Surface Treatment and Lubrication of Forged Blank Using Phosphate Treatment
1. Introduction
Phosphate treatment is a common surface treatment that is widely used in the metalworking industry to create a corrosion resistant finish and as a lubricant for cold forging operations. It is generally used in combination with oils and waxes to create a durable surface that can reduce friction and extend the tool life of any operation. The treatment involves the application of a phosphate coating onto the surface of the forged blank. This coating is then further coated with a lubricant such as an oil or wax.
2. Surface Preparation
In order to prepare the surface of the forged blanks for the phosphate treatment it is necessary to first ensure that all surfaces are clean and free of any organic material such as dirt, grease, or oil. This can be done by using a vacuum cleaner or by wiping down the surfaces with a damp, lint-free cloth. All surfaces should be dry before continuing with the surface preparation process.
The next step in the surface preparation process is to remove any surface irregularities that may have been created during forging or machining. This can be done by filing, chiseling, or grinding the surfaces in order to ensure that the coating will adhere properly. Once the surfaces are smooth, they should be washed with a mild detergent and then rinsed with clean water. The surfaces should then be dried thoroughly before continuing.
3.Chemical Adhesion Enhancers
In order to further ensure that the phosphate coating adheres properly to the surface of the forged blank, chemical adhesion enhancers can be used. These chemicals work to increase the surface tension between the coating and the substrate in order to ensure a strong bond. Some common chemical adhesion enhancers that are used in the process are:
•Sodium carbonate solution – this is a solution that is created by mixing sodium carbonate and water. This solution is then brushed onto the surface of the forged blank in order to increase the surface hydrophobicity.
•Electrolytic zinc phosphate solution – this is a solution that works to increase the surface tension of the coating and the substrate. The solution is created by mixing zinc phosphate and water.
•Phosphoric acid solution – this is a solution that is created by mixing phosphoric acid and water. It is used to etch the surface of the forged blank in order to ensure that the coating is able to adhere properly.
4.Applying the Phosphate Coating
Once the surface has been prepared and the adhesion enhancers have been applied, the phosphate coating can now be applied. The most common method of applying the coating is with an electroplating method. This process involves submerging the part in a solution containing the desired phosphate coating and then applying an electric current. The electric current causes the ions in the solution to bond to the surface of the forged blank. The part is then removed from the solution and washed with clean water in order to remove any excess coating material.
5. Oils and Waxes
Once the phosphate coating has been applied, the next step is to apply a lubricant such as an oil or wax in order to further reduce friction and extend the life of the tool. Generally, an oil or wax is applied by using a brush or roller to spread the lubricant onto the surface of the part. It is important that the lubricant is spread evenly and that any excess lubricant is removed to avoid contamination.
6.Conclusion
Phosphate treatment is a common surface treatment used in the metalworking industry to create a corrosion resistant finish and to reduce friction in order to extend the life of tools. It involves the application of a phosphate coating onto the surface of the forged blank followed by the application of a lubricant such as an oil or wax. The proper surface preparation is essential to ensure proper adhesion between the coating and the substrate. In addition, chemical adhesion enhancers can be used to increase the surface tension between the coating and the substrate. Finally, an oil or wax can be applied in order to further reduce friction.
