金屬表面處理工藝最佳做法

MetalFinishingProcessesBestractices

金屬表面處理工藝最佳做法

FundingprovidedbytheNewYorkStateDepartmentofEnvironmentalConservation.?

2016RochesterInstituteofTechnology.Anyopinions,results,findings,and/orinterpretationsof

datacontainedhereinaretheresponsibilityofRochesterInstituteofTechnologyanditsNYS

PollutionPreventionInstituteanddonotrepresenttheopinions,interpretationorpolicyofthe

Stale.

PlatingorConversionCoatings電鍍或轉(zhuǎn)化涂層

Overviewofplatingorconversioncoating電鍍或轉(zhuǎn)化涂層概述

Platingistheapplicationofametalormetalstoasubstrate,thetypicalsubstratebeing

metal.Atypicallinewillbededicatedtoaspecificbasemetalandaspecificplating.Forinstance,

aplatinglinemaybedesignedtoplatesteelpartswithalayerofcopperfollowedbychrome.

Sinceplatingisbeingappliedtothepart,thepartdimensionswillchangeinadirectrelationship

totheamountofplatingapplied.

Platingcanbeappliedeitherwithorwithouttheuseofelectricalcunenl.Forexample,there

isnickelplatingwhichrequireselectriccurrenttoforcethenickeltoplateoutonthepartsand

thereiselectrolessnickelplatingwhichwillplateoutspontaneouslybutslowlywithoutthe

applicationofanelectriccurrent.

Theconversioncoatingprocessisacoatingcreatedonthesurfaceofametalpartduetothe

reactionofthemetalsurfacewithachemical.Examplesofconversioncoatingsarephosphate,

chromate,blackoxide,andiriditeonaluminum.Aspecialtypeofconversioncoatingis

anodizingandwillbediscussedlater.Apartthathasaconversioncoatingwillhavedimensional

growththatisproportionaltotheconversioncoatingthicknessbutisnotadirectrelationshipas

inplating.Thisisbecausetheconversioncoatingisconsumingsomeofthesubstratemetalinthe

processofformingthecoating.Aconversioncoatingisgrowingintothepartasitisformedbut

isalsoofgreatervolumethantheoriginalmetal.Therefore,itbothgrowsintothepartand

expandsasthecoatingforms.

電鍍是將一種或多種金屬施加到基材上，典型的基材是金屬。一條典型的生產(chǎn)線將專

用于特定的金屬和特殊電鍍。例如，電鍍線可以設(shè)計(jì)為鋼零件鍍一層銅，之后鍍銘。由于

電鍍是應(yīng)用于零件，零件尺寸變化與電鍍量直接相關(guān)。

電鍍可在有或無電流時(shí)進(jìn)行。例如，鍍銀需要電流，迫使銀鍍在零件上，而化學(xué)鍍銀

會(huì)自發(fā)而緩慢地鍍上，不施加電流。

轉(zhuǎn)化涂層工藝是通過金屬表面與化學(xué)物質(zhì)反應(yīng)而在金屬零件表面形成涂層C轉(zhuǎn)化涂層

的例子是鋁上的磷酸鹽、輅酸鹽、黑色氧化物和鉞。一種特殊類型的轉(zhuǎn)化涂層是陽極氧化，

之后討論。具有轉(zhuǎn)化涂層的零件尺寸與轉(zhuǎn)化涂層厚度成正比增長，而不是電鍍那樣的直接

關(guān)系。這是由于轉(zhuǎn)化涂層在形成涂層過程中消耗了一些基材金屬。形成時(shí)轉(zhuǎn)化涂層在零件

中生長，但其體積也大于原始金屬。因此，既會(huì)生長到零件中，又會(huì)隨著涂層形成而擴(kuò)展。

Typicalstepsassociatedwithbothplatingandconversioncoating:

1.AlkalineCleaning(typicallyanalkalinechemistry)

2.RinsingExampleolanautomatichoistplatingline

3.AcidEtchingandAcidCleaners

4.Rinsing

5.PlatingorConversionCoatings

6.Rinsing

7.PartDrying

與電鍍和轉(zhuǎn)化涂層相關(guān)的典型步驟：

1、堿性清洗(通常是堿性化學(xué)性質(zhì))

ExampleofBlackOxideconversioncoatingonsteel

2、沖洗

3、酸蝕和酸洗劑

4、沖洗

5、電鍍或轉(zhuǎn)化涂層

6、沖洗

7.、零件干燥

ExampleofanautomatichoistplatinglinemagecourtesyofBakerTechnology.提供的目動(dòng)

提升電鍍線示例。

ExampleofBlackOxideconversioncoatingonsteelBakerTechnology鋼上黑色氧化轉(zhuǎn)化

涂層示例

SolutionRecovery溶液回收:

Themethodofeitherextendingthelifeofaplatingsolutionwillbeverydependentonthe

typeofplatingbeingdone.Thefollowingisanoverviewofthetechnologiesavailableto

recoveryorcontrolvariousplatingsolutions.

