Advantages of zinc aluminum flake coating.

Different advantages of zinc aluminum flake coating are as follows :

  1. No Hydrogen embrittlement – The treatment process of zinc aluminum flake coating do not involve treatment with acid for removal of corrosion products like mill scales, rust. Mechanical cleaning (shot blasting, grit blasting) followed by coating avoids the risk of hydrogen embrittlement.
  2. Overall coverage – The coating process is non electrolytic. Articles are coated by dip mode of application or spray mode of application depending on size, weight of article. The articles are coated ensuring complete coverage.
  3. Corrosion resistance – The corrosion resistance is higher due to overall coverage and also due to sacrificial protection of zinc /aluminum flakes. The film structure is like brisk wall minimizing penetration moisture. The film also has self healing property.
  4. Thermal stability – Cured film of zinc aluminum flakes do not changes its properties even at higher temperatures. There is no degradation in corrosion resistance property.
  5. Excellent adhesion and recoat ability – Zinc aluminum flakes coating film adheres firmly to metal surface. It has also excellent recoat ability. Top coat with different lubrication properties can be applied on zinc aluminum flake coating to further enhance different properties.
  6. Free from pollution – The water-based zinc aluminum flake coating process do not involve generation of waste water. The coating is free from water and air pollution.

Generally zinc aluminum flake coating process involves cleaning to remove oil, shot blasting to remove rust/mill scales, coating and curing. Desired properties are achieved essentially with two coats. The properties are further enhanced by application of suitable top coat.

New Generation Self-pH-Regulating Mirror Bright Finish Midphos Electroless Nickel Plating (ENP): Ginplate NI 4320 AutoP

GINPLATE NI 4320 AutoP is a Midphos, self-pH-regulated electroless nickel-plating (ENP) process, which provides a mirror bright finish.

Midphos ENP is commonly used on components exposed to mild environment for corrosion/wear resistance with an aesthetic appearance.

Electroless Nickel plating is an auto catalysed redox process that deposits an even layer of Nickel-phosphorus alloy coatings on a properly prepared surface. pH plays an important role in any redox process and it tends to change during the course of the chemical reaction due to generation of H+/OHions in the reaction vessel. During electroless nickel plating, the pH drops down due to generation of H+ ion, which needs readjustment by adding Ammonia or other base to maintain the alloy composition and plating speed. Hence, an auto-pH-regulated ENP process was a long-standing demand of ENP platers.

GINPLATE NI 4320 AutoP is specially designed to produce a consistent midphos EN deposits at a very good plating speed without any additional replenishment of Ammonia. The carefully formulated additives and buffer system of GINPLATE NI 4320 AutoP provides an excellent pH and bath stability without compromising the quality and speed of the plating. Mid Phosphorus ENP acts as a low-cost alternative for decorative and functional applications.

The GINPLATE NI 4320 AutoP is supplied as three separate liquid concentrates: GINPLATE NI 4320 AutoP A, GINPLATE NI 4320 AutoP B, and GINPLATE NI 4320 AutoP C.

CHARACTERISTICS OF COATING

  • Self-pH-Regulated process
  • Robust and Hybrid buffer system
  • Good plating Speed (15 – 22 μ/hr)
  • Phosphorous content 4.5 – 8.5% w/w)
  • Mirror bright finish
  • Long bath life (10 MTO)
  • Low operating cost
  • Good wear and abrasion resistance
  • Suitable for plating on wide variety of substrates, SS, MS, CS, Cu alloy & Al alloy
  • P-Content may be fine-tuned and controlled as per requirements of jobs.
  • Magnetic Deposit (<8.5% P-content)

 ADVANTAGES

  • No Ammonia is required to maintain the pH. Low maintenance cost and easier to maintain plating speed and alloy composition due to constant and consistent pH over the longer bath age.
  • Uniformity, hardness and corrosion/wear resistance makes it ideal for the parts or components that function under constant pressure or dynamic condition.
  • Plating with ENP can often eliminate the need for machining or polishing due to its good surface finish and uniform thickness distribution.
  • Midphos ENP provides large flexibility of thickness, volume, and alloy composition of the plating on metal/conducting surface. It can easily fill recesses or pits on the metal surfaces. This allows its application in a wider variety parts of industrial applications.

