Titanium Anode: The Key Technology for Efficient Electrolytic Phosphating
During the electrolysis process, the titanium anode for electrolytic phosphating can efficiently enhance the oxidation reaction, generate oxygen, and create favorable conditions for the formation of the phosphate film.
Positioning of Titanium Anode for Electrolytic Phosphating
In the complex system of electrolytic phosphating, the selection of anode materials is crucial. Titanium anode for electrolytic phosphating use industrially pure titanium as the substrate, with a surface coated with an iridium-tantalum metal oxide coating. The titanium substrate has advantages such as low density, high strength, and strong corrosion resistance, providing a solid and reliable support for the titanium anode. The surface iridium-tantalum oxide coating has high electrocatalytic activity, which can significantly reduce the overpotential of the oxygen evolution reaction and improve electrolysis efficiency. In highly corrosive electrolyte environments such as zinc phosphate and zinc nitrate, ordinary anode materials often cannot withstand the corrosion and will be rapidly corroded, leading to electrode failure. However, titanium anodes for electrolytic phosphating can work stably due to their excellent corrosion resistance, ensuring the continuous progress of the electrolytic phosphating process.
During the electrolysis process, the titanium anode for electrolytic phosphating can efficiently enhance the oxidation reaction, generate oxygen, and create favorable conditions for the formation of phosphate films. At the same time, the titanium anode for electrolytic phosphating has excellent dimensional stability. During long-term electrolysis, its shape and size do not change, which ensures the constant distance between electrodes, allowing the electrolysis process to proceed under a stable voltage, thereby ensuring the consistency and stability of the phosphating film quality.
Advantages of Titanium Anode for Electrolytic Phosphating
1.Performance advantages of titanium anode for electrolytic phosphating
In the complex system of electrolytic phosphating, the performance advantages of titanium anodes are very significant. They fundamentally reshape the technical indicators of electrolytic phosphating and provide a solid guarantee for the efficient operation of the entire process.
The titanium anode for electrolytic phosphating has a working voltage that can be reduced by 10% – 20% compared with the traditional graphite anode during the electrolysis process. In large-scale industrial production, this will directly lead to a significant reduction in DC power consumption.
Take a metal processing enterprise as an example. Before adopting titanium anode for electrolytic phosphating, the working voltage of lead anodes was relatively high. After replacing them with titanium anodes for electrolytic phosphating, the reduction in working voltage led to a significant decrease in DC power consumption.
Titanium anode for electrolytic phosphating can also withstand high current densities. Under the same electrolytic cell conditions, the production capacity of a single cell can be more than doubled. For example, a factory specializing in the production of metal wires, when using graphite anodes, has limited production capacity of a single cell due to the limited current density of graphite anodes. However, after switching to titanium anodes for electrolytic phosphating, the high current density has significantly improved production efficiency. A single cell can produce more phosphated wires that meet quality requirements, which not only meets the market demand for product quantity but also reduces equipment investment costs, because there is no need to add a large number of electrolytic cell equipment to increase production.
2.Process Optimization of Titanium Anode for Electrolytic Phosphating
The titanium anode for electrolytic phosphating, due to its insoluble characteristic, does not dissolve during the electrolysis process like lead anodes or graphite anodes, thereby avoiding contamination of the electrolyte. In traditional electrolytic phosphating processes, lead anodes produce lead ions after dissolution. These lead ions not only contaminate the electrolyte but also cause serious harm to the environment and human health. Moreover, during the use of graphite anodes, tiny particles will fall off and enter the electrolyte, affecting the purity and stability of the electrolyte. The titanium anode for electrolytic phosphating completely solves these problems, enabling the electrolyte to remain pure for a long time and reducing the treatment costs required due to electrolyte contamination.
Titanium anodes for electrolytic phosphating can also reduce the generation of free acids in the phosphating solution. During the electrolytic phosphating process, the generation of free acids can cause an imbalance in the pH of the phosphating solution. To maintain the balance between total acids and free acids, it is usually necessary to add alkaline substances for neutralization. However, frequent supplementation of alkaline substances not only increases production costs but also imposes higher requirements on the operating standards for mass production. Titanium anodes, through their own electrochemical reaction characteristics, slow down the generation rate of free acids, reduce the frequency of supplementing alkaline substances, make the production process more stable, and at the same time reduce the potential environmental impact caused by the use and disposal of acid and alkaline substances, which meets the requirements of modern industrial environmentally friendly production.
Application scenarios of titanium anodes for electrolytic phosphating
Electrolytic phosphating technology, as a metal surface treatment process, its core mechanism is to generate a phosphate conversion film in situ on the surface of the metal substrate through an electrolysis process. This process accelerates the reaction between metal cations and phosphate ions in the electrolyte through an applied electric field, forming a phosphate crystal layer that is tightly bonded to the substrate. Compared with traditional chemical phosphating, electrolytic phosphating breaks through the conventional autocatalytic film-forming mechanism. It directly controls the film-forming rate and crystal growth direction through electrochemical reactions, significantly improving the uniformity and compactness of the film layer. This technology can not only effectively improve the corrosion resistance and wear resistance of metals, but also realize the directional construction of functional film layers by adjusting electrolysis parameters. For example, in the process of steel wire electrolytic phosphating, when the activated substrate forms a phosphate film in a specific electrolyte, the removal of surface oxide scale and the activation step directly affect the quality of the subsequent film formation. This process can be achieved through room-temperature cleaning and anodic-assisted processes in the electrolytic cell.
The wire drawing process of high-carbon steel wire rods is a key technology, and the application of titanium anodes for electrolytic phosphating has brought significant improvements to this process.
In high-speed phosphating production lines with a speed of 55-60 m/min, traditional anode materials often struggle to meet the process requirements when faced with such a high production rhythm. After adopting titanium anodes for electrolytic phosphating, the phosphating time is significantly shortened to 5-6 seconds. This is because the titanium anodes for electrolytic phosphating have high-efficiency electrocatalytic activity, which can quickly promote the formation of the phosphating film. At the same time, the adhesion of the film layer is improved by 20%. This is because the titanium anode can precisely control the reaction conditions during the electrolysis process, making the combination between the phosphating film and the surface of the high-carbon steel wire rod tighter.
Why Choose Qixin titanium anode
Qixin Titanium is a manufacturer of titanium anodes from China., focusing on the R&D, manufacturing and application of Mixed Metal Oxide (MMO) coated titanium anodes.
Founded in 2006, with over 20 years of manufacturing experience, we provide stable and reliable titanium anode products suitable for multiple scenarios. We help enterprises improve electrolysis efficiency, reduce operating costs, and offer personalized customization to ensure long-term stable operation.
