Pre-Treatment Calculator

Surface preparation is the most critical factor in coating performance, accounting for up to 80% of coating failures when inadequate. Proper preparation ensures optimal adhesion, durability, and appearance.

The process removes contaminants, creates appropriate surface profile, and provides chemically active sites for coating adhesion. Different substrates require specific preparation methods.

Environmental conditions during preparation significantly affect process efficiency and final coating quality. Temperature and humidity must be controlled within specified ranges.

Light contamination includes fingerprints, dust, and minimal handling oils that can be removed with simple cleaning methods.

Moderate contamination involves manufacturing oils, cutting fluids, and light corrosion requiring alkaline cleaning and mild etching.

Heavy contamination includes thick oils, grease, rust, and scale requiring aggressive cleaning and mechanical or chemical removal methods.

Steel substrates require degreasing followed by acid etching or phosphate conversion coating for optimal corrosion protection and adhesion.

Aluminum requires deoxidation and chromate or chromium-free conversion coating to prevent galvanic corrosion and ensure adhesion.

Stainless steel needs special attention to remove passive oxide layers while maintaining corrosion resistance properties.

Basic quality preparation meets general industrial requirements with standard cleaning and etching procedures.

Automotive quality requires enhanced cleaning, precise conversion coating thickness, and strict contamination control.

Aerospace quality demands the highest standards with documented procedures, material traceability, and extensive quality control testing.

Temperature control is critical for chemical reaction rates and solution effectiveness. Low temperatures slow reactions while high temperatures may cause excessive etching.

Humidity affects drying times and can cause flash rusting on steel surfaces. Controlled environments prevent contamination during processing.

Air quality must be maintained to prevent airborne contaminants from redepositing on cleaned surfaces before coating application.

Water break testing verifies complete removal of organic contamination by observing water film continuity on the surface.

Conversion coating weight measurement ensures adequate coating thickness for corrosion protection and paint adhesion.

Surface roughness measurement confirms appropriate profile for mechanical adhesion without excessive texture.

Optimize chemical concentrations and temperatures to minimize processing time while maintaining quality standards.

Implement proper racking and handling procedures to maximize throughput and minimize labor costs per part.

Use multi-stage cleaning systems to extend chemical life and reduce waste disposal costs.

Implement dragout reduction techniques to minimize chemical losses and reduce waste treatment requirements.

Use closed-loop rinse systems to conserve water and reduce discharge volumes requiring treatment.

Consider chemical recovery systems for high-volume operations to reduce material costs and environmental impact.