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Technical Process Bulletin

BONDERITE 958*
BONDERITE 958*
Polycrystalline Conversion Coating Process
complete

Technical Process Bulletin

Technical Process Bulletin No. 234540
This Revision: 06/14/2006
BONDERITE 958*
Polycrystalline Conversion Coating Process
1.

Introduction:

BONDERITE 958 is formulated for immersion application to steel, galvanized

steel, electrogalvanized steel, zinc-alloy coated steel, and aluminum. The
metals may be treated individually or in mixed production.
The BONDERITE 958 process converts the metal surface to nonmetallic,
polycrystalline coating containing iron, manganese, nickel and zinc
phosphates. This coating provides high alkaline resistance and is
preferred as a paint base offering superior adhesion and durability.
addition, the coating also provides:

In

A.
B.
C.

A clean, grease-free surface

A nonconducting bond between the base metal and the paint
A chemically inert surface which prevents reaction between the metal
surface and the paint ingredients.

2.

Operating Summary:

Chemical:

Bath Preparation per 100 Gallons:

BONDERITE 958 Makeup

BONDERITE 958 Replenishing**
Additive 319
Primer 40
Additive 301
Additive 302
Primer 40
Accelerator 131
Accelerator 130 solution

23.4 pounds (2.24 gallons)

17 pounds (1.5 gallons)
3.7 pounds (0.3 gallon)
11.1 pounds (1.1 gallons)
3.1 pounds (.24 gallon)
2.7 pounds (.26 gallon)
4 pounds (0.4 gallon)
4 fluid ounces, or
8 fluid ounces

**May be replaced with BONDERITE 958 Replenishing C 15 pounds (1.2 gallon)

Operation and Control:

3.

Total Acid

18 to 26 points (ml)

Free Acid

0.6 to 1 point (ml)

Accelerator

2.0 to 3.5 points (ml)

Time

2 to 5 minutes

Temperature

115 5 Fahrenheit

NOTICE: This product is especially made for use under one or both of
U.S. Patents 4,838,957 and 4,961,794.
The Process:

The complete process for the BONDERITE 958 treatment normally consists of
the following steps:
A.
B.
C.
D.
E.
F.
G.
H.

Cleaning
Water rinsing
Surface conditioning
Treating with the BONDERITE 958 processing solution
Water rinsing
Treating with a post-treatment solution
Deionized water rinsing
Drying (optional)

4.

Materials:

Accelerator 130
Accelerator 131
Additive 301
Additive 302
Additive 319
BONDERITE 958 Makeup
BONDERITE 958 Replenishing
BONDERITE 958 Replenishing C (Optional)
FIXODINE (Conditioning agent)
PARCO CLEANER
PARCOLENE (Post treatment)
Primer 40

Testing Reagents and Apparatus

Accelerators 130 and 131 are the same base chemical; however, Accelerator
131 is a concentrated water solution while Accelerator 130 must be
dissolved in water (2 lb. per gal., U.S., of water makes a convenient 20%
solution).
5.

Equipment:

Process tanks and housings may be fabricated from mild steel plate,
however, equipment life will be greatly extended by using a 300 series
alloy stainless steel, such as 304 or 316. The 316L being preferred for
maximum tank life.
Process piping and pumps should likewise be constructed of 316 or 304
stainless steel alloys. Various formulations of plastic pipe may be used
with recommended support spacing, schedule 80 being generally 140
Fahrenheit. CPVC and PB may be used up to a maximum process temperature of
190 Fahrenheit. PVDF may be used for all expected temperature ranges and
may reduce the rate of scale buildup in process piping.
Heat exchanger plates should be polished 316 stainless steel. If gas fired
burner tubes are used, they should be made of schedule 80 mild steel pipe
or equivalent. All process circulation pump seals, valve seats, door
seals, etc., which come into contact with the process solution and
occasional acid equipment cleaners, should be EDPM, Viton or Teflon.
Note that while Hypalon is compatible with the process solution, it is not
compatible with acid equipment cleaners which may be used.
Chemical feed pump parts and other elastomers which may come into contact
with the concentrated replenishing chemical should be EDPM, Hypalon, Viton
or Teflon.
Support equipment available from Henkel Surface Technologies for this
process includes: chemical feed pumps, level controls, transfer pumps and
bulk storage tanks.
Our sales representative should be consulted for information on Henkel
Surface Technologies automatic process control equipment for this process
and any additional questions. In addition, the Henkel Surface
Technologies Equipment Design Manual may be consulted.
6.

