Frank Alkanes India Pvt Ltd

FRANK PHOS FZ-5

INTRODUCTION :
FRANK PHOS FZ-5 is an accelerated warm dip process which produces a fine smooth Zinc Calcium Phosphate coating on steel and zinc surfaces.

BENEFITS :
FRANK PHOS FZ-25provides the following important benefits.

PROTECTION AGAINST CORROSION :
FRANK PHOS FZ-5 protects Iron and steel surfaces against rusting and prevents rust creep under the paint film should the film become broken.

Saves Pre-rinsing FRANK PHOS FZ-5 gives the smooth coatings even after acid or alkali cleaning without special pre-rinsing.

IDEAL FOR PAINTING
FRANK PHOS FZ-5 provides an excellent foundation for paint on steel or zinc surfaces.

SUITABLE FOR ONE-COAT FINISHING
FRANK PHOS FZ-5 can be coated with a single coat of gloss paint. Its fine crystal formation ensures minimum paint sinkage into phosphate layer and hence minimum gloss reduction.

SIMPLIFIED PROCESSING
FRANK PHOS FZ-5 enables steel and zinc surfaces to be processed simultaneously.

EASY OPERATION :
FRANK PHOS FZ-2 is easy to operate and is controlled by simple tests requiring no special chemical knowledge. No fumes or odours are given off.

APPROVALS
FRNAK PHOS FZ-5 meets specification WPN/GEN/ 3:1965 as a class II/III accelerated process and the requirements of IS:3618:1966 class B/C.

USES
FRANK PHOS FZ-5 is ideal for a wide range of zinc and ferrous metal articles. Typical uses include car accessories, metal cases, signs and sheet metal parts. It is particularly recommended for articles which will have to withstand severe climatic conditions after painting.

SUMMARY OF OPERATION DATA
BATH MAKE-UP
For each 100 litres of bath, add to the water with stirring :
Process with FRANK TONE : FRANK PHOS FZ-5 - 5 Litres. FRANK TONE 1 Ltr . ( 20 gms. per ltr)
Process without FRANK TONE : FRANK PHOS FZ-5 – 5 Litres.

CONTROL POINTS ( GUIDANCE ONLY)

PROCESS

	WITH FRANK TONE	WITHOUT FRANK TONE
Points	25-35	25-35
Starch Iodide Paper test	Positive	-
FRANK TONE Titration	1-4 ml	-
Ferrous Concentration	-	0.04 – 0.5%
Immersion Time	10 -15 mts	10 -15 mts
Temperature	65-70° C	75 - 90° C

PROCESS
PRECLEANING
1.Remove all grease by degreasing with FRANK SOL, FRANK MOVES, or solvent wiping. Rinse where necessary.
2.Remove any rust and scale present by immersing in FRANKDINES and rinsing. Alternatively if the scale is heavy, the surface is best cleaned by sand blasting or alternatively by pickling and rinsing thoroughly in two stages.

PHOSPHATE COATING
Immerse in the FRANK PHOS FZ-5 bath with Frank Tone for 10-15 minutes at 65-70°C. The Bath may also be operated at 75-90°C. with out Frank Tone and with Iron built-up. Details are given in process without FRANK TONE.

RINSING
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.

NOTE For Defence specification work an additional hot water rinse is required before the final rinse.

DRYING
Dry using an oven on compressed air if necessary.
Small parts can be dried on a hot plate or centrifuge.

Sealing
Phosphate coatings are not in themselves rust-proof and must be sealed with paint or oils as soon as possible to provide permanent protection.

BATH MAKE-UP AND OPERATION:

Chemicals Required:

The process requires FRANK PHOS FZ-5, FRANK TONE Crystals and FRANK BOND for use in the final rinse.

MAKE-UP
1.Partially fill the tank with water and add 5.0 litres of FRANK PHOS FZ-5 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 its operating temperature.
4.Immediately before commencing production add 1 ltr.of FRANK TONE solution (Prepared by
dissolving 20 gms of Frank Tone in 1 Ltr. of Cold water ) for every 100 litres of bath ( when the process is operated with FRANK TONE)

PROCESS WITH FRANK TONE
Restore the working level of the bath regularly with tap water to make good evaporation and drag out losses. Check the FRANK PHOS concentration at least twice daily and the FRANKTONE concentration several times a day using the tests described below. Replenish if necessary. It is most important that the FRANK TONE is always maintained at the correct concentration.

BATH CONTROL
The FRANK PHOS FZ-5 and FRANK TONE concentration can be determined by simple tests, but more accurately by titration.
1.Check that the bath temperature is correct.
2.Dip a piece of starch iodide paper in the bath. After 15 seconds, colour change will indicate the concentration of the FRANK TONE as shown below.

