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Finishing Workshop Columbus, Ohio May 16-17, 2017

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Finishing Workshop Columbus, Ohio May 16-17, 2017 Finishing Workshop Columbus, Ohio May 16-17, 2017 Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Types of Multi- Stage Washers Pretreatment washers are designed and built to meet specification requirements produced in collaboration between chemical experts, finishing coaters and experience of the equipment builder. Tank 2 Return Pump Tank 1 Return Pump Multi- Stage Washer 1 Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Types of Multi-Stage Washers Various designs of washers with different types of application methods are available. The most common are: Spray – (Vertical, Horizontal, Chain Drive, Other.) Tank 2 Return Pump Tank 1 Return Pump Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Types of Multi-Stage Washers Various designs of washers with different types of application methods are available. The most common are: Immersion – Dip Tanks Tank 2 Return Pump Tank 1 Return Pump Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Application Methods for Multi-Stage Pretreatment Washer • Spray • Immersion • Waterfall • Combined Each method can be supplied by the equipment manufacturer and each has some advantages and disadvantages. The type of application typically chosen by the paint shop is based on many factors such as type of parts to be processed, throughput required, available space, project cost, etc.. 2 Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Application Methods for Multi-Stage Pretreatment Washer Spray Immersion Waterfall Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Types of Application: Listed below are a few advantages and disadvantages of different types of application methods of pretreatment: Type Advantages Disadvantages Impingement (Spray) Aggressive cleaning Atomization can Good coverage facilitate: Control of flow Cross contamination (Direction & Target Areas) between stages. Heat loss of solution. Part movement . Increased maintenance. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Types of Application: (Continued) Type Advantages Disadvantages Immersion (Dip) Very good coverage Possible air entrapment in part voids. No aggression (Must add agitation to facilitate cleaning.) Solution entrapment in part. Reduced production throughput. 3 Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Types of Application: (Continued) Type Advantages Disadvantages Waterfall Good coverage. Low aggression. Low cross contamination Geometry and between stages. orientation dependent. Low solution heat loss . Lower power required for pumping. Low maintenance. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Pretreating or (Preparing The Surface) Application Types: While there are different methods of surface cleaning and application of solutions, there is no perfect process. Any process has limitations. This is why this type of equipment must be evaluated and chosen based on important considerations. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Washers Functions Typically the pretreatment washer performs multiple processes to prepare the parts for receiving the finish coating: • Proper Cleaning • Proper Metal Treatment 4 Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Washers Functions Proper Cleaning – Removing unwanted contaminants from the part to prepare the substrate for Metal Treatment. Proper Metal Treatment - Application of chemicals designed to provide: 1. Effective adhesion of the applied finish coating. 2. Protection of the substrate under the finish coating. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning The first stage of the pretreat process is to prepare the surface of the metal for acceptance of the metal treatment. THE FOUNDATION This cleaning process is the most important step of the pretreatment. It is similar to the foundation of a building, everything is supported here. This is why the washer contains many tools and features to provide consistent repetitive results if operated and maintained properly. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Types of Washers Since time is limited we will focus on spray. 5 Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Types of Layouts for Spray Washers Courtesy of Amchem Products, Inc. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Proper Cleaning requires: Scrubbing or work by means of aggression on the part for removal of dirt, chips and debris. Chemical Reaction on the part for conditioning contaminants such as oils and other unwanted substances to be removed. Rinsing the parts for removal of excess chemicals and contaminates in solution. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Typical 4 Stage Pretreatment Washer Schedule Stage Time Temperature Length Entrance 9’ –0” Dwell times and 1st -Cleaner 90 sec. 130 F 30’ –0” stage Drain 13’ – 0” lengths base on a 2nd -Rinse 30 sec. Ambient 10’ –0” conveyor Drain 13’ – 0” speed of 20 FPM. 3rd –Rinse 30 sec. Ambient 10’ –0” Drain 13 ’-0” 4th –Treat 45 sec. Ambient 15’ –0” Exit 9’ –0” 6 Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Chemical experts have designed these processes for proper performance based on the chemical makeup of the solutions and the amount of contact time (dwell time) to the work piece. Changing the conveyor speed changes the dwell time of the parts in the washer along with the scrubbing, chemical reaction, rinsing & draining times. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Scrubbing – Stage 1 Cleaning Force Using impingement energy of spray helps to “Knock-Off” unwanted chips and debris. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Chemical Reaction – Stage 1 Application of the Chemical Solution Spray Nozzle technology can be flexible to apply the solution to the perimeter of the part utilizing various spray patterns and nozzle arrangements. 7 Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Rinsing – Stage 2 and or 3 Rinsing the parts is an important stage of the cleaning process! Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Rinsing – After Cleaning or Metal Treatment For proper rinsing the design of the washer should have: • Good spray coverage of the part with some impingent to properly clean away excess chemicals and debris after cleaning. • Proper overflow of the rinse tank to keep the rinse water clean. • Proper drainage of the parts to reduce drag out of cleaning chemicals into rinse tank. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Rinsing – After Cleaning or Metal Treatment For proper rinsing the design of the washer should have: • Proper pitch the floor drain boards to reduce chemical and contaminant drag out. Note: Typically drain boards between stages are pitched at a minimum of ¼” per foot and divided so that two- thirds of the length flows back to the preceding stage and one-third drains to the next stage. 8 Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Door at apex. Typically drains boards are split 2/3 length to preceding stage and 1/3 length to next stage. Pitched drain boards between stages. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Rinsing – After Cleaning or Metal Treatment For proper rinsing the design of the washer should have: Proper pitch of the floor to reduce chemical and contaminant drag out. Tank 2 Return Pump Tank 1 Return Pump WARNING: “Oil Canning” can occur in drain areas from foot traffic causing improper drainage of solutions. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Rinsing – After Cleaning or Metal Treatment For proper rinsing the design of the washer should have: Tank 2 Return Pump• Proper Tank 1 Return Pump containment of over spray with silhouettes. • Proper control of overspray with spray riser orientation. 9 Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Rinsing – After Cleaning or Metal Treatment For proper rinsing the design of the washer should have: • Good spray coverage of the part perimeter. • Quality of the rinse water using good automatic overflow and water makeup designs. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Cleaning - Spray Install limiting orifice to maintain proper water volume and Remove valve avoid excess handle to overflow. avoid accidental closure but keep in area for maintenance. Design & Maintenance of Pretreatment Washers for Non-Ferrous Metal Proper Metal Treatment - Spray Most of the same design principals for spray cleaning apply to the spray application of chemical solutions on the part for creating a protective coating. • This stage, after the cleaning process may or may not require a heated chemical solution. • If heated, the solution bath temperature should be properly maintained for consistent reaction properties. • Nozzle spray patterns may or may not be different. Many styles are available and can be recommended by the chemical company for the type of metal treatment being performed. • Lower
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