Classifications

• • C—CHEMISTRY; METALLURGY
  • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
  • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
  • C25D13/00—Electrophoretic coating characterised by the process
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
  • C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
  • C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
  • C23C22/34—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing fluorides or complex fluorides
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
  • B05D7/14—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
  • B05D7/50—Multilayers
  • B05D7/51—One specific pretreatment, e.g. phosphatation, chromatation, in combination with one specific coating
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
  • C09D5/44—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes for electrophoretic applications
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
  • C09D5/44—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes for electrophoretic applications
  • C09D5/4488—Cathodic paints
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
  • C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
  • C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
  • C23C22/34—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing fluorides or complex fluorides
  • C23C22/36—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing fluorides or complex fluorides containing also phosphates
  • C23C22/368—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing fluorides or complex fluorides containing also phosphates containing magnesium cations
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
  • C23C22/05—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions
  • C23C22/06—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6
  • C23C22/40—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing molybdates, tungstates or vanadates
  • C23C22/44—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using aqueous solutions using aqueous acidic solutions with pH less than 6 containing molybdates, tungstates or vanadates containing also fluorides or complex fluorides
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
  • C23C22/73—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals characterised by the process
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C22/00—Chemical surface treatment of metallic material by reaction of the surface with a reactive liquid, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
  • C23C22/82—After-treatment
  • C23C22/83—Chemical after-treatment
• • C—CHEMISTRY; METALLURGY
  • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
  • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
  • C25D13/00—Electrophoretic coating characterised by the process
  • C25D13/20—Pretreatment
• • C—CHEMISTRY; METALLURGY
  • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
  • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
  • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
  • C25D5/34—Pretreatment of metallic surfaces to be electroplated
  • C25D5/36—Pretreatment of metallic surfaces to be electroplated of iron or steel
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
  • B05D1/00—Processes for applying liquids or other fluent materials
  • B05D1/007—Processes for applying liquids or other fluent materials using an electrostatic field

Definitions

• the present invention relates to a novel product for the anticorrosion treatment of metal surfaces.
• a process is provided for the anticorrosion treatment of metal, in particular, steel surfaces.
• the anticorrosion treatment is primarily intended as a pre-treatment for a subsequent cathodic electro-dipcoating.
• Anticorrosion agents that involve an acidic aqueous solution of fluoro complexes have been known for some considerable time. They are increasingly employed as a replacement for chromating processes that due to the toxicological properties of chromium compounds are less and less used. Generally, solutions of fluoro complexes of this type contain additional anticorrosion agents that further improve the corrosion protection and paint adhesion.
• DE-A-19 33 013 describes in one embodiment a treatment solution that is an aqueous solution of ammonium hexafluorozirconate, sodium nitrate, cobalt nitrate and sodium m-nitrobenzene sulfonate and has a pH of 5.2.
• the solution can be used to treat zinc-, steel- or aluminum surfaces.
• EP-A-1 571 237 describes a treatment solution and treatment methods for iron-, zinc-, aluminum- and magnesium-containing surfaces. This solution has a pH in the range of 2 to 6 and contains 5 to 5000 ppm zirconium and/or titanium as well as 0.1 to 100 ppm free fluoride.
• the solution can further contain components selected from chlorate, bromate, nitrite, nitrate, permanganate, vanadate, hydrogen peroxide, tungstate, molybdate or each of the corresponding acids. Organic polymers can also be present.
• the metal surfaces can be rinsed with a further passivating solution.
• EP-A-1 405 933 discloses a composition that contains at least one metal from the group Ti, Zr, Hf and Si as well as a fluoride ion source for the treatment of iron and/or zinc surfaces, wherein defined conditions concerning the concentration ratios of both components are set.
• this solution can contain the same additional active substances as in EP 1 571 237.
• Metal ions selected from the group Ag, Al, Cu, Fe, Mn, Mg, Ni, Co and Zn can be present as further components.
• DE-A-100 10 758 discloses a treatment solution containing complex fluorides of Ti, Zr, Hf, Si and/or B as well as organic polymers particularly for zinc, aluminum and/or magnesium surfaces.
• the solution can also contain one or more of the metals Mn, Ce, Li, V, W, Mo, Mg, Zn, Co and Ni.
• Further potential additives are compounds that are known phosphatization accelerators for the phosphatization layer formation.
