Successive corrosion-protecting pre-treatment of metal surfaces in a multiple-step process

• US 8,679,586 B2
• Filed: 01/31/2011
• Issued: 03/25/2014
• Est. Priority Date: 08/12/2008
• Status: Active Grant

• Current Assignee: Henkel AG & Co KGaA
• Original Assignee: Henkel AG & Co KGaA
• Inventors: Czika, Franz-Adolf, Cornen, Sophie, Kroemer, Jens, Frank, Michael, Teubert, Nicole, Brouwer, Jan-Willem
• Primary Examiner(s): TUROCY, DAVID P
• Application Number:
  US13/017,241
• Publication Number:
  US 20110189401A1
• Time in Patent Office: 1,149 Days
• Field of Search: 427/327, 427/299, 427/331, 148/243, 148/247, 148/320
• US Class Current: 427/327
• CPC Class Codes: C23C 22/06 using aqueous acidic solutions with pH less than 6
• CPC Class Codes: C23C 22/34 containing fluorides or complex fluorides
• CPC Class Codes: C23C 22/361 containing titanium, zirconium or hafnium compounds
• CPC Class Codes: C23C 22/73 characterised by the process
• CPC Class Codes: C23C 22/77 Controlling or regulating of the coating process
• CPC Class Codes: C23C 22/78 Pretreatment of the material to be coated
• CPC Class Codes: C23C 22/80 with solutions containing titanium or zirconium compounds

Abstract

The present invention relates to a method for improving the corrosion-protecting pre-treatment of metal surfaces and using rinse water in a manner to conserve resources in such a corrosion-protecting pre-treatment, comprising a conversion treatment step using an aqueous composition comprising at least 50 ppm of the elements B, Si, Ti, Zr and/or Hf in the form of water-soluble compounds at a pH value of 3 to 5.5, wherein a minimum fraction of 10 ppm of the elements B, Si, Ti, Zr and/or Hf in the form of water-soluble compounds is present in the last pre-rinse step and a portion of the aqueous composition of the conversion treatment step is contained in the first post-rinse step. The resource-conserving use of the rinse water is accomplished according to the invention by way of a cascaded return of rinse water from the last rinse step to the first rinse step. The present invention also relates to a metallic component treated using the method according to the invention and to the use thereof in a process for applying a multi-coating system, in particular a paint system containing an organic binder, in industrial manufacturing.

Claims

1. A method for anticorrosion pretreatment of metal surfaces in a processing sequence comprising a conversion treatment stage (D) with an aqueous composition (1) containing in total at least 50 ppm of one or more of elements B, Si, Ti, Zr and Hf in the form of water-soluble compounds at a pH value of 3 to 5.5, wherein the metallic surfaces pass in succession through at least treatment stages of:

(A) optionally degreasing and cleaning;

(B) optionally rinsing with process water optionally containing part of the aqueous composition of the degreasing and cleaning stage (A);

(C) prerinsing with water containing in total at least 10 ppm of elements B, Si, Ti, Zr and/or Hf in the form of water-soluble compounds;

(D) conversion treatment with the aqueous composition (1);

(E) postrinsing with water containing part of the aqueous composition (1) of treatment stage (D);

(F) optionally second postrinsing with water containing part of the aqueous composition of postrinsing stage (E),

wherein the aqueous composition (1) of the conversion treatment stage (D) contains a proportion of fluorine bound in the form of fluoro complexes of the one or more elements B, Si, Ti, Zr and Hf or fluorine in excess and unbound in the form of free fluoride, and wherein pH value in the prerinsing stage (C) is in a range from 5 to 7.0, and

wherein a cascaded recirculation of aqueous medium from the final rinsing stage to the first rinsing stage proceeds such that in total at least 10 ppm of the elements B, Si, Ti, Zr and/or Hf in the form of water-soluble compounds are present in the prerinsing stage (C).

2. The method as claimed in claim 1, wherein in total at least 20 ppm of the elements B, Si, Ti, Zr and/or Hf are present in the prerinsing stage (C) in the form of water-soluble compounds.

3. The method as claimed in claim 1, wherein the proportion of the elements B, Si, Ti, Zr and/or Hf in the form of water-soluble compounds in the prerinsing stage (C) amounts to no more than 20%, relative to the proportion of the respective element in the conversion treatment stage (D).

4. The method as claimed in claim 1, wherein the pH value in the prerinsing stage (C) is in a range from 5.8 to 6.2.

5. The method as claimed in claim 1, wherein the pH value in the postrinsing stage (E) is in a range from 4.0 to 5.5.

6. The method as claimed in claim 1, wherein the metallic surfaces pass in succession through the following treatment stages:

(A) optionally degreasing and cleaning

(B) optionally rinsing with process water optionally containing part of the aqueous composition of the degreasing and cleaning stage (A)

(C) prerinsing with water containing in total at least 10 ppm of the elements B, Si, Ti, Zr and/or Hf in the form of water-soluble compounds and optionally part of the aqueous composition of rinsing stage (B)

(D) conversion treatment with the aqueous composition (1) containing part of the aqueous composition of prerinsing stage (C)

(E) first postrinsing with water containing part of the aqueous composition of treatment stage (D)

(F) optionally second postrinsing with water containing part of the aqueous composition of postrinsing stage (E),

wherein the final rinsing stage is supplied with deionized water.

