When bonded to a metal surface, iron phosphate prevents further oxidation of the metal. Its presence is partially responsible for the corrosion resistance of the Iron pillar of Delhi.
So according to the receipt and the bill that I paid, the chain garage I had do the "rust treatment" actually did to the work - but I really couldn't tell if it had improved at all on my previous phosphoric acid treatment of the rust. In fact it looked like more rust - but maybe that was the tannic acid color? Tannic acid is not as strong as phosphoric acid and so one comment on youtube says it is due to environmental standards that phosphoric acid is not used. In fact ferric phosphate is an insectide!
So instead of "removing" the rust - I have been converting the rust into ferric or iron phosphate. So the undercarriage has a strong black patina. It actually looks LESS black after they pressure washed it and did the tannic acid spray. Anyway I got another quart of phosphoric acid to turn the bottom of the car into a competition with the eternal Iron Pillar of Delhi!!
Yeah that's pretty much how the chassis or undercarriage looks.
Is that an alchemical stupa on top?
Well they were blacksmiths so yes it MUST be alchemical!! fascinating.
In a report published in the journal Current Science Balasubramanian says, the protective film was formed catalytically by the presence of high amounts of phosphorous in the iron—as much as one per cent against less than 0.05 per cent in today's iron. The high phosphorous content is a result of the unique iron-making process practiced by ancient Indians, who reduced iron ore into steel in one step by mixing it with charcoal.
Bellows placed at the bottom of the furnaces were operated at a controlled rate. The iron ore had to be reduced in order to obtain the iron. Iron ore is essentially oxide of iron and it is reduced by the carbon monoxide(CO) that is produced by the burning of charcoal in the bloomery furnace (or coking coal in a modern blast furnace).
Iron meant for corrosion-resistant applications contained higher phosphorous (P) contents. Therefore,it is reasonable to conclude that the ancient Indian metallurgists possessed the art of manufacturing ironand steel according to the desired application and corrosion-resistant steel was one among them. The excellent corrosion resistance of ancient Indian iron can be attributed to its relatively high phosphorus contents.This is due to the absence of CaO (calcium oxide, i.e.,limestone) in the charge of the bloomery furnace.
The end product of the bloomery furnace was a lump of direct reduced iron, which contained phosphorous as the major alloying element.The end product of the ancient Indian direct process of extracting iron can be called phosphoric iron.
Another factor in iron’s decline is the fact that certain essential steps were not shared by the master smiths with anybody except their favored apprentices. Traditional artisan communities in India never reveal full details to outsiders and when the communities disappeared, so did the methods.They should just say ALCHEMY!!
https://www.insa.nic.in/writereaddata/UpLoadedFiles/IJHS/Vol02_1_1_PRay.pdfAlchemy' in different countries with particular reference to India. It is shown that alchemy ... labour under the impression that in the ancient world the Greeks held the monopoly of all ... and varnishing of metals, and even coating the surface of one metal with a superficial layer of ... phosphorus by Brandt in A.D. 1674. This was ...
Jaina Alchemy pdfAlchemy
Like other alchemists of the time, Brand searched for the "philosopher's stone", a substance which supposedly transformed base metals (like lead) into gold. By the time his first wife died he had exhausted her money on this pursuit. He then married his second wife Margaretha, a wealthy widow whose financial resources allowed him to continue the search.
Like many before him, he was interested in water and tried combining it with various other materials, in hundreds of combinations. He had seen for instance a recipe in a book 400 Auserlensene Chemische Process by F. T. Kessler of Strasbourg for using alum, saltpetre (potassium nitrate) and concentrated urine to turn base metals into silver[citation needed] (a recipe which did not work).
Around 1669 he heated residues from boiled-down urine on his furnace until the retort was red hot, where all of a sudden glowing fumes filled it and liquid dripped out, bursting into flames. He could catch the liquid in a jar and cover it, where it solidified and continued to give off a pale-green glow. What he collected was phosphorus, which he named from the Greek word for "light-bearing" or "light-bearer."
Phosphorus must have been awe-inspiring to an alchemist: it was a product of man, and seeming to glow with a "life force" that did not diminish over time (and did not need re-exposure to light like the previously discovered Bologna Stone). Brand kept his discovery secret, as alchemists of the time did, and worked with the phosphorus trying unsuccessfully to use it to produce gold.