• WO 95/14539 describes treatment solutions for metal surfaces, particularly for aluminum, which contain complex fluorides of Ti, Zr, Hf, Si, Ge, Sn or B as well as organic hydroxycarboxylic acids containing at least 2 hydroxyl groups (wherein the hydroxyl groups of the carboxylic acid groups are not counted) per carboxylic acid group.
• a specific example of such an acid is gluconic acid.
• a coating process that meets these specifications is described in EP-A-1 433 876.
• the treatment of steel, zinc and aluminum surfaces is carried out with a solution that contains Zr, Ti and/or Hf as well as fluoride ions and additionally a water-soluble polyvinylamine or polyallylamine resin.
• a solution that contains Zr, Ti and/or Hf as well as fluoride ions is carried out with a water-soluble polyvinylamine or polyallylamine resin.
• an aqueous solution of fluorozirconic acid, polyallylamine, zinc nitrate, silica and ascorbic acid is employed. It is predicted here, that the organic polymer is a significant component in regard to the corrosion protection and the adhesion to paint.
• the presence of organic polymers in pre-treatment solutions is frequently undesirable as they can lead to difficulties in the waste water treatment.
• the present invention relates to a process for the anticorrosion treatment of bright metal surfaces, which are at least in part steel surfaces, wherein the metal surfaces are brought into contact with an acidic aqueous solution of a fluoro complex of at least one element M selected from the group B, Si, Ti, Zr and Hf, are rinsed with water and thereafter coated with a cathodically depositable electro-dipcoating, characterized in that
• the aqueous solution contains no more than 1 mg/l of an organic polymer with allylamine or vinylamine monomers (a first organic polymer), b) the aqueous solution additionally contains at least one further component which is selected from among: nitrate ions, copper ions, silver ions, vanadium or vanadate ions, bismuth ions, magnesium ions, zinc ions, manganese ions, cobalt ions, nickel ions, tin ions, buffer systems for the pH range from 2.5 to 5.5, aromatic carboxylic acids with at least two groups containing donor atoms, or derivatives of such carboxylic acids, silica particles with an average particle size of below 1 ⁇ m, c) after having been brought into contact with the aqueous solution of the fluoro complex and before being coated with the cathodically depositable electro-dipcoating, the metal surface is not dried.
• steel surfaces are understood to mean surfaces of steel, which are not top-coated with an additional metal, such as for example zinc or its alloys with nickel or aluminum.
• additional metal such as for example zinc or its alloys with nickel or aluminum.
• Bright metal surfaces are understood to mean metal surfaces, which are not yet coated with an anticorrosion coating. Accordingly, the process according to the invention concerns the first or sole treatment step, which produces an anticorrosion layer that in turn can serve as the basis for a subsequent coat of paint. Therefore, it is not a post-treatment of a previously produced anticorrosion layer, such as for example a phosphate layer.
• the aqueous solution contains no more than 1 mg/l of an organic polymer with allylamine or vinylamine monomers
• B) the aqueous solution contains a buffer system for the pH range from 2.5 to 5.5
• C) the aqueous solution additionally contains at least one further component which is selected from among: nitrate ions, copper ions, silver ions, vanadium or vanadate ions, bismuth ions, magnesium ions, zinc ions, manganese ions, cobalt ions, nickel ions, tin ions, aromatic carboxylic acids with at least two groups containing donor atoms, or derivatives of such carboxylic acids, silica particles with an average particle size of below 1 ⁇ m, D) after having been brought into contact with the aqueous solution of the fluoro complex and before being coated with the cathodically depositable electro-dipcoating, the metal surface is not dried.
• the aqueous solution contains no more than 1 mg/l of an organic polymer with allylamine or vinylamine monomers
• B) the aqueous solution additionally contains at least one further component which is selected from among: nitrate ions, copper ions, silver ions, vanadium or vanadate ions, bismuth ions, magnesium ions, zinc ions, manganese ions, cobalt ions, nickel ions, tin ions, a buffer system for the pH range from 2.5 to 5.5, aromatic carboxylic acids with at least two groups containing donor atoms, or derivatives of such carboxylic acids, silica particles with an average particle size of below 1 ⁇ m, C) after having been brought into contact with the aqueous solution of the fluoro complex and before being coated with the cathodically depositable electro-dipcoating, the metal surface is not dried, characterized in that the aqueous solution contains no more than 1 mg/l of an organic polymer differing from the above which contains no allylamine or vinyl
• aqueous solution contains no more than 1 mg/l of an organic polymer differing from the above which contains no allylamine or vinylamine monomers and which, at a concentration of no more than 50 g/l, has thickening or dispersant properties.
