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The phosphating and boriding production lines are two core equipment systems for chemical transformation and surface strengthening of metal workpieces, designed to meet the surface modification requirements of various materials and operational conditions. The phosphating line utilizes chemical transformation principles to form phosphate films, offering advantages such as low cost, corrosion resistance, and enhanced coating adhesion, making it suitable for small and medium-sized precision workpieces. The boriding line employs high-temperature chemical boriding to create a hard boride layer, emphasizing high hardness, wear resistance, and heat tolerance, ideal for heavy-duty and wear-resistant mechanical components. Both production lines adopt a three-stage continuous layout of "pre-treatment-core treatment-post-treatment," equipped with automated transfer and process control systems, enabling batch standardized production. They cover mainstream substrates such as carbon steel, alloy steel, and cast iron, and are widely used in industries including automotive, machinery, hardware, and aerospace.
The phosphating production line features an annual capacity of 80,000-150,000 tons per line, with processing speeds of 1-5 m/min and phosphating film thicknesses ranging from 1-10 μm. The borating production line has an annual capacity of 20,000-50,000 tons per line, processing cycles of 30-120 minutes per batch, and borating layer thicknesses of 5-50 μm. Customized intermittent or continuous layouts can be implemented based on workpiece dimensions and production capacity requirements, accommodating various production scales.
- Feed conveying unit: Equipped with chain/belt conveyors, compatible with workpiece dimensions (length 50-2000mm, width 30-800mm, single weight ≤100kg), operating speed 0.5-5m/min. Features automatic feeding and positioning devices with ±2mm repeat positioning accuracy to prevent workpiece stacking collisions and ensure uniform processing.
- Pre-degreasing tank: Material: PP/FRP (thickness ≥15mm), capacity: 10-20m³, temperature: 40-50℃, using alkaline degreasing solution (NaOH 3-5%, Na₂CO₃ 2-3%), combined with ultrasonic/spray stirring, treatment time: 2-3min, rapidly removes oil and dust from the workpiece surface to prevent oil contamination from affecting the adhesion of the phosphating film.
- Main degreasing tank: Connected in series with the pre-degreasing tank, the alkaline degreasing solution concentration is increased to 5-8%, with a temperature of 50-60°C and a treatment time of 3-5 minutes to enhance degreasing efficiency. The tank is equipped with a level gauge, temperature sensor, and automatic liquid replenishment device, ensuring a liquid level fluctuation of ≤±50mm and a temperature deviation of ≤±2°C.
- Pickling tank (optional): Made of PP plate (thickness ≥20mm), with hydrochloric acid concentration of 10-15% and temperature ranging from room temperature to-40℃. The treatment duration is 1-3 minutes, designed to remove surface scale and rust from corroded workpieces. Equipped with an acid circulation pump (flow rate 30-50m³/h) to achieve turbulent pickling and prevent localized under-pickling.
- Neutralization and Water Washing Tank: 3-4 series countercurrent rinsing stages, with Na₂CO₃ concentration in the neutralization tank maintained at 2-3% and pH controlled at 7-8, processing time 1-2 minutes; final rinse water conductivity ≤50μS/cm, thoroughly removing residual acid and degreasing solution on the workpiece surface to prevent residual chemicals from causing pinhole or pitting defects in the phosphating film.
- Phosphating tank: The main body is a steel tank lined with acid-resistant rubber (thickness ≥10mm) or PP plate (thickness ≥20mm), with a volume of 15-30m³. Different phosphating systems are selected based on the substrate and requirements, typically using zinc-based phosphating solution (ZnO 8-12g/L, H₃PO₄ 30-40g/L, accelerator 2-5g/L), at a temperature of 30-50℃, and a pH of 2.5-3.5.
- Mixing and Circulation System: The system employs an air agitation and spray system with an air agitation rate of 0.5-1 m³/(m²·min) and spray pressure of 0.3-0.5MPa to ensure thorough contact between the phosphating solution and the workpiece surface. It is equipped with a phosphating solution circulation pump (flow rate 40-60 m³/h) and a precision filter (5μm filtration accuracy) to remove sediment from the solution, preventing sludge accumulation at the tank bottom from affecting the quality of the phosphating film.
- Phosphating solution parameter control system: Online monitoring of phosphating solution concentration, pH value, temperature, and promoter content, with automatic chemical dosing through a liquid replenishment pump to ensure parameter stability; equipped with an automatic phosphating residue cleaning device, which periodically discharges sediment from the tank bottom. The sediment is processed through pressure filtration and disposed of in compliance with regulations.
- Auxiliary configuration: The tank is equipped with a heating device (steam/electric heating, power 30-50kW) to achieve precise temperature control; it is also fitted with an overflow tank to collect overflow phosphating solution, thereby reducing reagent consumption and lowering production costs.
- Water washing and sealing tank: Two-stage countercurrent rinsing to remove residual phosphating solution from the workpiece surface; the sealing tank uses water-soluble sealing agent (concentration 3-5%), at room temperature to-40°C, with a treatment time of 1-2 minutes, forming a sealing layer on the phosphating film surface to enhance corrosion resistance (neutral salt spray test ≥72h).
