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化成處理是用化學或電化學(electrochemical)處理金屬表面得到

金屬化合物

耐蝕性

色

化成處理的種類

1. 鉻酸鹽處理(Chromate conversion coatings)
2. 磷酸鹽處理(Phosphate conversion coating)
3. 金屬著色(Colaring of metals)
4. 化學研磨(Chemical polishing)

1. 2鉻酸鹽處理(Chromate Conversion Coatings)

鉻酸鹽處理應用在鍍鋅

(Zinc),鎘(Cadmium),銀(Silver),銅(Copper),黃銅(Brass), 錫(Tin)零件.鋁,鋅壓鑄品(Zinc Die-cast) 熱浸零件或其他金屬合金也有被鉻酸鹽處理的.一般採用簡單沒(immersion)在鉻酸鹽水溶液中但也有用噴霧法(spraying),刷洗法(brushing)或電解法(

electrolytic method).

17.2

鉻酸鹽處理的影響因素

1. 基材金屬的作用(Effect of bases Metals)
2. pH的影響(Effects of pH)
3. 六價鉻的濃度(Hexavalent Chromium Concentration)
4. 活性度(Activators)
5. 處理時間(Treatment Time)
6. 溶液溫度(Solution Temperature)
7. 溶液攪拌(Solution Agitation)
8. 溶液雜質(Solution Contamination)
9. 水洗(Rinsing)
10. 乾燥(Drying)

1. 2.2鉻酸鹽處理的評估(Evaluation)
2. 目測試驗(visual test): 用肉眼觀測顏色,均勻性(uniformity),光澤性(smoothness),附著性(adhesion)從顏色及虹色(iridescence)可辨別覆層厚度.
3. 加速腐蝕試驗(accelerated corrosion tests): 最常用的是ASTM B-117鹽霧噴射測試以評估耐腐蝕性
4. 濕度試驗(humidity tests): 此試驗較煙霧試驗更有用除非是海洋環境(marine atmospherp).做評估較實際狀況的耐腐蝕性
5. 水試驗(water tests): 浸在蒸餾水中測試腐蝕生成物的情形
6. 化學分析(chemical analysis): 用化學分析法測試六價鉻的含量做為耐蝕性的評估
7. 點試驗(spot tests): 用分析溶解覆層並作用基材的情形評估耐蝕性
8. 塗裝性能評估(performance tests for organic finishes): 測試塗裝覆著性及耐蝕性其方法有鉛筆硬度測定(pencil-hardness)膠帶測試(tape tests)彎曲測試(bending tests)及衝擊試驗(impect tests)

1. 2.3電解鹽處理

電解鉻酸鹽處理以已經大量取代浸沒方(immersion processes)法近來用混合溶液.鉻酸鹽(Chromates),磷酸鹽(Phosphates),氟化物(Fluorides)的混合液,電壓在100~200V的交流電或直流電處理,可得非常優良的硬度(hardness),耐熱性(heat resistance),厚度(thickness),及介電強度(dielectric strength).顏色從深綠色(dark green)到黑色依操作不同而改變.

17.3

磷酸鹽處理(Phospate Coatings) 磷酸鹽處理是將金屬基材(metal substrates)的表面轉化成新的非金屬(non-metallic)及非導電性(non-conductive)表面.磷酸鹽處理的主要目的有:
9. 塗裝的表面調節處理(precondition surfaces),使表面對塗料能接受(receive)且能保留(retain)及防止塗料下層間之腐蝕(under-paint corrosion).
10. 塑膠塗裝(plastic coatings)的表面前處理以加強結合力(bonding).
11. 金屬成型加工(metal forming operation)的表面調節處理(precondition),以利抽製成型劑的作用.

改進腐蝕性使臘

(wax)及防鏽油(rust-preventive oils)的作用更好

17.3.1

磷酸鹽處理反應機構(Mechanism)

大部份金屬磷酸鹽

(metal phosphates)不溶於水,但溶於礦物酸(mineral acids),當金屬浸入磷酸鹽水溶液中,輕微的酸浸漬(pickling)作用發生,金屬被溶解,氫氧產生,而酸化的濃度減少,則金屬離子轉化成金屬磷酸鹽沉積在金屬表面上.活性劑(activators)及其他添加劑可加速反應及改變造結算晶粒構造(modify microcrystalline structure)常用水的活性劑有硝酸鹽(nitrates),過氧化物(peroxides)等.磷酸鹽化成鍍層形成的反應如下:

12Fe+8NaH2PO4+10H2O+7O2---2Fe3(PO4)2*8H2O+2Fe3O4+4Na2HPO4

Fe+2H3PO4---Fe(H2PO4)+H2

　

3Zn(H2PO4)---Zn3(PO4)+4H2O

　

2Zn(H2PO4)2+Fe(H2PO4)+4H2O---Zn2Fe(PO4)2*4H2O+4H3PO4

　

　

17.3.2

磷酸鹽處理的流程 清潔 磷酸鹽處理 水洗 酸 洗 乾 燥 Clean Phosphating Rinse Acidified Dry off

17.3.3

磷酸鹽處理的功能 (no
12. 淨化表面及使表面成非鹼性狀態(non-alkaline condition).
13. 改進表面均勻性(uniformity).
14. 增加表面的接觸面積增加附著力.
15. 產生微洞(micro-cavities),內鎖(interlocking)被覆層,吸收及保住(hold and retain)潤滑油或成型加工劑及防銹劑.
16. 防止金屬刮傷(scoring and scratching).
17. 防止電化腐蝕(electrochemical and scratching).
18. 防止塗裝物質與金屬基材之作用.
19. 抑制腐蝕的擴散.

17.4

金屬著色配方組成(coloring of metal)
20. 鋼鐵染黑(blackening of low carbon and low alloy steel)

例

1 苛性鈉 醋酸鈉 重鉻酸鈉 水 溫度

例

2

苛性鈉

硝酸鉀 亞硝酸鉀 溫度

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