ZCl K3. Ammonia free Temperature tolerance up to 110 F (43 C), reducing cooling costs. Zinc Plating System

Transcription

1 is a two component, ammonia free, water soluble, zinc plating system suitable for either rack or barrel plating operations. is characterized by ease of control, consistent day to day operation, high temperature tolerance and excellent chromate receptivity. Mirror bright finish Excellent adhesion and ductility Excellent chromate receptivity Temperature tolerance up to 110 F (43 C) Suitable for either rack or barrel operations Ease of plating bath control Extremely economical to operate Ammonia free Temperature tolerance up to 110 F (43 C), reducing cooling costs PAVCO, Inc John Crosland Jr Drive Charlotte, NC Phone: Toll-free: or PAVCO INC ( ) Fax: Order Fax (for orders only)

2 2 Operating Parameters Rack: Barrel Operation Zinc: Potassium chloride: Boric Acid: Range oz/gal g/l oz/gal g/l oz/gal g/l Optimum 3.5 oz/gal 26 g/l 27.5 oz/gal 206 g/l 3.0 oz/gal 22.5 g/l Current Density: 1-80 amps/ft 2 Operating Parameters Barrel: Zinc: Potassium chloride: Boric Acid: amps/dm oz/gal g/l oz/gal g/l oz/gal g/l 3.0 oz/gal 22.5 g/l 27.5 oz/gal 206 g/l 3.0 oz/gal 22.5 g/l Current Density: 1-15 amps/ft amps/dm 2 Starter 2-6% 4 % ZCl BRT II % 0.1% ph: Temperature: F C Anode to Cathode Area: 1:1 minimum 90 F 32 C Equipment: Tank: Anodes: Anode Baskets: Anode Bags: Anode S-Hooks: Anode Bars: Filtration: Rectifier: Temperature Control: Ventilation: Agitation: Optional Equipment A polypropylene, PVC, or Koroseal lined tank is required. Use Special High Grade (SHG 99.99% pure) zinc balls or slabs. Titanium baskets are required. Keep the baskets filled with zinc anodes all the time and do not exceed 9 volts on the rectifier. Nylon or polypropylene bags are required for rack operations. Nickel plated S-hooks. Use copper anode bars, preferably shielded with plastic. Use a 5-15 micron cartridge packed with a filter aid or activated carbon. Filtration rate should be at least 1 tank turnover per hour. Sand filters have been found to work quite satisfactorily. Up to 12 volts The system is tolerant to temperatures ranging from F (18 43 C). A titanium heat exchanger is recommended for both cooling and heating. Recommended Air agitation is mandatory for rack operations. Automatic ph controller, brightener feeder and temperature control

3 3 Maintenance of the Solution: Zinc Potassium Chloride Boric Acid Starter ZCl BRT II Bath Makeup per 1,000 gallons (3,785 L): 1. Prepare a lined tank by leaching it with 5% hydrochloric acid for hours. 2. Rinse the tank. 3. Fill the lined tank with 500 gallons (2,000 L) of water. 4. Add 45 gallons (170 L) of 62.5% liquid zinc chloride and mix well to dissolve. 5. Add 200 pounds (90 kg) of boric acid and mix well to dissolve. 6. Add 1,700 pounds (770 kg) of potassium chloride and mix well to dissolve. 7. Hang slab anodes or zinc filled titanium anode baskets in the bath. 8. Add 40 gallons (151 L) of Starter 9. Add 0.5 gallons (1.9 L) of ZCl BRT II. 10. Add warm water to the 1,000 gallon (3,785 L) level. Analytical Procedures: Zinc Equipment 5 ml pipette 400 ml beaker Burette By analysis Reagents Acetate Buffer make this by dissolving 180 g of sodium acetate into 30 ml of acetic acid. Add deionized water to make one liter Xylenol Orange Indicator make this by dissolving 1 g of Xylenol Orange into 1 liter of DI water. 0.1M EDTA Procedure 1. Pipette a 5 ml bath sample into a 400 ml beaker. 2. Add approximately 150 ml of DI water. 3. Add 50 ml of acetate buffer. 4. Add 1 ml of Xylenol Orange indicator. 5. Titrate with 0.1M EDTA until the color changes from red to yellow. Calculation: ml of titration = zinc in oz/gal ml of titration 1.32 = zinc in g/l Total Chloride - Free Chloride Equipment 0.5 ml pipette 250 ml beaker Burette By drag-out & analysis By drag-out & analysis By drag-out & analysis 1 gal / 20,000 30,000 amp hrs ( ml/kah) Reagents Buffer (Mix dextrin and calcium carbonate in a 1:1 ratio) Chloride Indicator make this by dissolving 0.2 g of dichlorofluorescein into 70 ml of methyl alcohol. Add DI water to make 100 ml. 0.1N silver nitrate solution