APPLICATIONS

  • Chemical process industry
  • Medical and food processing industries
  • Aerospace Industries
  • Hydraulics
  • Tools and engineering instrument
  • Oil and gas industry
  • Automobile industry

Zinc Aluminum Flake Coatings

Use of ferrous and non- ferrous material is unavoidable in the industry due to its availability, strength, durability, work-ability and ability to recycle. Automobiles, bridges, house- hold appliances, power generation equipment’s, railways, engines etc. are manufactured using ferrous and non -ferrous materials by adjusting metal properties in terms of hardness, flexibility, resistance to corrosion, weight to strength ratio etc.

Loss of metal due to various types of corrosion processes is a perennial problem in the industry. Thousands of dollars are wasted due to loss of metal (corrosion) and also thousands of dollars are invested in protecting the metal from corrosion. This in turn increases the life span of manufactured items, avoids the probable risk of accident.

Use of different types of fasteners, nuts, bolts, clips are necessary to manufacture different articles. The adequate strength required for the articles is provided by different sizes of fasteners, nuts and bolts.  Fasteners are subjected to failure due to atmospheric corrosion, hydrogen embrittlement, temperature variations and bi- metallic corrosion.

Different types of phosphating systems and also painting systems with different types of resins, film thickness varying from few microns to few millimeters are used to protect the main structure. However higher film thickness of any coating is a limiting factor for fasteners.

 Different types phosphating, blackodizing, zinc plating followed by passivation layers are used to improve the corrosion protection of fasteners. However, zinc plating has limitations in terms of corrosion protection and possibility of hydrogen embrittlement. Adverse effect on environment due to use of hazardous chemicals also needs to be considered while using such coatings.

Zinc aluminum flake coating is developed with the extensive research to provide protection against all types of corrosion for fasteners, brake disc etc with a very thin film of 6~10 microns. Zinc aluminum flakes with water or solvent based, binders free from hexavalent chromium (environmentally friendly) and adequate additives to improve different properties are widely used in the industry. Even at low film thickness zinc aluminum flake coating provides excellent protection against corrosion considering different environmental cycles. Zinc aluminum flake coating also helps in preventing bi metallic corrosion.

Electroless Nickel – All You Need to Know

Electroless Nickel Plating (ENP) is the deposit of a nickel-phosphorous alloy coating by autocatalytic chemical reduction – without the electric current.

The majority of ENP for engineering purposes is a nickel-phosphorus alloy deposit containing 2 to 13% phosphorus by weight.

Higher the phosphorus content the greater is the corrosion resistance, however, on increasing the phosphorus content, the hardness of the coating decreases.

  • Highphos ENP: P-content 10 – 13%, high corrosion resistance (>25 µm, >1000 hrs NSS), hardness as plated 450 – 550 HV
  • Midphos ENP: P-content 6 – 9% moderate corrosion resistance (>25 µm, >96 hrs NSS), hardness as plated 550 – 650 HV
  • Lowphos ENP: P-content 2 – 5% low corrosion resistance (>25 µm, >24 hrs NSS), hardness as plated 700 – 800 HV

ENP is deposited by reducing Ni2+ cation to metallic nickel with a chemical reducing agent such as sodium hypophosphite or borohydride or DMAB. In the course of chemical reduction, some phosphorous generated gets deposited along with reduced Ni-metal to form a Ni-P Alloy Thickness of 15 – 75 µm, this is very common for most of the application, but for some specific applications high phosphorus ENP can edge above 75 µm also, especially, for very high corrosion and wear resistance requirements.

The advantages of electroless nickel plating

ENP offers excellent corrosion resistance against most of the common corrodents such as saltwater, carbon dioxide, oxygen, and hydrogen sulphide, etc.

High phosphorus deposit of ENP (10-13% phosphorous) is amorphous in nature, which means that there are no grain or phase boundaries to create active sites for the initiation corrosion.

The uniformity of ENP versus electrolytic deposits is very advantageous for plating irregular and complicated shapes of substrates. ENP deposits a uniformly thick coating across the whole substrate; even in slots, holes, and inside walls of the tubing.

Without heat treatment, corrosion-resistant of high phosphorus ENP is very high and also has good hardness and wear resistance properties. Hardness can be increased more than doubled by heat treatment with a bit of compromise in corrosion protection.

