1 Department of Manufacturing Engineering, Technical University of Denmark2 Department of Mechanical Engineering, Technical University of Denmark3 Office for Study Programmes and Student Affairs, Administration, Technical University of Denmark4 Danfoss A/S5 NKT Wireworks A/S6 Hempel A/S
With view to a replacement for chromate passivation, Molyphos was developed under the Danish Materials Programme I (MUP I). In the Danish Materials Programme II(MUP II), the further development of Molyphos a molybdate phosphate conversion coating has been undertaken by application of a sealer to give added protection against white rust formation of zinc coated components. Various coating systems have been investigated: The types of zinc plated coating include acid zinc, cyanide zinc, and Zn/Fe. Many types of sealer have been employed both water and solvent based. The coating systems have been exposed in salt spray tests, humidity tests, prohesion tests and field tests. The results show that a) barrel plated acid zinc specimens coated with Molyphos + sealer give comparable performance to chromate in field tests and b) a Zn/Fe substrate and Molyphos coating (plus selected sealer) gives comparable performance to chromate in the prohesion test. However no combination in the Molyphos system could compare with the performance of yellow chromate in the neutral salt spray test or humidity test, although Molyphos performs very well in the prohesion test. Welding tests have shown that components coated with sealers cause equipment problems during welding.