4 4 Procedure 1. Pipette a 0.5 ml sample of plating bath into a 250 ml Erlenmeyer flask. 2. Add approximately 100 ml of DI water. 3. Add one scoop, approximately 2 g of buffer. 4. Add 1 ml of chloride indicator. 5. Titrate with 0.1N silver nitrate until the color changes from yellow to pink. Calculation ml of 0.1N Silver Nitrate x = oz/gal total chloride (A) A x 7.49 = g/l total chloride (Am) Zinc in oz/gal x = oz/gal chloride associated with the zinc metal (B) B x 7.49 = g/l chloride associated with the zinc metal (Bm) A - B = oz/gal free chloride (C) Am - Bm = g/l free chloride (Cm) C x 2.1= oz/gal of potassium chloride Cm x 2.1 = g/l of potassium chloride Iron Test and Treatment per 1,000 gallons (3,785 L): Procedure 1. Add 30 ml of bath sample into a 100 ml beaker. If the sample is not clear, filter it. 2. Add 1 ml of 3.5% hydrogen peroxide. 3. Determine the concentration of the iron in the bath by the intensity of the color change. No change - no iron Slight precipitate - moderate iron Heavy precipitate - high iron 4. If the test indicates moderate or high iron, or if barrel spots are present, treat the bath for iron as follows: Dilute one pint (500 ml) of 35% or 50% hydrogen peroxide to 1 gallon (3.8 L) with water. Mix this diluted peroxide throughout the plating bath. Repeat steps 1 to 4 until the majority of the iron is precipitated. Filter out the precipitated iron. Boric Acid Equipment 5 ml pipette 125 ml Erlenmeyer flask Burette Reagents Bromocresol purple indicator 1N sulfuric acid 1N sodium hydroxide Mannitol Procedure 1. Pipette a 5 ml sample into a 125 ml Erlenmeyer flask. 2. Add 20 ml of DI water. 3. Add 1 ml of bromocresol purple indicator. 4. If the solution color is purple, start with step a. If the solution color is yellow, start with step b. a. Add 1N sulfuric acid dropwise until the solution turns yellow. b. Add 1N sodium hydroxide dropwise until the solution turns purple. c. Proceed with step Add at least 5 g of mannitol. Excess mannitol is required. If the solution doesn t change to yellow, the plating bath has no boric. 6. Zero the 1N sodium hydroxide burette and start titrating very slowly with 1N sodium hydroxide until the solution color changes from yellow to purple.

5 Gray 5 Calculation: ml of sodium hydroxide x 1.67 = boric acid in oz/gal *Note: The amount of sodium hydroxide added prior to Step 6 is NOT included. Boric acid in oz/gal x 7.49 = boric acid in g/l Hull cell troubleshooting: 267 ml Hull Cell: Agitation Mechanical or Air Temperature 90 F, 32 C Current & Time 2 amps/5 minutes Normal Panel Control Panel Normal Hull Cell Panel Observe From Left to Right Area 1 High Current Density Area 2 Mid Current Density Area 3 Low Current Density Low Current Density Problem Metal Contamination Problem High ph Low Potassium Chloride Low ZCl BRT II Blackish Discoloration Metallic contamination (either copper or cadmium) of the plating bath or the bright dip High Current Density Problem ener Problem Black Burn Semi- Low Zinc, Low Boric Acid, Low Starter, Low temperature Low ZCl BRT II

6 Black Discoloration Blister Frost 6 Gray Chromium Contamination High & Low Current Density Problem Skip Chromium Contamination Low Starter Iron Problem High Iron (Black color shows up after the bright dip or chromate) Rack and Barrel Operations: Pavco Inc s Hull Cell Scale: 1 AMP 2 AMPS. 3 AMPS. 5 AMPS. PANEL EDGE CU. FT. X 7.48 = GAL. GM/L X = OZ./GAL. OZ./GAL. X 7.5 = GM/LITER GAL. X 3785 = ML. A/SQ. FT. X = A/SQ. DM. AMPS./SQ. FT. 267 ML. OR 534 ML. HULL CELL TOTAL CURRENT 3 AMPS 5 AMPS. 7.5 GM./1000 ML. 7.8 ML./1000 ML. OR 2 GM/267 ML. HULL CELL = 1 OZ./GAL. = 6.25 LBS./100 GAL. 2 ML./267 ML. HULL CELL = 0.96 FL. OZ./GAL. = 6 PTS./100 GAL. 4 GM. 534 ML. HULL CELL = 1 OZ./GAL. = 6.25 LBS./100 GAL. 4 ML./534 ML. HULL CELL = 0.96 FL. OZ./GAL. = 6 PTS./100 GAL. AMPS./SQ. FT ML. HULL CELL PANEL EDGE