COLOUR OF TEST PAPER

• No FRANK TONE- Remains White
• Insufficient FRANK TONE- Pale Mauve
• Correct FRANK TONE - Blue to Dark Blue.
• Excess FRANK TONE - Black.

3. If necessary add more FRANK TONE solution prepared in water as given above.

NOTE;
It is important to have the correct amount of FRNK TONE IN FRANK PHOS baths and if required small additions should be made at regular intervals. Too much FRANK TONE or large infrequent additions, cause excessive sludge formation and wastage of FRANK PHOS , too little can result in an accumulation of iron salts which throws the bath out of balance. Such a bath often has a brown colour and although it still gives a slightly positive test for FRANK TONE (i.e it turns the FRANK TONE papers pale blue) , it does not produce normal coatings. The brown colour can be cleared by raising the temperature of the bath as much as possible and making successive additions of 20% w/v solution of FRANK TONE solution in water in small quantities at a time. While clearing the colour, brown fumes will be given off and heavy sludge will form. The bath should be desludge before bringing into use.

The accurate control tests are as follows:

FRANK PHOS FZ-5 strength by titration method.
1.Pipette 10 ml of the bath solution into a beaker.
2.Add a few drops of phenolphthalein indicator and mix by shaking.
3.Titrate with 0.1 N Sodium hydroxide added is the ‘Point ‘ of the bath .Add 180 ml of FRANK
PHOS FZ-5 per 100 litres of bath for each point below 25.

FRANK TONE TEST BY TITRATION
Before doing the titration, the bath is tested with starch iodide paper. It must be positive. If not, FRANK TONE Crystals, previously dissolved in water , must be added to ensure that the bath is Positive to starch Iodide paper test.

1. Pipette 50 ml bath solution into a flask.
2. Add 10 ml of 50% sulphuric acid and mix.
3.Titrate with N/10 pottassium Permanganate to a pink colour, which will persist for at least 15 seconds.
4.The number of ml of N/10 pottassium permanganate added is the FRANK TONE Titration.
5.Normal limits for FRANK TONE titration are 1-4 ; it is generally preferable to operate at the lower limit (preferred range 0.5 to 1.5 ml).
6.Add approximately 30 ml of 25% solution of FRANK TONE Crystals in water to raise the FRANK TONE titration by 1 ml.

PROCESS WITHOUT FRANK TONE
FRANK PHOS FZ-5 baths may be operated without FRANK TONE at a temperature of 75 - 90°C. Processing and bath operation are the same as described above. The coating obtained is slightly heavier, but it still retains its essential smooth texture and the bath forms even less sludge than when operated with FRANK TONE . Age fresh bath before use by heating to about 70-75 °C And adding 25-50 gms of degreased steel wool per 100 litres of solution. After about 10 minutes when the gassing has ceased remove the wool heat the bath to its operating temperature and bring into use. It is essential to have a minimum iron content of 0.04% to commence the phosphate coating.

NOTE
A bath which has been working above 75 °C , cannot be operated at a lower temperature by adding FRANK TONE Crystals.

Here again the FRANK PHOS FZ-5 bath is controlled by determining its strength and ferrous Iron concentration as follows:-
FRANK PHOS FZ-5 strength may be done accurately by titration method as before. Ferrous Iron titration must be done once daily as follows:-

DETERMINATION OF IRON CONCENTRATION :-
Pipette 10 ml sample of bath solution into a conical flask. Add 5 ml of 50% sulphuric Acid solution. Titrate with N/10 pottassium permanganate solution to a pink colour that persists for at least 15 seconds.
Ferrous Iron= No. of mls. Of N/10 Pottassium Permanganate required x 0.056 when the ferrous iron concentration reached 0.4% or more discard all or part of the bath.

MAINTENANCE
When the FRANK PHOS FZ-5 process is operated with FRANK TONE, sludge is formed as a natural product of the coating reaction. ( Much less sludge is formed when it is operated without FRANK TONE but heavier coating are deposited).
The sludge 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 onto the emptied rinse tank and discard the sludge. Wash out the FRANK PHOS tank and return the solution restore the bath to its operating level by adding water and the same proportion of chemicals used in the bath.

HANDLING PRECAUTIONS :
FRANK PHOS FZ-5 is slightly acid and clothing should be protected if there is any possibility of continuous or frequent splashing with the solution. Wash off any splashes on the skin at once with cold water. If the solution gets in the eyes, wash out with liberal quantities of water and obtain immediate attention.