延長電鍍?nèi)芤簤勖椒ㄊ苓M(jìn)行的電鍍類型影響很大。以下是可用于回收或控制各種電

鍍?nèi)芤旱募夹g(shù)概述。

Chromeplating鍍銘：

Therearethreerecoveryareasfromachromiumplatingprocesstank.

鍍銘工藝罐有三個(gè)回收區(qū)。

1.Exhaustsystem排氣系統(tǒng)

MeshPadMistEliminatorsintheventilationsystemprovidetwoadvantages.First,theyare

veryeffectiveasthefirststageinchromemistremoval.Secondthebackwashoperationforthe

meshpadsallowsthechromicacidtoberecoveredandreturnedtotheplatingtank.

通風(fēng)系統(tǒng)中的網(wǎng)狀墊式除霧器具有兩個(gè)優(yōu)點(diǎn)。首先，作為銘霧去除的第一階段非常有

效。其次，網(wǎng)墊的反洗允許可回收銘酸，返回電鍍槽。

2.Rinsetank沖洗罐

Sinceachromeplatingtankistypicallyheatedandthereforelosingvolumedueto

evaporation,astagnantprimaryrinsetankshouldbeusedformake-upsolutiontothechrome

tank.Inaddition,aporouspotdescribedbelow,canconcentratethechromicacidinarinsetank

forrecovery.

由于鍍銘罐通常加熱，因此，因蒸發(fā)而損失體積，因此，應(yīng)使用靜止的一級(jí)沖洗罐補(bǔ)

充鍍格槽溶液。另外，以下描述的多孔罐可濃縮沖洗罐中的銘酸回收。

3.Platingtank電鍍槽

Ceramicporouspotsareonecommerciallyavailablemethodofkeepingthenon-chromium

metalcontaminantstoaminimum.Thetechnologyistheuseofaceramic"pol"asamembrane

andtheuseofelectrodestopullthenon-chromiummetalionsintothepotwhileleavingthe

chromicacidionsinthetank.Thepotissuspendedinthechrometankwithitsownrectifierto

providecontinuousfiltrationofthemetalcontaminants.Onesourceoftheporouspotequipment

isHardChromePlatingConsultants,Inc.

陶瓷多孔罐是一種非格金屬污染物保持在最低限度的市售方法。這一技術(shù)是利用陶瓷

“罐”作為膜，利用電極將非銘金屬離子推入罐內(nèi)，同時(shí)將銘酸離子留在罐內(nèi)。罐懸掛在有

其整流器的鍍格槽中，連續(xù)過流金屬污染物。多孔罐設(shè)備的一個(gè)硬鍍銘咨詢公司。

Methodsofplatingsolutionrecoveryfromrinses從沖洗液中回收電鍍液的方法：

Thegoalinsolutionrecoveryistoputtherecoveredsolutionbackintotheplatingtankina

formthatwillnotnegativelyinfluencetheplatingorconversioncoatingtankchemistry.

溶液回收的目標(biāo)是回收溶液以不會(huì)負(fù)面影響電鍍或轉(zhuǎn)化涂層槽化學(xué)的形式將回用回

收到電鍍槽。

Directevaporativelossadditions直接蒸發(fā)損失添加

Thesimplestmethodistohaveastagnantrinsetankforthefirstrinseandusethisrinse

waterasmake-upwaterintheprocesstank.Thisisparticularlyusefulforhotprocesstankssince

theprocesstankisregularneedofwateriocompensateforevaporation.Inthecaseoflower

temperatureprocesstankswithminimalevaporation,therinsewatercontainingprocess

chemistrywillneedtobeconcentratedbeforebeingaddedbacktotheprocesstank.Thiscanbe

accomplishedofflinewithanevaporativesystemtoconcentratetherinsewatertothecorrect

processconcentration.Thentheconcentratecanbeusedaschemicalmake-upsolutioninthe

processtank.

最簡單的方法是在第一次沖洗時(shí)使用靜止沖洗罐，將這種沖洗水用作工藝水罐中的補(bǔ)

充水。由于工藝罐需要定期補(bǔ)償蒸發(fā)的水，這對(duì)于熱工藝罐特別有用。對(duì)于蒸發(fā)量最小的

低溫工藝罐，含工藝化學(xué)品的沖洗水需要在加會(huì)工藝罐之前需要濃縮。這可通過離線蒸發(fā)

系統(tǒng)完成，將沖洗水濃縮至適當(dāng)?shù)墓に嚌舛取Ｖ鬂饪s液可用作工藝罐中的化學(xué)補(bǔ)充溶液。

Onewarningregardingintroductionofprocesschemistryfromrinsewaterisinthescenario

wherethedragoutfromtheprocesstanktotherinsetankservesthepurposeofremoving

processtankimpurities.Inthissituation,thereuseoftherecoveredchemistrywillshortenthe

processbathlifebyreintroducingtheimpurities.Thealuminumanodizingprocessisanexample

wherethedragoutlossesfromtheanodizingtankincludedissolvedaluminumwhichtendsto

buildupinthetankandneedstoberemovedanyway.