• the aqueous solution contains a quantity of fluoro complex such that the concentration of the element M is in the range from 1 to 5000 mg/l, preferably in the range from 5 to 1000 mg/l and in particular in the range from 10 to 500 mg/l.
• the element M is selected from among the group Si, Ti, Zr and Hf and in that the aqueous solution contains on average at least 1, preferably at least 3, in particular at least five fluoride ions per ion of the element M.
• the aqueous solution furthermore also contains 1 to 1000 mg/l of fluoride ions which are not attached to the element M.
• aromatic carboxylic acid is selected from among hydroxycarboxylic acids, aminocarboxylic acids, nitrocarboxylic acids and carboxylic acids with at least two carboxyl groups, or derivatives thereof.
• the aqueous solution contains 0.1 to 300 mg/l, preferably 1 to 30 mg/l of copper and/or silver ions.
• aqueous solution contains 0.1 to 1000 mg/l of the stated aromatic carboxylic acid or derivatives thereof.
• the aqueous solution contains 10 to 1000 mg/l, preferably 50 to 500 mg/l of silicon in the form of silica particles with an average particle size of below 1 ⁇ m.
• aqueous solution contains a buffer system for the pH range from 2.5 to 5.5.
• It is an object of the invention to provide a composition comprising an acidic, chromium-free aqueous solution of a fluoro complex of at least one element M selected from among the group B, Si, Ti, Zr and Hf with a pH value in the range from 2 to 5.5 for the treatment of metal surfaces, characterized in that it additionally contains
• a buffer system for the pH range from 2.5 to 5.5 b) one or more components selected from among: copper, tin ions, bismuth ions, aromatic carboxylic acids with at least two groups containing donor atoms, or derivatives of such carboxylic acids and for aqueous solutions with an organic polymer content of no more than 1 mg/l silicon in the form of silica particles with an average size of below 1 ⁇ m.
• the treatment solution can contain aromatic carboxylic acids, as one of the previously stated components, which have at least two groups containing donor atoms in the molecule.
• Donor atoms are those atoms that carry free electron pairs, by which they can coordinate to transition metal ions. Typical donor atoms are oxygen, nitrogen and sulfur atoms.
• the carboxylic group of the aromatic carboxylic acid is therefore itself already a group that contains donor atoms.
• An aromatic carboxylic acid with at least two carboxylic groups in the molecule therefore falls under the stated definition.
• Those aromatic carboxylic acids, which carry, for example at least one hydroxyl group, at least one amino group or at least one nitro group in addition to the carboxylic group also fall under the definition. Examples of these carboxylic acids are the various positional isomers of benzene dicarboxylic acid, especially phthalic acid, or the various positional isomers of hydroxy-, amino- or nitro-benzoic acid.
• aromatic carboxylic acids are preferred, in which at least two groups containing donor atoms are disposed in such a way that through the donor atoms, 5-, 6- or 7-membered chelate complexes with transition metal ions can be formed.
• Particularly preferred aromatic carboxylic acids are therefore: phthalic acid, salicylic acid, o-aminobenzoic acid or o-nitrobenzoic acid.
• aromatic carboxylic acids containing only a single benzene ring the corresponding acids with condensed ring systems can be used, for example the acids derived from naphthalene or anthracene.
• Derivatives of the stated aromatic carboxylic acids can also be employed. Among these are meant those molecules, in which one or more hydrogen atoms of the basic structure (e.g. hydrogen atoms on the aromatic core, hydrogen atoms of the hydroxyl or amino groups or hydrogen atoms of the carboxyl groups) are replaced by other atoms or groups of atoms.
• one or more hydrogen atoms of the basic structure e.g. hydrogen atoms on the aromatic core, hydrogen atoms of the hydroxyl or amino groups or hydrogen atoms of the carboxyl groups
• silica particles with an average particle size of below 1 ⁇ m are known under various generic names to the person skilled in the art. They are called, for example, colloidal silica, precipitated silica or pyrogenic silica.
• the average particle size which is preferably in the range of about 0.01 ⁇ m to about 1 ⁇ m, can be determined by light scattering methods or by electron microscopy.
• an aqueous solution is added that on toxicological grounds is essentially free of chromium (VI) compounds and preferably contains no chromium compounds of any kind. Traces of chromium compounds, which can arrive in the treatment solution by being leached out of stainless steel containers, are not considered to render the solution “chromium containing”.
