ADVANTAGES OF INORGANIC CONVERSION COATINGS
Formulated to replace traditional iron phosphate products, these products require no or very little heat to deposit an inorganic conversion coating. Conventional iron phosphate products, on the other hand, can require temperatures of 130-160oF. Another benefit of this new technology is usage; a maximum of about 2% by volume, for the stand-alone coater, is needed in the bath compared to approximately 2-4% by volume with conventional iron phosphates.
These type of coatings provide a microcrystalline surface in the nanometer (10-9m) range and require a short contact time of 15 to 30 seconds. Conventional iron phosphate coatings are usually in the micrometer (10-6m) range and require at least 45 to 60 seconds contact time. The "nanocrystals" formed increase the surface area of the substrate thus enhancing paint adhesion, corrosion protection and consequently salt-spray results. These inorganic conversion coatings do not require a non-chrome post treatment seal to achieve high performance adhesion, under film corrosion and salt-spray resistance.
These new technology coatings also contain no regulated heavy metals and eliminate phosphate from the process bath. Sludge is also reduced to a minimum while waste treatment costs and other effluent issues are greatly diminished. Reduced sludge formation results in considerably lower maintenance costs since fewer bath dumps are needed and the incidence of plugged nozzles and other problems are reduced. Rinse water consumption is also reduced because of the lower amount of total dissolved solids present in these new coating baths. Lower total dissolved solids means less rinse water overflow is needed to maintain proper rinse integrity.

Salt Spray Performance
The corrosion resistance performance of these inorganic conversion coatings is compared below to conventional iron phosphate coatings (organic accelerator) with TGIC polyester and hybrid powder paint systems on cold-rolled steel and aluminum substrates.
Paint SystemSubtrateInorganic Conversion Coating
2% conc., 80F bath,
30 seconds contact time		Iron Phosphate Conversion Coating
4% conc., 140F bath,
60 seconds contact time		Salt-Spray Exposure
(ASTM B-117)
TGIC PolyesterCold Rolled Steel0.5mm creepage from scibe1.8mm creepage from scibe504 hours
TGIC PolyesterAluminum0.2mm creepage from scibe1.0mm creepage from scibe1008 hours
HybridCold Rolled Steel2.0mm creepage from scibe4.3mm creepage from scibe504 hours
HybridAluminum0.4mm creepage from scibe2.2mm creepage from scibe1008 hours
Test panels were prepared and tested according to ASTM B-117 and evaluated according to ASTM D-1654 Method 2. Ratings were taken of the average creepage failure from the scribe mark after a predetermined number of hours of exposure.
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