有關(guān)沖洗水中引入工藝化學(xué)品的一個(gè)警告是工藝罐沖洗到?jīng)_洗罐的廢酸液起到去除

工藝管雜質(zhì)作用時(shí)。在這種情況下，回收的化學(xué)物質(zhì)的再利用將通過重新引入雜質(zhì)而縮短

工藝浴壽命。鋁陽極氧化,匚藝是一個(gè)例子，其中陽極氧化槽中的廢酸損失包括會(huì)在罐中積

累的溶解鋁，無論如何都需要去除。

IonExchange離子交換

Thepurposeofionexchangeistocaptureandconcentratethedissolvedmetalsinaplating

solutionrinse.Oncecapturedbytheionexchangeresin,themetalcanberemovedduringthe

regenerationprocess,concentratedbyevaporationandreturnedtotheplatingtank.Again,there

arcpotcntialiyotherchemicalsintheplatingbathwhicharcnotcapturedbytheionexchange

(organicssuchassaccharin)andthereforeneedtobeaddedto(heplatingbathtomaintainthe

properconcentrations.

Iftheionexchangeregenerationsolutioncannotbeusedforplatingtankadditions,itmay

havehighvalueforitsmetalcontent.SomecompaniessuchasInmetcoareveryinterestedin

metalrecoveryduetothevalueofthemetal.Copper($3.81/lb),nickel($10.21/Ib),andchrome

($5.81/lb)allhaverelativelyhighmarketvalue(2010)andthereforeareworthconsideringfor

scraprecovery.

離子交換的目的是捕集和濃縮電鍍液沖洗液中溶解金屬。一旦由離子交換樹脂捕集，

金屬可在再生過程中去除，通過蒸發(fā)濃縮，返回電鍍槽。同樣，電鍍液中可能存在其他未

由離子交換捕集的化學(xué)物質(zhì)(有機(jī)物，如糖精)，因此，需要加入電鍍液中，以保持適當(dāng)

的濃度。

如果離子交換再生溶液不能用于電鍍槽補(bǔ)充，其金屬含量可能具有很高的價(jià)值。由于

金屬的價(jià)值，Inmelco等一些公司非常關(guān)注金屬回收。銅(3.81美元/磅)、鍥(10.21美

元/磅)和格(5.81美元/磅)都具有較高的的市場價(jià)值(2010年)，因此，值得考慮廢料

回收。

Electrodialysis電滲析

Electrodialysisisverysimilartodiffusiondialysisinthatthereisasemi-permeable

membranethatallowspreferentialpassageofsomeionswhileexcludingothers.Theprocessof

movingionsselectivelyacrossthemembraneisacceleratedbytheuseofelectrodesbeyondthe

membranestohelpdrawtheionsthroughthemembranes.Thistechnologyistypicallyusedin

nickelandelectrolessnickelplatingtorecoverthenickelchemistryfromtheprimaryrinsetanks.

電滲析與擴(kuò)散滲析非常相似，有一個(gè)半透膜，允許一些離子優(yōu)先通過，而排除其他離

子。通過是所有膜外電極，有助于離子吸引通過膜，從而加速離子選擇性地通過膜的過程。

這一技術(shù)通常用于鍍銀和化學(xué)鍍銀，回收一級(jí)沖洗槽中的銀化學(xué)物質(zhì)。

ReverseOsmosis反滲透

Reverseosmosisistypicallyusedtoconcentratethedesiredchemicalsfromadilute

solution.

Theprocessinvolvesamembranethatispermeabletowaterandsmallionssuchassodium

orpotassiumbutnotlargerions.Pressureisappliedtothesolutiontoforcewaterthroughthe

membraneandleavingbehindthechemicalsofvalue.Platingsolutionsofhighvaluecanbe

concentratedfromrinsesolutionsandrecoveredforreuseusingthismethod.Platingsolutions

suchasIkjlkjlkjcanberecoveredinthisway.

反滲透通常用于濃縮稀釋溶液中的化學(xué)物質(zhì)。

這一工藝采用可滲透水和鈉或鉀之類的小離子而不是較大離子的膜。對(duì)溶液施加壓力,

迫使水通過膜，留下有價(jià)值的化學(xué)物質(zhì)。沖洗溶液中可濃縮出高價(jià)值電鍍液，廖勇這種方

法回收和再利用。可以這種方式回收電鍍液。

Metalrecoveryfromrinses沖洗液中金屬回收

Electrowinning電解沉積

Concentratedrinsescanbesenttoanelectrowinning(electroplating)tanktoplateoutthe

metalwhichcanthenbesentoutasscrapmetalratherthanbeingtreatedbyothermeans.The

wastewaterfromtheelectrowinningprocesswillstillneedtobetreatedformetalbutthemetal

contentwillbemuchlowerandthereforecostlesstotreatandcostlessforsludgedisposalsince

thesludgevolumewillbemuchreduced.

