	29
4	32
5	34
6	37
7	40
8	42
9	45
10	48

TITRATION METHOD
1.Pipette 10 ml of the bath solution into a beaker.
2.Add a few drops of phenolphthalein indicator solution and mix by shaking. 3.Titrate with 0.1N sodium hydroxide until a permanent pink colour is obtained. 4.The number of ml. of 0.1N sodium hydroxide added are the points of the bath. Add 180 ml ( for a 5% V/V bath solution) of FRANK PHOS FM-2 per 100 litres of bath for each ml.

BATH CONCENTRATION	CORRECT LEVEL
3	18
4	24
5	30
6	36
7	42
8	48
9	54
10	60

NOTE       

For  high points baths  a 2ml. Sample of the bath can be used  for titration, but 5 must then multiply the titration figure.

ACID RATIO

The acid ratio normally remains constant and need not be checked provided the FRANK PHOS FM-2 

bath is kept fully worked while at operating temperature and cooled  down when not in use . If the bath

has been underworked or has been standing idle for some time its points be corrected and then its acid

ratio checked at working temperature as follows:

1.Pipette 10 ml.  of the bath solution into  a beaker and dilute to about 100 ml. with distilled water.

2.Add a few drops of methyl orange indicator and mix by shaking.

3.Titrate with 0.1N sodium hydroxide until a definite yellow colour is obtained. The number of ml.added

    is the free acid titration of the bath and is about 5 ml. for a 30 point bath.

Acid Ratio = free acid x 100 / Total Acid = Methyl orange titration x 100 / Phenolphthalein titration

The acid ratio should normally be 13-16 but the optimum value depends on the type of steel and its surface condition. A high acid ratio may cause incomplete coatings, a reddish cast to the coating, or non-adherent coatings, high acid ratio is indicated when gassing persists beyond the usual processing time.

FERROUS IRON TITRATION

1.Pipette a 10 ml. Sample of the FRANK PHOS FM-2 bath in to a beaker or conical flask and dilute to

   approximately 100 ml . with distilled water.

2.Add about 20 drops of 50% sulphuric acid ( C.P.)

3.Titrate with 0.1N potassium permanganate solution from a burette until a pink colour, stable for at least

   15 seconds, is obtained.

4.Record the number of milliliters of 0.1N Potassium Permanganate used as the ferrous – Iron titration.

FERROUS IRON CONTROL

 

When treating steel parts in a Frank Phos FM-2 bath, some ferrous iron is formed in the bath and it is desirable to control this factor within limits to produce uniform coatings. The iron concentration limits

for any given to produce uniform coatings, The Iron concentration limits for any given  bath will vary, depending upon the type  of steel being treated, hardness, surface condition, etc, Normally the most

uniform results are obtained when the ferrous iron titration are within 3.6 ml and 7.2 ml although excellent

Coatings are often obtained in production above and below these limits. The widest limits, which will

Produce acceptable coatings, should be established for a particular job by actual production trials.

Iron control is important. Excessively high iron concentrations may cause

1. a) Incomplete coatings in normal time cycle.

b)Non- adherent coatings.

c)Light grey instead of dark grey to black coatings.

In the  FRANK PHOS FM-2 bath is not heavily loaded and is normally worked within the operating

constants the iron control may not be so necessary.

MAINTENANCE

During processing sludge is formed as a natural by-product of the coating reaction. This accumulates in the bottom of the tank and when it begins to interfere with the processing, the bath should be cleaned out.

To do this, allow the sludge  to settle, decant  the clear solution into the emptied rinse tank and discard the

sludge. Wash out the FRANK PHOS FM-2 tank and return  the solution. Fill the bath to its operating level with tap water and add FRANK PHOS FM-2  to bring the bath to its working strength.

HANDLING PRECAUTIONS

FRANK PHOS FM-2  is slightly acidic and clothing should be protected if there is any possibility  of

Continuous or frequent splashing with the solution. Wash off any splashes at once with cold water .

If the solution gets  in the eyes wash out with liberal quantities of water and obtain immediate medical

Attention.