7. The method as claimed in claim 6, wherein the cascaded recirculation of aqueous medium from the final rinsing stage to the first rinsing stage proceeds such that at least part of the medium which contains the elements B, Si, Ti, Zr and/or Hf in the form of water-soluble compounds and is to be recirculated from the postrinsing stage (E) into the prerinsing stage (C) is not directly returned and this part of the medium to be recirculated

a) is adjusted to a pH value of greater than 5.0,

b) any precipitate which is being formed is separated from the rinsing water, and

c) optionally the rinsing water, from which precipitate has been removed in step b), is subjected to either an ion exchange method or to reverse osmosis,

and the rinsing water treated in this manner is likewise returned as part of the medium to be recirculated into the prerinsing stage (C).

8. The method as claimed in claim 7, wherein the aqueous composition (1) of treatment stage (D) contains a proportion of fluorine bound in the form of fluoro complexes of the one or more of elements B, Si, Ti, Zr and Hf or in excess and unbound in the form of free fluoride, wherein the part of the medium to be recirculated from the postrinsing stage (E) which is not directly returned to the prerinsing stage (C) is adjusted in step a) with an alkaline solution which contains no calcium ions to a pH value of greater than 5.0, then any precipitate which is being formed is separated from the rinsing water and the rinsing water treated in this manner is returned as part of the medium to be recirculated into the prerinsing stage (C).

9. The method as claimed in claim 7, wherein the aqueous composition (1) of treatment stage (D) contains a proportion of fluorine bound in the form of fluoro complexes of the one or more of elements B, Si, Ti, Zr and Hf or in excess and unbound in the form of free fluoride, wherein the part of the medium to be recirculated from the postrinsing stage (E) which is not directly returned to the prerinsing stage (C) is combined in step a) with such a quantity of an aqueous solution of Ca(OH)₂, which contains no more than 0.1 wt. % of undissolved Ca(OH)₂, that the pH value of the rinsing water rises to a value in a range from greater than 5.0 to no greater than 7.0.

10. The method as claimed in claim 6, wherein the cascaded recirculation of aqueous medium from the final rinsing stage to the first rinsing stage proceeds continuously and at a constant volumetric flow rate.

11. The method as claimed in claim 6, wherein the metallic surfaces are at least in part surfaces of iron and/or steel.

12. A metallic component which has been anticorrosion pretreated according to the method as claimed in claim 6.

13. A process for applying a multilayer system in industrial manufacture wherein the metallic component of claim 12 comprises a substrate in said process.

14. An article of manufacture comprising the metallic component as claimed in claim 12.

15. The method as claimed in claim 6, wherein the cascaded recirculation of aqueous medium from the final rinsing stage to the first rinsing stage proceeds such that

in total at least 20 ppm of the elements B, Si, Ti, Zr and/or Hf are present in the prerinsing stage (C);

the proportion of the elements B, Si, Ti, Zr and/or Hf in the form of water-soluble compounds in the prerinsing stage (C) amounts to no more than 20%, relative to the proportion of the respective element in the conversion treatment stage (D);

pH of the postrinsing stage (E) is in a range from 4.0 to 5.5; and

content of components of the aqueous composition (1) of the treatment stage (D) in the first postrinsing stage (E) is at least equally as high as the content of these components in the final prerinsing stage (C).

16. A method for the anticorrosion pretreatment of metal surfaces in a processing sequence comprising a conversion treatment stage (D) with an aqueous composition (1) containing in total at least 50 ppm of the elements B, Si, Ti, Zr and Hf in the form of water-soluble compounds at a pH value of 3 to 5.5, wherein the metallic surface passes in succession through at least the following treatment stages of:

(A) optionally degreasing and cleaning;

(B) optionally rinsing with process water optionally containing part of the aqueous composition of the degreasing and cleaning stage (A);

(C) prerinsing with water containing in total at least 10 ppm of the elements B, Si, Ti, Zr and/or Hf in the form of water-soluble compounds;

(D) conversion treatment with the aqueous composition (1);

(E) postrinsing with water containing part of the aqueous composition (1) of treatment stage (D); and

(F) optionally second postrinsing with water containing part of the aqueous composition of postrinsing stage (E),

wherein the aqueous composition (1) of the conversion treatment stage (D) contains a proportion of fluorine bound in the form of fluoro complexes of the elements B, Si, Ti, Zr and/or Hf or fluorine in excess and unbound in the form of free fluoride and wherein the pH value in the prerinsing stage (C) is in a range from 5 to 7.0; and

wherein the final rinsing stage is supplied with deionized water and a cascaded recirculation of aqueous medium from the final rinsing stage to the first rinsing state proceeds such that in total at least 10 ppm of the elements B, Si, Ti, Zr and/or Hf in the form of water-soluble compounds are present in the prerinsing stage (C), the treatment stage (D) being excepted from the cascaded recirculation and aqueous medium not being fed indirectly and directly into the treatment stage (D) from the final rinsing stage.

17. The method as claimed in claim 16, wherein the metallic surface passes in succession through the following treatment stages:

(A) degreasing and cleaning;

(B) rinsing with process water optionally containing part of the aqueous composition of the degreasing and cleaning stage (A);

(C) prerinsing with water containing in total at least 10 ppm of the elements B, Si, Ti, Zr and/or Hf in the form of water-soluble compounds and optionally part of the aqueous composition of rinsing stage (B);

(D) conversion treatment with the aqueous composition (1) containing part of the aqueous composition of prerinsing stage (C);

(E) first postrinsing with water containing part of the aqueous composition of treatment stage (D);

(F) second postrinsing with water containing part of the aqueous composition of postrinsing stage (E).