LEVEL-II

Quality Management System

Procedure

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(Complying to API Q1 9th Edition & ISO 9001:2015)

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Phosphating Process
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Document No: Prepared By: QA/QC Engineer

QSP-34 Sign. & Date
Rajumon Joseph
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Revision No: Reviewed By: Asst. Manager- QHSE / MR

02 Sign. & Date
Tejas B. Suthar
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Date: Approved By: Managing Director

02.01.2018 Sign. & Date
Thomas Arakal

Engineering Pumps for Better Performance and Longer Life

Plot No TP010502 • National Industries Park • Jebel Ali Free Zone - 262673 l
Dubai, United Arab Emirates • Ph: +971-4-880-6262 Fax: +971-4-880-6263 |
info@hydromiddleeast.com www.hydromiddleeast.com www.hydroinc.com

DOCUMENT NO: QSP-34 REVISION: 02 DATE: 02.01.2018 Page 1 of 7

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Quality Management System Procedure

Procedure for Phosphating Process

Contents
1.0 PURPOSE ........................................................................................................................................... 3

2.0 SCOPE ................................................................................................................................................ 3

3.0 RESPONSIBILITY ................................................................................................................................. 3

4.0 CHEMICALS REQUIRED ...................................................................................................................... 3

5.0 PROCEDURE ...................................................................................................................................... 4

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5.1 Process Sequence ......................................................................................................................... 4

5.1.1 Cleaning................................................................................................................................. 4

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5.1.2 Water Rinisng ........................................................................................................................ 4
5.2 Bath Make Up ............................................................................................................................... 4
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5.3 Bath Operation.............................................................................................................................. 4
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5.4 Bath Control .................................................................................................................................. 5
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5.4.1 Total Acid titration ................................................................................................................ 5

5.4.2 Ferrous Iron titration ............................................................................................................ 5
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5.5 Bath Replenishment...................................................................................................................... 5

5.6 De-Sludging ................................................................................................................................... 6

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5.7 Coating Thickness Acceptance ...................................................................................................... 6

6.0 RECORDS ........................................................................................................................................... 6

7.0 FORMS............................................................................................................................................... 7

8.0 REVISION HISTORY: ........................................................................................................................... 7

DOCUMENT NO: QSP-34 REVISION: 02 DATE: 02.01.2018 Page 2 of 7

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Quality Management System Procedure

Procedure for Phosphating Process

1.0 PURPOSE

This procedure provides guidelines to establish, implement the phosphating process and to monitor
the phosphating bath within the acceptable levels as recommended by the chemical product
manufacturer “Chemtall”.

The Gardobond G 4098 phosphating process is formulated for the treatment of iron and steel bearing
surfaces to reduce wear and eliminate scuffing, galling and “pick-up” particularly during the running-
in period of working parts. The treatment converts the metallic surface to manganese / iron
phosphate coating with high oil absorptive and corrosion resistance qualities.

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2.0 SCOPE

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This Manganese phosphate coating procedure covers only for immersion method of coating for
carbon & low alloy steels.
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3.0 RESPONSIBILITY
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The designated operators and QC inspectors shall be responsible for preparing & monitoring of
phosphate bath solutions & verification of quality of the part / product.
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Production Manager and Workshop manager shall ensure that phosphating process is implemented
as per this procedure.
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Quality Assurance / Quality control team shall be responsible for validating this special process and
ensuring necessary controls are established as per the Validation of special process procedure.
4.0 CHEMICALS REQUIRED
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• Gardobond G 4098
• Phenolphthalein indicator solution
• 0.1N potassium permanganate
• Phosphoric / Sulphuric acid solution
• 0.1 N sodium hydroxide

DOCUMENT NO: QSP-34 REVISION: 02 DATE: 02.01.2018 Page 3 of 7

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Quality Management System Procedure

Procedure for Phosphating Process

5.0 PROCEDURE

5.1 Process Sequence

The complete process for application of Gardobond G 4098 consists of the following steps:

o Cleaning, e.g. Gardoclean® alkali cleaner or equivalent de-greaser

o Cold water rinsing
o Gardobond G 4098 manganese phosphate pre-treatment
o Water rinsing
o Gardolene post treatment

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 Drying, oiling (or)
 Gardorol dewatering oil / soluble oil
Refer Work Instruction WI-07 (Phosphating Process) for detailed process flow.

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5.1.1 Cleaning
All metal to be processed should be free from rust, oil, grease and other foreign matter. The
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cleaning of the work prior to treatment with the Gardobond G 4098 solution is very important, in
order to promote a uniform coating and avoid excessive build-up. Aqueous cleaning is the normal
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method but solvent or vapor degreasing or degreaser may be used.
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5.1.2 Water Rinsing

After cleaning, the work should be thoroughly rinsed with cold water. The rinse should be
overflowed continuously at a rate, which will keep it clean and free from contamination. Detailed
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instructions for operation and control of water rinses are given in Technical Information Sheet
‘Water Rinses’.
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5.2 Bath Make Up

Type D – General Applications

1. Determine the working volume of the tank and run in clean water until it is about two-thirds
full and heat to about 95°C;
2. Add 53 litres (67 kg) of Gardobond G 4098 per 1000 litres of working solution required.
3. Make up to operating level with clean water, mix thoroughly and reheat to 95°C.