7 7 Troubleshooting Chart: Problem Cause Solution High current density (HCD) Low zinc level Add zinc chloride burn High current Reduce current Low boric acid Add boric acid Low temperature Raise temperature Low Starter Add Starter HCD bright dips black, or barrel work exhibits hole pattern defects Low current density (LCD) area dull or hazy High iron High ph Low total chloride Low Starter Metallic or organic contamination Treat for iron with diluted hydrogen peroxide Reduce ph Add potassium chloride Add Starter Treat with zinc dust or carbon Poor LCD coverage High ph Reduce ph Low total chloride Add Potassium Chloride Low Starter Add Starter Low/High ZCl BRT II Check ZCl BRT II level in Hull cell Metallic contamination Treat with zinc dust High zinc level Dilute the bath (> 6oz/gal or 45 g/l) Excess peroxide added Electrolyze bath Organic contamination Treat with carbon LCD area bright dips black Metallic contamination Treat with zinc dust Overall Haze Low Starter Add Starter Low ZCl BRT II Add ZCl BRT II Inadequate agitation Increase agitation Poor cleaning Improve cleaning Work rusting before plating Acidify rinses Poor bright dip Remake bright dip or try HCl instead of nitric acid Blue bright chromate out of Remake chromate balance or contaminated Temperature too high Decrease temperature Overall Dullness Low Starter Add Starter Low ZCl BRT II Add ZCl BRT II Metallic contamination Treat with zinc dust High temperature Decrease temperature ph too low Raise ph Organic contamination Treat with carbon

8 8 Problem Cause Solution Slow Plating Speed Low zinc level Add zinc chloride Low chloride level Add potassium chloride Low Starter Add Starter Weak pickle or pickling problem Add more hydrochloric acid to the pickle or make a new pickle Low temperature Raise temperature Low current Increase current Smut formation in pickling Add PavPrep to the pickle Roughness Inadequate filtration Improve filtration Low Starter Add Starter Low anode area Increase anode area Particles from anodes Bag the anodes Current too high Lower the current Blistering Poor cleaning &/or pickling Improve pre-treatment Organic contamination Treat with carbon Metallic contamination Treat with zinc dust Chromium contamination Treat with peroxide High current Lower current High ZCl BRT II Low Starter Hold ZCl BRT II Add Starter Flaking or star dusting High ZCl BRT II Hold ZCl BRT II Low Starter Add Starter Current interruption Check all contacts High current Lower current High ph Reduce ph Waste Treatment: Dispose of the concentrates or solutions thereof according to local waste treatment regulations. Safety: Handling Pavco mandates that the following safety equipment be used when handling chemicals in an electroplating environment: safety glasses, face shield, plastic or rubber apron, rubber gloves and safety shoes. Chemicals should only be handled by trained and experienced personnel. Storage Store Pavco products in a clean, well ventilated room which temperature remains above 45 F (7 C). Pavco products should remain in their original container with the lid or cap tightened. Drum pumps or pails must be clean prior to dispensing Pavco products to prevent contamination. If Starter or BRT II freezes during shipment or storage, warm the product to and mix it well before use. Emergency Procedures Refer to the MSDS for detailed emergency procedures. Eye Contact Seek immediate medical attention. Flush the eyes with water for 15 m minutes. Skin Contact Remove all contaminated clothing. Wash the skin with soap and water. Seek medical attention. Inhalation Remove the person to an area with fresh air. Seek medical attention if necessary. Ingestion Seek immediate medical attention Spill Dike the area to contain the spill. Refer to the MSDS for clean-up. Notify the proper authorities if required. *NOTE: Refer to the MSDS for detailed emergency medical procedures.

9 9 Product Description & Shipping: Starter (ZB1000) is a light amber liquid. The specific gravity is with a ph less than 7.0. ZCl BRT II (ZB1010) is a colorless liquid. The specific gravity is with a ph less than 6. Both products are available in 5 gallon containers, 55 gallon drums, or 275 gallon totes. Revision Date: 10/4/18 WARRANTY AND DISCLAIMER Technical information and recommendations contained herein are believed to be reliable, however, the accuracy or completeness thereof is not guaranteed. No statement or recommendation shall constitute a representation unless set forth in an agreement in writing by the seller and manufacturer. NO WARRANTY OR MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS MADE. The following warranty is made in lieu of any other warranties, express, implied, or statutory. Products are warranted to be free from defects on material and workmanship at the time sold. The sole obligation of the seller and manufacturer under this warranty shall be to replace any product defective at the time sold. Under no circumstances shall the manufacturer or seller be liable for any loss, damage, expense, direct or consequential, arising out of the use of or inability to use the product. Materials shall not be returned to the seller or manufacturer without express written permission. No information or suggestions given by us shall be deemed to be a recommendation to use any product in conflict with any existing patent rights.