ENP offers a cost-effective solution for applications subject to conditions where wear and corrosion are factors; extending service life and providing a lower-cost alternative to corrosion-resistant alloys, particularly where carbon steel suffers localised corrosion; flange attack or weld corrosion.

What are the properties of the deposit and factors affecting them?

ENP provides excellent corrosion protection and uniformity in thickness of deposit along with good hardness. The phosphorus content of the deposit can be chosen as per the requirement of the application.

At Grauer & Weil our technical team understands each customers’ application and its requirement before recommending the optimum phosphorus level – the higher the phosphorus content the greater the corrosion resistance but lower the hardness.

Hardness of ENP can be increased by heat treatment but this produces a micro-crack in the deposit which reduces the corrosion resistance of the coating.

Uniform thickness distribution and alloy composition on complex shapes are the biggest advantages of Electroless plating over electroplating.

How does heat treatment affect ENP?

ENP is at its most corrosion-resistant in its amorphous phase. Heat treatment causes particles of nickel phosphide (Ni-Ni3P) to precipitate, destroying the amorphous character of the deposit. With highphos ENP deposits, this occurs at temperatures between 300 and 395 °C.

How well does ENP adhere to substrates?

Adhesion is dependent on effective cleaning of the substrate. With good surface preparation adhesion to carbon steel is between 200-420 MPa. With stainless steels, the bond strength is usually between 120-160 MPa.

What factors affect plating quality?

There are several factors affecting plating quality and they should be effectively managed by your surface finishing partner.

– Surface preparation: Rough, badly machined surfaces with uneven metal surfaces, burrs, or cold shuts cannot be effectively plated.

– Cleaning: Surfaces must be free from oils, dirt, and soaps formed by saponification of oils by alkaline cleaners.

– Control of the baths and operating parameters: Temperature, pH, nickel ion concentration, and hypophosphite concentration all need to be carefully managed to ensure high quality and consistent plating finish.

What are the fabrication/finishing requirements before plating?

Weld spatter should be removed, sharp edges radiuses and weld roots ground smooth. When refurbishing/remanufacturing components it is important that corroded areas are ground to a flat surface.

Some other key considerations

When looking to choose a suitable partner for your electroless nickel plating requirements it is important to check for several factors:

– Will surface inspection be completed prior to plating?

– Are the chemicals supplied by a certified ENP product supplier?

– Are ENP solutions made up with demineralized (DM) water?

– Is continuous filtration of the bath to 3 microns done along with air agitation?

– Is bath chemistry (Ni2+, hypo, buffer, etc.) monitored regularly by chemical analysis?

– How regularly are plating Tanks cleaned?

– Is the inspection of the plating line carried out to sufficient levels?

Growel Wire Drawing Oils

Growel Specializes in the development & manufacture of lubricating oils used in the wire drawing industry.

The Indian Market hitherto was dominated by multinational corporations, Growel drawing oil has developed a made in India range of highly advanced range of products specifically geared for the wire drawing industry.

These wire drawing products are categorized as per the material used for the wire manufacture –

  • MS & steel wire drawing oils
  • Aluminium wire drawing oils
  • Copper tube drawing oils
  • Copper wire drawing oils

MS & steel wire drawing oils –

GRODAL NOX UM – Water-soluble lubricating compound for MS & SS wire drawing as well as deep drawing applications.

GRODAL STEEL NOX / NOX –

This is a pasty material based on vegetable oil & surfactants used for steel, MS, black & galvanized wires. In many industries, it is also used for deep drawing purposes.

Aluminium drawing oils –

Growel’s lubricants cover all the aluminum wire production stages:

Rod breakdown (RBD)

Intermediate drawing.

Fine-wire drawing

Extra-fine wire drawing

Coiling and/or bunching

Products –

GRODAL STAMP DE 2010 –

This product is mainly used in vanishing, drawing, stamping & blanking applications.

It is especially suitable for aluminum & its alloys.

GRODAL DRAW 300 –

This is a low viscosity fine aluminum wire drawing oil free from sulphur, chlorine, zinc & is, therefore, suitable for super finishing of ferrous, non-ferrous & yellow metals.

Multifunctional semi-synthetic oil for aluminum or its alloys. This range of drawing oils is specially designed for excellent lubrication, extreme cooling power & better detachment from aluminium.