His recipe was:
The chemical reaction Brand stumbled on was as follows. Urine contains phosphates PO43−, as sodium phosphate (i.e. with Na+) in the form of microcosmic salt, and various carbon-based organics. Under strong heat the oxygen atoms from the phosphate react with carbon to produce carbon monoxide CO, leaving elemental phosphorus P, which comes off as a gas. Phosphorus condenses to a liquid below about 280°C and then solidifies (to the white phosphorus allotrope) below about 44°C (depending on purity). This same essential reaction is still used today (but with mined phosphate ores, coke for carbon, and electric furnaces).
- Boil urine to reduce it to a thick syrup.
- Heat until a red oil distills up from it, and draw that off.
- Allow the remainder to cool, where it consists of a black spongy upper part and a salty lower part.
- Discard the salt, mix the red oil back into the black material.
- Heat that mixture strongly for 16 hours.
- First white fumes come off, then an oil, then phosphorus.
- The phosphorus may be passed into cold water to solidify.
Brand's process yielded far less phosphorus than it could have done. The salt part he discarded contained most of the phosphate. He used about 5,500 litres of urine to produce just 120 grams of phosphorus. If he had ground up the entire residue he could have got many times more than this (1 litre of adult human urine contains about 1.4g of phosphorus salts, which amounts to around 0.11 grams of pure white phosphorus).
Poor Man's Alchemy - review of Phosphoric Acid project - youtube
“There is a neutral axis where there is no stress in the frame. Holes and welding at the neutral axis will not significantly affect frame strength.https://www.gmupfitter.com/files/media/photo/843/2018_Chassis_BstPrac_093017.pdf
HolesSo the holes are in the neutral zone on the frame.
It is important to locate holes in the least critical area possible. In high-load areas, place holes near the neutral axis of the side rail or horizontal center line of the web.
Flangeshttps://www.gmupfitter.com/files/media/photo/843/2018_Chassis_BstPrac_093017.pdf
GM does not recommend drilling holes in frame flanges. Drilled holes
in frame flanges will reduce fatigue life significantly. See Figure 10,
page 9.
Holes
When drilling holes for mount brackets, supports and outriggers in
the frame rail vertical side wall, SVMs should observe the following
recommendations:
• Material between the edge of the hole and inside of upper or lower
flange must not be less than 37 mm (1.5 in.).
• The minimum edge distance between any two holes must be larger
than twice the diameter of the larger hole.
• No hole should exceed 20 mm (0.75 in.) in diameter.
To avoid premature failure, SVMs should observe these general
guidelines:
• Use existing holes wherever possible.
• Locate holes no closer to the top or bottom flange than existing
holes placed by the chassis manufacturer.
• Avoid placing holes in the lower one-third of the web in the area
immediately behind the cab.
Shear Plate Attachmentshttps://www.4x4community.co.za/forum/showthread.php/173572-Cracked-chassis!-can-you-weld-it
Whenever possible, use existing holes to attach shear plates to
the frame side rails. When additional holes are required, make
sure they are no larger than 20 mm (0.75 in.) in diameter. Drill
holes at least 63.5 mm (2.5 in.) apart, in web area only (not in
top/bottom flanges).
Chassis welding/repair is not as clear cut as some seem to think, you need to establish the cause first. That will tel you what action you need to take and size of the repair to prevent it happening again. Just slapping a bunch of patch plates/box sections could make things worse.There is a rule of thumb, what you do to one side, you do to the other side. On lighter chassis's where repairs are in critical area's you don't want to over stiffen one beam over the other. This is very relevant in the 50Ton and up trailers, where patch plates can cause complete failure on the beam.https://sites.google.com/site/edanneberg/home/metal-work-and-resto-s/rusty-frame-parts
Phosphoric Acid converts Rust (the reddish-brown Iron Oxide) to Ferric Phosphate, a black substance that is stable and offers some protective properties of its own. Heavy rust may take several applications over several hours (or even days). To allow it work for as long as possible, I usually cover the sprayed areas with Saran-Wrap to keep it from flashing off (evaporating) too quickly, while I began work on another section of the frame.
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