1.2.

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Iron phosphate is the most commonly used conversion coating in the general
industrial market. An iron phosphate solution produces a thin, bumpy, or amorphous
metal phosphate top coating over an iron oxide base. The surface of the material will
typically have a gray to blue iridescent or blue-gold iridescent color after application
depending on the coating weight and the base metal.Atypical iron phosphate consists
of phosphate salts, accelerators/oxidizers, and an optional surfactant package.
The acid salt content, type and amount of accelerator, and the type and amount
of acid etchants are adjusted to produce different formulas. Iron phosphate coating
formulations commonly contain oxidizers and/or accelerators to generate reactivity
on the metal surface. Oxidizers, such as nitrite or chlorate, act to initiate attack
on ferrous parts, providing the iron for the iron phosphate coating. Accelerators,
such as molybdate or vanadate, provide active sites for iron phosphate deposition.
The particular oxidizer or accelerator used in a particular product may affect the
performance or appearance

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Aconversion coating is a chemically applied treatment that is used over a clean metal
surface to enhance adhesion and corrosion resistance. Iron and zinc phosphate coatings
are the most commonly applied conversion coatings. Other conversion coatings
include manganese, chromate, zirconium-based products, and vanadium/zirconiumbased
products. A conversion coating converts the surface of a metal substrate to
Part Preparation Processes and Equipment 23
a uniform, inert surface, which increases paint bonding, minimizes the spread of
corrosion under the film if the coating is cut, and improves the overall corrosion
resistance of the final product.
Conversion coatings are developed on both ferrous (iron based) and nonferrous
surfaces (zinc, aluminum, terne, and manganese). Parts are subjected to an acidic bath
in which a chemical conversion forms a complete film on the part surface, changing
the chemical and physical nature of the metal surface.
of the final coating.
In a three-stage iron phosphate washer, the cleaning and coating are combined
by incorporation of a surfactant package in the iron phosphate solution. A source of
fluoride ions may be added if aluminum is also being processed to increase the etching
effect on the oxide surface of the aluminum.
Iron phosphate coatings can be applied by hand wipe, handheld wand, immersion,
or spray washer. The most effective and commonly used method is a multistage spray
washer. The number and type of process stages is directly dependent on finished part
requirements. Spray washers for iron phosphating are built with as few as two stages
and as many as eight. The following list shows the typical sequence of stages from
two to eight.
• Stage two—clean/coat, rinse
• Stage three—clean/coat, rinse, rinse/seal
• Stage four—clean/coat, rinse, rinse/seal, deionized (DI) water rinse
• Stage five—clean, rinse, phosphate, rinse, rinse/seal
• Stage six—clean, rinse, phosphate, rinse, rinse/seal, DI rinse
• Stage seven—clean, clean, rinse, phosphate, rinse, rinse/seal, DI rinse
• Stage eight—clean, rinse, clean, rinse, phosphate, rinse, rinse/seal,
DI rinse
The iron phosphate coating weight, measured in milligrams per square foot
(mg/ft2) or grams per square meter (g/m2), varies with phosphate formulas and
24 Paint Technology Handbook
TABLE 1.3
Performance Results with Different Spray Systems
Number of
Stages
Metals
Treated
Degree of
Cleaning
Coating
Weights (mg/ft2)
Coating
Adhesion
Corrosion
Resistance
Two Steel Light 25 Fair Poor
Three Steel, zinc, aluminum Moderate 25 Good Fair
Four Steel, zinc, aluminum Moderate 25–45 Good Fair
Five Steel, zinc, aluminum Moderate 25–70 Good Good
Six Steel, zinc, aluminum,
stainless steel, copper,
bronze, magnesium
Good 25–90 Very good Good
washer arrangements. The quality of paint adhesion and corrosion resistance is
affected by the coating weight. Table 1.3 shows typical results of additional steps
in the iron phosphate spray washer.
1.2.2 COATING WEIGHT
Phosphate coating weight is measured with test panels that have been run through the
washer with all of the process variables under control. After a clean, fresh panel is run
through the washer, it is removed, dried, and tested by weighing the panel, removing
the coating, and weighing the panel a second time as described next. Clean cotton or
surgical gloves are worn to avoid contamination of the sample with skin oils.
• Determine the area of the panel in square feet (width × length)
• Weigh the panel, correct to three decimal places (0.000) and record the
first weight
• Immerse the panel in 10% CrO3 in water by weight at 160◦F for
10 min
• Rinse with tap water or DI water, if it is available and dry
• Weigh the part again, correct to three decimal places, and record the second
weight
Then, complete the formula:
1st wt. in grams − 2nd wt. in grams × 1000
Area in square foot
= mg/ft2
1.2.3 IRON PHOSPHATE CONTROLS
In addition to the number of process stages, the factors that will affect the weight of
an iron phosphate coating are time, temperature, concentration, acid consumed (pH),