- Drying unit: Hot-air tunnel drying system with 60-100℃ temperature and 1-3m/s airflow, operating for 2-5 minutes. The workpiece surface moisture content must be ≤0.1% to prevent post-drying rusting and ensure compatibility between the phosphating film and subsequent coating/processing.
- Export inspection and material handling: Utilizes belt conveyors + manual material handling, equipped with a phosphating film thickness gauge (accuracy ±0.1μm) and an adhesion tester (scratch test ≥ grade 1). The system automatically detects phosphating film thickness and bonding strength, with non-conforming products automatically sorted, while qualified workpieces are stored or transferred to the next process.
- PLC control system: Equipped with Siemens S7-1200/S7-1500 series, it coordinates all-line equipment for automated regulation of phosphating solution parameters, temperature, and treatment duration. The system stores over 50 process parameters, supports rapid workpiece specification switching, and requires minimal manual intervention.
- Online monitoring and recording: Real-time monitoring of liquid level, temperature, pH value, and conductivity in each tank, with automatic data recording and upload to the central control room. Supports remote monitoring and historical data traceability, achieving a fault alarm accuracy rate of ≥99%, facilitating operation and maintenance troubleshooting.
- Safety interlock system: Overfill/overtemperature alarm for tank, automatic shutdown upon chemical leakage, emergency power cut for personnel entering hazardous areas, equipped with emergency sprinkler system to ensure production safety.
- Phosphating film parameters: Zinc-based phosphating film thickness 1-10μm, film weight 1-5g/m², adhesion (scratch test) ≥ grade 1, neutral salt spray test (after sealing) ≥ 72h, film layer uniform and dense, without defects such as white spots, sagging, or exposed substrate.
- Phosphating solution control: Zinc-based phosphating solution (ZnO 8-12g/L, H₃PO₄ 30-40g/L, accelerator (NO₃⁻) 2-5g/L), temperature 30-50℃, pH 2.5-3.5; monitor concentration 1-2 times weekly and replenish chemicals promptly to prevent film quality degradation caused by solution aging.
- Processing time control: Based on the workpiece material and film thickness requirements, the phosphating time should be controlled within 1-5 minutes. Insufficient time results in an excessively thin film layer, while prolonged exposure may cause film delamination or roughness.
- Pre-treatment control: Ensure no residual chemicals on the workpiece surface after water washing, with conductivity ≤50μS/cm, to prevent residual acid solution, degreasing solution, and phosphating solution from reacting and affecting the adhesion and uniformity of the film layer.
- Material transfer unit: Equipped with overhead/gantry cranes (5-30t lifting capacity) and specialized lifting devices (hooks/beams), compatible with workpiece dimensions (length 500-8000mm, width 300-2000mm, single weight ≤30t), operating at 0.1-0.5m/s, precisely transports workpieces to the pre-treatment area to prevent collision damage.
- De-fatting tank: Made of Q235 steel with acid-resistant rubber lining, capacity 50-100m³, operating temperature 60-80℃. Uses alkaline degreasing solution (NaOH 8-12%, Na₃PO₄ 5-8%) with steam heating and mechanical stirring. Treatment time 10-20min to completely remove surface oil and grease, ensuring optimal bonding of boron infiltration layer.
- Pickling tank: Material: PP/FRP (thickness ≥25mm), Hydrochloric acid concentration: 15-20%, Temperature: 40-50℃, Treatment time: 15-30min. This process removes surface oxide scale, rust, and passivation film from workpieces. Large workpieces are equipped with a pickling tank agitator to enhance pickling uniformity and prevent localized residual oxide scale.
- Water washing and drying tank: 2-stage countercurrent rinsing at room temperature for 5-10 minutes to remove residual pickling solution from the workpiece surface; the drying tank employs hot air drying at 80-120°C for 10-15 minutes, ensuring the surface moisture content of the workpiece is ≤0.1% to prevent oxidation and porosity defects during boronization.
- Clamping and anti-seepage device: Customized clamping tools are designed according to the workpiece shape to fix the workpiece and prevent deformation under high temperature; anti-seepage coatings (glass powder + binder) are applied to areas that do not require boronizing (e.g., threads, mating surfaces) to avoid the boron infiltration layer affecting the mating accuracy of the workpiece.
- Boronizing furnace: The main body is a heat-resistant steel furnace (material Cr25Ni20), lined with insulating material (alumina fiber). The furnace chamber dimensions are customizable (standard 1000×800×1500mm), using resistance heating/gas heating, with heating power of 50-200kW, maximum operating temperature of 1050℃, and temperature fluctuation ≤±5℃.
- Boronizing medium and loading: A solid boronizing agent (iron boride + boron carbide + fluoride catalyst, ratio 3:1:0.5) is uniformly mixed with the workpiece and loaded into a heat-resistant steel basket, or a coating method (applying boronizing paste to the workpiece surface) is used to ensure full contact between the boronizing agent and the workpiece surface.
