Manganese Phosphate Coating
Manganese phosphate coating is a specialized treatment for iron and steel components, using a dilute solution of phosphoric acid and proprietary chemicals. This process creates a crystalline, oil-absorptive coating that provides excellent wear resistance. During the continuous immersion process, grain refiners are introduced before the components are immersed in the manganese phosphate solution. These grain refiners promote the formation of small crystals, controlling the microscopic finish of the coating.

The resulting coating, with a weight of up to 40g/m², is ideal for new parts such as pinions, gears, camshafts, and bearings. The crystalline structure retains a significant amount of lubricant and rust-inhibiting oil, reducing galling in moving parts. For bearings, the manganese phosphate coating enables a continuous lubricant film, enhancing wear resistance and overall performance.

Zinc Phosphate Coating
Zinc phosphate coatings are applied by immersing components into a proprietary zinc-based solution, creating a coating typically ranging from 10-30 g/m². This coating primarily serves as a binder for oils, rust-preventative waxes, and as an undercoat for bonded lubricant coatings. One popular bonded lubricant used by Wallwork Newcastle Ltd is Molykote, which creates a permanent, dry lubricating film with a low coefficient of friction and corrosion resistance.

Advanced Coating Equipment
Wallwork Newcastle Ltd operates a fully automated phosphate coating line, ensuring precision in every stage of the process. Components are processed on racks, with each phase controlled by a PLC-driven cycle that adjusts immersion times based on the desired coating depth. Quality control is maintained through regular process audits of bath chemistries, coating weight tests, and scanning electron microscopy to measure crystal size and density.

Key Benefits

• Enhanced wear resistance and lubrication for components like gears, camshafts, and bearings.
• Reduced galling and improved break-in performance for new parts.
• Continuous lubricant film formation, improving longevity and performance.
• High-quality, controlled coating processes for consistent results.

Choose Wallwork Newcastle Ltd for high-performance phosphate coatings that enhance the durability and efficiency of your components.