Phosmatt - Phosphating Process
 

Vapormatt Phosmatt Phosphating system

 
 
THE PHOSMATT PROCESS
 
 

The Phosmatt Process will apply the phosphate coating to previously dirty, greasy, scaled and 
 

corroded surfaces, removing the contaminants and starting the phosphate layer, all in one 

 

process.  Even painted surfaces can be stripped and re-phosphated without added 

 

complications.

 

 

The Phosmatt process time required, including all surface preparation is half that necessary for

 

the conventional phosphate stage alone in a normal dip method.

 

 

(Excluding up to five extra pre-phosphating stages for de-rusting, de-greasing and rinsing, which

 

are necessary with conventional methods).  

 

 

The space required for a Phosmatt Process Plant is much less than for spray or dip phosphating

 

lines, which have to include all the aforementioned pre-phosphating stages and incorporate

 

longer phosphate treatment sections to counteract the slower processing speed.

 

 

The Phosmatt Process is simple in principle.

It uses a normal closed-circuit wet blast

technique, as perfected by Vapormatt

Engineers over many years, to simultaneously

etch, de-grease, de-rust and de-scale the 

surface  - leaving a very clean, chemically

active surface which is totally unprotected

from its surroundings.  The Phosmatt

Process uses a heated phosphate solution as

the carrier for the blast media: chemical

action immediately starts with the phosphate

when the virgin, unprotected metal surface is

exposed.  Small, fast growing crystals result.

 

To continue the crystal growth, without 

re-blasting them away (once all the surface

contaminants have been removed), the surface

is further rinsed with phosphate solution alone,

from a special nozzle.  This produces the

main build-up of the phosphate layer, a very

fast build-up which in practice takes only the

same time as rinsing the component to

remove surface debris.  With zinc phosphate,

coating weights of 6 grms/metre squared can

quickly be obtained.

 

Finally, as with conventional phosphating

methods, the treated components have to be

rinsed in running water to avoid corrosion, and

then dried.  However, if a water-based 

coating paint is the next process, this is not

necessary.

Phosmatt Process

Advantages

 ·

Much quicker process - minutes rather

 

than hours.

 

 

 ·

No pre-treatment required (No separate

 

degreasing, de-rusting, or cleaning is

 

necessary).

 

 

 ·

Considerably less space required.

 

 

 ·

Less energy and phosphate solution

 

consumed: all solutions kept in 

 

thermally-insulated closed surrounds.

 

 

 ·

Less water used.

 

 

 ·

Phosphate solutions are automatically

 

filtered to remove flock and other

 

contaminants.

 

 

 ·

Only simple ventilation is required,

 

unlike open tanks in conventional

 

systems.

 

 

 ·

Environmentally safer process.

 

 

 ·

Solutions are auto-electronically 

  

monitored, giving high quality control.

  

 

 ·

Re-phosphating of selected areas, 

 

without stripping whole component, 

 

can be achieved.

 

 
 

The Phosmatt Process is suitable for

automatic or manual operation, dependent

upon the quantity, form, size and variety of

components to be processed.

 
 

Phosmatt process - schematic diagram - crystal growth

 

The Phosmatt Process produces many close

packed crystals which adhere directly onto the

metal substrate.

 

This gives a far more corrosion and shock

resistant coating than the larger, less well

adhered crystals which are formed using

traditional processes.

 

 

 

Typical Applications Of The Phosmatt Process
   
 

1.

Removal of old paint and substrates from

ordnance and engineering components,

then re-phosphating.

 

2.

De-scaling of metal billets, wire, rod, 

tube then phosphating prior to cold 

extrusion or drawing.

 

3.

Oil and scale removal from metal parts,

then phosphating to improve adhesion of

paint.
 

 

 

 

4.

Cleaning and phosphating of transmission

components and sliding engineering parts,

to provide or assist lubrication.

 

5.

Cleaning and phosphating of metal parts to

provide a corrosion-free surface layer.

 

 

6.

Preparation of surface to provide very high

rubber-to-metal bond strength.

   
 

Typical applications of the Phosmatt process

Typical applications of the Phosmatt Process.

 

 
 

 

VAPORMATT REPORT
 

  PHOSMATT  -  An Alternative Phosphating System
 

  The Phosphating of steel surfaces has long been recognised as an excellent pre-treatment for
  painting, coating, or bonding.  The chemical interchanges are fully understood and the materials
  available are sophisticated, easy to use, and their sales are backed-up by high standards of
  expertise and technical support.
   