- Temperature and atmosphere control system: Multiple temperature sensors are installed in the furnace to monitor the furnace temperature in real time, with automatic heating power adjustment via PLC; inert gas (nitrogen) is used for protection to prevent high-temperature oxidation of workpieces, with a nitrogen flow rate of 5-10 m³/h and oxygen content in the furnace ≤0.1%.
- Cooling system: After boronizing, a combined furnace and air cooling method is employed. The workpiece is first cooled in the furnace to below 600°C, then air-cooled. Alternatively, oil or water cooling may be used depending on the material, with controlled cooling rates to prevent cracking. The final temperature of the cooled workpiece should not exceed 80°C.
- Cleaning and slag removal: Perform sandblasting/shot blasting (pressure 0.4-0.6MPa) to remove residual boronizing agent and loose boronized layer on the workpiece surface, ensuring the boronized layer surface is smooth without slag inclusion or loose defects.
- Subsequent strengthening treatment (optional): For workpieces requiring high hardness, quenching + tempering can be performed to enhance the hardness and toughness of the matrix; for workpieces requiring corrosion resistance, passivation/electroplating can be applied to prolong service life.
- Grinding and Inspection: Equipped with manual/mechanical grinding tools to remove burrs and flash from the workpiece surface, and to grind the mating surface dimensions; employs a microhardness tester (hardness ≥1800HV), metallographic microscope, and ultrasonic flaw detector to inspect the hardness, thickness, microstructure, and adhesion of the boronized layer, ensuring no defects such as cracks or delamination.
- Export material handling and stacking: Use overhead cranes to transfer materials to the cutting area, where they are sorted and stacked to prevent collision damage to the boronized layer. Non-conforming items require reprocessing (re-treatment + boronization), while qualified items are stored in the warehouse.
- PLC control system: Equipped with Siemens S7-1500 series, it regulates key parameters including boronizing furnace temperature, holding time, cooling rate, and nitrogen flow rate. The system supports automatic temperature adjustment (heating, holding, cooling) to precisely control the boronizing process while minimizing manual intervention.
- Temperature monitoring and recording: Real-time multi-point temperature monitoring in the furnace, with automatic data recording to generate process curves, supporting historical data traceability for optimizing boronization process parameters.
- Safety interlock system: over-temperature/over-pressure alarm for boronizing furnace, gas leakage-linked gas cutoff, cooling system fault alarm, emergency shutdown button, equipped with fireproof and explosion-proof devices to ensure safety in high-temperature operations.
- Boronizing layer parameters: thickness 5-50μm, microhardness ≥1800HV, no delamination in bonding strength (hammer test), uniformity deviation of boronizing layer ≤±5μm, high-temperature resistance ≤800℃, wear resistance 5-10 times that of ordinary steel.
- Boronizing process control: Boronizing temperature 850-1050°C, holding time 30-120 min. Higher temperature and longer holding time result in thicker boronized layer. Nitrogen flow rate 5-10 m³/h to maintain inert atmosphere in the furnace and prevent workpiece oxidation.
- Boronizing agent control: Precise proportion of solid boronizing agents (iron boride: boron carbide: catalyst = 3:1:0.5), regular replacement of aged boronizing agents to avoid affecting boron infiltration efficiency; uniform thickness of boronizing paste coating (0.5-1mm) to ensure consistent boronized layer thickness.
- Cooling control: Strictly control the cooling rate, and cool the furnace to below 600°C before removal to avoid rapid cooling-induced cracking of workpieces and delamination of the boronized layer. For brittle materials such as alloy steel and cast iron, the cooling time should be extended.
| Comparison Dimension | Phosphating Line Equipment | Boriding Line Equipment | | ---- | ---- | ---- | | Core Principle | Chemical Conversion (formation of phosphate film) | High-temperature Chemical Boriding (formation of boride hard layer) | | Treatment Temperature | 30-60°C (low-temperature) | 850-1050°C (high-temperature) | | Film/Boriding Layer Thickness | 1-10μm (thin film) | 5-50μm (hard boriding layer) | | Core Performance | Corrosion resistance, improved coating adhesion | High hardness, high wear resistance, heat resistance | | Suitable Workpieces | Small-to-medium precision workpieces (single weight ≤100kg) | Heavy-duty large workpieces (single weight ≤30t) | | Production Efficiency | High (1-5m/min) | Moderate (30-120min/batch) | | Equipment Cost | Mid-to-low (single line 80-300 million yuan) | Mid-to-high (single line 300-1000 million yuan) | | Environmental Requirements | Phosphating wastewater (phosphorus-containing) treatment required, no significant exhaust emissions | High-temperature exhaust and boriding residue treatment required, higher environmental investment | | Service Life | Film layer lifespan 3-8 years (indoor) | Boriding layer lifespan 8-20 years (heavy-duty conditions) | | Post-Processing | Compatible with coating and cold working processes | Suitable for heavy-duty, wear-resistant conditions, with post-treatment options available |
- Daily inspection: Check the liquid level, chemical concentration, and temperature of each tank before daily startup, confirm that the conveying equipment, pump sets, valves, and heating devices are operating normally, and immediately stop the machine to address any leaks or abnormal noises to prevent fault escalation.
