Process Instruction

Gardobond® G 4098/10
Nickelfree-phosphating process for iron materials to reduce sliding friction.
Application by immersion.

Scope
Gardobond G 4098/10 is a phosphating process for iron materials on the basis of
manganese phosphate. The Gardobond G 4098/10 process is applied by immersion.
The phosphate coatings generated improve the wear resistance of moving parts. The
weight of the manganese phosphate coatings amounts to 5 - 25 g/m². The phosphate
coatings generated with Gardobond G 4098/10 correspond to the specification DIN EN
12476, code Fe/Mnph g f. During storage of the Gardobond G 4098/10 concentrate, a
small amount of brown solids may settle at the bottom of the tank. This does not affect the
quality of the product.

Chemicals required

Gardobond G 4098/10 (make-up and replenishment solution)

Gardobond Additive H 7050 (accelerator)
Gardobond Additive H 7203 (neutralisation agent, manganese containing)

Operation procedure

Cleaning - rinsing - pickling (if necessary) - rinsing (if the parts are pickled) - activating -
phosphating - rinsing - rinsing - drying.

Pre-treatment

Prior to phosphating remove all contaminants from the part surface.

Cleaning and degreasing

Cleaning and degreasing can be done with alkaline cleaners.
Alkaline cleaners are supplied by us under the designation Gardoclean.

Rinsing
Carefully rinse with water after cleaning with alkaline cleaners.
CHEMETALL GMBH Trakehner Straße 3  registered trademark
D-60487 Frankfurt a. M. The above data have been compiled to the best of our knowledge on the basis of thorough tests and
P. O. Box 90 01 70 with regard to the current state of our long practical experience. No liabilities or guarantee deriving
D-60441 Frankfurt a. M. from or in connection with this leaflet can be imputed to us. - Reproduction, in whole or in part, only
Phone: +49 (69) 7165-0 with our express permission.
Fax: +49 (69) 7165-3018
Surface Treatment Internet: http://www.chemetall.com
 Gardobond G 4098/10

Rinsing after alkaline cleaning

Immersion time: 1 - 2 minutes (repeated immersion)
Bath temperature: without heating
Operate the rinsing bath with fresh water supply.

Activating
Immersion time: 1 - 2 minutes
Bath temperature: room temperature - 50°C with pre-rinsing agent
80 - 90°C without pre-rinsing agent
For more detailed information, see the process instructions "Activating pre-rinse prior to
phosphating on the basis of manganese phosphate with Gardolene V 6560 A +
Gardolene V 6561 B or Gardolene V 6560 A + Gardolene V 6562 C".

Bath make-up

For 1000 litres of phosphating bath add

146 l (190 kg) of Gardobond G 4098/10.
This bath make-up corresponds to a concentration of 80 total acid points and approx. 14
free acid points.

Bath operation

Immersion time: 5 - 20 minutes

Bath temperature: 80 - 95°C
Bath concentration: 80 total acid points
13 - 16 free acid points
The ratio of free acid points : total acid shall be of
1:5 - 1:6

The optimum operating conditions are established by our Technical Service upon start-up
of the line.

Bath control

The bath concentration is controlled by determining the total acid pointage, free acid
pointage and iron pointage.
Determine the total acid pointage and the free acid pointage several times per day. Iron
separates from the bath solution during material throughput. Hence, the iron pointage
should be determined at least once per day.
Prior to sampling, fill the bath tank with water to operating level and thoroughly mix the
solution.

page 2 of 5
 Gardobond G 4098/10

Total acid pointage

Pipette 5 ml of phosphating bath into an Erlenmeyer flask. Dilute the solution with approx.
50 ml of distilled water and add 10 - 15 drops of phenolphthalein indicator. Titrate with
0.1 N sodium hydroxide testing solution until the colour changes to red. The ml of 0.1 N
sodium hydroxide consumed multiplied by 2 indicates the total acid pointage.
Free acid pointage
Pipette 5 ml of phosphating bath into an Erlenmeyer flask. Dilute the solution with approx.
50 ml of distilled water and add 5 drops of bromophenol blue indicator. Titrate with
0.1 N sodium hydroxide until the colour changes from yellow-green to blue-grey. The ml of
0.1 N sodium hydroxide consumed multiplied by 2 indicates the free acid pointage.
Iron pointage
Pipette 10 ml of phosphating bath into an Erlenmeyer flask. Dilute the solution with
approx. 100 ml of distilled water and add 5 ml of 50% sulfuric acid and 2 g of urea. Titrate
with 0.1 N potassium permanganate testing solution until the faint red colouring persists
for approx. 20 seconds. The ml of 0.1 N potassium permanganate consumed indicates the
iron pointage.
Iron points x factor 0.56 = g iron(II)/litre bath solution
Max. value: 7 - 9 iron points (4 - 5 g of iron(II) per litre of bath solution)
Roughness

