346 Electroplating, odizing and Metal Treatment Hand Book

Heavy zinc phosphate coatings ori steel exhibit a more platelike

structure than manganese phosphate . Two varieties are normall y
encountered . When maximum corrosion protection is desired, an iron
content is maintained in the phosphating solution and a crystal structure
is produced . The orientation is principally parallel to the metal surface
and the layered structure offers an excellent surface for the retention of
corrosion resistant oils and waxes.
When a heavy zinc phosphate is used to facilitate cold deformation
such as encountered in the drawing of wire and tubing, cold shaping,
cold extrusion, etc., the phosphating solution is operated under iron-free
conditions resulting in a crystal structure showing a high percentage of
crystals oriented vertically to the metal surface. These thin plates may be
lubricated by one of several methods, including lime, borax, specialized
soaps and oils. In some cases, the surfaces of the individual crystals may
be converted to a zinc . soap. These lubricated plates then provide a
multitude of slipping surfaces that promote the ease of cold deformation .
When a phosphate coating is used to promote paint bonding on
steel or zinc coated steel, a number of options are available to the finishing
engineer. A zinc phosphate coating may be desired for superior
performance in retarding the lateral creep of corrosion between the
organic coating and the metal originating at a scratch through the coating
to the metal. Typical crystal structures for a zinc phosphate formed from
the same solution on steel and galvanized steel. The coating on steel is
tightly bonded to the surface and the effective surface area of the
phosphate coating is considerably greater than the underlying metal.
The phenomenon assists in increasing the adhesion of the organic coating
which is further promoted by increasing the number of sites for mechanical
locking of the coating to the phosphate crystals.
A zinc phosphate coating on a galvanized surface shows a different
structure. In this case, the individual crystals are well-defined and are
distributed in a random orientation on the surface. Note that these
photomicrographs are at a higher magnification than that used for the
corrosion resistant or drawing phosphates. A fine grained phosphate is
desirable for a paint base in order to provide acceptable gloss with
minimum organic coating thickness.
A less expensive but still effective phosphate treatment to promote
paint bonding utilizes a so-called iron phosphate treatment on steel or
zinc rich surfaces. It consists of an extremely fine grained deposit of
mixed oxides and phosphates of iron. The crystal structure is so fine that
the coating is often classified as amorphous. When the same solution
used to produce this coating on steel is used to treat a galvanized surface.