GRODAL STAR DE 1422 –

40 CST viscosity product -Multifunctional semi-synthetic oil for aluminium or its alloys specific for wire rod breakdown and drawing. Final diameter above 0.6 mm.

GRODAL STAR DE 1422-90-

40 CST viscosity product -Multifunctional semi-synthetic oil for aluminium or its alloys Specific for wire rod breakdown and drawing. Final diameter above 0.4 mm.

GRODAL STAR DE 1422 R-

170 CST viscosity product- Multifunctional semi-synthetic oil for aluminium or its alloys Specific for wire rod breakdown and drawing. Final diameter above 0.9 mm.

GRODAL STAR DE 1422 H-

22 CST viscosity product – Semi-synthetic oil for the drawing of aluminium and its alloys fine-wires (Al/Mg). Exit diameter above 0.5 mm. Corrector additive for GRODAL STAR DE 1422 R and TADAL STAR DE 1422/90.Suitable for enameled aluminium wire drawing.

GRODAL STAR DE 1422 F-

12 CST viscosity product – Semi-synthetic oil specially designed for the drawing of aluminium fine-wires. Suitable for the production of enameled wire. Exit diameter below 0.5 mm. Corrector additive for GRODAL STAR DE 1422 and GRODAL STAR DE 1422/90.

COPPER TUBE DRAWING OIL –

GRODAL TUB 3000 –

This is a synthetic oil specially designed for drawing copper pipes. This product is also suitable for inner drawing & is free from mineral oils, sulphur & chlorinated esters. 

GRODAL TUB M 01F-

A synthetic oil suitable for inner copper tube drawing.

GRODAL FIL C-14-

Light viscosity stranding oil for aluminium & copper. This product has a high cooling ability.

COPPER WIRE DRAWING & ANTI TARNISH FLUIDS

GRODAL CU 860 & GRODAL CU 661 –

These products are added to water to prevent tarnish & oxidation on copper tubs, wires, rods, etc.

GRODAL CU SYN DRAW 12 –

An all synthetic product with lubricity, corrosion inhibitors & surfactants. This product is free from binding, enameled wire rejections, oil separation & insoluble copper soap formation.

GRODAL CU 1350 N

Multipurpose emulsionable semi-synthetic oil for copper and enameled copper wire. High stability and high detergency. It provides high benefits with low maintenance costs. Suitable for an enameled wire.

OPERATING DATA

Wire type                                             Concentration % volume

Copper

Rod                                                                12 -18

Intermediates                                                  4 – 10

Fine                                                                3 – 5

Annealing                                                        1 – 1.5 max

Grodal Syncool 2 – Surface Protector Cum Coolant For Pump Industry

Grodal Syncool 2 is the “GROWEL” make surface protector cum coolant widely used in Pump Industry for Submersible / Open well / Self Priming Pump-sets. Its primary application is to protect the inner surface of the motor against Rust and Corrosion which increases the working lifespan for the Motor to a long time.

Grodal Syncool 2 :- Major Benefits

1. Due to its well-balanced formulation it reduces the pump set’s choked-up problem with the help of world-class cleaning agent cum rust inhibitor additives. Exhibits excellent performance on cast iron body washing/cleaning & rust protection.

2. Easy start-up even at low voltage due to choking free operation.

3. Increased life of thrust bearing and bushing due to synthetic water- soluble lubricity additives.

4. No pressure generation after using Grodal Syncool 2 in the pump, resulting in no gas formation into the closed system due to the additives.

5. Our product is chlorine & phenol-free.

6. Increases the overall efficiency, based on specific requirements as 20% dilution with DM water to 100%.

7. Toxicity test carried out NABL approved lab resulting passes.

8. Our product Grodal Syncool 2 is formulated with top quality water-soluble additives.

9. We strongly recommend this product to use in the pumps Instead of plain water by pump manufacturer to avoid rusting & to boost the overall performance in operation by 5-6%.