- Chemical Management: Prepare degreasing solution, phosphating solution, and borating agent strictly in accordance with process requirements, conduct regular concentration testing, and replenish or replace aged chemicals promptly; store hazardous chemicals (acids, alkalis, borating agents) separately, implement leak-proof and corrosion-resistant protective measures, and equip with emergency response materials.
- Environmental Compliance: Ensure proper operation of wastewater, exhaust gas, and solid waste treatment facilities. Phosphating wastewater must undergo phosphorus removal and neutralization treatment (standard: pH 6-9, TP ≤0.5mg/L). Borating solid waste shall be disposed of in compliance after solidification treatment to eliminate environmental exceedance risks.
- Safety Protection: Operators must wear acid/heat-resistant gloves, face shields, and protective clothing, and strictly prohibit non-compliant operations. Warning signs shall be installed in high-temperature, high-pressure, and chemical areas to prohibit unauthorized personnel entry. Regular emergency drills shall be conducted to enhance safety response capabilities.
- Equipment Maintenance: Clean sediment from all tanks and filtration devices weekly, inspect pipeline and seal wear conditions; perform monthly calibration and maintenance of heating devices, sensors, and control systems; conduct annual anti-corrosion testing and repairs on furnace bodies and tanks to extend equipment service life.
- Phosphating solution maintenance: Filter the phosphating solution 1-2 times per week to remove suspended impurities; replace part of the phosphating solution once monthly to prevent excessive residue accumulation at the tank bottom from affecting phosphating efficiency; regularly test the accelerator content to avoid insufficient levels causing loose or excessively thin film formation.
- Water washing control: Strictly maintain the conductivity of final rinse water at ≤50μS/cm, and regularly replace rinse water to prevent residual chemicals from entering subsequent processes, which could cause phosphating film defects or peeling of subsequent coating layers.
- Drying control: Maintain drying temperature at 60-100°C to prevent phosphating film aging and brittleness due to excessive heat, and ensure complete drying without rusting caused by insufficient temperature.
- Boronizing furnace maintenance: Regularly inspect the furnace body insulation layer and heating element wear, and replace damaged components promptly; Clean residual boronizing agent and oxide scale in the furnace chamber monthly to ensure uniform temperature distribution; Strictly prohibit over-temperature operation to prevent furnace deformation and damage.
- Atmosphere control: Ensure proper nitrogen protection during boronization, with oxygen content in the furnace ≤0.1% to prevent excessive oxygen from causing workpiece oxidation and degradation of boronized layer quality; regularly inspect nitrogen pipeline sealing to prevent leaks that may lead to safety incidents.
- Cooling and clamping: Strictly adhere to the cooling process to prevent workpiece cracking caused by rapid cooling; ensure secure clamping of the workpiece to avoid loosening or dropping under high temperatures, while preventing the clamping tool from obstructing the workpiece surface, which may result in localized absence of boron infiltration layer.
- Sealing treatment: When applying the sealing coating, ensure even coverage without gaps, maintaining a thickness of 0.5-1mm to prevent coating detachment that could form boron seepage layers in non-borated areas, which would compromise the workpiece's fit accuracy.
- Phosphating line: Suitable for automotive components (body, chassis stampings, bolts), hardware products (door/window fittings, tools), appliance casings, and construction machinery parts, it is required to enhance coating adhesion and provide moderate corrosion resistance, serving as the core pretreatment process prior to painting.
- Boronizing treatment line: Suitable for heavy-duty mechanical components (gears, shafts, molds), aerospace auxiliary parts, wear-resistant tools (cutting tools, measuring tools), and engine components, requiring high hardness, high wear resistance, and high-temperature resistance for heavy-duty and harsh working conditions.
- Capacity and Workpiece Matching: Small hardware factories and automotive component plants (annual capacity ≤80,000 tons) may opt for phosphating treatment lines; large machinery manufacturing plants and heavy industry enterprises (annual capacity ≥20,000 tons) may choose boronizing treatment lines, with customized intermittent/continuous layouts based on workpiece dimensions.
- Performance requirements considerations: For enhanced coating adhesion and low-cost corrosion resistance, the phosphating treatment line is preferred; for high wear resistance, high-temperature tolerance, and heavy-duty adaptability, the boronizing treatment line is preferred. Although the initial investment is high, the long-term maintenance cost is low, and the service life of the workpiece is prolonged.
- Cost and environmental considerations: For initial projects with limited budgets and stringent environmental controls (particularly requiring strict management of phosphorus-containing wastewater), a phosphorus-free phosphating treatment line can be selected. For projects with sufficient budgets, demanding operating conditions, and the capacity to bear environmental investments, a boronizing treatment line may be chosen, accompanied by comprehensive exhaust gas and waste residue treatment facilities.