Surface Preparation:

Cleaning:
All metal to be treated with the processing solution must be free from
grease, oil and other foreign matter before the treatment. A complete line
of cleaners is available and our representative will recommend the proper
one for each installation.
Surface Conditioning:
A FIXODINE conditioning pretreatment, is required in the process to obtain
the proper crystal structure. Our representative can recommend the best
method for its use.
7.

Treating with the BONDERITE 958 Processing Solution:

Buildup:
Fill the tank abut three-fourths full with cold water.

NOTE:

The buildup must be completed before heat is applied to the bath.

For each 100 gal. of working solution volume, add:

23.4 pounds (2.24 gallons) of BONDERITE 958 Makeup
17 pounds (1.5 gallons) of BONDERITE 958 Replenishing**
3.7 pounds (0.3 gallon) of Additive 319
*11.1 pounds (1.1 gallons) of Primer 40
3.1 pounds (0.24 gallon) of Additive 301
*4 pounds (0.4 gallon) of Primer 40
2.7 pounds (0.26 gallon) of Additive 302
*4 pounds (0.4 gallon) of Primer 40
*The addition of Primer 40 must be in the three incremental additions shown
on each increment must be added slowly to the bath. The bath should be
allowed to mix completely after each addition. Add sufficient water to
bring the solution up to the working level and then heat to the operating
temperature.
**may be replaced with 15 pounds (1.2 gallons) of BONDERITE 958
Replenishing C.
The following alternative method which will reduce the amount of sludge
generated during initial build-up is recommended for locations with a
processing tank made of mild steel. For each 100 gallons of working
solution, add 15.1 pounds (1.5 gallons) of Primer 40. Follow with the slow
addition of the other materials in the other listed. Add sufficient water
to bring the solution to the working level. When all these additions have
been made, check the free acid of the bath and use the remaining Primer 40
to adjust the free acid to the operating value. Then heat to the operating
temperature.
The solution is ready for use on zinc coated and aluminum surfaces. When
treating steel articles (either alone or mixed with galvanized or
aluminum), Accelerator must be added. Immediately before processing any
work, add 2 oz. of Accelerator 131 or 4 oz. of Accelerator 130 solution per
100 gal. of working volume and mix thoroughly. The treatment of
significant amounts of aluminum will require the addition of an additive.
Our representative can recommend the proper additive and the best method
for its use.
Operation:
Time:
Temperature:

2 to 5 minutes
110 to 120 Fahrenheit

8. Testing and Control:

Never piper by mouth, use a pipet filler.
Total Acid:
Pipet a 10 ml sample into a 150-ml beaker. Add 5 drops of Indicator 3.
Titrate with Titrating Solution 11 to the development of a permanent, faint
pink color. The ml of Titrating Solution 11 used is the total acid value
in points.
Total acid range: 18 to 26 points (ml).
To increase value
(0.17 gallon) per
or:
To increase value
(0.10 gallon) per

1.0 point using BONDERITE 958 Replenishing:

100 gallons.
1.0 point using BONDERITE 958 Replenishing C:
100 gallons.

