SaitechAI — Metal Pretreatment Chemicals Formulator’s Toolkit

Bath Make-up — Dilution (C₁V₁ = C₂V₂)

Convert concentrate to working solution.

C₁ (concentrate, % or g/L)

V₁ (volume of concentrate, L) (or leave 0)

C₂ (target bath conc., % or g/L)

V₂ (final bath volume, L)

If V₁=0, we compute V₁ = (C₂·V₂)/C₁ and water = V₂ − V₁.

Normality / Molarity Helpers

Quick prep for titrants and indicators.

Equivalent weight (g/eq)

Target Normality (N)

Prepare volume (L)

Purity (%) (optional)

FA / TA Titration & Ratio

For phosphating and conversion-coating bath control.

FA: Alkali normality, N_FA

FA: Alkali volume used (mL), V_FA

TA: Alkali normality, N_TA

TA: Alkali volume used (mL), V_TA

Sample volume (mL)

Factor (common 49 for H₃PO₄-eq) adjust per method

ppm ⇄ g/L ⇄ % w/v Converter

For accelerators (nitrite/nitrate/chlorate), metals, etc.

Enter a value

Unit

Replenishment Dosage

Add concentrate to restore target concentration after drop.

Current conc. C_curr (% or g/L)

Target conc. C_tgt (% or g/L)

Bath volume V_bath (L)

Concentrate strength C_conc (% or g/L)

Addition (L) = ( (C_tgt − C_curr) × V_bath ) / C_conc

Drag-out Loss Estimator

Estimate chemical loss via carry-over.

Work surface area processed (m²/h)

Drag-out film thickness on part (µm)

Bath density (kg/L)

Bath concentration (g/L)

Approx: Volume dragged (L/h) ≈ Area × (thickness µm × 10⁻⁶ m) → m³/h → L/h; mass of active ≈ volume × (conc g/L).

Coating Weight (g/m²)

Weigh-strip-reweigh method.

Weight before (g)

Weight after strip (g)

Panel area (m²)

Panels count (if combined area)

Salt-Spray Quick Log

Record hours to first rust (Rf), creep at scribe, blistering notes.

Sample ID

Hours to Rf

Creep at scribe (mm)

Blistering (ASTM D714)

Notes

Costing — Bath & per m²

Estimate chemical cost to prepare bath and treat area.

Bath volume (L)

Target conc. (g/L)

Chemical price (₹/kg)

Treated area per bath (m²) (estimate)

Cost/bath (₹) = (V × C / 1000) × Price; g/L→kg: ÷1000.

Sludge Factor Estimate

Rough sludge yield from coating formation & impurities.

Coating weight (g/m²)

Area processed per day (m²)

Sludge factor (% of coating mass) typ. 30–80

Bath days between cleanouts

Notes & Assumptions

FA/TA factor “49” is common for phosphoric acid equivalence; confirm your method factors.
Drag-out model is approximate; validate with plant measurements (weir, rinse analysis).
Sludge % varies with steel grade, throughput, phosphate type, & filtration efficiency.
Always corroborate calculator outputs with lab titration and on-line QA checks.

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