• treatment solutions containing no more than 1 ppm, particularly no more than 0.1 ppm chromium, are understood as “chromium free”.
• the treatment solutions to be employed according to the invention do not represent phosphatization solutions, i.e. they do not lead to the formation of an amorphous or crystalline phosphate layer.
• the treatment solutions preferably contain no more than 1 g/l inorganic phosphate or phosphoric acid, calculated as PO 4 3 ⁇ .
• phosphate contents in the range of 10 to 500 mg/l, for example, can be tolerated and can even improve the action of the treatment solution.
• the stability of concentrates, from which the aqueous treatment solutions to be used in the process according to the invention can be manufactured by dilution with water, can be improved by adding thickeners and/or dispersants. These thickeners and/or dispersants are then also present in a suitably diluted state in the ready for use aqueous treatment solution. Their presence in the treatment solution can be tolerated, such that a treatment solution of this type can be used in the process according to the invention. Accordingly, the aqueous treatment solution can be wherein it contains no more than 1 mg/l of another organic polymer than such a polymer that does not contain allylamine or vinylamine monomers, and that, at a concentration of no more than 50 g/l, has thickening or dispersing properties. Examples of such polymers are polymers or copolymers of unsaturated carboxylic acids, carbohydrates or proteins.
• the aqueous treatment solution contains no more than 1 mg/l of an organic polymer containing allylamine or vinylamine monomers, preferably 0 to 1 mg/l.
• other polymers can be present. Among these are the previously stated polymers with thickening and/or dispersing properties.
• the treatment solution can contain additional polymers with known positive activity in anticorrosion treatment. Exemplary polymers of this type (including those with thickening and/or dispersing properties) are:
• aqueous treatment solution contains no more than 1 mg/l of organic polymer.
• the pH of the acidic treatment solution is preferably in the range 2 to 5.5, particularly 3.5 to 5.
• the pH is preferably adjusted to the stated acidic range by adding the fluoro complex at least partially in the form of an acid. However, it can also be adjusted by means of another acid, for example nitric acid. According to the invention and according to this first aspect of the invention, no measures are required, and preferably should be even avoided, which would dry the metal surface after it has been contacted with the aqueous solution of the fluoro complex and before being coated with the cathodically depositable electro-dipcoating.
• An unintentional drying can however occur during a unit shutdown when the treated metal surface, for example an automobile body or a part thereof, is exposed to air between the bath containing the aqueous solution of the fluoro complex and the electro-dipcoating bath. This unintentional drying is harmless, however.
• nitrate ions 0.1 to 5000 mg/l, preferably 1 to 3000 mg/l, in particular 10 to 1000 mg/l, copper-, silver-, cobalt- or nickel ions: each 0.1 to 300 mg/l, preferably 1 to 30 mg/l, vanadium- or vanadate ions: 1 to 2000 mg/l, preferably 5 to 500 mg/l (calculated as vanadium), bismuth-, magnesium-, zinc-, manganese- or tin ions: each 1 to 2000 mg/l, preferably 5 to 500 mg/l, buffer system for the pH range 2.5 to 5.5: in sufficient quantity that the pH of the solution does not change by more than 0.2 units when a 1 N acid or base per liter solution is added, aromatic carboxylic acids containing at least two groups containing donor atoms, or derivatives of such acids: 0.01 to 1000 mg/l, preferably 1 to 500 mg/l, silicon in the form of silica particles with an average particle size of less than 1 ⁇ m: 10 to 1000 mg/
• An acetic acid/acetate buffer is particularly suitable as the buffer system for the stated pH range.
• a further suitable buffer system is based on potassium hydrogen phthalate.
• the aqueous solution contains a quantity of fluoro complex such that the concentration of the metal M is in the range from 1 to 5000 mg/l, preferably in the range from 5 to 1000 mg/l and in particular in the range from 10 to 500 mg/l.
• Zirconium and/or titanium is particularly preferred as the metal M.
• the element M is selected from the group Si, Ti, Zr and Hf, and in that the aqueous solution contains on average at least 1, preferably at least 3, in particular at least five fluoride ions per ion of the element M.
• the statement “on average” means the calculated atom ratio of fluoride ions to M ions in the aqueous solution.
• the aqueous solution can also contain more fluoride ions than is required for the complete formation of hexafluoro complexes.
• fluoride ions are present in the fluoro complex and that the excess fluoride ions are present as so-called “free fluoride”. They can be in the form of, for example HF and/or water-soluble salts thereof.