When a lower surface roughness after phosphating is required, we recommend the use of
our additive Gardobond Additive H 7050. With the addition of 5 g/L to the phosphate
bath, the pickling time and therefore the surface roughness will be considerably reduced.
When the pickling rate decreases, the Gardobond Additive H 7050 can be added again
as described above.

Bath replenishment

Total acid pointage

The total acid pointage are maintained by adding Gardobond G 4098/10.
For each total acid point consumed add per 1000 litres of phosphating bath
1.8 l (2.4 kg) of Gardobond G 4098/10.

Free acid pointage

With a total of 80 total acid points, the free acid points should be of 13 - 16. If the free acid
points exceeds 16, add Gardobond Additive H 7203. To reduce the acid pointage by 1
free acid point add per 1000 litres of phosphating bath 650 g of Gardobond Additive
H 7203, suspended in 10 times the amount of water.

page 3 of 5
 Gardobond G 4098/10

Iron content
The iron(II) content can be kept constant by adding finely-effervescent, oil-free
compressed air or by using a ventilation stirrer.
After iron precipitation it may be necessary to desludge the solution. Prior to further
treatment, titrate the total acid pointage and free acid pointage and replenish to nominal
value or neutralize with Gardobond Additive H 7203.
The optimum operating conditions can be determined in co-operation with our Technical
Service.

De-sludging

The sludge accumulated due to phosphating or iron precipitation must be periodically

removed. This is done in a settling tank or a suitable filtering equipment. The bath solution
above the sludge can also be pumped into an empty rinsing tank.
After returning the clear solution to the bath tank, fill the latter with water to operating level
and thoroughly mix the solution. Determine the total acid pointage and the free acid
pointage and replenish with Gardobond G 4098/10 to nominal value.

Rinsing

After phosphating, carefully rinse with water.

1st rinsing bath

Immersion time: 1 - 2 minutes (repeated immersion)
Bath temperature: without heating
Operate the 1st rinsing bath with fresh water supply.

2nd rinsing bath

Immersion time: 1 - 2 minutes
Bath temperature: 80 - 90°C
Discard the water from the 2nd rinsing bath from time to time.

Drying

After draining, quick and thorough drying of the parts is required. We recommend driers
with air circulation and fresh air supply.
Part temperature: 110 - 150°C

page 4 of 5
 Gardobond G 4098/10

Post-treatment

Protect the phosphated parts by lubricating or greasing within 24 hours after phosphating.
Gardorol corrosion protection oils are supplied by us.

Equipment

Gardobond G 4098/10 bath

Bath tank
General-purpose constructional steels to DIN EN 10025, with acid-proof rubber lining
Chromium nickel steel, material number 1.4541
Chromium nickel molybdenum steel, material number 1.4541
Butyl rubber

Heating elements
Chromium nickel molybdenum steel, material number 1.4571
Fluorinated plastics

Rinsing baths

Bath tank and heating elements

General-purpose constructional steels to DIN EN 10025
If pickling is required, the rinsing bath downstream of the pickling stage must be acid proof,
e.g. made of general-purpose constructional steels to DIN EN 10025 with acid-proof
rubber lining.

Labour and environmental prote ction

For transport, storage, use and waste treatment of chemicals in concentrated or diluted
form as well as bath solutions, the appropriate local legislation must be followed.
Further specific information on the products can to be obtained from the EC Safety Data
Sheets. For the used solutions the hazard code on the label should to be followed.

Waste disposal

All effluent discharge must be treated in accordance with national legislation and local
regulations prior to discharge to the sewer.

SCDE 12 / 15 - 2

page 5 of 5