Electrowinningisverycommoninpreciousmetalplatingsincetheelectrowinningsystem

canbeinstalleddirectlyintherinsetanksandthereforekeepsthepreciousmetalconcentrations

verylowinthefinalrinsesbykeepingtheconcentrationslowintheprimaryrinses.Asafinal

preciousmetalrecoverystep,thefinalrinsecanalsoberecirculatedthroughanionexchange

systemtoscavengetheremainingpreciousmetalinthefinalflowingrinsebeforetherinsegoes

towastewatertreatment.

濃縮沖洗液可進(jìn)入電解沉積(電鍍)槽，鍍出金屬，之后作為廢金屬送出，而不是通

過其他方式處理。電解沉積過程產(chǎn)生的廢水依然需要處理進(jìn)入，但金屬含量低得多，因此

處理成本更低，由于污泥體積將大大減少，污泥處理成本也更低。

電解沉積在貴金屬電鍍中非常常見，由于電解沉積系統(tǒng)可以直接安裝在沖洗槽中，從

而保持一級(jí)沖洗中的低濃度，使最終沖洗中的貴金屬濃度保持非常低的水平。作為最后的

貴金屬回收步驟，最后的沖洗液也可以通過離子交換系統(tǒng)再循環(huán)，在沖洗液進(jìn)入廢水處理

之前，去除最終流動(dòng)沖洗液中的剩余貴金屬。

PlatingorConversionCoatingswithnodizingasaSpecialCase特殊情況下的電鍍或轉(zhuǎn)化

涂層

OverviewofAnodizing陽極氧化概述

Thetermanodizingistypicallyusedtodescribetheconversioncoatingappliedto

aluminum.Itcanalsobeusedtodescribeconversioncoatingappliedtotitanium,magnesium,

niobium,ortantalumparts.Thedifferencebetweenanodizingandatypicalconversioncoatingis

thatanodizingisgeneratedbyacombinationofbothchemicalconversionandelectriccurrentat

themetalsurface.Theelectricalcurrentforcestheanodizinglayertoformbothfasterandthicker

thanitwouldbychemicalreactionalone.Anotheraspectofanodizingisthattheanodizing

processleavesmicroporesinthecoalingwhichcanbefilledwithdyesioproduceawiderange

ofpartcolors.

陽極氧化一詞通常用于描述應(yīng)用于鋁的轉(zhuǎn)化涂層。也可用于描述應(yīng)用于鈦、鎂、銀或

留零件的轉(zhuǎn)化涂層。陽極氧化與典型轉(zhuǎn)化涂層之間的區(qū)別在于，陽極氧化是由金屬表面的

化學(xué)轉(zhuǎn)化和電流共同形成C電流使得陽極氧化層形成比僅是通過化學(xué)反應(yīng)更快、更厚。陽

極氧化的另一個(gè)方面是陽極氧化過程會(huì)在涂層中留下微孔，可以填充染料，從而產(chǎn)生各種

顏色的零件。

Typicalstepsassociatedwithanodizing與陽極氧化相關(guān)的典型步驟：

1.AlkalineCleaning(maybeamodifiedalkalinecleaningtoavoidpitting)

2.Rinsing

3.AcidEtchingandAcidCleaners(maycontainfluoridestoremovealuminumoxides)

4.Rinsing

5.Anodizing

6.Rinsing

7.Dyeing（optional）

8.Rinsing

PorotityinanunteiMmodtftdturlx4

r

9.Scaling

iO.Rinsing

11.PartDrying

癡6Surl9C^n-routf“Po/porousCM(fromTKyotantL2

1、堿洗（可能是一種避免點(diǎn)蝕的改良?jí)A洗）?ndATo/wU.CZnuaya3_________

2、沖洗

Exampleofcolorcapabilityinanodizing

3、酸蝕和酸洗劑（可能含去除氧化鋁的氟化物）

4、沖洗

5、陽極氧化

6、沖洗

7、染色(可選)

8.、沖洗

9.、密封

10、沖洗

11、零件干燥

Fig.6.Surfaceandcrosssectionnearoutersurfaceofporousoxide(FromT.Kyotani,L.

Tsai,andA.Tomita,ChemistryofMaterials,Vol.8,p2109,1996).多孔氧化物近外表面的

表面好斷面

Exampleofcolorcapabilityinanodizing陽極氧著色能力的例子

Dyeing染色

Thedyeingoperationinanodizingisratheruniquecomparedtootherchemicalprocess

stepsinmetalfinishing.Typicallythedyesusedareorganicandcanbesensitivetoacidfromthe

anodizingprocessorcontaminantsintherinsewater.Therefore,post-anodizingrinsingiscritical

beforepartsgointothedyetankstoavoidcontaminationofthedyetanks.Thepre-dyerinse

needstobeahighpuritywaterrinsesuchasdeionizedwaterandroomtemperatureorcooler

water.Theuseofaheatedpre-dyerinsewouldbegintosealtheporesintheanodizedsurface

andcouldreducethedyepickupintothepores.Dependingonthedye,airagitationiseither

requiredorforbidden.Thedyemanufacturershouldbeabletoprovidethebestpracticesfortheir

dyes.Thedyeingtanksaretypicallyheatedperthedyemanufacturer^instructions.Thewarm

dyeisdrawnintotheporesoftheanodizedlayerduetocapillaryaction.

