Phosfan - Brochure - Final

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Brochure

Phosfan™ = BAT & unique Zinc-Phosphate conversion coatings

Breakthrough dry initialization stage for savings = Quick ROI

© 2016 Phosfan Ltd. All Rights Reserved.

2© 2016 Phosfan Ltd. All Rights Reserved.

• Ultra-Fine Zinc-Phosphate coating structure with no refining

operations & chemicals

Phosfan™ introduction

Phosfan 15g/m² x3000


Phosfan™ Ultra-fine comparison

Calcium-modified Zinc-phosphate Phosfan Ultra-fine structure


• Phosfan™ semi-dry zinc phosphate process, substantially

decreases chemical usage as well as energy, time, water and

effluents.

• Line is controlled and monitored automatically with minimum

maintenance.

• 25%-40% saving of operating cost.

• Phosfan™ can be applied to steel, stainless-steel and aluminum

as well as other metal substrates as a base for paintings,

coatings or stand alone process.

The Technology Advantages


• Only two types of chemicals needed for the coating process.

• Phosfan™ has a development tool for Functional & Multi-

functional coatings.

• Ecological:

– Process temp. of 32ºC even for Heavy Zinc-phosphate = less

energy

– Closed loop system with no liquid waste

– 40% less sludge

• Best Available Technology

The Technology Advantages – cont.

Phosfan™ Coating uniqueness

Phosfan™ offers heavy Zinc Phosphate ultra-fine coating structures


Common coating structure

Phosfan™ ultra fine structure


Phosfan™ cross section

Steel

Phosfan™ layer


• With the same equipment and process Phosfan™ can be

applied on any metallic substrate as Steel, Stainless-steel

& Aluminum.

Substrates

Phosfan™ on steel 15g/m² x500


Phosfan™ coating on Stainless Steel


Phosfan™ coating on Aluminum


Phosfan™ coating of Zinc HDG


• Phosfan™ is a development tool for functional & Multi-

functional coatings. We are able to add additives to the

zinc-phosphate structure to improve functionality of the

coatings.

Some examples:

– Metallic additives

– Dry lubricants

– Pigments

– Organic materials

– Inorganic materials

Composite coatings

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Phosfan™ Composite coating

Zinc phosphate with Zinc additives

© 2016 Proffimat S.R Ltd. All Rights Reserved.

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Zinc phosphate with dry lubricant (MoS2) additives before and after friction


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Zinc phosphate with pigmentsColoring is done without adding process stages

On sintered carbon steel and MIM parts



Phosfan™ can be applied on fasteners and any small and

medium part as a superior base for top coats and paints.

Initial focus Applications

Phosfan™ is an excellent pretreatment for metal inserts for rubber molds.


• Phosfan™ withstands at least 24 hours in Salt Spray test

without oiling or sealing vs. 2 hour requirement of MIL-

DTL-16232G Class C.

• Phosfan™ + Zinc-Flake or other top coats - Dramatically

increases corrosion protection Vs. conventional solution

• Phosfan™ provides excellent adhesion of paints to

substrate regardless of Zinc-phosphate coating thickness.

• Phosfan™ provides excellent adhesion of molded rubber

to substrate regardless of coating thickness.

Phosfan Vs. Others

Salt spray test

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Phosfan™ coating without oiling or sealingafter 48 hours

21 gr/m²16 gr/m²


MIL-DTL-16232G Class C requirement is 2 hours

IMPACT adhesion test

SampleThickness

(g/m²)

IMPACT (lb*In)

Direct Reverse

1 Phosfan™ 8.6 >50 >50

2 Phosfan™ 9.2 >50 >50

3 Phosfan™ 7.9 >50 >50

4 Bonderit 4.5 40 30



Zinc-phosphate + Powder polyester coating 60-80µm

© 2016 Phosfan Ltd. All Rights Reserved. 19

Phosfan™ 9.2gram/m²: Impact 50Lb*in

IMPACT adhesion test


Pulling adhesion test

Powder coating of 316 Stainless Steel, epoxy primer (blue) + polyester coating (black). Surface pretreatment - Zinc Phosphate coating, PHOSFAN™ process.

Results range from 19 to 24 Mpa without a significant correlation to coating thickness.

