Application Instructions

Process Instructions for Application of the POLYZAM-0,5 Epilam

1. Introduction

Polyzam-0,5 is a multi-component composition based on fluorine-containing surface-active agents (SAA). It may be used as an agent for processing of hard surfaces, in order to improve their wear resistance, to reduce friction and wear of heavy-duty assemblies, mating surfaces of machines and mechanisms, tools for metal processing by pressure, cutting etc., and to improve the dynamics of process equipment functioning.

The Polyzam-0,5 composition may be used to process the surfaces of the following tools and machine parts:

- drill bits;

- taps;

- chasers;

- milling cutters;

- cutters;

- dies (punching and drawing);

- press molds (mechanical rubber articles production, tire production, pressure molding of plastics and rubbers);

- webs for saws (hand and power) etc.;

- rolls;

- worm screws;

- drawing nozzles;

- bearings;

- grinding wheels (ceramic)*;

- gauges;

- loaded friction pairs;

parts of precision friction assemblies in instruments and mechanisms etc.

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* Ceramic grinding wheels are processed with Epilam as per 3.2 below, and dried as per 4.4.

2. Article Preparation for Epilam Coating

2.1. De-Preservation of Articles **.

To be carried out in a hot water bath (at temperatures of 75 to 100°С), or by washing with a hot water jet until no lubricant is visible on the surface ***.

2.2 Where it is not practicable to de-preserve an article using hot water, one of the two below-described methods is advisable, using a mixture of Б-70 “Galosh” gasoline and ethyl alcohol (ratio of 1:1).

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** Where the articles are coated with protective preservation grease. Articles of polymeric materials, mechanical rubber goods, and grinding tools are not subject to de-preservation. They shall be cleaned free of dust and other impurities by weeping them with a cotton wool wad or a brush (or with a compressed air jet).

*** Warning! The precision parts processing temperature at all stages of epilaming shall not exceed 50°С.

Wash the surface with gasoline-and-alcohol mixture using a brush or a wad (cotton wool, gauze, clean rags) as per GOST1012-72.

2.2.2. In Solvent Vapors

To be carried out in special vapor chambers with a backflow condenser, at the solvent boiling point.

2.2.3. To avoid greasing, especially that of working surfaces, prevent direct contact of the parts with unprotected hand skin.

2.2.4. In case of fat stains, additionally clean the article in a bath of Б-70 “Galosh” gasoline.

2.3. Drying

The de-preservation completed, dry the articles in the air at a temperature of at least 20°С and at a relative air humidity not exceeding 70% for 3 to 6 hours, or at 110-120°С in a desiccator, for at least 30 minutes..

3. Article Treatment with Polyzam-0,5 Epilam

3.1. Cold Method

Place the articles in a metal basket and immerse it in the Epilam solution for 10 to15 minutes. Every 3 minutes, lift and re-immerse the basket to stir the solution and to improve its access to the articles’ surface. Carefully watch that the articles be constantly covered with the solution and not be exposed to air.

This technique is inapplicable if the solution is stirred with an agitator or circulated with a pump.

The cold method is the only one to treat precision products. It may also be used to treat other articles if other methods are impracticable.

The manual method is preferable for large-size articles, with Epilam applied to the surface with a brush, cotton wool wad or a spray gun (at least three times).

3.2. Hot Method

Place the articles in a metal basket and put it in the bath of an epilaming plant (the plant shall be provided with a low-temperature refrigerator or a water-cooled refrigerator). Fill the bath in such a way that the articles be completely covered with Epilam solution, and seal the bath. Heat Epilam to reach the solvent’s boiling point (Freon-113’s boiling point is 47.5°С), and keep the parts in it for at least 30 to 60 minutes. Cool the solution down, and drain it to a collector. Open the bath lid, take the articles out, and dry them in the air for 10 to 15 minutes.

3.3. Combined Method

To be used when an epilaming plant cannot be used. After degreasing and drying in a desiccator, place the heated articles into a bath with an Epilam solution, and immediately close it tightly with a lid to avoid losses of solvent. Keep the parts in the solution until they are completely cooled down, take them out of the bath, and dry in the air for 10 to 15 minutes.

4. Article Drying and Heat Setting

4.1. Dry the treated articles at a room temperature and relative air humidity not exceeding 70% for 3 to 6 hours. The articles may be blown with air or inert gas (W_rel. < 70%). This method is generally applied to drying of large-size and precision products. For other products, heat setting is preferable.

4.2. Heat Setting

Place the Epilam-treated articles in an oven and keep exposed to a temperature of 110-120°С for 30 to 60 minutes.

Mechanical rubber goods, polymeric products etc. shall be dried at 50°С for 3 to 4 hours. In this timespan, the article will regain its initial geometric dimensions, which may have changed due to the material swelling in the solvent.

5. Safety Precautions

When handling the Polyzam-0,5 composition, the safety precautions shall meet the requirements for Freon-113.

Polyzam-0,5 shall be kept in a gastight container away from heating appliances and from direct sun beams.

The working area for solution application shall have local exhaust ventilation (an exhaust hood or cowl).

It is forbidden to use open flame or faulty (sparking) in the process area.

In a contact with open flame, the fluorine-containing SAA will decompose yielding heavily toxic products (anhydrous hydrogen fluoride, phosgene fluoride).

The personnel shall be wearing a protective overall or suit and rubber gloves.

6. Spillage and Waste Disposal

Any spilled Polyzam-0,5 shall be strewn with sand or sawdust and collected into a special waste container, after which, the floor shall be washed with a large quantity of water.

SAA solution, when not reusable, may be returned to the supplier for recovery, or removed to a local disposal ground for burial or burning.