Wire Drawing Chemical - Heavy Zinc Phosphate Compound, Light Green Liquid For Enhanced Lubrication And Corrosion Resistance

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About : Kemphos - 821

Kemphos - 821 is a heavy zinc phosphate compound, which produces excellent Zinc/Iron phosphate coating on Iron and steel supplementary finishes. This product needs accelerator addition in the bath periodically. The conversion coating produced with Kemphos-821, when used in conjunction with suitable lubricant, reduce friction under low medium and high forming on steel, cold shaping drawing of wire and tubes etc. Lubricants and drawing compounds become firmly anchored to the phosphate coating for improved drawing.

Production Specifications

Product Operating Data

Product Operating Procedure

Pickling
Pickling should be carried out either in sulphuric or Hydrochloric Acid, in combination with suitable acid Inhibitors in sufficient strength to remove rust and scale present on the work.

Rinsing
The stage rinsing should be followed after the pickling process, first rinse with cold water and finally rinse with jet pressure. The rinsing tank should be cleaned regularly.

Phosphating
Fill the tank 2/3 with clean water and add recommended amounts of kemphos-821. Fill the tank to the operating level with water and mix thoroughly and for total acid and if necessary add enough kemphos-821 to bring total acid to operating level and mix thoroughly. Add 3035 gm of kemphos-002 accelerator in the bath by dissolved in cold water. After phosphating with Kemphos-821, the work should be rinsed with continuous flowing water and subsequently once again rinsed in hot neutralizing solution. The neutralizing solution is made up with 0.1 kg of soda ash per 100 litres of bath.

Operating Recommendation
Proper rinsing is very much essential after pickling in mineral acids, in order to remove the acid residues from the surface of the work. Any carry over of the acid to the phosphating tank will lead to excessive sludge formation leading to deterioration of phosphate coating and high chemical cost.

Testing and Control Procedure
The Kemphos-821 is controlled by simple titration for total acids. Ferrous Iron concentration of Kemphos-002 (Accelerator) by titration method.

Total Acidity
Pipe out 10 ml. bath solution into a beaker. Add 5-10 drops of indicator Phenolphathalein. Fill the burette to the zero mark. And titrate with N/10 sodium Hydroxide solution. Stir the solution until pink colour appears. Note volume of N/10 Sodium Hydroxide solution used.

Free Acidity
Pipette out 10 ml. of bath solution into a beaker. Add 5-10 drops of Methyle Orange Indicator. Fill the burette to the zero mark and titrate with N/10 Sodium hydroxide Solution. Stir the solution until pink colour appears. Note volume of N/10 sodium Hydroxide solution used.

Accelerator Titration
Pipette out 10 ml. of bath solution into flask. Add 5 ml of concentration H₂SO₄ and mix, Titrate against N/10 Kmno₄ solution a pink colour which will persist for few seconds. Note the number of ml of N/10 KmnO₄ added in the solution. Normal limits of Kemphos-002 (Accelerator) titration is 2-6 ml. Lower limit is preferable, Prior to titration. Starch lodide test should be positive. Approximately 30 ml of 25% Kemphos-002 (Accelerator) solution in water should be added to increase the Kemphos-002 (Accelerator) pointage by 1 ml.

Determination of Iron Contents
Pipette out 10 ml of bath solution in 150 ml. conical flask. Add 2ml. of 50% and titrate with N/10 KmnO₄ (3.16gm/litrs) solution to a pink end point persisiting for 15 seconds. Multiply the titration reading with 0.056 to get percentage of ferrous Iron in the bath.

A fresh bath when aged with steel wool or steel scrap as described earlier should give ferrous Iron concentration of about ferrous 0.5% for a normal loading in the bath, the ferrous Iron concentration will stay with 0.05% o 4%.

Chemical Replenishment
Add 135 ml. Of Kemphos-821 per 100 ltrs. Bath for each point lacking. The bath should be kept with in 1 ml of the specified titration values.

During the processing sludge is formed and the same is accumulated in the bottom of the tank. It should be removed at regular intervals. Sludge removal is carried out by decanting the clear solution is restored to its operating level by adding water and chemical in the recommended proportion as used in the original bath.

Safety Measures
Kemphos-821 is an acidic liquid material, and while handling proper care should be taken. Protect eye, skin by means of goggles, aprons, gloves etc. If it comes in contact with skin and eyes wash thoroughly with a flush of water and get medical advice.

General Information

Corrosion Resistance: Excellent
Lubrication During Wire Drawing: Excellent.