• six fluoride ions per ion of the metal M (M selected from Si, Ti, Zr, Hf) are present in the fluoro complex, and the aqueous solution still contains 1 to 1000 mg/l of fluoride ions which are not attached to the metal M, which is desirably zirconium.
• the aqueous solution contains at least 0.1 mg/l, preferably at least 1 mg/l and particularly at least 10 mg/l of nitrate ions.
• the upper limit of the nitrate concentration is chosen more from economic than technical grounds, the economic grounds also including the costs of the waste water disposal.
• the upper limit of the nitrate ion concentration can be chosen, for example as 5000 mg/l, preferably 3000 mg/l and particularly 1000 mg/l.
• the aqueous solution can contain copper ions and/or silver ions as additional components according to feature b). They can be present instead of the nitrate ions or be together with them.
• the aqueous solution preferably contains 0.1 to 300 mg/l, particularly 1 to 30 mg/l of copper ions and/or silver ions.
• the aqueous solution contains at least one aromatic carboxylic acid, as defined above, or derivatives thereof.
• Salicylic acid is particularly preferred.
• the aromatic carboxylic acid can be present together with the nitrate ions and/or the copper ions and/or the silver ions. It is preferably present in a concentration of at feast 0.1 mg/l, preferably at least 1 mg/l and particularly at least 10 mg/l.
• the upper limit of the concentration is again more conditional on economics than on technical concerns.
• the upper concentration level of the aromatic carboxylic acid can be 1000 mg/l, preferably 500 mg/l and especially 400 mg/l.
• the aqueous treatment solution contains a buffer system for the pH range 2.5 to 5.5, as already described.
• aqueous treatment solutions contain at least one of the components described above in more detail: nitrate ions, copper ions and/or silver ions, aromatic carboxylic acids, silica particles with an average particle size of below 1 ⁇ m and/or a buffer system for the pH range 2.5 to 5.5. Two or more of these components can also be present together. The presence of further components in addition to the preferred stated five can have a favorable effect on anticorrosion and paint adhesion.
• one or more of the following components can be present: vanadium- or vanadate ions, cobalt ions, nickel ions, manganese ions, tin ions, bismuth ions, magnesium ions and zinc ions.
• vanadium- or vanadate ions cobalt ions
• nickel ions nickel ions
• manganese ions tin ions
• bismuth ions magnesium ions
• zinc ions zinc ions
• a treatment solution which in addition to one of the five stated preferred components (nitrate ions, copper ions and/or silver ions, aromatic carboxylic acids, silica particles, buffer system), contains both zinc ions as well as magnesium ions, is particularly preferred.
• the aqueous treatment solution can additionally contain aluminum ions. They can be introduced in the form of soluble salts, for example in the form of the nitrates.
• the aqueous treatment solution preferably contains 1 to 1000 mg/l, especially 10 to 500 mg/l of aluminum ions.
• Aluminum ions can serve as “complexers” for excess free fluoride ions, as with these they form stable fluoro complexes. Free fluoride ions are produced in the aqueous treatment solution because the metal M, for example zirconium, precipitates out, probably in the form of oxides, onto the treated metal surface. In this way, the fluoride ions that were originally attached to the metal M are released.
• the increased pickling effect of the aqueous solution caused by free fluoride ions can be reduced by the presence of the aluminum ions owing to the complex formation.
• the aqueous treatment solution can contain compounds that are employed in layer forming phosphatization as so-called “accelerators”.
• These accelerators have the property of capturing hydrogen atoms that are produced by the pickling attack of the acids on the metal surface. This reaction, also known as “depolarization”, facilitates the attack of the acidic treatment solution on the metal surface and thereby accelerates the formation of the anticorrosion layer.
• Accelerators which are listed in the previously stated document DE-A-199 33 189, can be employed, for example:
• the present invention also includes a process variant, in which after having been brought into contact with the aqueous solution of a fluoro complex and before being coated with the cathodically depositable electro-dipcoating, the metal surface is rinsed with an aqueous solution that contains one or more components selected from among compounds or salts of the elements cobalt, nickel, tin, copper, titanium and zirconium and/or from among water-soluble or water-dispersible organic polymers.
• a second aspect of the present invention rests on the provision of an acidic, chromium-free aqueous solution of a fluoro complex of at least one element M selected from among the group B, Si, Ti, Zr and Hf with a pH in the range from 2 to 5.5 for the treatment of metal surfaces, wherein it additionally contains one or more components selected from among: tin ions, bismuth ions, buffer system for the pH range from 2.5 to 5.51 aromatic carboxylic acids with at least two groups containing donor atoms, or derivatives of such carboxylic acids.