與金屬表面處理的其他化學(xué)工藝步驟相比，陽極氧化中的染色操作相當(dāng)獨(dú)特。通常使

用的染料為有機(jī)，且可能對(duì)陽極氧化過程中的酸或沖洗水中污染物敏感。因此，零件進(jìn)入

染料槽之前的陽極氧化后沖洗至關(guān)重要，避免污染染料槽。染料前沖洗需要高純度水沖洗,

如去離子水和室溫或溫度稍低的水。從加熱染料前沖洗開始密封陽極氧化表面中的孔隙，

可能減少進(jìn)入染料。根據(jù)染料，需要或禁止空氣攪拌。染料制造商應(yīng)能夠提供染料的最佳

做法。染色罐通常按照染料制造商的說明加熱。由于毛細(xì)作用，加熱的染料吸入陽極氧化

層孔隙中。

Sealing密封

Thesealingoperationisthefinalstageoftheanodizingprocess.Immersionofananodized

partintohot(boilingpoint)watercausestheporestosealoverduetotheslightsolubilityofthe

aluminumoxideoftheanodizedsurface.Ihisprovidesstainandcorrosionprotectionforaclear

anodizedsurfaceandpreventsdyemigrationordegradationinadyedsurface.Thehotwater

usedinsealingalsoneedstobehighpuritysuchasdeionizedwater.Sealingadditivesarealso

sometimesusedsuchasnickelacetatewithboricacid.Theuseofadditivesrequiresadditional

wastewatertreatment.

密封操作是陽極氧化工藝的最后階段。由于陽極氧化表面氧化鋁輕微溶解性，陽極氧

化零件浸入熱（沸點(diǎn)）水中會(huì)導(dǎo)致孔封閉。這為清潔的氧極氧化表面提供污染和腐蝕保

護(hù)，并防止染料在染色表面遷移或降解。用于密封的熱水也需要高純度，如去離子水。rr

時(shí)也使用密封添加劑，如醋酸銀和硼酸。使用添加劑需要其他廢水處理。

Solutionrecovery溶液回收

Anodizingsolutionistypicallysulfuricacid.Asmallamountofdissolvedaluminumis

helpfultotheanodizingprocess.However,concentrationlimitsaresuggestedbythe

manufacturersofspecialtychemicalmixesforanodizing.InAluminumHowTo,The

Chromating-Anodizing-HardcoatingHandbookbyH.R.Probert,theauthorrecommends

concentrationsnohigherthan12gramsperliterofdissolvedaluminum.

Methodsofdissolvedaluminumconcentrationcontrol:

1.Decantandreplace

Aknownamountofsolutionisremovedfromtheanodizingtanksuchthatanadditionof

thesamevolumeoffreshacidwillreducethetotaldissolvedaluminumtobetween5and8

gramsperliter.Theacid-aluminumsolutionthatisremovedcaneitherbepurifiedoff-line,

disposedofashazardouswaste,orbeusedforotherpurposesintheplatingarea.

2.Diffusiondialysis

Thisprocessisabletocontrolthealuminumconcentrationintheanodizingtankwiththe

useofaselectivemembranethatallowssulfuricacidthroughthemembranewhileholdingback

thedissolvedaluminum.Mcch-ChcmAssociates,Inc.isonecompanythatprovidesthistypeof

equipmentforacidrecovery.

3.Acidsorption

Theprocessofacidsoiptionisaresincolumnmethodofholdingbacktheacidwhile

allowingthedissolvemetaltopassthrough.Aback-flushoftheresinwithpurewaterallowsthe

acidtoberecoveredfromtheresinandputbackintotheanodizingtank.Thewastefromthis

processwillbehighindissolvedaluminumandsmallamountsofacid.Onecompanythat

manufacturesacidsorptionequipmentisEco-Tcc,Inc.

