Phosphating Steel with Pre-Deposited Activation Particles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing anti-corrosive coated steel products often result in incomplete removal of functional coatings, leading to uneven phosphating surfaces with poor adhesive adhesion due to residual coating layers obstructing activation particles from reaching the steel surface.
Innovation Solution
Applying additional activation particles to the steel product before or during tempering and coating steps, allowing for improved phosphating even if the functional coating is not completely removed, enhancing the uniformity and adhesion of the phosphate layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a functional coating is applied to the steel flat product before forming, then the formability and adhesion during forming are improved, but residues of the functional coating remain on the surface after cleaning, preventing uniform phosphating
Solution Approach 1:
Activation particles are applied to the steel flat product before the functional coating is applied, so that when phosphating occurs later, the activation particles are already in position to promote uniform phosphate crystal formation. This preliminary placement of activation particles ensures that even with functional coating residues present, the phosphating process can proceed uniformly across the surface.
2Manufacturing precision
If a cleaning step is performed to remove the functional coating, then the surface should be clean for phosphating, but the cleaning step is incomplete and residues remain, leading to uneven phosphate crystal formation
Solution Approach 1:
The phosphating process itself serves to address the presence of functional coating residues. By applying activation particles beforehand, the phosphating process can proceed effectively even without complete removal of functional coating residues, as the activation particles compensate for the imperfect surface cleanliness and promote uniform phosphate crystal formation regardless of residual contamination.
3Manufacturing precision
If activation particles are applied only after cleaning, then the phosphating should be uniform, but the functional coating residues block the activation particles from reaching the steel surface, resulting in poor adhesion
Solution Approach 1:
Activation particles are applied to the steel flat product before the functional coating is applied, ensuring that the activation particles are already embedded or adhered to the surface. This preliminary application allows the activation particles to overcome the blocking effect of functional coating residues, as they are already in contact with the steel surface and can effectively promote uniform phosphate crystal formation with improved adhesive adhesion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a more uniform, finely crystalline phosphate layer with improved mechanical stability and adhesive properties, reducing porosity and enhancing corrosion resistance.
Implementation Method 1
Applying activation particles to the formed component from step (E)... Applying a phosphate coating to the formed component from step (F)... yields improved phosphated surfaces... exhibiting in particular better adhesive adhesion... a more uniform, finely crystalline phosphate layer
Implementation Method 2
a more uniform, finely crystalline phosphate layer with improved mechanical stability and adhesive properties
Implementation Method 3
Applying a phosphate coating to the formed component from step (F)... a phosphate layer is formed that consists in areas of differently sized zinc phosphate crystals
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a method for producing a formed component, comprising at least the following steps: (A) providing a steel strip product; (B) skin-passing the steel strip product from step (A); (C) applying a functional coating to the steel strip product from step (B); (D) forming the steel strip product from step (C) in order to obtain a formed component; (E) removing the functional coating from the formed component from step (D); (F) applying activation particles to the formed component from step (E); and (G) applying a phosphate coating to the formed component from step (F), wherein additional activation particles are applied to the steel strip product before and/or during step (B) and/or before and/or during step (C).