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In the automotive painting pretreatment process, one-step phosphating method is suitable for bodies with an aluminum content of ≤40%, while two-step phosphating (phosphating + passivation) can handle high-aluminum or all-aluminum bodies. This paper compares their process characteristics, consumable consumption, and body appearance quality. Case analysis reveals that when the aluminum content is low (below 30% in this case), the two-step method consumes approximately 20% more materials per vehicle than the one-step method. Furthermore, the two-step process is prone to causing streaks and pit defects on the surface of aluminum outer panels after electrophoretic painting. These streak defects can be mitigated by optimizing phosphating parameters and spray processes, while pitting defects can be reduced by adjusting the aluminum sheet's Electro Discharge Texture(EDT) process. The research demonstrates that for production lines with low aluminum content, the one-step phosphating method holds significant advantages in both economy and final quality.

, authors=Shaopeng Song, authorsList=Shaopeng Song, authorCompany=null, correspAuthors=null, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, fund=null), CN=ArticleExt(id=1309475173653373573, articleId=1309475173192000131, tenantId=1146029695717560320, journalId=1189873562199433220, language=CN, title=一步法与两步法前处理磷化对成本和车身外观质量的影响分析, columnId=1190284220841955836, journalTitle=汽车工艺与材料, columnName=生产现场, runingTitle=null, highlight=null, articleAbstract=

汽车涂装前处理工艺中，一步法磷化适用于铝含量不高于40%的车身，两步法磷化（磷化+钝化）可处理高铝或全铝车身，对比了2种磷化方法的工艺特点、耗材消耗与车身外观质量。案例分析显示，在铝含量较低时（本案例中铝含量低于30%），两步法单车耗材量比一步法高约20%，且电泳后铝外覆盖件表面易出现条纹和麻坑缺陷。通过优化磷化参数和喷淋工艺可缓解条纹问题，调整铝材电火花毛化处理（EDT）工艺可减少麻坑。研究表明，对于铝含量较低的生产线，一步法在经济性和质量方面更具优势。

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宋绍朋（1982—），男，高级工程师，硕士学位，研究方向为汽车制造、车身焊接与涂装设备及工艺规划。

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宋绍朋（1982—），男，高级工程师，硕士学位，研究方向为汽车制造、车身焊接与涂装设备及工艺规划。

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