Investigation of alternative phosphating treatments for nickel and hexavalent chromium elimination

The phosphating processes are widely used in industry as surface treatments for metals, especially for low thickness plates, improving the adhesion between the metallic surface and the paint coating, and increasing the durability of paint systems against corrosion attacks. The tricationic phosphates containing zinc, nickel and manganese are commonly applied on steel. There is much discussion about the replacement of nickel by another element in order to have an environmentally friendly phosphating process. Niobium as a replacement for nickel has been evaluated. The most significant environmental impacts of phosphating processes are related to the presence of nickel and hexavalent chromium used in the process, this last as a passivation treatment. Nickel and hexavalent chromium are harmful to human and environment leading to contamination of water and soil. In the present study phosphate layers containing zinc, manganese and niobium have been evaluated and characterized on galvanized steel, and the results were compared with phosphates containing zinc, manganese and nickel, or a bicationic phosphate layer with zinc and manganese. Although the use of hexavalent chromium is not recommended worldwide, it is still used in processes for sealing the porosity of phosphate layers. This element is carcinogenic and has been associated with various diseases. Due to the passivation characteristics of niobium, this study also evaluated the tricationic bath containing niobium ammonium oxalate as a passivation treatment. The results showed that it could act as a replacement for the hexavalent chromium. The results of the present study showed that formulations containing niobium are potential replacements for hexavalent chromium and similar corrosion protection was obtained for the phosphate containing nickel or that with niobium. The morphology observed by scanning electron microscopy, gravimetric tests, porosity and adhesion evaluation results indicated that the phosphate obtained with passivation treatment in niobium containing solution could be considered as a promising alternative to replace passivation with hexavalent chromium ions. Despite of the promising results, adjustments in the baths to obtain stability are still needed and should guide the next steps of the subject of this research. (author)