Research on the Use of TRIZ to Improve the Quality of Phosphate Coatings

TRIZ methodology, which companies are continuously using to solve complex problems occurring in the field, is being used as a representative tool of Problem Based Learning (PBL) in university education.This study is a PBL case that uses TRIZ (Theory of Inventive Problem Solving) to solve problems that occurred in the phosphate coating process.The phosphate coating process is a widely used surface treatment technology applied as a pretreatment method to enhance the corrosion resistance of steel products or to improve adhesion properties.Typically, to maintain a stable coating quality, various management parameters are established with predefined criteria.Key control parameters include the accelerator concentration, total acid, free acid, and immersion time of the workpiece, as well as the temperature of the phosphating bath.However, despite maintaining these parameters within the designated conditions, unexplained occurrences of rust formation continue to be reported.To address this issue, stricter control of post-treatment processes, such as drying time and drying temperature, has been necessitated.This situation has led to excessive equipment specifications and increased energy consumption.In this study, we systematically analyze the factors influencing rust formation and evaluate the functionality of existing equipment within the process using the TRIZ methodology.Through this approach, we aim to identify the fundamental causes of rust occurrence and propose optimal solutions to mitigate this issue.The ultimate goal of this study is to establish new management standards that can improve both the stability and efficiency of the phosphating process, thereby contributing to the overall enhancement of coating quality.