陽極氧化溶液通常是疏酸。少量溶解的鋁有助于陽極氧化過程。但是，陽極氧化專用

化學(xué)混合物的制造商建議了濃度限制。作者建議溶解鋁的濃度不高于12g/Lo

溶解鋁濃度控制方法：

1、撇出和更換

從陽極氧化槽中去除出已知量的溶液，從容加熱相同體積的新鮮酸，將總?cè)芙怃X降低

到5?8g/L之間。去除的酸一鋁溶液可以離線提純，作為危險(xiǎn)廢物處理，或用于電鍍區(qū)域

的其他用途。

2、擴(kuò)散透析

這一過程使用硫酸可通過的選擇性膜，控制陽極氧化槽中的鋁濃度，同時(shí)阻止溶解的

鋁。Mech-ChemAssociates,Inc.是一家提供這類酸回收設(shè)備的公司。

3.酸吸附

酸吸附過程是一種樹脂柱方法，用以阻止限，同時(shí)允許溶解金屬通過。用純水反洗樹

脂，可回收樹脂中的酸，回到陽極氧化槽。這一過程產(chǎn)生的廢物溶解鋁高，含少量的酸。

Eco-Tec,Inc.是一家生產(chǎn)酸吸附設(shè)備的公司。

PaintingProcess涂漆工藝

OverviewofPainting涂漆概述

Thepaintingprocessisconsideredtobetheapplicationofaliquidorganiccoatingtoa

substrate.Substratescanbeplastic,wood,metal,ceramic,foam,paper,etc.The“paint“canvary

fromsolventbasedto100%solidsinthecaseofUVcuringliquids.Sothepaintcanbeliquid

duetovariouscarrierssuchassolventsorwatertoatwo-partepoxypaintorUVcuringpaint

thatcurebycross-linkingratherthandryingbytheevaporationofthecanier.Thepaintcanbe

appliedbyvarioussprayingmethodssuchaselectrostaticspray,highpressurespray,HVLP(high

volume,lowpressure)spray,etc.

涂漆工藝視為液態(tài)有機(jī)涂料用于基材上。基材可以是塑料、木材、金屬、陶究、泡沫、

紙張等。“漆''可以是溶劑基到UV固化液體時(shí)的100%固體。因此，由于載體不同，如

溶劑或水，漆可以是液體，到通過交聯(lián)固化而不是載體蒸發(fā)染色的兩-部分環(huán)氧樹脂漆或

UV固化漆。漆可采用靜電噴涂、高壓噴涂、HVLP（大容量、低壓）噴涂等多種噴涂方法。

Typicalstepsinapaintingprocess涂漆過程中的典withverylittleoverspea

型步驟:

1.AlkalineCleaning(typicallyanalkalinecleaner)

2.Rinsing

3.Phosphating(optionalsteptoimproveconosionprotectionandpaintadhesion)

4.PartDrying

5.Painting

6.PartDrying(orDryingandCuring)

1、堿性清洗(通常是堿性清洗劑)

2、沖洗

3、磷化(提高防腐蝕和油漆附著力的可選步驟)

4、零件干燥

5、涂漆

6、部分干燥(或干燥和固化)

Exampleofelectrostaticpaintspraying,withverylittleoverspraybehindtheparts靜電噴

漆示例，零件后面幾乎沒有X度噴涂ImagecourtesyofProductsFinishing.

ElectrophoreticPaintingProcess電泳涂漆工藝(E-Coat)

OverviewofE-CoatingE?涂層概述

TheE-coatprocessisbestdescribedasacrossbetweenplatingandpainting.Itisaprocess

whereametalpartisimmersedinawater-basedsolutioncontainingapaintemulsion.Anelectric

voltageisappliedtothepartcausingthepaintemulsiontocondenseontothepart.Apartcanbe

paintedbothinsideandout,wherevertheliquidisabletoreachametalsurface.Thecoating

thicknessislimitedbytheappliedvoltage.Asareasofhighvoltagebuildacoatingtheybecome

insulatorsthusallowinglowervoltageareastobuildup.Finally,theinteriorofapartcanbe

coatedsincetheexteriorisfullyinsulatedbythecoating.

Followingthepaintingtank,arinsetankremovestheresidualemulsionfromthepartand

recyclesitbacktothepainttankbyultrafiltration.TheE-coatiscuredbyhealandthecuring

timeandtemperatureisdeterminedbytheE-coatchemistry;epoxy,acrylic,etc.

ThepreparationstepsforE-coatareidenticaltoplatingstepsinthatthemetalsurfacemust

bechemicallyclean.

E-coat工藝描述最好電鍍和涂漆之間的交叉。是將金屬部件進(jìn)入含油漆乳化的水一基

溶液中的過程。電壓作用于零件，導(dǎo)致油漆乳化凝結(jié)在零件上。只要液體能夠到達(dá)金屬表

面,零件內(nèi)部和外部都可以涂漆C涂層厚度受施加電壓的限制C隨著高壓區(qū)域形成涂層.

