Ford Motor Company Limited

Parker Chemical Company

John Huff

Ronald W Zurilla

Robert A Sensoli

John C Cooper

Ronald Rene Wiggle

Irena A Nagisetty

Dimitre P Filev

Alan E Hyrila

Vladimir Hospadaruk

A phosphate bath control system and method is provided that tracks the set points of one or more of the major process variables of the phosphate bath independently of variations in the production conditions. A detector determines the current values of Zinc, Manganese and Total Acid provides data to a controller which exponentially filters the data and processes the filtered data in accordance with fuzzy logic rules. The controller periodically updates the flow rate of one or more pumps that control the flow of liquid concentrates to the bath in order to maintain a desired concentration of the various constituents of the bath. Control of an accelerator is provided by incorporating in the controller an additional algorithm for indirect estimation of the accelerator concentration based on a math model which represents the material balance of the accelerator in the bath.

Method and system for controlling phosphate bath constituents

A method for increasing the resistance to alkaline dissolution of a phosphate conversion coating on a corrodible metal surface by an improved zinc phosphate conversion coating together with articles coated by this method are disclosed. The substrate is exposed to the phosphating solution by spraying or immersion to chemically effect a reaction with the substrate. First divalent metal cations are selected from magnesium and transition metals having a hydroxide with lower solubility in alkaline solution than zinc hydroxide. The other source of necessary metal cations is zinc and its cations are herein termed second divalent metal cations. In the preferred embodiment, the first divalent metal cations comprise aobut 84 to about 94 mole percent of the total first and second divalent metal cations in the bath. The deposited coating has first divalent metal cations (chemically combined with phosphate ions) present in an amount of at least 15 mole percent of the total first and second divalent metal cations in the coating.

Alkaline resistant phosphate conversion coatings

A method for increasing the resistance to alkaline dissolution of a phosphate conversion coating on a corrodible metal surface by an improved zinc phosphate conversion coating together with articles coated by this method are disclosed. The substrate is exposed to the phosphating solution by spraying or immersion to chemically effect a reaction with the substrate. First divalent metal cations are selected from magnesium and transition metals having a hydroxide with lower solubility in alkaline solution than zinc hydroxide. The other source of necessary metal cations is zinc and its cations are herein termed second divalent metal cations. In the preferred embodiment, the first divalent metal cations comprise about 84 to about 94 mole percent of the total first and second divalent metal cations in the bath. The deposited coating has first divalent metal cations (chemically combined with phosphate ions) present in an amount of at least 15 mole percent of the total first and second divalent metal cations in the coating.

A zinc phosphate coating bath and its application to metal is disclosed characterized in that the bath contains 80 to 94, preferably 84 to 94, mole percent nickel cations, 0.5 to 10 mole percent manganese cations and 5.5 to 19.5 mole percent zinc cations together with solubilizing amounts of phosphate ions or phosphate ions in combination with ions of acids other than phosphoric acid.

Alkaline resistant manganese-nickel-zinc phosphate conversion coatings

A method is disclosed of protecting heated aluminum based metals subject to heat transfer through the metal to a circulating aqueous cooling solution in contact therewith. The initially constituted cooling solution contains an alkali metal silicate in an adjusted amount above 0.2 gram per liter. The solution while functioning in the cooling system is then exposed to an alkali metal silicate glass causing the glass to progressively dissolve and stabilize the silicate at a level of at least 0.1 gram per liter. The initially prepared solution may also contain ethylene or propylene glycol, alkali metal phosphates and tetraborates in a ratio greater than 4:1, and nitrate, mercaptobenzothiazole or tolyltriazole.

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Detroit, MI, United States of America

John Huff