K Ghaffarzadeh - Iran Khodro Company, Engineering Department of Paint & Coating. (P E. IKCO)
F Farzanegan - R&D Manager, Kiyafarin, Co.

The phosphate process is a method for improving the metal surfaces resistant against environmental effects, corrosion, impact, rust, and also to increase the adhesion of the other layers on the metal surfaces. The phosphate of metals as first treatment in automotive paint industry, have principles rule in mechanical and chemical resistance for protection of car body from factor corrosion. One of trouble which has been in last film is roughness of surface that is possible related to phosphate sludge amount on surfaces. The phosphate sludge especially sediment on vertical surfaces and partly it is reason of roughness form and decrease chemical and mechanical properties of surfaces. Claims of this project shows, how many factors effect on amount and morphology structure sludge, inspection of some factors such as Zn+2, Ni+2, Mn+2 cations amount, free and total acidity, temperature, Accelerator, Replenishment on the steel sheets and fluoride anion on the Galvanization sheets, shows relation between parameters for sludge reduce. Also, we consider all of these factors when will be have the best phosphate coats on the metal plates in laboratory & pilot room with the lowest sludge amount at phosphate tank .Our main aim in this project is research & separate analysis of all effective factors in decrease phosphate sludge amount at phosphate tank, low cost, improvement quality & operator ergonomic in P.T process. Certainly the last results will be presented in frame of tables & charts showing in future.

Effectual parameters, Phosphate appearance, Amount of phosphate sludge, Phosphate coating weight, Crystallography