1、- m Manufacturing Standards u-PL 053-8000 tLL FlNE Y-A IN t NA PROVEMENT OF RUNNINGJN AND REDUCTlON OF WEAR Feinkristalline Mangan-Eisen-Phosphatierung 1. Scope This Manufacturing Standard lays down recommended processes by which a fine crystalline manganese-iron phosphate coating can be applied to
2、heavy duty machine parts, which meets Engineering Specifications WSD-M3P33-A2 and S-M3PI 5-A. 2. Apphcation In this process a phosphate coating, is applied to the surface, which effectively prevents formation of scuffing and erosion during the nmning-in period. 3. Process Only the following processe
3、s are approved for the production of fine crystalhne manganese iron coatings in accordance withe WSD-M3P-3242 and S-MSPISA. Before a process is selected, its intended use shall be agreeed with Product Enginnering. A process, once selected. shall be applied in its entirety. It is not permissible to c
4、ombine, e -g. the pte-treatment of Process A with the intetmediac treatment of Process B. 3.1 Cleaning Parts to be treated shall be delivered in pre-cleaned condition free of tust and other soil. This is usually achieved by sending parts through an appropriate production washing machine. *tion Proce
5、ss A Process B Process C 3.2 Pre-Treatment Material: Matuf. Standard: Hydrocarbon based cold cleaner or equivalent U-MB 003-8006 or equivalent Strongly aikaline cleaner U-MB 005-8034 or equivalent Weak alkaline cleaner U-MB 0058033 or equivalent Concentration: A I : 4 mixture of U-MC 004-800 1 and p
6、a bath can be operated in alternative strenghs Rinse in running, cold water Pre-heat by immersion in hot water Water - 95 to 100C 1 to 2 minutes U-MB 003-8005-O 1 Depends upon rate and type of plant : bath can be used within its capacity 1. Total Acid Points *: 45 to 55 Total Acid Points *: 30 to 80
7、 Free Acid Points *: 6 to 11 - Acid Ratio: (Total ):(Free) = (4J to 7,0):(l) - 2. Total Acid Points: 85 to 89 Free Acid Points : 14 to 23 Temperature: Time: Acid Ratio: (Total):(Free)=(4,5 to 6,5):( 1) 95 to 9SC 95 to 98C Nominal 8 to I2 minutes or as required to maintain specified coating thickness
8、 95 to 9SsC Nominal IO to 30 minutes or as required to maintain specific coating thickness * Definition of -Points” see under 5.2 -Titrations”. Plating February 1996 u-PL 053-8000 Page 2 of 5 u-PL 053-8000 35.2 Phosphate Coatineoatino for Steel with more than 0.9% Chromiam Material: Manganese phosph
9、ate concentrate Manuf. Standard: U-MB 003-8005-02 U-MB 003-8005-02 Total acid points *: 125 to 145 Free acid points *: 17 to 29 Acid ratio: (Total):(Free)=(S to 7):(l) Temperature: 95 to 98OC 95 to 98C Time: Nominal 8 to 12 minutes or as required to maintain specified coating thickness 3.6 Rinse Rin
10、se with cold water Rinse with cold water 3.7 m Rinse with hot water Rinse with hot water Temperature: 50 to 60C 50 to 60C 3.8 Corrosion Protection (for storage and shipment only) U-MB 003-8005-O I _- Rinse with cold water Rinse with hot water 50 to 60C Immerse parts in a solution of water-miscible c
11、oolant / lubricant having at least 5% oil content in the bath, at a temperature of 60+-2C and a pH-value of not less than 8. 3.9 J&Qlg Blow off with compressed air only if siutable workingplace with exhausting-system is available (Process A. B, C). 4. General Every revision to the rext of this speci
12、fication requires prior agreement with Product Engineering. All,marerials to this Manufacturing Standard require approval in line with Procedure EU-Ii-dl. Plating Februav 1996 U-PL 053-8000 Page 3 of 5 U-PL 053-8000 5. Maintenance and Control of Phosphate-Coating-Bath 5.1 Initial Bath Make-Uo Each 0
13、,25 kg of U-MB 003-8005-O l/-O2 to every I00 litres phosphating solution represents one point. 5.2 Titrations. (Note: 1 Point = 1.0 ml of titrating agent) Total acid ooints: Titrate 10.0 ml bath solution with n/10 soda-solution against phenolphthalein as an indicator until colour turns pale red- vio
14、let. Free acid uoints: Titrate 10.0 ml bath solution with n/IO soda lye against bromophenol blue as an indicator until colour turns from y,ellow to blue. Iron ooints: Titrate IO,0 ml bath solution plus 20 drops of a 50% sulphuric acid solution with n/10 potassium petmanganate until colour turns red,
15、 remaining so for about 20 seconds. The f0llowinP atrolies to maximum iron content: 7 Iron Points - 4 g Fe(H) per litre bath solution at 30 to 50 Total Acid Points. I4 Iron Points - 8 g Fe(B) per lime bath solution at 90 Total Acid Points. 5.3 Correction of Total Acid Points Value In order to raise
16、the acid content by one point, 0,16 hue of U-MB 008OO5-Ol/-O2 concentrate must be added per 100 litres bath solution. These replenishments must take place at frequent intervals. The required value of Total Acid Points shall not drop by more than 2 points. 3.4 Correction of Free Acid Points For each
17、free acid point above the specified value, 60 g manganese carbonate shall be added for every 100 lines bath solution. The amount of manganese carbonate, required for neutrahzation, is added to the bath slowly and distributed as evenly as possible over the whole bath surface area in the form of a 10
18、% aqueous suspension, until the manganese carbonate is dissolved. Plating February 1995 U-PL 053-8000 Page 4 of 5 u-PL 053-8000 5.5 G-s Instruction Parts (and their racks) should be removed from the bath if there is any break in production and prior to any free acid corrections: The bonder container
19、 is filled IO 213 with softened or demineralized water. The required amount of phos- phating agent is added to the bath, which is then brought up to its working level by the addition of water and then well mixed. Finally the bath is heated to the working temperatureof 92 to 98C. Only then can phosph
20、ating begin. When production is interrupted for a longer period, it is benificial for durability, that the phosphating path temperature is lowered to 92T. When the phosphating plant is not operating continously, the batii temperatures should be set in accordance with the instructions ofthe phosphate
21、 material suppliers. 6. Health and Safety The chemi& used in this process are either acids or alkalis. The Occupational Health and Safety functions shall be informed in advance of the intended use of the process and appropriate measures shall be taken. 7. General Informations Setting up and checking
22、 the phosphating plant is best begun one hour before production stap. 7.2 Control The function of the temperature-regulation-equipment and the level-regulator for replenishing evaporation loss shall be checked continously. A general cleaning and checking of the whole plant shall be carried out each
23、week. 8. Eaivronmental Control - Waste and Effluent Disposal Effluent shall be diverted into the industrial effluent pipeline for further treatment in a waste-water-treatment-plant if one is available. If not, separate treatment for the removal of heavy metals may be necessary. Before dumping the ph
24、osphating containers, the waste-treatment-plant has to be informed. 9. Related Standards U-MB 003-8005 U-MB 003-8006 W-MB 003-8007 U-MB 003-8034 U-MC 004-8001 Concentrate. Manganese Phosphating, Wear-Resistance Cleaner. Dip, before Manganese Activator. Manganese Phosphate Cleaner. Strong Alkali Kerosene February 1995 Plating U-PL 053-8000 Page 5 of 5