1.9 pounds

1.4 pounds

Replenishing is best accomplished by adding the chemical continuously with

a metering pump into a turbulent area of the tank. Adjust he metering rate
to hold the total acid value within the specified range.
Mechanical Loss:
Replace any drop in points due to a mechanical loss of solution (sludge
cleanout, leaks, etc.) by adding the chemicals used for buildup in the same
proportions as specified for buildup.
Free Acid:
Pipet a 10 ml sample into a 150-ml beaker. Add 5 drops of Indicator 11.
Titrate with Titrating Solution 11 until the yellow color just changes to
bluish-green by daylight or fluorscent light, or to blue-violet by
incandescent light. The ml of Titrating Solution 11 used is the free acid
value in points.
Free acid range:

0.6 to 1.0 points (ml).

To increase value
(0.09 gallon) per
or:
To increase value
(0.05 gallon) per

0.1 point using BONDERITE 958 Replenishing:

100 gallons.
0.1 point using BONDERITE 958 Replenishing C:
100 gallons.

To decrease the Free Acid value by 0.1 point:

(2.1 fluid ounces) per 100 gallons.

1.0 pound

0.65 pound

0.17 pounds of Primer 40

Excessive use of Accelerator 130 solution or 131 chemical can cause low
free acid value. Should this occur, maintain the free acid value above the
minimum level even if this results in a total acid above the recommended
range.
Avoid heating the solution above the recommended range or for extended
periods with little or no metal being treated. These conditions, along
with excessively large replenishing chemical additions, are the main causes
of high free acid value.
Accelerator:
When steel is processed, either alone or with zinc or aluminum, add
Accelerator and control its concentration properly. If steel is not
processed and no Accelerator is used, this test may, of course, be omitted.
Partially fill the Saccharometer with processing solution. Tip the
Saccharometer to dispel all entrapped air in the closed end and to permit
the solution to completely fill the closed end of the tube. Hold the tube
upright and completely fill with processing solution. Approximately 75 ml
of processing solution will be required.
Add approximately 2 grams (1/2 teaspoonful) of Reagent 137 into the
Saccharometer tube. Stopper the tube opening and invert so that Reagent
137 flows into the closed end. These procedure steps should be done as
rapidly as possible to obtain accurate reproducible results.
Place the Saccharometer upright on a Table top and remove the stopper.
After a minimum of three minutes or when the evolution of gas ceases,
record the milliliters of gas trapped in the closed end of the tube. This
measurement is the accelerator value in points.
Accelerator range:

2.0 to 3.5 points (ml).

To increase value 1.0 point: 2 fl. oz. of Accelerator 131 or 4 fl. oz. of
Accelerator 130 Solution per 100 gal.
Replenishing is best accomplished by adding the chemical continuously with
a metering pump near the spray pump intake or into a turbulent area of the
tank as far removed as practical from the addition point for the BONDERITE
chemical.
9.

After Treatment:

Water Rinsing:
After BONDERIZING, the metal should be thoroughly sprayed with cold water.
The rinse should be overflowed at a rate sufficient to prevent excessive
accumulation of processing solution.
Post Treatment:
The BONDERIZED metal, wet from the water rinse, is treated with a dilute
post treatment solution. This treatment materially increases the corrosion
resistance of the coating and is an essential part of the process. A
number of post treatment chemicals are available and the proper one for
each installation will be recommended.
Deionized Water Rinse:
After the post treatment, the treated metal must be thoroughly rinsed with
deionized water. Use of deionized water is essential to prevent
contamination of the solution in the electropaint tank. The design of the
equipment is important to obtaining the desired result with a minimum
amount of deionized water. Our representative should be consulted.
10.

Storage Requirements:

Additive 301 Chemical may freeze if stored below 25 Fahrenheit. The

remaining chemicals can freeze if stored for prolonged periods of time at
or below 0 Fahrenheit. Freezing is not detrimental and if frozen, thaw in
a warm place and stir thoroughly before using. It is recommended that the
chemicals be stored where temperatures will not reach the freezing point.
11.

