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Phosmatt

Phosmatt 

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The PHOSMATT PROCESS is simple in principle. It is a normal closed-circuit wet blast technique, as perfected by VAPORMATT Engineers over many years, to simultaneously etch, de-grease, de-rust and de-scale the surface – leaving a very clean, chemically active surface which is totally unprotected from its surroundings. The PHOSMATT PROCESS uses a heated phosphate solution as the carrier for the blast media: chemical action immediately starts with the phosphate when the virgin, unprotected metal surface is exposed. Small, fast growing crystals result.

To continue the crystal growth, without re-blasting them away (once all the surface contaminants have been removed), the surface is further rinsed with phosphate solution alone, from a special nozzle. This produces the main build-up of the phosphate layer, a very fast build-up which in practice takes only the same time as rinsing the component to remove surface debris. With zinc phosphate, coating weights of 6 grms/metre squared can quickly be obtained.

Finally, as with conventional phosphating methods, the treated components have to be rinsed in running water to avoid corrosion, and then dried. However, if a water-based coating paint is the next process, this is not necessary.

 

The PHOSMATT PROCESS is suitable for automatic or manual operation, dependent upon the quantity, form, size and variety of components to be processed.

The PHOSMATT process time required, including all surface preparation, is half that necessary for the conventional phosphate stage alone in a normal dip method. (Excluding up to five extra pre-phosphating stages for de-rusting, de-greasing and rinsing, which are necessary with conventional methods). The space required for a PHOSMATT PROCESS plant is much less than for spray or dip phosphating lines, which have to include all the aforementioned pre-phosphating stages and incorporate longer phosphate treatment sections to counteract the slower processing speed.

 

 

Traditional PreTreatment Process   Phosmatt PreTreatment
     
CLEANER DEGREASER Hot detergents
   
|    
PRE-RINSE Water
   
|    
2ND RINSE Hot water
   
|    
DE-SCALE + ETCH Hot alkali or acid
   
|    
PRE-RINSE Water
   
|    
2ND RINSE Hot water
   
|    

DIP OR SPRAY PHOSPHATING
-------
SLOW LAYER
BUILD UP
Hot Phosphate

 
 
PHOSMATT
Clean De-grease
Etch De-scale
Paint removal
-------
FAST LAYER
BUILD UP
Hot Phosphate & Abrasive
|   |
RINSE Water
 
RINSE Water
|   |
DRY
 
DRY

 

The PHOSMATT process produces many close packed crystals which adhere directly onto the metal substrate. This gives a far more corrosion and shock resistant coating than the larger, less well adhered crystals which are formed using traditional processes.

 

Schematic Diagram of Crystal Structure

Phosmatt Process   Traditional  Phosphate Process
     
1. Small close pack crystals-fast grow.   1. Large open structure crystals-slow grow.
2. Metal substrate with many nucleation sites.   2. Oxide/Hydroxide layer.
    3. Metal substrate with few nucleation sites.

 

 

COATING TYPE (BS 3189)
TYPE APPLICATION METAL ION COATING WEIGHTS
(g/m2)
MIN     MAX
1a Protection under sealants Wear resistance Fe (Iron)
MN (Manganese)
7.5     -----
       
1b Protection under sealants Cold extrusion Zn (Zinc) 7.5     -----
       
2 Paint base wire and tube drawing Zn (zinc) 4.5     7.5
       
3 Paint base Zn (Zinc) 1.5     4.5
       
4 Paint base Fe (Iron) 0.2     1.5

 

Typical Applicatins of the Phosmatt Process

  Removal of old paint and substrates from ordnance and engineering components, then re-phosphating.
  De-scaling of metal billets, wire, rod, tube, then phosphating prior to cold extrusion or drawing.
  Oil and scale removal from metal parts, then phosphating to improve adhesion of paint.
  Cleaning and phosphating of transmission components and sliding engineering parts, to provide or assist lubrication.
  Cleaning and phosphating of metal parts to provide a corrosion-free surface layer.
  Preparation of surface to provide very high rubber-to-metal bond strength.

 

Phosmatt Process Advantages

  Much quicker process - minutes rather than hours.
  No pre-treatment required (No separate degreasing, de-rusting, or cleaning is necessary).
  Considerably less space required.
  Less energy and phosphate solution consumed: all solutions are kept in thermally-insulated closed surrounds.
  Less water used.
  Phosphate solutions are automatically filtered to remove flock and other contaminants.
  Only simple ventilation is required, unlike open tanks in conventional systems.
  Environmentally safer process.
  Solutions are auto-electronically monitored, giving high quality control.
  Re-phosphating of selected areas, without stripping whole component, can be achieved.

 

 


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