SURFACE TREATMENT

The specialist staff in the own laboratory is working permanently on the improvement of existing processes as well as the development of new processes for optimal solutions, which are realised in the engineering department. Finally in the workshops Staku builds complete production devices. Customers appreciate especially the work out of innovative and individual system solutions offering all necessary services from conception to running operation of the device to him. from one single supplier.

Ephos-line

One of the processes Staku developed is the Ephos-line. The Staku-Ephos-technology is a continuous electrolytic zinc-calcium phosphating process and is applicable for the coating of cold heading and steel wire material. In general, all wire diameters from 3 to 20mm can be operated with the same drawing speed of about 60m/min. The capacity of a single-wire-line at a diameter of 20mm is about 8.8to/hr., those of a 36 multi-wire-line and wire diameter of 3.0 mm is about 7.1to/hr. Cleaning and surface treatment with the Ephos-technology is used on descaled and annealed wire rod, predrawn and annealed wire and patented steel wire. The most used methods for the descaling of the wire rod are shot blasting or a combination of mechanical bend descaling and electrolytic pickling system.
The inline-production offers the possibility to do the descaling and the phosphating process in one pass. In case of cold heading qualities, the final production step is a skin pass. Caused by the fine crystal structure of the electrolytic deposited zinc-calcium-phosphate layer, the results of cold forming – and drawing processes are at its best by coating weights between 6 and 10g/m2.
Special advantages of Ephos with regard to the traditional chemical phosphating:
– Bigger adhessive strength of the layer caused by the fine crystall structure
– Avoidance of waste water to neutralise does not require any permission by the government for the installation of Ephos-line.
– No creation of iron-phosphate-sludge leads to: Avoidance of bath cleaning shifts, saving of about 40% fresh chemicals and no disposal of sludge
– Saving of heat energy caused by smaller bath volumes (3000ltr.) and lower bath temperatures at only 50°C.
– Low consumption of electrical power for the coating process, e.g. the costs for the coating of 8.8 to of wire 20mm dia. is less than EUR 1.

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