• the treatment solution can contain aromatic carboxylic acids as one of the previously stated components, which have at least two groups containing donor atoms in the molecule.
• Donor atoms are those atoms that carry free electron pairs, by which they can coordinate to transition metal ions. Typical donor atoms are oxygen, nitrogen and sulfur atoms.
• the carboxylic group of the aromatic carboxylic acid is therefore itself already a group that contains donor atoms.
• An aromatic carboxylic acid with at least two carboxylic groups in the molecule therefore falls under the stated definition.
• Those aromatic carboxylic acids, which carry, for example at least one hydroxyl group, at least one amino group or at least one nitro group in addition to the carboxylic group also fall under the definition. Examples of these carboxylic acids are the various positional isomers of benzene dicarboxylic acid, especially phthalic acid, or the various positional isomers of hydroxy-, amino- or nitro-benzoic acid.
• aromatic carboxylic acids are preferred, in which at least two groups containing donor atoms are disposed in such a way that through the donor atoms, 5-, 6- or 7-membered chelate complexes can be formed with transition metal ions.
• Particularly preferred aromatic carboxylic acids are therefore: phthalic acid, salicylic acid, o-aminobenzoic acid or o-nitrobenzoic acid.
• aromatic carboxylic acids containing only a single benzene ring the corresponding acids with condensed ring systems can also be used, for example the acids derived from naphthalene or anthracene.
• Derivatives of the stated carboxylic acids can also be employed. Among these are meant those molecules, in which one or more hydrogen atoms of the basic structure (e.g. hydrogen atoms on the aromatic core, hydrogen atoms of the hydroxyl or amino groups or hydrogen atoms of the carboxyl groups) are replaced by other atoms or groups of atoms.
• one or more hydrogen atoms of the basic structure e.g. hydrogen atoms on the aromatic core, hydrogen atoms of the hydroxyl or amino groups or hydrogen atoms of the carboxyl groups
• aqueous solution is added, which on toxicological grounds, is essentially free of chromium (VI) compounds and preferably contains no chromium compounds of any kind. Traces of chromium compounds, which can arrive in the treatment solution by being leached out of stainless steel containers, are not considered to render the solution “chromate-containing”.
• treatment solutions containing no more than 1 ppm, particularly no more than 0.1 ppm chromium, are understood as “chromium free”.
• the treatment solutions according to the invention do not represent phosphatization solutions, i.e. they do not lead to the formation of an amorphous or crystalline phosphate layer.
• the treatment solutions preferably contain no more than 1 g/l inorganic phosphate or phosphoric acid, calculated as PO 4 3 ⁇ .
• phosphate contents in the range of 10 to 500 mg/l, for example, can be tolerated and can even improve the action of the treatment solution.
• the pH of the acidic treatment solution is preferably in the range 2 to 5.5, particularly 3.5 to 5.
• the pH is preferably adjusted to the stated acidic range by adding the fluoro complex at least partially in the form of an acid. However, it can also be adjusted by means of another acid, for example nitric acid.
• the one or more essential components are preferably present in the following concentrations:
• tin ions 1 to 2000 mg/l, preferably 5 to 500 mg/l
• bismuth ions 1 to 2000, preferably 5 to 500 mg/l
• buffer system for the pH range 2.5 to 5.5 in sufficient quantity that the pH of the solution does not change by more than 0.2 units when a 1 N acid or base per liter solution is added
• aromatic carboxylic acids 0.1 to 1000, preferably 1 to 500 mg/l.
• this aqueous solution can contain one or more of the following components:
• nitrate ions 0.1 to 5000 mg/l, preferably 1 to 1000 mg/l, copper-, cobalt-, nickel- and/or silver ions: each 0.1 to 300 mg/l, preferably 1 to 30 mg/l, vanadium- or vanadate ions: 1 to 2000, preferably 5 to 500 mg/l (calculated as vanadium), magnesium ions: 1 to 2000, preferably 5 to 500 mg/l, manganese ions: 1 to 2000 mg/l, preferably 5 to 500 mg/l, zinc ions: 1 to 2000, preferably 5 to 500 mg/l,
• the aqueous solution contains both zinc ions as well as magnesium ions in addition to at least one of the stated essential components (tin ions, bismuth ions, buffer system for the pH range 2.5 to 5.5, aromatic carboxylic acids or derivatives thereof). Moreover, the presence of copper ions and/or silver ions is preferred.