How to use Grodal Syncool 2 in pumps:-

  • First flush & clean the Submersible / Open well / Monoset motor cooling system by soft / Tap water. Fill with one part (1Ltr) “Growel” make Grodal Syncool 2 & 4 parts (4Ltr) of DM water or drinking water in to the motor up to specified / marking level. Then complete the assembly of a motor by tightening the screw with washer & ‘O’ ring. Ensure there is no leakage. Before final installation submersible motor must check (start) for 1-2 minutes. If it starts smoothly then the submersible motor is ready for installation. During this check,
    Grodal Syncool 2 develops a synthetic polymer layer inside the motor. This layer protects the inner surface against rust/corrosion.

Advantages of Using Grodal Syncool 2 :

  • Grodal Syncool 2 is beneficial commercially as well as technically.
  • Consumption benefit of our product is as under:
APPLICATION COMPETITOR PRODUCT RATIO GROWEL RATIO
Washing CI Parts of motor with Gun Metal Bush 30 % 20 %
Washing CI Parts of motor with Carbon Bush 30 % 4 %
Washing of Rotor/Stator 30 % 20 %
Coolant filling at testing/dispatch 12.5 % 10 %
  • Grodal Syncool 2 has better performance in terms of Rust Protection compare to competitor’s product
  • We have small packing like 1 Kg, 5 kg & 30 Kgs
  • Overall benefit of 8 to 10 % with Grodal Syncool 2

Heart of plating.

At Growel, automation is at the heart of all our plating plants. Keeping this in mind our team, in technical collaboration with Utikal Automation Germany, is working with GalvCon V4.0, a PC-based software exclusively developed for atomization of surface finishing processes. The software is developed to be rich in features and provide ease in operation even when there is a need for replacement and modification.

This automation package is developed in such a way that the “intelligent part” of the software is written on the PC whereas the “driving program”, which rarely requires any changes, is written to the PLC. A highly reliable and powerful TCP/IP connection is established with Siemens S7 controller which requires no special drivers or third-party software for communication.

Initiating the plant operation is as easy as entering the article number and quantity to be loaded, the software initiates the cycle with minimum manual intervention.

Each article is pre-assigned with a unique process flow program (sequence of movement with time) and a power program (current density setting). Every article is capable of having a different process flow and current density program. The system has no limitation on the number of articles and their subsequent programs. The process program is designed to include parameters such as order of the baths, residence times, current setting in electrolytic baths, automatic dosing, temperature control in heating/cooling baths, and control of accessories along with visualization. The most powerful feature of this software is the capability of having flexible cycles. With this feature different articles having different process flow programs (different articles need to be processed in different baths with different timings) can be loaded onto the plant as per the user’s output demand.

The software is designed in such a way that the operator is allowed to load articles randomly as required and the intelligence of the software will decide the right sequence of the flight bar movement in the plant. The loaded flight bars may be temporarily stored at the buffer station or maybe directly taken for processing. The software will calculate the most efficient sequence of flight bar entry into the plant ensuring the most optimal usage of the baths and the transport wagons.

GalvCon V4.0 enjoys the following features and advantages:

  • Multi-level Password protection for avoiding operator level errors.
  • Multiple computers can be connected in the network for visualization but only one PC has the master process control.
  • Remote system connectivity is possible for process and status visualization through the Internet.
  • A special Loading terminal can be provided, to select the article while loading with visual identification.
  • Vast flexibility for process control.
  • Software can be quickly tailored to suit user needs.
  • Process and current programs can easily adapt to change in plant structure.
  • High stability and reliability.

GRODAL GLASS 339 – Glass Grinding Fluids Challenges & Opportunities

In the early days of glass processing, water was used as a coolant and lubricant.  However, the use of diamond-tipped tools in glass processing with only water as a coolant led to the following problems in glass grinding operations:

  • Marked decrease in process efficiency
  • Runaway cost escalation on account of rapid wear and tear of diamond tools.
  • Extensive corrosion of plant & machinery
  • Undesirable pH increase of the grinding solution

Due to the brittle nature of glass and the stresses of glass grinding, the coolant used to aid the grinding process has to fulfill a number of requirements. As an example, fine glass particles are produced during the grinding process which instead of settling at the bottom, remains suspended in the water thereby reducing the effectiveness of the water to act as a coolant. In addition, these glass particles had an abrasive effect during the operation, creating unacceptable scratches on the toughened glass.

Rising to the needs of the industry, Growel has specifically designed a high-performance grinding fluid/coolant- GRODAL GLASS 339 which now eliminates these problems.

