Troubleshooting Guide For Iron Phospate Process

PROBLEM DEFINITION

POSSIBLE CAUSES

SOLUTION ADVICES

1.Poor Cleaning Parts

Concentration

If concentration is low, make a chemical addition. If it’s high, dilute bath solution to proper concentration with water.

Temperature

Increase/decrease temperature.

pH

If the ph is not in designated paramaters, bath pH should be adjusted by its chemical.

If the bath ph can not adjusted, should use a proper acid for decreasing the bath ph or should use a proper base for increasing the bath ph.

Time

Increase a little bit of the treatment time in case your line is an immersion. Decrease the conveyor speed in case your line is a spray.

Dirty Nozzles

Clean up the nozzles.

Dirty Rinsing Tank

Clean up the rinsing tank.

Nozzle Layout

Pay attention of the nozzle alignment and if the pressure is low, it will need to be increased.  

2. Insufficient Phosphate Coating

Concentration

If the concentration is low, you need to make a chemical addition. If the concentration is high, It may need to be dumped a some of the bath and make a water addition.

Time

Increase/decrease temperature.

pH

If the ph is not in designated paramaters, bath pH should be adjusted by its chemical.

If the bath ph can not adjusted, should use a proper acid for decreasing the bath ph or should use a proper base for increasing the bath ph.

Time

Increase a little bit of the treatment time in case your line is an immersion. Decrease the conveyor speed in case your line is a spray.

Eligibility of the control results in case the problem sources can be either insufficient degreasing or surface cleaning;

See. Problem 1.

3. Flash Rusting

Drying Time/Temperature

Change the drying temperature and time according to interconnected.

Chemical and Water Accumulation on the Indented Parts of the Surface

For preventing the water accumulation on the parts, the hanger should be realigned.

Conveyor Line Stoppage

For preventing stoppage of the conveyor line, add mist nozzles between steps.

Avoid conveyor line halts (stop-and-go).

Conveyor Speed

If the conveyor line is fast, an insufficient coating will happen. If the conveyor line is slow, powdery film on the part will be coming out. Adjusting the speed according to the situation.

Eligibility of the control results in case the problem sources can be either insufficient degreasing or surface cleaning;

See. Problem 1.

Eligibility of the control results in case the problem source can be insufficient phosphate coating;

See. Problem 2.

4.Lower pH

Concentration

Adjust a proper concentration. (After a while working in the new bath, ph will rise.)

5.Higher pH

Concentration

Adjust a proper concentration. (If the bath life is expired, ph will rise. In case that  bath should be renewed.)

6.Mottling, Stripe Phosphate Coating

pH

If the pH is low, mottling will appear. In that case should be increased the pH.

Rinsing

Clean up or renew the rinsing water.

Eligibility of the control results in case the problem sources can be either insufficient degreasing or surface cleaning;

See. Problem 1.

7. Powdering

pH

High pH may cause a powdering. Decrease the pH.

Phosphate Concentration

High phosphate concentration may cause a powdery film on the part. Dilute phosphating solution to proper concentration.

Drying Temperature

High temperature may cause a powdering. Decrease the temperature.  

Stages Inter Transition

Slow or halting (stop-and-go) stages inter transition will cause a chemical drying on the surface of the material. Adjusting the process according to the situation.

Rinsing

Check the rinsing bath TDS and nozzles and then clean up.

8. Smut or Stain Remainings

pH

Attain the pH to the designated parameter.

Eligibility of the control results in case the problem sources can be either insufficient degreasing or surface cleaning;

See. Problem 1.

Injection Pressure of Nozzles

Adjust the cleaning nozzles and its pressure.

9. Poor Adhesion

Eligibility of the control results in case the problem sources can be either insufficient degreasing or surface cleaning;

See. Problem 1.

Eligibility of the control results in case the problem source can be insufficient phosphate coating;

See. Problem 2.

10. Foaming

Bath Temperature

If the bath temperature is low, should be increased.

Pressure

Nozzles may clogged. Clean up the nozzles and decrease the pressure.

Concentration

Concentration may be high. Decrease the concentration of the solution.

11.Water Stain

Rinsing

Clean up the rinsing water.

12.Lower/Higher Chemical Consumption

Nozzle Layout

Pay attention of the nozzle alignment.

Bath Life

The bath should be renewed in case the solution life is expired.

13.High TDS in Rinsing Baths

Baths, Tanks and Nozzles Cleaning Control

Clean up the rinsing system.

Eligibility of the control results in case the problem sources can be either insufficient degreasing or surface cleaning;

See. Problem 1.