便往絕緣體，可形成低壓區(qū)域。最后，由于外部完全由涂層絕緣，可對(duì)內(nèi)部進(jìn)行涂層。

在涂漆罐之后，沖洗罐去除零件中的殘留乳化，通過超濾循環(huán)回油漆罐。E-coat通過

熱固化，固化時(shí)間和溫度由E-coat化學(xué)性質(zhì)決定；環(huán)氧樹脂；丙烯酸等

由于金屬表面必須經(jīng)過化學(xué)清理，E-coat的準(zhǔn)售步驟與電鍍步驟相同。

TypicalstepsinanE-coatprocessformetalparts金屬部件的E-coat中的典型步驟：

1.AlkalineCleaning(typicallyanalkalinecleaner,butsubstratedependent)

2.Rinsing

3.AcidEtchingandAcidCleaners

4.Rinsing

5.Wettingagentdip

6.E-coat

7.E-coatrinsingandrecovery

8.DIRinsing

9.Curingwitheitherconventionorinfra-redover(orboth)

1、堿性清洗(通常是堿性清洗劑，但與基材相關(guān))

2、沖洗

3、酸蝕和酸洗劑

4.、沖洗

5、潤濕劑浸漬

6、E-coat

7.E?coat沖洗和回收

8、去離子沖洗

9、采用常規(guī)或紅外線(或兩者)固化

Wettingagentdip潤濕劑浸漬

SomeE-coatmanufacturersrecommendawettingagentdipinthetankimmediatelybefore

theE-coattank.Thisistypicallytopreventbubblesfromadheringtothepartsastheygointothe

e-coattank.AnybubbleattachedtothepartsurfacewillpreventE-coatdepositionandwill

causeapaintdefectinthefinishedpari.

一些E-coat制造商推薦在E-coat罐之前立即將潤濕劑浸入罐中。這通常是為了防止

氣泡在零件進(jìn)入電泳槽時(shí)粘附在零件上。任何附著在零件表面的氣泡都會(huì)阻止電泳涂層的

沉積，會(huì)導(dǎo)致成品零件出現(xiàn)油漆缺陷。

E-coatrinsingandrecovery沖洗和恢復(fù)

AnadvantagetotheE-coatprocessisthecaseofrecoveringtheE-coatthatgetscarriedby

thepartstotheE-coatrinsetank.TheE-coatrinseisconstantlyfilteredthroughanultrafiltration

unitwhichseparatestheE-coatemulsionfromthecarriersolutionandreturnsittotheE-coat

tank.MostoftheE-coatisrecoveredinthisway.

E-coai工藝的一個(gè)優(yōu)點(diǎn)是易于回收由零件攜帶到E-coai沖洗槽的E-coat(>E-coai沖

洗液通過超濾裝置不斷過濾，超濾裝置，分離E?coal乳化與載體溶液，將返回E-coai罐。

大部分E-coat都以這種方式回收

CuringofE-coat固化

SinceE-coatisessentiallyliquidpaintonceithascoatedapart,itwillrequireacuring

cyclebasedonthetypeofpaintchemistrybeingused.Asanexample,anacrylic-urethanetype

E-coatwillrequireacuringtemperatureof320°Ffor20minutes(metaltemperature,specified

forElectroclear2800,productofPPG).Aswithpaints,theenergyusedtocuretheE-coatwill

dependonthepartsizeandpartgeometry.Simplegeometriesmaybeabletobecured

completelywiththeuseofinfraredhealingsincetheinfraredisline-of-sightandheatsthemetal

surfacewithoutneededtoheatthewholepart.Forcomplexgeometries,aconvectionovenis

typicallyneededtofullycuretheE-coatinallareasofthepart.

SincetheE-coatchemistrycanbeachemicalcross-linkingprocess,thefullcurerequires

bothtimeandtemperaturetoobtaintheoptimumcoatingproperties.

Moreinformationoninfraredcuringcanbefoundinthepowdercoatingdryingandcuring

processdescription.

由于一旦涂上零件后E-coat實(shí)質(zhì)上是液體油漆，需要一個(gè)基于使用涂料化學(xué)類型的固

化周期。例如，丙烯酸-聚氨酯型E-t涂層需要32()°F固化溫度20min(金屬溫度，指定

用于PPG產(chǎn)品)。與油漆一樣，用于固化E-涂層的能量將取決于零件尺寸和零件幾何形

狀。簡單的幾何形狀可以使用紅外線加熱完全固化，由于紅外線是視線范圍內(nèi)，且加熱加

熱金屬表面，而不需要加熱整個(gè)零件。對(duì)于復(fù)雜的幾

何形狀，通常需要對(duì)流烘箱完全固化零件所有區(qū)域的

E-coato

由于E-coat化學(xué)可以是化學(xué)交聯(lián)過程，因此，完

全固化需要時(shí)間和溫度取得最佳涂層性質(zhì)。

紅外固化的更多信息見粉末涂層干燥和固化工藝描述。

ExtremeexampleofE-coatingacomplexpart復(fù)雜零件電泳涂層的極端示例

PowderCoatingProcess粉末涂層過程

OverviewofPowderCoating粉末涂層概述

Thepowdercoatingprocessisverysimilartoapaintingprocessexceptthatthe“paint”isa

drypowderratherthanaliquid.Thepowderstickstothepartsduetoelectrostaticchargingof

thepowderandgroundingoftheparts.Anysubstratecanbeusedthatcantoleratetheheatof

curingthepowderandthatcanbeelectricallygroundedtoenhancechargedparticleattachment.

