FRANK PHOS FZ-1 is a chemical intended for accelerated hot dip process which produces medium to heavy Zinc iron phosphate coatings on steel.
FRANK PHOS FZ-1 provided the following important benefits:
FRANK PHOS FZ-1 protects iron and steel surfaces against rusting.
FRANK PHOS FZ-1 immersion times can be varied to give medium or heavy coatings as required.
FRANK PHOS FZ-1 medium weight coatings provide a very good foundation for paint and prevent rust creep under paint should the film become broken.
● Produces highly adherent coatings.
● Designed to tolerate higher load ratios and hence very little control is needed.
● Special accelerators and refiners produce highly refined, heavier coatings in a very short time.
● Coating weight of 8-20 gms/ Sq.m is easily achieved.
● Produces highly corrosion resistant coatings.
● Coating weight can be varied from medium to heavy by varying the coating time.
FRANK PHOS FZ-1 heavy weight coating provide an excellent base for stains and oils and are recommended for small component parts requiring rust protection with minimum build-up on threaded surfaces.
FRANK PHOS FZ-1 has low processing costs and requires a minimum of plant maintenance.
FRANK PHOS FZ-1 is easy to operate and is controlled by simple tests requiring no special Chemical knowledge. No fumes or odours are given off.
FRANK PHOS FZ-1 meets specification WPN/GEN/ 3:1965 as Class 1 accelerated process and The requirements of I.S.3618:1966 Class A2.
FRANK PHOS FZ-1 is ideal for a wide range of ferrous metal articles like car accessories, Metal cases, signs, stampings, castings, forgings, sheet metal parts and small components like nuts and bolts.
● Bath make up : 3 litres FRANK PHOS FZ-1 & 2 litres Frank Activator per 100 litres of water.
●Bath Pointage : 25 – 35
●Iron Content : 0.05 – 0.4%
●Bath Temperature : 80 - 90◦C
●Immersion Time : 7 – 30 minutes.
● Coating weight : 8 – 20g/sq.m.
1. Remove all grease by Trichloroethylene degreasing, FRANK SOL, FRANK MOVE FG-3 or Solvent wiping. Rinse where necessary.
2. The surface is best cleaned by shot blasting or alternatively by pickling and rinsing thoroughly in two stages.
Immerse in the FRANK PHOS FZ-1 bath for 7-30 minutes at 80-90◦C. The immersion time depends on the type of coating required. Heavier weight coatings with increased corrosion resistance are obtained by lengthening the immersion time 20-30 minutes and this type of coating is ideal where stain or oil is to be used.
Rinse in clean running water followed by a hot water rinse containing a trace of FRANK BOND. FRANK BOND in the final rinse counteracts the effects of any hardness in the rinse water and improves the corrosion resistance. It also acidifies the surface slightly before drying and thereby ensures good paint adhesion even under prolonged humid conditions.
DRYING
Dry, using an oven or compressed air if necessary . 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.
SEALING
Phosphate Coatings are not in themselves rust-proof and must be sealed with paint, stain or oils as soon as possible to provide permanent protection. Details of FRANK STAIN FBS will be made available on request.
BATH MAKE – UP & OPERATION
Chemical required
The Process requires FRANK PHOS FZ-1, FRANK ACTIVATOR , FRANK BOND for use in the final rinse.
MAKE-UP
1. Partially fill the tank with water and add 3 litres of FRANK PHOS FZ-1 for every 100 litres of bath.
2. Fill the bath up to its operating level with water and stir the solution thoroughly.
3. Heat the bath to 70-75°C and add a few kgs of degreased steel wool or scarp metal. After about 20 minutes, when the gassing has ceased, remove the metal. Repeat the operation until a minimum Iron content of
0.05% is built.
4. Add 2 Litres of FRAK ACTIVATOR per 100 litres of bath and mix thoroughly. Check the pointage and adjust to working concentration by adding FRANK PHOS FZ-1. Heat the bath to the 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 the FRANK PHOS FZ-1 concentration twice daily as described below and the iron concentration once
daily. Before testing adjust the FRANK PHOS FZ-1 bath to its normal working level with tap water, stir and check that the bath is at its working temperature.
FRANK PHOS FZ-1 CONCENTRATION
This can be measured accurately by titration.