Powder epoxy coating on low carbon steel with surface pretreatment - Zinc Phosphate coating, PHOSFAN™ process.

Results range from 19 to 24 MPawithout a significant correlation to coating thickness.


Rubber molding adhesion


1.Adhesion test per ASTM D-429b.

2.Natural rubber, hardness 52 Shore “A”.

3.Primer Chemlok 205

4.Metal Adhesive Chemlok 252X

5.Sample’s width – 25 mm

6.Test speed – 50mm/min


15 g/m²10 g/m²6 g/m²Coating

thickness

10.769.929.32

Adhesion value per

sample width N/mm

10.0413.5611.36

12.8811.2014.64

12.7610.7612.64

12.4413.6014.36

11.7611.8112.46Average

1.291.682.21STDEV

Rubber molding adhesion

1. No significant adhesion value difference between coatings with different thicknesses were found.

2. For all samples tested the failure was cohesive or the rubber was destroyed: the rubber strength was less than adhesion value.

Process parameters


1. During the Phosfan™ process only three parameters

are monitored: Temperature, Acidity & Density.

2. Only two types of chemicals are needed for coating.

3. Phosfan™ is applied at 32ºC for any substrate and

any coating thickness.

4. No need for frequent laboratory tests.

5. Phosfan™ process liquids run in a closed loop.

6. No need for frequent sludge removal from

Phosphating bath.

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Zinc Phosphate Process

Temperature (°C)

ImmersionTime (Min.)

Coating Weight (g/m²)

* Henkel Company, Parkerizing® 210™

77-88No published

data>11

** TRIPLE E MANUFACTURING INC.

88-99 25-30 >11

PHOSFAN™ 30-32 10 >14

Processes comparison


* Data from Henkel’s brochure** Data from Triple E’s publications


According AMS Handbook, V.5, Surface Engineering, p. 386

Monitoring requirements

# Controlled parameterRegular Zn

phosphate coating process

PHOSFAN™ Zn phosphate coating process

1 Phosphating solution

1.1 Total acid titration Hourly N/R

1.2 Free acid titration Hourly N/R

1.3 Acidity, pH N/R Automatically

1.4 Density, kg/L N/R Automatically

2 Alkali cleaner stage titration Twice per shift N/R

3Alkalinity of water rinses before

phosphating

Twice per shift N/R

4Acidity of water rinse after

phosphating

Twice per shift N/R

5 Activating rinse concentration Twice per shift N/R

6Conductivity of recirculated deionized rinse, 100µS max

Once per shift N/R


According AMS Handbook, V.5, Surface Engineering, p. 387

Tank and Solution Maintenance

# Operation Maintenance

Schedule

Common Zinc phosphate process

Phosfan™, Zinc phosphate process

1 Acid pickle Empty and clean Biweekly None

2 Cold rinse Empty and clean Biweekly None

3 Alkaline rinse Empty and clean Monthly None

4 Alkaline cleaner Empty and clean Daily None

4Heated acid

cleanoutQuarterly None

5 Hot rinseHeated acid

cleanoutQuarterly None

6Zinc

phosphate Empty and clean Daily

N/R, Automatically corrected

Heated acid cleanout

Quarterly None

7 Hot rinse Empty and clean WeeklyN/R, Automatically

corrected

Heated acid cleanout

Quarterly None

8 Acid rinse Empty and clean Weekly None

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Item Current PhosfanTM Saves

Labor 0.06 0.045 25%

Consumables 0.05 0.030 40%

Energy 0.04 0.017 58%

Others 0.07 0.030 43%

Total Cost 0.20 0.122 39%

Cost effectiveness

Phosfan™ process significantly saves operation costs

– up to 40% savings (Israeli expenses USD):



• Phosfan™ saves 25%-40% of operating costs

• Only two types of chemicals needed for the coating

process.

• Phosfan™ has a development tool for Functional & Multi-

functional coatings.

• Ecological:

– Process temp. of 32ºC even for Heavy Zinc-phosphate

– No liquid waste

– 40% less sludge

• Best Available Technology

Summary

Contact information

Itzhac Rozentul, Phosfan Chairman & COO

[email protected]

+972-54-492-3047

Eli Blumenreich, Phosfan CEO

[email protected]

+972-54-240-6459


Documents

Phosfan - Brochure - Final