• 한국산학기술학회논문지
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• 제18권10호
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• pp.603-610
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• 2017

탄약을 포함한 다양한 산업 분야에서 사용되는 철강 재료는 부식에 취약하므로, 표면 그대로 사용하는 것은 바람직하지 않다. 따라서 도금, 도장, 화성처리와 같은 표면 처리 이후 사용하여야 하는데, 탄약 제조 과정에서는 주로 아연계 인산염 피막 처리가 사용되고 있다. 표면 처리 기법 중 하나인 아연계 인산염 피막은 금속 표면을 화학적으로 처리하여 안정성이 높은 화합물 층을 표면에 고착시키는 방법으로, 크게 도장 하지용 경인산염 피막과 부식 방지용 중인산염 피막으로 나뉘어지는데, 아연계 인산염 피막은 전산도, 철 함량과 같은 여러 가지 인자에 의해 피막의 품질과 내식성이 결정된다. 본 연구에서는 전산도 및 철 함량이 탄약 부식 방지 목적으로 사용되는 아연계 중인산염 피막의 중량 및 내식성에 미치는 영향에 대하여 알아보았다. 철 함량에 따라 피막의 구조가 치밀해지며, 내식성이 향상되는 결과를 확인할 수 있었으나, 전산도는 피막의 두께와 중량에만 영향을 주고 내식성에는 큰 영향을 주지 못하였다. 위 결과를 토대로 탄약 제조 과정에서 사용되는 인산염 피막 처리 공정의 최적 제어 수준을 제시하였다.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 춘계학술대회 논문집
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• pp.149-154
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• 2007

The zinc prosphate film treatments used to lubricating treatment of mostly cold forging processes. But there are several problems happened to lubricating treatment process such as happening harmful environment on person, complex lubrication processing occurring in energy and time consumption, eco-destructive and chemical by-product generation, the needs of waste disposal etc. As a result, a water-soluble lubricant was developed to replace the perfect or some of the zinc prosphate film in the world. In order to solve these problems, this study evaluated the performance of the typical water-soluble. In this study, for these requirement inquiry of two part. First, about possibility of replace zinc phosphate lubricant, quantitatively evaluation developed of water-soluble lubricant for cold forging vs zinc phosphate lubricant. Second, About optimization of coating Process use to equipment with practicable automatic coating Process. The performance evaluation of these lubricants was conducted using the double cup extrusion test and spike forging test. With the use of the commercial FE code DEFORM, friction factor calibration curves, i.e. cup height ratio vs. punch stroke and spike height vs. punch stroke, were established for different friction factor values. By matching the cup height ratio and the punch stroke and spike height vs. punch stroke from experiment to that obtained from FE simulations, the friction factor of the lubricants was determined. Survey of comparative analysis use to SEM that sprayed lubricant surface structure of grain shape and characteristic of lubricant performance based on grain shape and deformed lubricant surface expansion. As a result, developed lubricant were found to perform comparable to or better than zinc phosphate. And thought this result, innovatively cope with generated problem of existing lubrication process.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2006년도 춘계학술대회 논문집
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• pp.195-198
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• 2006

Zinc phosphate coating is required in nearly all steel cold forging operations. However, the chemical byproducts of this lubricant system are difficult to dispose of and have a negative environmental impact. In order to replace zinc phosphate based lubricants partially or completely, candidate lubricant has been developed in this study. The performance evaluation of these lubricants was conducted using the double cup extrusion test and spike forging test. With the use of the commercial FEM code DEFORM, friction factor calibration curves, i.e. cup height ratio vs. punch stroke and spike height vs. punch stroke, were established for different friction factor values. By matching the cup height ratio and the punch stroke and spike height vs. punch stroke from experiment to that obtained from FE simulations, the friction factor of the lubricants was determined. Three water-soluble lubricants; namely, Mec Homat, Royalcoat, and the developed lubricant were found to perform comparable to or better than zinc phosphate.

• 한국정밀공학회지
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• 제27권1호
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• pp.84-90
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• 2010

The cold forging Process applies surface lubricant coating in order to smooth the friction during the cold forging process. Currently, most of the lubrication processes apply the zinc phosphate coating, which requires 11 steps and disposes sludge. But the water based lubrication process, which has been newly developed, takes 3 steps only and does not cause sludge. In this study, we present the optimal condition of water based lubrication for the cold forging of axle shaft by an experimental design method. Experimental results with minitab shall be able to predict the optimum water based lubricating conditions for the cold forging processes.