1. Pipette 10 ml of the bath solution in to a beaker.
2. Add a few drops of Phenolphthalein indicator and mix by shaking.
3. Titrate with 0.1 N Sodium hydroxide until a permanent pink colour is obtained.
4. The number of ml of 0.1 N sodium hydroxide added is the “Point” of the bath.
5. The strength of the bath when titrated as above will give a minimum pointage of 26.0.
6. Add 150 ml of FRANK PHOS FZ-1 per 100 litres of bath for each point rise below 30.0 points
IRON CONCENTRATION
When treating steel parts some ferrous iron is formed in the bath. Where the bath is not heavily loaded, or is used intermittently, the ferrous iron concentration remains constant at 0.05 – 0.4% and need not be
measured or controlled. If the bath is heavily loaded @ 1 sq.ft/ litre of bath per hour, the ferrous iron concentration may need controlling. This can be done by adding 1.25 litres of FRANK ACTIVATOR to the bath
with every 10 litres of FRANK PHOS FZ-1 added to maintain the points.
If the ferrous iron content should build up, the coating reaction will slow down and chalky or loose Coatings may be produced. The bath can be restored to its normal condition by discarding a portion of the bath,
replenishing it with fresh water and adjusting the strength with FRANK PHOS FZ-1.
Alternatively, the following procedure may be adopted to reduce iron content by 0.05% for every 1000 litres of bath capacity.
METHOD 1
1. Take about 500 g of Caustic soda and dissolve in about 5 lit of water.
2. To this add about 600 ml of 100 volumes ( 30%) Hydrogen Peroxide and mix thoroughly.
3. Without much delay pour this solution into the bath.
4. Mix thoroughly and only after allowing the sludge to settle, the work should be processed.
METHOD 11
1. Take about 200g of FRANK TONE and dissolve in about 1 litre of water and pour slowly into the bath.
2. Take about 500 gm of Caustic soda and dissolve in about 5 lit of water and pour slowly into the bath
3.Mix thoroughly and only after allowing the sludge to settle, the work should be processed.
NOTE:
1.If drip feed additions are available, the additions of Caustic Soda can be avoided.
2. This is the maximum recommended quantity per shift, and higher dosages than the above should be avoided to maintain the bath balance.
ESTIMATION OF IRON IN THE BATH
The ferrous iron concentration is to be checked by titration as follows: 1 Pipette 10 ml of the bath solution into a beaker and dilute to about 100 ml with distilled water.
2.Add about 2 ml of 50% Sulphuric acid an titrate with 0.1 N potassium permanganate ( 3.16gm/ lit) until a permanent faint pink colour is obtained. The no.of ml. of potassium permanganate added is a measure of
the ferrous iron in the bath.
% of IRON = Titration Value x 0.056.
| Titration in ml | % Iron |
|---|---|
| 1.0 | 0.06 |
| 3.0 | 0.17 |
| 5.0 | 0.28 |
| 7.0 | 0.39 |
| 9.0 | 0.50 |
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 FZ-1 tank and return the solution. Restore the operating level by
adding tap water, FRANK PHOS FZ-1 in the same proportions as the original bath.
| NO | PROCESS | CHEMICAL | CONC. | TEMP. | TIME |
| 1 | DEGREASING | FRANK MOVE FG-.3 | 5-8% | 85 - 90°C | 15-20 Mts. |
| 2 | RINSING | --- | --- | AMBIENT | FLASH |
| 3 | DESMUTTING or DESCALING (Optional) | CAUSTIC SODA | 20% + 7% +KMnO₄ | 70 - 80°C | 5-10 Mts |
| 4 | RINSING | --- | --- | AMBIENT | FLASH |
| 5 | DERUSTING | FRANK DINE FDR-4 | 33%V/V | AMBIENT | 5-10 Mts |
| 6 | RINSING | --- | --- | AMBIENT | FLASH |
| 7 |
RINSING (OPTIONAL) |
--- | --- | AMBIENT | FLASH; |
| 8 | SURFACE CONDITIONING | FRANK SURFINE TX | 0.3-0.5% (W/V) | AMBIENT | FLASH |
| 9 | ZINC PHOSPHATING | FRANK PHOS FZ-1 AND FRANK ACTIVATOR |
3% 2% |
75 - 90°C | 15-20 Mts |
| 10 | RINSING | ---- | --- | AMBIENT | FLASH |
| 11 | RINSING (OPTIONAL) | ---- | --- | AMBIENT | FLASH |
| 12 | PASSIVATION | FRANK BOND | 0.05% V/V | 60 -70°C | 1Mt. |
| 13 |
DE – WATERING CUMRUST PREVENTIVE |
FRANK RUST TECH WD 1901 / 1902 |
--- | AMBIENT | 1-5 Mts |
HANDLING PRECAUTIONS
FRANK PHOS FZ-1 is slightly acidic and clothing should be protected if there is any possibility of splashing with the solution. Wash off any splashes at once with cold water. If the solution gets in the eyes wash
out with liberal quantites of water and obtain immediate Medical attention.
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