Finishing materials by phosphating
URN: SEMMPF341
Business Sectors (Suites): Materials Processing and Finishing Suite 3
Developed by: Enginuity
Approved on:
30 Mar 2020
Overview
| This standard identifies the competencies you need to carry out rack and barrel phosphating operations, in accordance with approved procedures. You will be required to access the appropriate specifications, to check that these are the current issue and to extract all necessary information in order to carry out the phosphating operations. You will be required to carry out all necessary pre and post-preparations to the components and this will include such items as cleaning, rinsing, drying, sealing, oiling, wax coating and other appropriate treatments. You will be expected to prepare and adjust the phosphating solutions to give satisfactory deposits at optimal productivity levels. You will need to carry out tests on the treated components to ensure deposits meet their specification requirements. You will be expected to identify any defects in the process and to adjust the various parameters to correct them. Your responsibilities will require you to comply with organisational policy and procedures for the phosphating activities undertaken and to report any problems with these activities or with the materials and equipment used, that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying rack and barrel phosphating procedures. You will understand the phosphating procedures used and their application, and will know about the base materials, finishing materials and their preparation requirements, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the finished components are to the required standards and to the customer's expectations. Your knowledge will also include effluent treatment for the waste streams from the phosphating and associated processes. You will understand the safety precautions required when carrying out the preparation and phosphating operations. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace and towards the environment. |
Performance criteria
You must be able to:
| 1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines 2. follow relevant job instructions and specifications 3. ensure the material surfaces to be treated are prepared for the finishing operations 4. check that the finishing equipment and treatment solutions are set up and maintained at required operating conditions and levels 5. carry out finishing according to operating procedures and to meet specifications 6. check that the treated workpiece achieves the required characteristics and meets the finishing specification 7. deal promptly and effectively with problems within your control and report those that cannot be solved 8. ensure that work records are completed, stored securely and available to others, as per organisational requirements 9. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements |
Knowledge and Understanding
You need to know and understand:
| 1. the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials) 2. the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you 3. the hazards associated with the activities, and how to minimise them and reduce risks 4. the personal protective equipment and clothing (PPE) to be worn during the activities 5. the types of phosphating processes that are used 6. the types of specifications that are used during the phosphating activity and how to check that they are current 7. how to assess component suitability for phosphate coating (to include methods of handling, methods of pre-treatment, the phosphating method to be applied) 8. how to identify coating specifications and how to advise customers about coating weights and post-treatments 9. the properties of phosphated deposits 10. how to set up phosphating equipment and techniques to use it (including limitations of geometry of parts for phosphate coating, operation and locations of emergency stops) 11. how to clean and prepare the components in readiness for the phosphating process 12. the properties of different sealants and corrosion resistant top coats 13. how to decide the most cost effective technique for processing (such as spray, barrel) to give required deposit specification 14. how to make up process solutions, safely, and correctly 15. recognition of phosphating defects, and their prevention 16. how to identify and correct phosphating faults and the importance and control of temperature 17. the de-embrittlement and reactivation procedures 18. how to test coated components for specification compliance 19. how to carry out visual assessment of workpieces for deposit continuity and crystal structure 20. how to neutralise and precipitate out effluent waste streams 21. the benefits of agitation, and the need to move components as little as possible, to prevent coating damage, but avoid touch marking 22. the effects of contaminants in phosphating solutions 23. how to control and assess concentrate dosing rates 24. the cleaning and maintenance of the phosphating processing plant and equipment, including the use of 5S or similar techniques 25. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve 26. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Finish materials by phosphating, carrying out all of the following activities: 1. use the correct issue of process and other related specifications 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. ensure that the equipment is correctly prepared for the phosphating operations 4. ensure that any meters and gauges to be used are within their calibration periods 5. clean all tools and equipment on completion of the phosphating activities 6. complete the production documentation (condition/pre-treatment of substrates, coating material preparation, equipment settings, confirmation of standard of finish) 7. leave the work area in a safe and clean condition 2. Carry out one of the following phosphate processes: 1. zinc phosphating 2. iron phosphating 3. manganese phosphating 4. multiple ion phosphating 3. Measure and correct two of the following phosphate process conditions: 1. temperature 2. deposition rate 3. total and free acidity of phosphate solution 4. complete coverage by coating 5. processing time plus two more from the following 6. effectiveness of inhibition in acid pickling process 7. total and free alkalinity of cleaners 8. effectiveness of rinsing 9. contamination levels in cleaners 10. temperature of cleaners 4. Use one of the following methods for locating/processing the components: 1. rack phosphating 2. barrel phosphating 3. wiring components for phosphating 4. spray phosphating 5. other processing method (baskets) 5. Carry out one of the following post-phosphating operations: 1. chromate or organic sealing 2. oiling 3. staining 4. wax coating 5. dry components at appropriate temperatures 6. Carry out all of the following on hardened steel components: 1. de-embrittlement of hardened steel components and correct record keeping 2. reactivate de-embrittled components so that they will accept post-phosphate treatments 7. Carry out **two** of the following phosphating activities: 1. dispose of spent phosphate solutions 2. de-sludge the phosphating tank 3. change and replenish post-phosphating sealant 4. clean the tank thoroughly 5. prepare new phosphate solutions 6. heat solutions to operating temperature 8. Carry out one of the following quality control procedures: 1. thickness testing by microsectioning or coating weight measurements 2. satisfactory dryness of deposit after post-treatment processes 3. corrosion testing 4. assessing continuity of deposit 5. torque tension testing 9. Check phosphate coatings applied to components comply with one of the following quality and accuracy standards: 1. military or aviation standards 2. current industry standards and codes of practice 3. international standards 4. company standards and requirements 5. customer standards and requirements |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
2
Indicative Review Date
31 Mar 2023
Validity
Current
Status
Original
Originating Organisation
SEMTA
Original URN
MPF3.41
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; finishing; phosphating; zinc; manganese; iron; parameters; equipment