General Maintenance:

In the operation of the process, some insoluble residue, normally referred

to as sludge, is formed as a by-product of the chemical reaction. This
material settles to the bottom of the tank and should be removed regularly
before its presence causes dusty coatings or interferes with the operation
of the spraying system. An excellent method of removal is an arrangement
whereby a portion of the solution and sludge is pumped into a settling tank
from which the settled sludge may be periodically discharged into
containers, preferably after the solution is returned to the processing
tank. The pump (for desludging) should preferably be made from stainless
steel, but mild steel may be used with a somewhat shorter life. Another
satisfactory method is to transfer the solution to a rinse tank, leaving as
much sludge as possible in the bottom of the processing tank. The sludge
may then be removed by any convenient means.
When the solution has been heated for some time, scale will foam on the
heating unit and must be removed at intervals so that adequate heat
transfer will occur and the proper processing temperature will be
maintained. To remove the scale, dry the heat transfer surface either by
removing it from the solution of by pumping the solution from the tank.
The scale may then be removed by a suitable chemical or mechanical method.

12.

Waste Disposal Information:

Applicable regulation covering disposal and discharge of chemicals should

be consulted and followed.
Disposal information for chemical products used in this process is given on
the Material Safety Data Sheet for each product.
The processing bath is acidic and contains phosphate, fluoride, nitrate and
heavy metals. Waste treatment and neutralization may be required prior to
discharge to the sewer. (Refer to Waste Treatment Information Bulletin
WT1005, available on request).
The processing bath and sludge can contain ingredients other than those
present in the chemical as supplied and analysis of the solution and/or
sludge may be required prior to disposal.
13.

Precautionary Information:

When handling the chemical products used in this process, the first aid and
handling recommendations on the Material Safety Data Sheet for each product
should be read, understood and followed.
The processing bath is acidic and may cause irritation of the skin and
eyes. The bath contains nickel which can cause sensitization or allergic
skin reactions which may be accentuated by heat and humidity. Do not get
in eyes, on skin or on clothing. Refer to the Material Safety Data Sheet
for appropriate protective clothing. In case of contact, follow the
recommendations on the Material Safety Data Sheet for BONDERITE 958 Makeup.

Testing Reagents and Apparatus

(Order only those items which are not already on hand)
Code

Quantity

Item

205500 ......... 1 ............ Acid Dropping Bottle

592462 ......... 4*............ Beaker, 150-ml
592477 ......... 1 ............ Buret Assembly, 25-ml Automatic
592398 ......... 1 qt ......... Indicator 3 (Phenolphthalein)
592402 ......... 1 qt ......... Indicator 11 (Bromphenol blue)
592475 ......... 2 ............ Indicator Dropping Bottle
592492 ......... 2* ........... Pipet, 10-ml Volumetric
592494 ......... 1 ............ Pipet Filler
592499 ......... 1 ............ Pitcher, Graduated, Plastic
205137 ......... 1 bottle ..... Reagent 137
593826 ......... 2* ........... Saccharometer
594334 ......... 1 ............ Thermometer, Floating
592427 ......... 1 gal ........ Titrating Solution 11 (0.1N NaOH)

*Includes one more than actually required, to allow for possible breakage.

-* * * * * -

Registered trademark of Henkel Corporation.

Henkel Technologies
32100 Stephenson Highway
Madison Heights, MI 48071
Telephone: 248-583-9300
Fax: 248-583-2976

"The information presented herein is our interpretation of certain test results and field experience
to date. This information is not to be taken as warranty or representation for which we assume
legal responsibility, nor as permission or recommendation to practice any patented invention
without a license. It is offered solely for your consideration, investigation and verification."
Henkel Corporation.

Henkel Technologies
32100 Stephenson Highway
Madison Heights, MI 48071
Telephone: 248-583-9300
Fax: 248-583-2976

"The information presented herein is our interpretation of certain test results

and field experience to date. This information is not to be taken as warranty
or representation for which we assume legal responsibility, nor as
permission or recommendation to practice any patented invention without a
license. It is offered solely for your consideration, investigation and
verification." Henkel Corporation.

Revision date: 03/02/1999Print date: 09/18/2006

------------------------------------------------------------------------------------------------------------------------------------------------Verborgene Felder: 10Parker Amchem

Form Revised 04 June 2001