The phosphating and boriding production lines are two core equipment systems for chemical transformation and surface strengthening of metal workpieces, designed to meet the surface modification requirements of various materials and operational conditions. The phosphating line utilizes chemical transformation principles to form phosphate films, offering advantages such as low cost, corrosion resistance, and enhanced coating adhesion, making it suitable for small and medium-sized precision workpieces. The boriding line employs high-temperature chemical boriding to create a hard boride layer, emphasizing high hardness, wear resistance, and heat tolerance, ideal for heavy-duty and wear-resistant mechanical components. Both production lines adopt a three-stage continuous layout of "pre-treatment-core treatment-post-treatment," equipped with automated transfer and process control systems, enabling batch standardized production. They cover mainstream substrates such as carbon steel, alloy steel, and cast iron, and are widely used in industries including automotive, machinery, hardware, and aerospace.
The phosphating production line features an annual capacity of 80,000-150,000 tons per line, with processing speeds of 1-5 m/min and phosphating film thicknesses ranging from 1-10 μm. The borating production line has an annual capacity of 20,000-50,000 tons per line, processing cycles of 30-120 minutes per batch, and borating layer thicknesses of 5-50 μm. Customized intermittent or continuous layouts can be implemented based on workpiece dimensions and production capacity requirements, accommodating various production scales.
- Feed conveying unit: Equipped with chain/belt conveyors, compatible with workpiece dimensions (length 50-2000mm, width 30-800mm, single weight ≤100kg), operating speed 0.5-5m/min. Features automatic feeding and positioning devices with ±2mm repeat positioning accuracy to prevent workpiece stacking collisions and ensure uniform processing.
- Pre-degreasing tank: Material: PP/FRP (thickness ≥15mm), capacity: 10-20m³, temperature: 40-50℃, using alkaline degreasing solution (NaOH 3-5%, Na₂CO₃ 2-3%), combined with ultrasonic/spray stirring, treatment time: 2-3min, rapidly removes oil and dust from the workpiece surface to prevent oil contamination from affecting the adhesion of the phosphating film.
- Main degreasing tank: Connected in series with the pre-degreasing tank, the alkaline degreasing solution concentration is increased to 5-8%, with a temperature of 50-60°C and a treatment time of 3-5 minutes to enhance degreasing efficiency. The tank is equipped with a level gauge, temperature sensor, and automatic liquid replenishment device, ensuring a liquid level fluctuation of ≤±50mm and a temperature deviation of ≤±2°C.
- Pickling tank (optional): Made of PP plate (thickness ≥20mm), with hydrochloric acid concentration of 10-15% and temperature ranging from room temperature to-40℃. The treatment duration is 1-3 minutes, designed to remove surface scale and rust from corroded workpieces. Equipped with an acid circulation pump (flow rate 30-50m³/h) to achieve turbulent pickling and prevent localized under-pickling.
- Neutralization and Water Washing Tank: 3-4 series countercurrent rinsing stages, with Na₂CO₃ concentration in the neutralization tank maintained at 2-3% and pH controlled at 7-8, processing time 1-2 minutes; final rinse water conductivity ≤50μS/cm, thoroughly removing residual acid and degreasing solution on the workpiece surface to prevent residual chemicals from causing pinhole or pitting defects in the phosphating film.
- Phosphating tank: The main body is a steel tank lined with acid-resistant rubber (thickness ≥10mm) or PP plate (thickness ≥20mm), with a volume of 15-30m³. Different phosphating systems are selected based on the substrate and requirements, typically using zinc-based phosphating solution (ZnO 8-12g/L, H₃PO₄ 30-40g/L, accelerator 2-5g/L), at a temperature of 30-50℃, and a pH of 2.5-3.5.
- Mixing and Circulation System: The system employs an air agitation and spray system with an air agitation rate of 0.5-1 m³/(m²·min) and spray pressure of 0.3-0.5MPa to ensure thorough contact between the phosphating solution and the workpiece surface. It is equipped with a phosphating solution circulation pump (flow rate 40-60 m³/h) and a precision filter (5μm filtration accuracy) to remove sediment from the solution, preventing sludge accumulation at the tank bottom from affecting the quality of the phosphating film.
- Phosphating solution parameter control system: Online monitoring of phosphating solution concentration, pH value, temperature, and promoter content, with automatic chemical dosing through a liquid replenishment pump to ensure parameter stability; equipped with an automatic phosphating residue cleaning device, which periodically discharges sediment from the tank bottom. The sediment is processed through pressure filtration and disposed of in compliance with regulations.
- Auxiliary configuration: The tank is equipped with a heating device (steam/electric heating, power 30-50kW) to achieve precise temperature control; it is also fitted with an overflow tank to collect overflow phosphating solution, thereby reducing reagent consumption and lowering production costs.
- Water washing and sealing tank: Two-stage countercurrent rinsing to remove residual phosphating solution from the workpiece surface; the sealing tank uses water-soluble sealing agent (concentration 3-5%), at room temperature to-40°C, with a treatment time of 1-2 minutes, forming a sealing layer on the phosphating film surface to enhance corrosion resistance (neutral salt spray test ≥72h).
