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– Mạ điện dùng phản ứng điện di hay điện hóa Faraday, kết tủa kim loại cần mạ lên bề mặt vật mạ (gọi là Obj). Khi bề mặt vật mạ không được tẩy sạch dầu mỡ (do quá trình gia công cơ khí để lại) và gỉ (do lưu kho, xâm thực hóa học, độ ẩm, nước mưa v.v… trước khi mạ) thì phản ứng điện di / điện hóa diễn ra không hoàn toàn. Lực liên kết bề mặt kém nên lớp mạ chóng bị bong tróc, thậm chí bong tróc ngay trong quá trình mạ.

– Sơn phủ / tráng dùng liên kết cơ lý, tạo một lớp màng phủ trên bề mặt đối tượng. Lớp màng này có thể là sơn (sơn lỏng thông thường, sơn tĩnh điện dạng lỏng kiểu “nhúng”, sơn tĩnh điện dạng bột), phun gốm plasma, tráng men và / hay nhúng kim loại nóng. Bề mặt vật sơn phủ – tráng không sạch dầu và gỉ sẽ tạo các điểm / mảng rỗ, tạo điều kiện bong tróc, vỡ gẫy lớp sơn – phủ – tráng bề mặt, ảnh hưởng nghiêm trọng đến chất lượng sản phẩm.

Tẩy rửa – vần đề nền tảng của nhiều vấn đề.

Mạ điện / sơn phủ – tráng (trong đó rất quan trọng đối với sơn tĩnh điện) vv.. thì độ sạch bề mặt là rất quan trọng. Tẩy rửa phải được thực hiện tốt và phải hoàn tất trước khi mạ, phun sơn hay nhúng (với sơn tỉnh điện “nhúng” zirconium hay chromium hoặc phun ceramic-plasma / tráng men) và trước phosphate-hóa (hay manganat-hóa hoặc magienat-hóa với sơn tĩnh điện “bột” hoặc mạ kẽm nóng). Nói một cách khác, qui trình tẩy sửa quyết định sự thành công của ngành mạ điện / sơn phủ – tráng.

Qui trình tẩy rửa bề mặt cổ điển.

Vài trăm năm tồn tại của ngành mạ điện / sơn phủ – tráng đã hình thành một qui trình tẩy rửa (tên gọi mỹ miều là xử lý bề mặt). Qui trình hoàn chỉnh (thường xuyên bị cắt bớt) bao gồm 7 bước:

1- Thấm ướt bề mặt : tạo điều kiện tiếp xúc tốt giữa bề mặt Obj và các chất tẩy rửa.

2- Tẩy rửa bằng dung môi : (thường dùng acid nồng độ cao cho rẻ tiền) nhằm hòa tan / đánh bật các chất bám / mảng bám trên bề mặt Obj, tạo điều kiện cho các bước tiếp theo.

3- Trung hòa bề mặt bằng nước hoặc có hóa chất.

4- Tẩy rửa bằng xà phòng / chất kiềm. Mục tiêu là phá, bóc dầu mỡ còn sót lại trên bề mặt Obj. Đặc biệt là dầu mỡ tạo lớp ngăn điện hóa đối với mạ điện và sơn tĩnh điện nên bước tẩy dầu (mỡ) là rất quan trọng. Ở VN thì bước này thường được kết hợp với xô chậu, bàn chải và vô số thứ linh tinh khác. Tuy nhiên những vị trí “hiểm” của Obj có cấu tạo phức tạp, ngóc ngách hay ống sâu thì đều … lờ đi vì bó tay.

5- Trung hòa bề mặt bằng nước.

6- Tẩy rửa bằng acide : nhằm tẩy sạch các vết bám của silic, của carbone và gỉ, đặc biệt đối với kim loại đen và sắt carbone.

7- Trung hòa bề mặt bằng nước / sấy khô.

Qui trình 7 bước này để lại hậu quả môi trường nặng nề vì các dư chất hóa học mang theo kim loại nặng liên tục thải vào môi trường, mà lại có hiệu quả khá kém. Tuy nhiên nó vẫn được dùng phổ biến vì … không có cách nào khác.

Qui trình Wambuakim tẩy rửa bề mặt : xanh & hiện đại.

Qui trình Wambuakim (còn gọi là qui trình 7 in 1) sử dụng :

–          Nước muối là chất thấm ướt bề mặt.

–          Siêu âm động lực tác động lên bề mặt để bóc tách mảng bám.

–          Phản ứng điện hóa tạo kiềm bề mặt để tẩy dầu mỡ.