  However, the methods of applying the chemicals have changed little over the last 50 years, so
  that for most companies, this still means that a long series of immersion or spray operations are
  necessary to clean, degrease, etch, phosphate, neutralise, rinse and dry.  In many instances, up
  to 12 separate operations are necessary.
   
  There is however a system which offers IN A SINGLE OPERATION - simultaneous degreasing,
  cleaning, etching, and phosphating.  In most cases the ONLY additional stations are a post-
  phosphating rinse and drying.  The savings in space and time can be spectacular.  The system is
  called PHOSMATT.

 

  THE PHOSMATT SYSTEM
   
  It has long been accepted that wet-blasting is an effective preparation for phosphating, since it is
  environmentally friendly and produces a CLEAN, ETCHED, AND VERY ACTIVE, NASCENT
 

SURFACE.  Provided no delay occurs  

between wet blast cleaning and phosphating, 

then excellent results are achieved.  

 

It follows therefore, that if delays were reduced

to nil, results should be even better.  By

adding the correct mixture of chemicals to

the water in a wet blast system, the 

conditions for immediate application of 

chemical to the nascent surface are

achieved.

 

Blasting takes place at pressures of up to

80 p.s.i. and the surface is bombarded by a 

fast-cutting grit, water containing the chemical

mix, and compressed air.  As the surface is

cleaned and etched, the chemicals, already in

contact, react to begin the formation of 

phosphate crystals.  Obviously if blasting at

high pressure continues, then the crystals 

would be constantly removed and replaced, 

but by moving the blasted surface out of line

of direct impingement, or by reducing 

pressure, the crystals develop to form a 

complete coating.  At this point, chemical

reaction ceases and the coating is complete.

Phosmatt pre-treatment process
 

  Coatings are applied very quickly - often in seconds.  The rapid build-up and violent agitation
  produces a fine-textured, very dense coating, giving excellent bond strength and highly 
  effective "creep" protection.

 

Coating types and weights

   

 

  LIMITATIONS
   
  No process caters for every possibility and although Phosmatt is adaptable and versatile, it has
  its' weaknesses.
   
  Difficulty can be experienced if complex components are involved, since abrasive grits can be
  trapped in fine holes - particularly threads or blind holes.  Finally, when heavy primary scale is
  present, the system may prove to be too slow and the build-up of removed scale can be
  detrimental to the chemical balance.
   

  EQUIPMENT
   
  Generally speaking, the equipment is similar to that used in conventional wet or vapour blast
  cabinets.  Because of the chemical element, stainless steel or coated steels are used 
  throughout.
   
  Manually operated machines are not very practical because of the relatively high temperatures,
  but simple machines of this type are available.  More practical and useful are tumble blasting
  units, conveyorised or through-flow machines, and a variety of rotary table types.  However, the
  majority of the Phosmatt machines supplied to date would be considered custom-built or
  designed for a specific range of components.
   
 

Vapormatt 1217 Phosmatt barrel machine

             Vapormatt 1217 Phosmatt Barrel Machine.

Vapormatt 1210 Phosmatt Tumble Barrel Machine.

  Filtration is an important feature of Phosmatt equipment and use is made of a wide range of
  techniques.  A free-standing filtration tank is used to provide the control and management of the
  chemical balance.  Slurry from the blast / phosphate station passes through a centrifugal
  separator which removes the blast media (grit).  The liquids pass on to the filter tank where
  re-heating takes place and where sensors detect and indicate the need for fresh chemicals.
  These are injected by a metering system so that the correct balance is always maintained.
   
 

Phosmatt filtration and chemical re-heating tank

 Phosmatt filtration and chemical re-heating tank.

   
  Waste products including ; oil, grease, fine oxide particles, broken-down media, and chemical
  by-products are constantly removed as the liquids pass through a moving bed filter unit equipped
  with a paper roll filter.
 
  The entire process and management systems are programably controlled.

 

 

 

  CONCLUSIONS
   
 
1). Phosmatt offers an alternative method of applying phosphate coatings.
 
2). Phosmatt offers degreasing, cleaning, etching, phosphating in a single operation.
 
3). Phosmatt uses conventional, proven chemicals throughout.
 
4). Phosmatt saves space, time and energy.
 
5). Phosmatt provides superlative coatings, while reducing environmental health hazards.

 

 
 
                                                                        Author:   George Wallis
                                                                        Vapormatt Limited.
   
 
   
 

Vapormatt Ltd reserves the right to change without notice any of the specifications included on this web site.  The content is for illustration only and does not constitute an offer for sale, it should be noted that machines illustrated may include optional items not included in the basic specification.
 
 

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