• An acetic acid/acetate buffer is particularly suitable as the buffer system for the stated pH range.
• a further suitable buffer system is based on potassium hydrogen phthalate.
• the aqueous solution contains a quantity of fluoro complex such that the concentration of the metal M is in the range from 1 to 5000 mg/l, preferably in the range from 5 to 1000 mg/l and in particular in the range from 10 to 500 mg/l.
• Zirconium and/or titanium is particularly preferred as the metal M.
• the element M is selected from the group Si, Ti, Zr and Hf, and in that the aqueous solution contains on average at least 1, preferably at least 3, in particular at least five fluoride ions per ion of the element M.
• the statement “on average” means the calculated atom ratio of fluoride ions to M ions in the aqueous solution.
• the aqueous solution can also contain more fluoride ions than is required for the complete formation of hexafluoro complexes.
• fluoride ions per M ion are present in the fluoro complex and that the excess fluoride ions are present as so-called “free fluoride”. They can be in the form of, for example HF and/or water-soluble salts thereof.
• six fluoride ions per ion of the metal M (M selected from Si, Ti, Zr, HD are present in the fluoro complex, and the aqueous solution still contains 1 to 1000 mg/l of fluoride ions which are not attached to the metal “M”, which is desirably zirconium.
• the aqueous solution contains at least one aromatic carboxylic acid, preferably salicylic acid, or derivatives thereof.
• This can be present together with the bismuth ions and/or the buffer system. It is preferably present in a concentration of at least 0.1 mg/l, preferably at least 1 mg/l and particularly at least 10 mg/l.
• the upper limit of the concentration is again more conditional on economics than on technical concerns.
• the upper concentration level of the aromatic hydroxycarboxylic acid can be selected as 1000 mg/l, preferably 500 mg/l and especially 400 mg/l.
• the aqueous treatment solution contains a buffer system for the pH range 2.5 to 5.5, as already described.
• the aqueous treatment solution can additionally contain aluminum ions. They can be introduced in the form of soluble salts, for example in the form of the nitrates.
• the aqueous treatment solution preferably contains 1 to 1000 mg/l, especially 10 to 500 mg/l of aluminum ions.
• Aluminum ions can serve as “complexers” for excess free fluoride ions, as with these they form stable fluoro complexes. Free fluoride ions are produced in the aqueous treatment solution because the metal M, for example zirconium, precipitates out, probably in the form of oxides, onto the treated metal surface. In this way, the fluoride ions that were originally attached to the metal M are released.
• the increased pickling effect of the aqueous solution caused by free fluoride ions can be reduced by the presence of the aluminum ions owing to the complex formation.
• the aqueous treatment solution can contain compounds that are employed in layer forming phosphatization as so-called “accelerators”.
• accelerators have the property of capturing hydrogen atoms that are produced by the pickling attack of the acids on the metal surface. This reaction, also known as “depolarization”, facilitates the attack of the acidic treatment solution on the metal surface and thereby accelerates the formation of the anticorrosion layer.
• Accelerators can be employed, for example, which are listed in the previously stated document DE-A-1 99 33 189:
• the treatment solution can contain polymers with known positive activity in anticorrosion treatment.
• polymers with known positive activity in anticorrosion treatment examples are:
• aqueous solution contains no more than 1 mg/l of organic polymer.
• the aqueous solution additionally contains 10 to 1000 mg/l, preferably 50 to 500 mg/l of silicon in the form of silica particles with an average particle size of less than 1 ⁇ m.
• the stated silica particles with an average particle size of less than 1 ⁇ m are known under various generic names to the person skilled in the art. They are called, for example, colloidal silica, precipitated silica or pyrogenic silica.
• the average particle size which is preferably in the range of about 0.01 ⁇ m to about 1 ⁇ m, can be determined by light scattering methods or by electron microscopy.
• the treatment solution can be manufactured at the place of use by dissolving the stated components in water and adjusting the pH.
• aqueous concentrates are usually provided to the place of use, diluted with water and the pH optionally adjusted to produce the ready-for-use treatment solution.
• an aqueous concentrate belongs to the second aspect of the invention, which on dilution with water by a factor of about 10 to about 100, particularly by a factor of about 20 to about 50 and optionally adjusted in pH, results in an acidic, chromium-free, aqueous solution of fluoro complexes according to the previous description.
• the concentrates can contain polymers with thickening and/or dispersing properties.
