Inline Pre-Treatment System Solution for P.C. Strandwire with WiTechs Mechanical Descaling Equipment and Electro-Phosphating Line (Ephos®) from STAKU

The wire rod is subsequently propelled by a horizontal wire rod pay-off system in a combined pull-in, bending and straightening machine (BDM-2S / EG). The scale layer is broken and the wire is straightened without cracks. The wire pull in is considerably facilitated by this system concept.

In the following double-head sanding descaler (SEZ-6-302S), the wire will be cleaned and surface pre-treated for the further coating process through two sanding belts with min. 98% cleanliness result.

The next wire preparation step is done by an electro-phosphating plant (Ephos®) Inline from STAKU.

Production range:

  • Wire inlet ø8.0 – 15.0mm
  • Wire outlet drawing speed up to 10m/s
  • Wire inlet speed up to 1.5m/s

For example:

  • Wire inlet ø13.0mm
  • Finished wire ø5.0mm
  • Wire inlet speed 1.2m/s
  • Wire outlet drawing speed 8m/s

> Mechanical descaling with inline phosphating at the same drawing speeds as conventionally pickled wires without sacrificing quality.

Horizontal pay-off with coil pusher, model HAF/CVE

Pull-in – bending and straightening with model BDM/2S-EG

Mechanical descaling with double-head sandbelt descaler, model SEZ-6-302S

Advantages of this electrolytic process compared to classical chemical phosphating

  • Bath temperature only 45 ° C instead of 80 ° C
  • Sludge-free process
  • 33% less zinc by replacement with calcium
  • 40% lower chemical requirements due to compact and fine crystalline layer
  • 3 seconds coating time compared to 7 minutes for classic procedures
  • Elimination of highly toxic activation chemicals
  • High binding forces prevent shearing during forming
  • No waste of old acid, use of economy flushing technology reduces wastewater by 40%
  • No after-treatment with soaps, lime or similar
Row wire rod
Bended

Sanded

E-Phosphated

The images under the microscope show the different layer structure.

1st picture: Ephos
2nd picture: Classic zinc phosphating

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