WCA November 2022

Technology News

Technology for CHQ production Since the invention of the e-phos electro phosphating process in 1998, Staku has experienced worldwide growth for single- and multi-wire applications of preparing the wire surface for cold forming.

Other claimed benefits include high quality in-line production at high speed and quality; homogeneous coating quality around the surface; no voids resulting from contact spots; and a fully automated chemical analysis and metering system connected to a Level 2/3 process data network. All bath temperatures are between 50 and 60°C, with a closed-loop system that provides optimal heat retention, for lower energy costs. There is no formation of waste sludge or rinse water at disposal, and no down time for bath cleaning, due to permanent in-line filtration. The use of electrochemical reaction reduces chemical usage, and there is no harsh chemical odour or equipment contamination in the surrounding area. different methods of descaling, based on the wire diameter range produced on the machine: a double sand belt cleaning machine for 5.5 to 16mm diameters; and Staku recommends two

The company says that, while the product quality and environmental aspects were superior to traditional techniques, in the beginning the throughput of the process was not comparable with coil processing systems. Staku’s newly developed method of wire contacting inside the coating chamber has enabled the company to almost double the line speed and the approximate annual capacity. The company’s modern manufacturing concept offers environmentally friendly processes that avoid the use of acids, with equipment that requires a small footprint and no foundation work for secondary containment. e-phos off-line device with a four-ton-spooler for the production of phosphate steel wires

Wire surface after traditional coating process and after e-phos in-line coating system

The are electrically deposited by ion migration from the anode to the wire surface, which is polarised as the cathode. For optimisation of the coating quality around the wire surface, the electrodes are built in a round shape. The DC power also suppresses the pickling process that is necessary for traditional phosphating. Because the iron ions from the wire cannot contaminate the phosphate solution, the formation of phosphate sludge cannot occur, saving chemicals and reducing waste cost. Staku-Anlagenbau GmbH www.staku-gmbh.de zinc-phosphate crystals

a four-turbine shot blaster machine for 17 to 38mm diameters. The electro-phosphating process is driven by a DC power source that creates an electrical potential higher than the natural one existing between the elements iron and zinc. The system voltage is low, and does not exceed 8 to 13V, making it safe for the operator.

Invented in 1952.

Fit for the future.

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November 2022