- Drying unit: Hot-air tunnel drying system with 60-100℃ temperature and 1-3m/s airflow, operating for 2-5 minutes. The workpiece surface moisture content must be ≤0.1% to prevent post-drying rusting and ensure compatibility between the phosphating film and subsequent coating/processing.
- Export inspection and material handling: Utilizes belt conveyors + manual material handling, equipped with a phosphating film thickness gauge (accuracy ±0.1μm) and an adhesion tester (scratch test ≥ grade 1). The system automatically detects phosphating film thickness and bonding strength, with non-conforming products automatically sorted, while qualified workpieces are stored or transferred to the next process.
- PLC control system: Equipped with Siemens S7-1200/S7-1500 series, it coordinates all-line equipment for automated regulation of phosphating solution parameters, temperature, and treatment duration. The system stores over 50 process parameters, supports rapid workpiece specification switching, and requires minimal manual intervention.
- Online monitoring and recording: Real-time monitoring of liquid level, temperature, pH value, and conductivity in each tank, with automatic data recording and upload to the central control room. Supports remote monitoring and historical data traceability, achieving a fault alarm accuracy rate of ≥99%, facilitating operation and maintenance troubleshooting.
- Safety interlock system: Overfill/overtemperature alarm for tank, automatic shutdown upon chemical leakage, emergency power cut for personnel entering hazardous areas, equipped with emergency sprinkler system to ensure production safety.
- Phosphating film parameters: Zinc-based phosphating film thickness 1-10μm, film weight 1-5g/m², adhesion (scratch test) ≥ grade 1, neutral salt spray test (after sealing) ≥ 72h, film layer uniform and dense, without defects such as white spots, sagging, or exposed substrate.
- Phosphating solution control: Zinc-based phosphating solution (ZnO 8-12g/L, H₃PO₄ 30-40g/L, accelerator (NO₃⁻) 2-5g/L), temperature 30-50℃, pH 2.5-3.5; monitor concentration 1-2 times weekly and replenish chemicals promptly to prevent film quality degradation caused by solution aging.
- Processing time control: Based on the workpiece material and film thickness requirements, the phosphating time should be controlled within 1-5 minutes. Insufficient time results in an excessively thin film layer, while prolonged exposure may cause film delamination or roughness.
- Pre-treatment control: Ensure no residual chemicals on the workpiece surface after water washing, with conductivity ≤50μS/cm, to prevent residual acid solution, degreasing solution, and phosphating solution from reacting and affecting the adhesion and uniformity of the film layer.
- Material transfer unit: Equipped with overhead/gantry cranes (5-30t lifting capacity) and specialized lifting devices (hooks/beams), compatible with workpiece dimensions (length 500-8000mm, width 300-2000mm, single weight ≤30t), operating at 0.1-0.5m/s, precisely transports workpieces to the pre-treatment area to prevent collision damage.
- De-fatting tank: Made of Q235 steel with acid-resistant rubber lining, capacity 50-100m³, operating temperature 60-80℃. Uses alkaline degreasing solution (NaOH 8-12%, Na₃PO₄ 5-8%) with steam heating and mechanical stirring. Treatment time 10-20min to completely remove surface oil and grease, ensuring optimal bonding of boron infiltration layer.
- Pickling tank: Material: PP/FRP (thickness ≥25mm), Hydrochloric acid concentration: 15-20%, Temperature: 40-50℃, Treatment time: 15-30min. This process removes surface oxide scale, rust, and passivation film from workpieces. Large workpieces are equipped with a pickling tank agitator to enhance pickling uniformity and prevent localized residual oxide scale.
- Water washing and drying tank: 2-stage countercurrent rinsing at room temperature for 5-10 minutes to remove residual pickling solution from the workpiece surface; the drying tank employs hot air drying at 80-120°C for 10-15 minutes, ensuring the surface moisture content of the workpiece is ≤0.1% to prevent oxidation and porosity defects during boronization.
- Clamping and anti-seepage device: Customized clamping tools are designed according to the workpiece shape to fix the workpiece and prevent deformation under high temperature; anti-seepage coatings (glass powder + binder) are applied to areas that do not require boronizing (e.g., threads, mating surfaces) to avoid the boron infiltration layer affecting the mating accuracy of the workpiece.
- Boronizing furnace: The main body is a heat-resistant steel furnace (material Cr25Ni20), lined with insulating material (alumina fiber). The furnace chamber dimensions are customizable (standard 1000×800×1500mm), using resistance heating/gas heating, with heating power of 50-200kW, maximum operating temperature of 1050℃, and temperature fluctuation ≤±5℃.
- Boronizing medium and loading: A solid boronizing agent (iron boride + boron carbide + fluoride catalyst, ratio 3:1:0.5) is uniformly mixed with the workpiece and loaded into a heat-resistant steel basket, or a coating method (applying boronizing paste to the workpiece surface) is used to ensure full contact between the boronizing agent and the workpiece surface.
