CHEMPHOS 111

(Manganese Iron Phosphate)

CHEMPHOS 111 is an hot dip process giving a heavy Manganese Iron phosphate coating
on Iron and Steel

BENEFITS

CHEMPHOS 111 provides the following important benefits.

PROTECTION AGAINST RUSTING

CHEMPHOS 111 also gives outstanding protection against corrosion and when stained
and oiled will often protect the article from rusting throughout its normal life.

LOW FILM BUILD UP

CHEMPHOS 111 coatings give only about 10 – 20 gms/m2.

ECONOMICAL PROCESS

CHEMPHOS 111 gives excellent protection against wear and rusting at an extremely low
cost.

EASY OPERATION

CHEMPHOS 111 is easy to operate and is controlled by simple tests requirement to

APPROVALS

CHEMPHOS 111 meets WPN/GEN/3:1965 as a class I accelerated process and meets the
requirements of IS 3618/1966 class A1.
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USES

CHEMPHOS 111 is ideal for use on moving parts such as piston rings, gears and cam
shafts, to give maximum protection against wear, particularly during running in. It forms
a coating integral with the metal and when oiled and used a bearing surface it holds the
oiled between the moving parts, thereby maintaining lubrication and bearing the burden
of the first wear. In use the coating quickly becomes very smooth so that friction is
reduced and tearing and scuffing of the metal is eliminated. Thus the CHEMPHOS 111
coating protects the metal, prevents seizure, fretting corrosion and excessive wear and
consequently greatly increases the life of the moving part.

CHEMPHOS 111 can also be used to protect against corrosion and is particularly suitable
for coating, tools, nuts, bolts, service equipment and similar parts which can be stained
and oiled but not readily painted.

OPERATING DATA

BATH CONCENTRATION 5 – 10% CHEMPHOS 111 by volume

BATH POINTS 30 –60

BATH TEMPERATUREOC 95 – 100oC

IMMERSION TIME 15 –30 Minutes (Till gassing ceases)

COATING WEIGHT 1000 – 4000 mg/ft2.

FERROUS IRON TITRATION 7.2 ml Maximum

PROCESS

After degreasing and derusting, an extra rinse in near boiling water may be used to heat
the work almost to the temperature of the CHEMPHOS bath thus accelerate the start of
the phosphating. After rinsing, dry as much as possible if a fine grained coating is
required.
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PHOSPHATING COATING

Immerse in the CHEMPHOS 111 bath at 90 – 100oC. The optimum temperature range is
normally 90 – 100oc. The coating time varies from 10-20 minutes depending on the
surface condition of the work being treated, the precleaning method used and the bath
concentration.

In general, the finer coating obtained at the shorter immersion times and higher
concentrations are better for wear prevention. High points is not normally if the coating
is required solely for protection against corrosion.

The coating is NOT complete until GASSING (REACTION) CEASES.

NOTE: When treating springs, the BATH POINT must not be more than 30.

RINSING

For wear prevention

A single hot water rinse is normally sufficient but it increased corrosion resistance is
required the work can be given an additional CHEMLYTE 10 rinse.

For corrosion resistance

Rinse for 30-45 seconds in clean running water and then in hot water containing 25ml of
CHEMLYTE 10 per 100 litres of water. CHEMLYTE in the final rinse counter acts the
effects of any hardness in the rinse water and improves the corrosion resistance.

DRYING AND SEALING

For wear resistance

Either dry and apply a CHEMTEC dewatering oil or dip the phosphated parts in a 2-5%
emulsion of soluble cutting oil in water at 65-93oC immediately after rinsing. This
reduces staining on cast Iron caused by traces of moisture and is preferable where work
cannot be dried rapidly.
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For corrosion resistance

Dry, if necessary using an oven or compressed air, and paint, stain or oil as soon as
possible. Heavy gauge steel parts often contain sufficient latent heat to dry the surface
and no extra heat is needed, small parts can be dried on a hot plate or in a heated
centrifuge.

BATH MAKE UP AND OPERATION

Chemical required

The process required CHEMPHOS 111 and CHEMLYTE for use in the final rinse

BATH MAKE UP

1. Partially fill the tank with water and add CHEMPHOS 111. Normally baths are
made up with 3-5 litres of CHEMPHOS 111 per 100 litres of bath, but if a finer
coating is required, e.g. for wear prevention, a stronger bath containing up to 8-
10litres of CHEMPHOS per 100 litres of bath may be preferable.

2. Fill the bath up to its operating level with water and stir the solution thoroughly.

3. Heat the bah to about 70oC and add few kilos of degreased Steel Wool or scrap
metal. After about an hour, when the gassing has ceased, remove the metal and
titrate for the Iron build up. Repeat this operation of `ageing’ until the Ferrous
Iron titration is 4.0 ml. Remove the metal and heat the bath to its operating
temperature, the bath is now ready for use.

BATH CONTROL

Restore the working level of the bath regularly with tap water to make good evaporation
and drag-out losses. Check the CHEMPHOS 111 concentration and Ferrous Iron titration
twice daily as described below . Before testing adjust the CHEMPHOS bath to its normal
working level with tap water, stir and check that the bath is at its working temperature.
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CHEMPHOS 111 CONCENTRATION

This can be measured by titration

1. Pipette 10ml of the bath solution into a beaker.

2. Add a few drops of Phenolphthalein indicator solution and mix by shaking.

3. Titrate with 0.1N Sodium Hydroxide until a permanent pink color is obtained.

4. The number of ml of 0.1N Sodium Hydroxide added are the points of the bath.
Add 160ml of CHEMPHOS 111 per 100 litres of bath for each ml below the
required points.

NOTE: For high points baths a 2ml sample of the bath can be used for titration, but the
titration figure must then be multiplied by 5.

FERROUS IRON TITRATION

1. Pipette a 10ml sample of the CHEMPHOS 111 bath into a beaker or conical flask
and dilute to approximately 100 ml with distilled water.

2. Add about 20 drops of 50% Sulphuric Acid (C.P)

3. Titrate with 0.1N Potassium Permanganate solution from a burette until a pink
color, stable for at least 15 seconds.

4. Record the number of milliliters of 0.1N Potassium Permanganate used as the

FERROUS IRON CONTROL

When treating steel parts in a CHEMPHOS bath, some Ferrous Iron is formed in the bath
and it is desirable to control this factor within limits to produce uniform coatings. The
Iron concentration limits for any given bath will vary, depending upon the type of steel
being treated, hardness, surface condition etc, normally, the most uniform results are
obtained when the Ferrous Iron titration are within 3.6ml and 7.2 ml although excellent
coatings are often obtained in production above and below these limit. The widest limits
which will produce acceptable coatings should be established for a particular job by
actual production trials.

Iron control is important. Excessively high Iron concentration may cause

 Incomplete coatings in normal time cycle

 Non adherent coating and

 Light gray instead of dark gray to black coatings (sometimes lowering wear and
corrosion resistance)

MAINTENANCE

During processing sludge is formed as a natural by-product of the coating reaction. This
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 into the emptied rinse tank and clean the phosphating tank and return the
solution. Fill the bath to its operating level with tap water and add CHEMPHOS to bring
the bath to its working strength.

SERVICE

All CHEMPHOS plants are put into operation by TCF’s Technical Staff who give the
operation in charge the few instructions necessary to ensure the best possible results.

HANDLING PRECAUTIONS

CHEMPHOS is slightly acidic 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 medical attention.

FURTHER INFORMATION

For further information on chemical processes for pretreatment of metal surfaces

OFFICE THIN – CHEMIE FORMULATIONS

Email : [email protected]

Website : www.thinchemie.com