• 한국표면공학회지
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• 제52권4호
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• pp.233-238
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• 2019

The formation behavior of zinc phosphate conversion coating (ZPCC) on SCM430 alloy was investigated in 25 vol.% of 1M ZnO + 170 ml/L solution containing various $Fe(NO_3)_2$ concentrations, using open-circuit potential(OCP), electrochemical impedance spectroscopy(EIS), cyclic polarization(CP) curve and tape peel test. OCP of SCM430 alloy and corrosion current density increased with increasing $Fe(NO_3)_3$ concentration. Resistance of films formed on SCM430 alloy by chemical conversion treatment decreased with increasing $Fe(NO_3)_3$ concentration. Color and adhesion of chemical conversion coatings became darker and worse, respectively, with increasing $Fe(NO_3)_3$ concentration. It is concluded that addition of $Fe(NO_3)_3$ into a zinc phosphating bath leads to faster reaction to form porous surface coatings with poor adhesion and corrosion resistance.

• Corrosion Science and Technology
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• 제6권5호
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• pp.239-244
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• 2007

Corrosion protection of automotive steels has traditionally been assured by using a zinc phosphate metal pretreatment followed by the deposition of a cathodic electrocoat system. This system has been developed and optimized over the years into a highly robust and dependable system with a high performance. However, in terms of efficiency and use of resources and energy, the need is now felt to develop a simpler system with fewer steps, shorter lines, less energy requirements (curing and e-coat deposition) and less stringent waste disposal requirement (phosphate sludge). We report here on the development of a one-step system that can possibly replace both the zinc phosphate and the e-coating processes. Such a system is based on the so-called superprimer concept that we have recently developed for the replacement of chromate pretreatment and chromate-containing primers in the aerospace industry. With some modifications, such systems can also be adapted for use in the automotive industry.

• 한국표면공학회:학술대회논문집
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• 한국표면공학회 2012년도 춘계학술발표회 논문집
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• pp.322-323
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• 2012

This study discussed the formation of phosphate conversion coatings on AZ31 Mg alloy (AZ31) from the zinc phosphating bath with various concentrations of sodium fluoride (NaF). The effects of NaF on the formation, structure, composition and electrochemical behavior of the phosphate coatings were examined using scanning electron microscopy (SEM), X-ray diffraction (XRD) weight balances, open circuit potential (OCP) transients, potentiodynamic polarization curves and immersion test. The coatings were composed of two layers: an outer $Zn_2(PO_4)_3.4H_2O$ (hopeite) crystal layer and an inner amorphous of $MgZn_2(PO_4)_2$. NaF concentration is emphasized to be highly effective in the formation of the hopeite crystal and etching and coating rates. Potentiodynamic polarization and immersion test showed that the coatings formed in the zinc phosphating bath with addition of NaF have much higher corrosion resistance than bare AZ31.

• Corrosion Science and Technology
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• 제6권4호
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• pp.206-210
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• 2007

Aerospace aluminum alloys such as Al alloy 2024-T3 and 7075-T6 are subject to localized corrosion due the existence of intermetallics containing Cu, Mg or Zn. Chromate is currently widely used in the aerospace industry as the corrosion inhibitor for these alloys. However, chromate needs to be replaced due to its strong carcinogenicity. In this study, an extensive pigment screening has been performed to find replacements for chromates. Different categories of inhibitors were evaluated by immersion tests, DC polarization tests and other methods. Phosphates, zinc salts, cerium salts, vanadates and benzotriazole were found to be effective inhibitors for AA7075. Among those inhibitors, zinc phosphate was found to be the most effective in our novel, silane-based, one-step aqueous primer system. The performance of this primer is comparable to that of currently used chromate primers in accelerated corrosion tests, while it is completely chromate-free and its VOC is about 80% less than that of current primers. Studies by SEM/EDS showed that the unique structure of the superprimer accounts for the strong anti-corrosion performance of the zinc phosphate pigment. The self-assembled stratified double-layer structure of the superprimer is characterized by a less-penetrable hydrophobic layer at the top and a hydrophilic layer accommodating the inhibitors underneath. The top layer functions as the physical barrier against water ingress, while the lower layer functions as a reservoirfor the inhibitor, which is leached out only if the coating is damaged by a scratch or scribe. The presence of a silane in the primer further improves the adhesion and anti-corrosion performance of the primer.

• 공업화학
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• 제18권3호
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• pp.296-302
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• 2007

6가 크롬의 크로메이트 코팅제의 대체를 위한 3가 크롬의 크로메이트 코팅용액의 제조에 관한 것이다. 본 연구에서 제안된 코팅제는 3가 크롬원으로서 $KCr(SO_4)_2$를 35~45 g/L, 인산계 화합물로서 $NaH_2PO_4$를 20~30 g/L을 주성분으로 하고 여기에 금속계 황산화물로서 $CoSO_4$ 10~20 g/L, $ZnSO_4$ 10~20 g/L의 조성으로 구성된 것이다. 이 제안된 3가 크롬 코팅용액을 사용하여 pH 2.0~2.2, 상온에서 담지시간 20~25 s의 조건하에 시안아연도금체에 코팅된 피막은 염수분무시험결과 5% 백청발생까지 120 h 이상 견디는 우수한 내식성을 발현하였다.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 2006년도 추계학술대회 논문집
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• pp.377-378
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• 2006