- Temperature and atmosphere control system: Multiple temperature sensors are installed in the furnace to monitor the furnace temperature in real time, with automatic heating power adjustment via PLC; inert gas (nitrogen) is used for protection to prevent high-temperature oxidation of workpieces, with a nitrogen flow rate of 5-10 m³/h and oxygen content in the furnace ≤0.1%.
- Cooling system: After boronizing, a combined furnace and air cooling method is employed. The workpiece is first cooled in the furnace to below 600°C, then air-cooled. Alternatively, oil or water cooling may be used depending on the material, with controlled cooling rates to prevent cracking. The final temperature of the cooled workpiece should not exceed 80°C.
- Cleaning and slag removal: Perform sandblasting/shot blasting (pressure 0.4-0.6MPa) to remove residual boronizing agent and loose boronized layer on the workpiece surface, ensuring the boronized layer surface is smooth without slag inclusion or loose defects.
- Subsequent strengthening treatment (optional): For workpieces requiring high hardness, quenching + tempering can be performed to enhance the hardness and toughness of the matrix; for workpieces requiring corrosion resistance, passivation/electroplating can be applied to prolong service life.
- Grinding and Inspection: Equipped with manual/mechanical grinding tools to remove burrs and flash from the workpiece surface, and to grind the mating surface dimensions; employs a microhardness tester (hardness ≥1800HV), metallographic microscope, and ultrasonic flaw detector to inspect the hardness, thickness, microstructure, and adhesion of the boronized layer, ensuring no defects such as cracks or delamination.
- Export material handling and stacking: Use overhead cranes to transfer materials to the cutting area, where they are sorted and stacked to prevent collision damage to the boronized layer. Non-conforming items require reprocessing (re-treatment + boronization), while qualified items are stored in the warehouse.
- PLC control system: Equipped with Siemens S7-1500 series, it regulates key parameters including boronizing furnace temperature, holding time, cooling rate, and nitrogen flow rate. The system supports automatic temperature adjustment (heating, holding, cooling) to precisely control the boronizing process while minimizing manual intervention.
- Temperature monitoring and recording: Real-time multi-point temperature monitoring in the furnace, with automatic data recording to generate process curves, supporting historical data traceability for optimizing boronization process parameters.
- Safety interlock system: over-temperature/over-pressure alarm for boronizing furnace, gas leakage-linked gas cutoff, cooling system fault alarm, emergency shutdown button, equipped with fireproof and explosion-proof devices to ensure safety in high-temperature operations.
- Boronizing layer parameters: thickness 5-50μm, microhardness ≥1800HV, no delamination in bonding strength (hammer test), uniformity deviation of boronizing layer ≤±5μm, high-temperature resistance ≤800℃, wear resistance 5-10 times that of ordinary steel.
- Boronizing process control: Boronizing temperature 850-1050°C, holding time 30-120 min. Higher temperature and longer holding time result in thicker boronized layer. Nitrogen flow rate 5-10 m³/h to maintain inert atmosphere in the furnace and prevent workpiece oxidation.
- Boronizing agent control: Precise proportion of solid boronizing agents (iron boride: boron carbide: catalyst = 3:1:0.5), regular replacement of aged boronizing agents to avoid affecting boron infiltration efficiency; uniform thickness of boronizing paste coating (0.5-1mm) to ensure consistent boronized layer thickness.
- Cooling control: Strictly control the cooling rate, and cool the furnace to below 600°C before removal to avoid rapid cooling-induced cracking of workpieces and delamination of the boronized layer. For brittle materials such as alloy steel and cast iron, the cooling time should be extended.
| Comparison Dimension | Phosphating Line Equipment | Boriding Line Equipment | | ---- | ---- | ---- | | Core Principle | Chemical Conversion (formation of phosphate film) | High-temperature Chemical Boriding (formation of boride hard layer) | | Treatment Temperature | 30-60°C (low-temperature) | 850-1050°C (high-temperature) | | Film/Boriding Layer Thickness | 1-10μm (thin film) | 5-50μm (hard boriding layer) | | Core Performance | Corrosion resistance, improved coating adhesion | High hardness, high wear resistance, heat resistance | | Suitable Workpieces | Small-to-medium precision workpieces (single weight ≤100kg) | Heavy-duty large workpieces (single weight ≤30t) | | Production Efficiency | High (1-5m/min) | Moderate (30-120min/batch) | | Equipment Cost | Mid-to-low (single line 80-300 million yuan) | Mid-to-high (single line 300-1000 million yuan) | | Environmental Requirements | Phosphating wastewater (phosphorus-containing) treatment required, no significant exhaust emissions | High-temperature exhaust and boriding residue treatment required, higher environmental investment | | Service Life | Film layer lifespan 3-8 years (indoor) | Boriding layer lifespan 8-20 years (heavy-duty conditions) | | Post-Processing | Compatible with coating and cold working processes | Suitable for heavy-duty, wear-resistant conditions, with post-treatment options available |
- Daily inspection: Check the liquid level, chemical concentration, and temperature of each tank before daily startup, confirm that the conveying equipment, pump sets, valves, and heating devices are operating normally, and immediately stop the machine to address any leaks or abnormal noises to prevent fault escalation.