• polymers with thickening and/or dispersing properties are polymers or copolymers of unsaturated carboxylic acids, carbohydrates or proteins. They can be present in a concentration of up to 50 g/l.
• a downwards adjustment is made by adding an acid, wherein either the acid form of the fluoro complex of the metal M or nitric acid is suitable.
• An upwards adjustment of pH can be effected with any basic substance, for example with a solution of alkali metal hydroxides or -carbonates, ammonia or organic amines.
• basic compounds or salts for example metal oxides, -hydroxides or -carbonates, which represent the possible active components in the treatment solution, can also be added to increase the pH.
• magnesium or zinc oxides, -hydroxides or -carbonates can be used here.
• a process for the anticorrosion treatment of bright metal surfaces further belongs to the second aspect of the present invention, wherein the metal surface is contacted with a previously described aqueous solution according to the second aspect of the invention.
• the metal surface is then rinsed with an aqueous solution that contains one or more components selected from compounds or salts of the elements cobalt, nickel, tin, copper, titanium and zirconium and/or from water-soluble or water-dispersible organic polymers.
• the bright metal surface is contacted with the acidic, aqueous solution of a fluoro complex for a period of 0.5 to 10 minutes, preferably for 1 to 5 minutes.
• This can be carried out by dipping into the treatment solution or by spraying the treatment solution.
• the temperature of the aqueous solution of a fluoro complex is preferably in the range 15 to 60° C., especially in the range of 25 to 50° C.
• rinsing is preferably carried out with water, especially fully deionized water. After this, the previously described final rinse can optionally follow. In this case, another rinse is subsequently made with water.
• the treated metal surfaces are transferred without drying into a bath for the cathodic electro-dipcoating.
• Table 2 recites the bath composition for the pre-treatment in the process cycle according to Table 1 with drying after pre-treatment, and corrosion results.
• climate change test was according to VDA 621-415: average corrosion after 70 days in mm, and stone impact damage after 70 days, scale from 0.5 to 5 according to DIN 55996-1 (the smaller the better).
• Examples 1 and 2 prove the favorable effect of an addition of salicylic acid, when the pre-treatment layer is dried (second aspect of the invention).
• an addition of citric acid (Comparative Example 2) has a rather negative result.
• Table 3 recites the bath composition for the pre-treatment in the process cycle according to Table 1 without drying after pre-treatment (“wet on wet”), and corrosion results.
• climate change test was according to VDA 621-415: average corrosion after 35 days in mm.
• Example 3 proves the favorable effect of an addition of nitrate and silica, when the pre-treatment layer is not dried (first aspect of the invention).
• a new test solution was used in the procedure according to Table 1 to compare panels that were dried after pretreatment to those coated wet on wet.
• the following treatment solution was employed for the pre-treatment (treatment time: 5 min.), wherein panels for (Comparative Example 4) were dried after pre-treatment and panels (Example 4) were not dried after the pre-treatment and prior to dipcoating: 150 mg/l Zr, 400 mg/l nitrate (added as nitric acid), 200 mg/l Si (added as colloidal silica), pH 3.8.
• the so pretreated panels were subjected to a climate change test according to VDA 621-415: average corrosion after 70 days in mm is shown in Table 4.
• Example 4 shows that in the presence of nitrate and silica, better results are obtained without drying than with drying (first aspect of the invention).
• Table 5 recites the bath composition for the pre-treatment in the process cycle according to Table 1 without drying (“wet on wet”), after pre-treatment and corrosion results.
• climate change test was according to VDA 621-415: average corrosion after 70 days in mm, and stone impact damage after 70 days, scale from 0.5 to 5 according to DIN 55996-1 (the smaller the better).
• Example 5 proves that the addition of 20 mg/l of copper (as Cu(NO) 3 ) to the conversion bath in the “wet on wet” process yields significantly better infiltration values in the climate change test.
• Table 6 recites the bath composition for the pre-treatment in the process cycle according to Table 1 without drying (“wet on wet”), after pre-treatment and corrosion results.
• climate change test was according to VDA 621-415: average corrosion after 70 days in mm, and stone impact damage after 70 days, scale from 0.5 to 5 according to DIN 55996-1 (the smaller the better).
• Examples 7 and 8 in comparison show that the addition of the accelerator nitroguanidine (50 mg/l) to the conversion bath resulted in a further improvement in the climate change test in regard to the corrosive paint infiltration and also significantly smaller K-values in the stone impact damage test.

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