–          Phản ứng điện hóa tạo acide bề mặt để tẩy gỉ.

–          Phản ứng điện hóa thuận nghịch để trung hòa bề mặt.

–          Phun sương nước để loại bỏ muối dư.

Qui trình Wambuakim đã được sử dụng ở CTy Cơ Khí Phương Nam, Q9, TP HCM (1998); CTy Cơ Khí Hợp Nhất (Vĩnh Viễn, Q10 TP HCM (2000); CTy Rạng Đông, Thủ Thừa, Long An (2001); CTy Sơn Tĩnh điện Nhật Hạ, KCN Tân Bình (2004); CTy Sơn Tĩnh điện Đồng Tâm, Nguyễn Văn Quá, Tân Bình (2005); CTy lắp ráp Ô Tô Sài Gòn SAGACO (2007) và một số CTy khác.

Phân tích kỹ thuật :

1/. Vật mạ Obj nối điện được nhúng vào bồn chứa nước muối ăn NaCl / nH2O có bố trí điện cực. Một dòng điện xoay chiều trong vài giây làm cho bề mặt Obj vật mạ phóng xuất khí H2 và O2, một lượng nước Javel NaClO có hoạt tính bề mặt và tẩy màu rất cao được tạo ra, tấm ướt và tẩy sơ bộ bề mặt Obj.

2/. Cùng lúc, siêu âm động lực tần số 27 KHz (đến 43 KHz) liên tục tác động trên bề mặt Obj trong suốt quá trình tẩy rửa, bóc tách tất cả các vật chất đã phân ly trong qui trình kim_techno.

3/. Dòng điện một chiều với cực (-) là Obj được cấp trong thời gian thích hợp. Phản ứng Ion tạo kiềm trên bề mặt Obj kết hợp với bọt khí và siêu âm phân hóa và tống dầu mỡ khỏi bề mặt Obj.

NaCl   —>   Na+  +  Cl-

Na+   +  H2O  —>  NaOH + ½ H2 /^

(hidro thoát ra ở âm cực / Obj và oxi thoát ra ở dương cực bố trí trên thành bồn chứa).

4/. Dòng điện đảo cực, phản ứng điện hóa tạo Chlohidric acide trên bề mặt, trung hòa kiềm, sau đó đánh tan gỉ sét.

Cl-   +  H2O  —>  HCl + O2 /^

(oxi thoát ra ở dương cực / Obj và hidro thoát ra ở âm cực bố trí trên thành bồn chứa).

5/. Dòng điện xoay chiều lại được cấp, trung hòa ngay acid dư + lớp ferrate xốp được tạo ra. Nếu mục tiêu là mạ điện thì không cần mục (5) này. Obj được nhấc khỏi bồn tẩy rửa. Nước phun dạng sương đẩy trôi lượng muối dư bề mặt Obj.

Quá trình làm khô sau đó hoàn tất quá trình tẩy rửa.

Biểu hiện :

–          Vật tẩy được khử bỏ từ dầu mỡ đến gỉ sét.

–          Bề mặt được lớp ferrate xốp màu xám bảo vệ nên không bị tái gỉ và tạo điều kiện cho sơn tĩnh điện bám chắc.

Hiệu quả kinh tế – kỹ thuật :

–          Gọn nhẹ : Chỉ 1 bồn tẩy rửa duy nhất, không rườm rà như qui trình 7 bước. Riêng đối với sơn tĩnh điện, qui trình kim_techno còn loại bỏ 3 bước của quá trình phosphate hóa.

–          Không dùng dung môi và các chất tẩy rửa độc hại, qui trình kim_techno an toàn, thân thiện và không gây ô nhiễm môi trường.

–          Có thể tự động hóa hoàn toàn.

–          Chi phí tổng thể rất thấp, khoảng 25% đến 30% so với qui trình cổ điển.

Các khoản mục đầu tư.

1/. Bồn tẩy rửa 7 in 1 : 01

2/. Buồng phun sương nước : 01.

3/. Máy phát siêu âm + phát điện động lực lập trình 5 (đến 7) đề mục : 01.

(Bản chiết tính đầu tư chi tiết, xin các bạn liên lạc riêng)

—————————-

Wambuakim

27 / 7 / 1997

—————————

Update tại CTy Vũ Lân

75 Cầu Bươu, Thanh Trì, Hà Nội

10 / 10 / 2012

 

2.499 Trả lời “TẨY RỬA DẦU MỠ VÀ GỈ CHO NGÀNH MẠ VÀ SƠN PHỦ / TRÁNG”

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