- Chemical Management: Prepare degreasing solution, phosphating solution, and borating agent strictly in accordance with process requirements, conduct regular concentration testing, and replenish or replace aged chemicals promptly; store hazardous chemicals (acids, alkalis, borating agents) separately, implement leak-proof and corrosion-resistant protective measures, and equip with emergency response materials.
- Environmental Compliance: Ensure proper operation of wastewater, exhaust gas, and solid waste treatment facilities. Phosphating wastewater must undergo phosphorus removal and neutralization treatment (standard: pH 6-9, TP ≤0.5mg/L). Borating solid waste shall be disposed of in compliance after solidification treatment to eliminate environmental exceedance risks.
- Safety Protection: Operators must wear acid/heat-resistant gloves, face shields, and protective clothing, and strictly prohibit non-compliant operations. Warning signs shall be installed in high-temperature, high-pressure, and chemical areas to prohibit unauthorized personnel entry. Regular emergency drills shall be conducted to enhance safety response capabilities.
- Equipment Maintenance: Clean sediment from all tanks and filtration devices weekly, inspect pipeline and seal wear conditions; perform monthly calibration and maintenance of heating devices, sensors, and control systems; conduct annual anti-corrosion testing and repairs on furnace bodies and tanks to extend equipment service life.
- Phosphating solution maintenance: Filter the phosphating solution 1-2 times per week to remove suspended impurities; replace part of the phosphating solution once monthly to prevent excessive residue accumulation at the tank bottom from affecting phosphating efficiency; regularly test the accelerator content to avoid insufficient levels causing loose or excessively thin film formation.
- Water washing control: Strictly maintain the conductivity of final rinse water at ≤50μS/cm, and regularly replace rinse water to prevent residual chemicals from entering subsequent processes, which could cause phosphating film defects or peeling of subsequent coating layers.
- Drying control: Maintain drying temperature at 60-100°C to prevent phosphating film aging and brittleness due to excessive heat, and ensure complete drying without rusting caused by insufficient temperature.
- Boronizing furnace maintenance: Regularly inspect the furnace body insulation layer and heating element wear, and replace damaged components promptly; Clean residual boronizing agent and oxide scale in the furnace chamber monthly to ensure uniform temperature distribution; Strictly prohibit over-temperature operation to prevent furnace deformation and damage.
- Atmosphere control: Ensure proper nitrogen protection during boronization, with oxygen content in the furnace ≤0.1% to prevent excessive oxygen from causing workpiece oxidation and degradation of boronized layer quality; regularly inspect nitrogen pipeline sealing to prevent leaks that may lead to safety incidents.
- Cooling and clamping: Strictly adhere to the cooling process to prevent workpiece cracking caused by rapid cooling; ensure secure clamping of the workpiece to avoid loosening or dropping under high temperatures, while preventing the clamping tool from obstructing the workpiece surface, which may result in localized absence of boron infiltration layer.
- Sealing treatment: When applying the sealing coating, ensure even coverage without gaps, maintaining a thickness of 0.5-1mm to prevent coating detachment that could form boron seepage layers in non-borated areas, which would compromise the workpiece's fit accuracy.
- Phosphating line: Suitable for automotive components (body, chassis stampings, bolts), hardware products (door/window fittings, tools), appliance casings, and construction machinery parts, it is required to enhance coating adhesion and provide moderate corrosion resistance, serving as the core pretreatment process prior to painting.
- Boronizing treatment line: Suitable for heavy-duty mechanical components (gears, shafts, molds), aerospace auxiliary parts, wear-resistant tools (cutting tools, measuring tools), and engine components, requiring high hardness, high wear resistance, and high-temperature resistance for heavy-duty and harsh working conditions.
- Capacity and Workpiece Matching: Small hardware factories and automotive component plants (annual capacity ≤80,000 tons) may opt for phosphating treatment lines; large machinery manufacturing plants and heavy industry enterprises (annual capacity ≥20,000 tons) may choose boronizing treatment lines, with customized intermittent/continuous layouts based on workpiece dimensions.
- Performance requirements considerations: For enhanced coating adhesion and low-cost corrosion resistance, the phosphating treatment line is preferred; for high wear resistance, high-temperature tolerance, and heavy-duty adaptability, the boronizing treatment line is preferred. Although the initial investment is high, the long-term maintenance cost is low, and the service life of the workpiece is prolonged.
- Cost and environmental considerations: For initial projects with limited budgets and stringent environmental controls (particularly requiring strict management of phosphorus-containing wastewater), a phosphorus-free phosphating treatment line can be selected. For projects with sufficient budgets, demanding operating conditions, and the capacity to bear environmental investments, a boronizing treatment line may be chosen, accompanied by comprehensive exhaust gas and waste residue treatment facilities.