5.3 Bath Operation

The process consists of immersing the properly cleaned and rinsed articles in the Gardobond G 4098
solution for a period of 5 ~ 30 Minutes at 96° - 99°
DOCUMENT NO: QSP-34 REVISION: 02 DATE: 02.01.2018 Page 4 of 7
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Quality Management System Procedure

Procedure for Phosphating Process

In this processes, maximum corrosion resistance can be obtained by leaving components in the
solution for 30 minutes, although uniform coatings are normally obtained in 5 to 15 minutes. It is
advisable not to leave articles in the working solution of a type D process beyond 30 minutes.

The thickness of the coating obtained by this treatment depends on the method of cleaning, type of
metal alloy, hardness and surface finish. In general, the dimensional increase is usually of the order
of 4 to 8 μm.

5.4 Bath Control

The bath concentration is controlled by determining the total acid pointage and iron pointage.

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5.4.1 Total Acid titration

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Take a 5 ml sample of the working solution, add about 10 drops of phenolphthalein indicator and
titrate with 0.1 N sodium hydroxide until the colour changes from colourless to pink. The number of
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ml of 0.1 N sodium hydroxide required is known as the Total Acid Pointage of the working solution.

QC-Inspector shall record the total acid titration in “Phosphating Log (HME-FMT-87)”
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Acceptance level – 14 to 16 (Total Acid Points)

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5.4.2 Ferrous Iron titration

Take a 10 ml sample of the working solution, add 10 … 20 drops of phosphoric / sulphuric solution
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and titrate with 0.1N potassium permanganate until the appearance of a pink colour which persists
for 20 seconds. Note the number of ml of 0.1N potassium permanganate required and substitute for
“A” in the equation below:
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Concentration of ferrous iron (g/l) = 0.56 x A

Acceptance level – 1 to 2 g/l

5.5 Bath Replenishment

Total Acid Point

To increase the Total Acid by one point add, per 1000 litres of phosphating solution: 4.1 litres (5.2
kg) of Gardobond G 4098

DOCUMENT NO: QSP-34 REVISION: 02 DATE: 02.01.2018 Page 5 of 7

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Quality Management System Procedure

Procedure for Phosphating Process

Ferrous iron content

The treatment of iron and steel articles in the Gardobond G 4098 solution results in the formation
of ferrous iron in the solution and its presence, within certain limits, is essential for producing a
coating having uniform corrosion and wear resistance. It is not possible to establish a specific iron
content that is suitable for all steels because of the difference in their chemical composition,
hardness, surface finish, cleaning and a number of other factors

To increase ferrous iron by 1 g/l add, per 1000 litres of phosphating solution:
1.25 kg of powdered iron or steel wool (this should be cleaned first to remove oil).

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To reduce the ferrous iron content by 1 g/l add, per 1000 litres of phosphating solution:
1.2 kg of Gardobond-Additive H 7203, mixed with a little cold water to make a slurry, plus 1.25 litres

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(1.2 kg) of Gardobond-Additive H 7002. This slurry should then be added to the bath with stirring.
A precipitate will form as the mixture is added. This should be allowed to settle before processing
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any work in the tank.
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5.6 De-Sludging
The sludge accumulated due to phosphating or iron precipitation must be periodically removed.
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This is done in a settling tank or a suitable filtering equipment. The bath solution above the sludge
can also be pumped into an empty rinsing tank. After returning the clear solution to the bath tank,
fill the latter with water to operating level and thoroughly mix the solution.
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5.7 Coating Thickness Acceptance

Following the above procedure, the component will be coated with 5 - 25g / m2 or 500 ~2500 mg/
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Sq. ft of phosphate protective coating.

The coating thickness will be checked once in 3 months as part of the process validation
(Phosphating Validation Record HME-FMT-84) or whenever required for the special process
validation.

6.0 RECORDS

Phosphating Process and Titration Log is maintained as required by this procedure, API Q1 9th Edition
and ISO 9001:2015.

DOCUMENT NO: QSP-34 REVISION: 02 DATE: 02.01.2018 Page 6 of 7

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Quality Management System Procedure

Procedure for Phosphating Process

7.0 FORMS

Document Doc. No.

Phosphating Process Log HME - FMT- 87
Phosphating Validation Record HME - FMT- 84

8.0 REVISION HISTORY:

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Sr. No. Revision No. Revision Date Revision Description

1 00 Initial Release Incorporate with the requirements of API Q1 8th Edition.

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2 01 10.07.2014
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Incorporate with the requirements of API Q1 9th Edition.

Revised the procedure with the latest technical data

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3 02 02.01.2018 sheet requirements of Gardobond G 4098 – Rev.
kb2011/10
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DOCUMENT NO: QSP-34 REVISION: 02 DATE: 02.01.2018 Page 7 of 7

National Industries Park, Dubai, United Arab Emirates T: +971 4 8806262 - F: +971 4 8806263
This document is electronically signed and verified, All Contents are the property of HME, Do not copy or use without permission.