Thepowderflowsandcuresduringtheapplicationofheat.

Severaladvantagesofpowdercoatingoverpaintsare:

Powderrecoveryforreuse

NoVOCgenerationthereforenoVOCdestructionrequired

Canbemoredurablethanpaints(powderchemistrydependent)

Severaldisadvantagesofpowdercoatingoverpaintsare:

Canhavelesslevelingthanpaint(moreorangepeel)

Curingistypicallymoreenergyintensivethanpaintdryingduetohighertemperature

requirements

Surfacepreparationbeforepowdercoatapplicationisstillcriticalforadhesionanddefect

avoidance.

粉末涂層工藝與漆裝工藝非常相似，只是“涂料”是干粉末，而不是液體。由于粉末的

帶靜電和零件和接地，粉末會(huì)粘附在零件上。可使用耐受固化粉末熱量且可電接地任何基

材，增強(qiáng)帶電顆粒的附著V粉末加熱期間流動(dòng)和固化。

與油漆相比，粉末涂料的幾個(gè)優(yōu)點(diǎn)是：

粉末回收再利用

不產(chǎn)生VOC,因而不需要損毀VOC

比油漆更耐用(取決于粉末化學(xué)性質(zhì))

粉末涂料與油漆相比的幾個(gè)缺點(diǎn)是：

流平性不如油漆(更多橘皮)

由于更高的溫度要求，固化通常比油漆干燥更耗能

粉末涂層應(yīng)用前的表面處理對(duì)于?附著力和避免缺陷依然至關(guān)重要。

Typicalstepsinapowdercoatingprocessformetalparts:金屬零件粉末噴涂工藝中的典

型步驟

1.AlkalineCleaning(typicallyanalkalinecleaner,butsubstratedependent)

2.Rinsing

3.Phosphating(optionalsteptoimprovecorrosionprotectionandadhesion)

4.PartDrying

5.PowderCoaling

6.DryingandCuring(typicallyenergyintensivesincerelativelyhightemperaturesare

requiredtogetthepowdertoliquefyandflow*)

*Powdercoatingformulatorshavebeenworkingtoreducethecuretemperaturestoallow

theprocesstobeusedontemperaturesensitivematerials.

1、堿性清洗(通常是堿性清洗劑，但取決于基材)

2、沖洗

3、磷化(提高防腐蝕和附著力的可選步驟)

4、部分干燥

5.、粉末涂層

6、干燥和固化(由于粉末液化和流動(dòng)需要較高的溫度，通常能耗高*)

?粉末涂料配方設(shè)計(jì)師一直在努力降低固化溫度，使這與工藝可用于對(duì)溫度敏感材料。

DryingandCuring干燥和固化

Theenergyintensiveoperationsinthepowdercoatingoperationaredryingandcuring.

Typicaldryingandcuringoperationsarewiththeuseofconvectionovens.Theuseofconvection

heatingcanbeveryslowandverycostlyifthepartsarelargeandheavysincetheevaporationor

curingwillbedependentonthebulktemperatureofthepart.Essentiallythewholepartmustbe

hotenoughtocausethepartsurfacetoeitherdryorthepowdercoattocure.Therefore,large

volumesofairneedtobeheatedandexhaustedfromtheconvectionoventoeffectivelydryor

curetheparts.

Thisismuchlessofaproblemforthinwalledorlowmasspartssincethehotaircanheat

thepartsrelativelyquicklywitharesultantfasterdryingorcuringprocess.

粉末涂料操作中能源密集型操作是干燥和固化。典型的干燥和固化操作使用對(duì)流烘箱。

由于蒸發(fā)或固化將取決于零件的整體溫度，如果零件又大又重，采用對(duì)流加的使用可能非

常慢且成本非常高。零件表面干燥或粉末涂層固化實(shí)質(zhì)上需要整個(gè)零件足夠熱C因此，需

要加熱，并從對(duì)流烘箱中排出大量空氣，有效地干燥或固化零件。

由于加熱空氣可較快加熱零件，從而加快干燥或固化過程，這對(duì)于薄壁或低質(zhì)量零件

問題要小得多。

Dependingonthepartgeometry,simplegeometriescanbedriedandcuredusinginfrared

heating.Theheatingoccursatthepartsurfacewithlittleairheatingofbulkheatingofthepart.

Therefore,thehealenergyisgoingwhereitisneeded,iothesurface.Itisalsoaveryrapid

heatingprocess,againsincethereisinstantinfraredlightabsorption.

Anotheradvantageofinfraredheatingisinthepowdercoatcuringprocess.

Therapidpartsurfaceheatingresultsinbetterpowderflowandlesschanceofdustordirt

defectssincethereisverylittleairflowtodepositparticlescomparedtoconvectionheating.

根據(jù)零件兒何形狀，簡單的幾何形狀可