GRODAL GLASS 339 is a synthetic coolant concentrate based on ester additives that are designed to cool and lubricate extreme machining operations on flat toughened glass such as edge grinding, drilling, milling, etc. Exceptional Bio-Stability permits operation with hard water up to 450 ppm. It keeps the tools clean and allows the glass powder to settle easily.

GRODAL GLASS 339 – APPLICATION GUIDELINES

Stir with water in the desired (usually 0.2% to 0.5%) ratio to a homogeneous solution.

For a higher lubricity ratio, it can be increased to 1 – 1.5%.

Special additives in the Grodal Glass 339 keeps the surfaces of the diamond tool sharp. This in turn maintains grinding performance and substantially reduces glass processing time. The absence of these vital additives would necessitate the frequent replacement of the diamond tool, thereby leading to an exponential rise in operation cost.

One of Grodal Glass 339’s many real-world application successes includes the case study of one of our key customers engaged in the manufacture of mobile phone scratch guard glass. Their organization was using an imported cutting fluid @ 2.5% concentration level resulting in their use of 140-150 liters of fluid daily. Upon switching to Grodal Glass 339 at 1.5% their consumption reduced to 80-90 liters daily. Our customers also reported a marked reduction in the amount of fuming they were experiencing during cutting operations. Advantages ranged from the locally available and as-needed supply of cutting fluid to the measurably superior performance of the Grodal Glass 339. 

New Generation Lead-Cadmium Free Highphos Electroless Nickel Plating (ENP): Ginplate NI 625

Ginplate Ni 625 is an advanced RoHS electroless nickel plating (ENP) process. Highphos ENP is commonly used on components exposed to aggressive usage or hostile environments. It is specially designed to produce deposits that exhibit superior performance for engineering and functional applications. ENP process is also suitable for difficult to plate substrate and geometry. The carefully formulated additives of Ginplate Ni 625 provide excellent stability to the bath solution and good plating speed.

In many applications, the use of Micro Plating High Phosphorus ENP allows the substitution of less expensive materials as a low-cost alternative for hard to machine or stainless steel alloys.

The Ginplate Ni 625 is supplied as three separate liquid concentrates: Ginplate Ni 625 A, Ginplate Ni 625 B, and Ginplate Ni 625 C.

CHARACTERISTICS OF COATING

  • 10-12% phosphorus
  • High corrosion and wear resistance
  • High hardness
  • Uniform thickness distribution (100% coverage)
  • Low coefficient of friction
  • Pits and pore-free amorphous coating
  • Suitable for High Build-up Applications (>10 Mils), especially required in the petrochemical industry
  • Narrow melting temperature, suitable for brazing and welding
  • Non-magnetic deposit
  • Zero or little compressive internal stress

ADVANTAGES

No electricity is required for ENP which makes it more accurate, efficient, and cost-effective.

Uniformity, hardness, and high corrosion/wear resistance make it ideal for the parts or components that function under extreme environmental conditions.

Plating with highphos ENP can often eliminate the need for machining or polishing due to its good surface finish and uniform thickness distribution.

The lack of porosity, due to its amorphous nature also adds to its strength and makes it an obvious choice for a heavy-duty finish.

Highphos ENP provides large flexibility of thickness and volume of plating on metal/conducting surfaces. It can easily fill recesses or pits on the metal surfaces. This allows its application in a wider variety of parts of industrial applications including oil field valves, valve pumps, driveshafts, electrical/mechanical tools, and engineering equipment, etc.

SUBSTRATES

  • Aluminium & its alloy
  • Brass
  • Copper Alloys
  • Stainless Steel
  • Tool Steel

APPLICATIONS

  • Petrochemical Industry
  • Aerospace Industries
  • Hydraulics
  • Tools and engineering instruments
  • Food processing & Medical Instruments
  • Automobile industry

Authored by- Dr. Haritosh Mishra

How Choosing The Right Lubricant Can Reduce Equipment Costs?

Lubricants are largely used in industries.  Lubricants are substances that are used to reduce friction between surfaces. Different types of lubricants are used to improve the performance of machines and make the machines effective.   Lubricants help to reduce the wear and tear of machines and equipments, they reduce the maintenance cost and help in the smooth functioning of the machine.  Lubricants elongate the lifespan of the machines.