Phosphate Coating Calculator

Calculate phosphate conversion coating weight, chemical consumption, and bath life for pretreatment processes.

Part surface area (sq ft)

Phosphate type (1-3)

Bath temperature (°F)

Immersion time (sec)

Concentration (%)

Bath volume (gal)

Parts per hour

Tab to move between fields

Coating weight (mg/sq ft)

300

Bath life (days)

104

Chemical use (oz/sq ft)1

Daily chemical usage (gal)250

Daily throughput (sq ft)32,000

Rinse water (gal/hr)40

How to Use This Calculator

Enter Part surface area (sq ft), Phosphate type (1-3), and Bath temperature (°F).
Set Immersion time (sec), Concentration (%), and Bath volume (gal).
Adjust Parts per hour as needed.
Review Coating weight (mg/sq ft) and Bath life (days).
Use Chemical use (oz/sq ft) and Daily chemical usage (gal) to inform your decision.

How the result changes with Bath temperature (°F)

Part surface area (sq ft): Surface area of parts per batch.
Phosphate type (1-3): 1=Iron phosphate, 2=Zinc phosphate, 3=Manganese phosphate.
Bath temperature (°F): Operating bath temperature.
Immersion time (sec): Part immersion time in seconds.
Concentration (%): Phosphate solution concentration.
Bath volume (gal): Total tank volume in gallons.
Parts per hour: Throughput rate.

Identify Input Parameters
4 parameters
Part surface area (sq ft) = 200, Phosphate type (1-3) = 2, Bath temperature (°F) = 145, Immersion time (sec) = 120 = 7 input(s) provided
Calculate Coating weight
300 = 300
Calculate Bath life
Bath life = max(1, round(bathVolumeGal / max(0.1, sludgeFactor) * 2))
104 = 104
Calculate Chemical use
1 = 1
Calculate Daily chemical usage
Daily chemical usage = dailyChemOz / 128
250 = 250