Case Study 01 · Semiconductor

Environmentally Friendly Pre-Coating Surface Treatment for Sheet Metal Products Used in the Semiconductor Industry

ACE Malaysia is implementing a phosphate-free zirconium conversion process that combines stronger environmental performance with disciplined, production-ready quality control.

Qualification programme in progress

Phosphate-freeNo phosphorus or intentionally added heavy metals in the conversion stage

Up to 1,000 hNeutral salt-spray validation achieved in previous zirconium trials

5 substrate typesSteel, galvanized steel, aluminium, zinc alloy and magnesium alloy

Low-sludge processSimpler bath management with reduced waste and energy demand

The challenge

A cleaner pretreatment route without compromising corrosion protection.

Semiconductor equipment supply chains increasingly require phosphate-free surface preparation, lower wastewater loading and robust material traceability. The change must still deliver dependable coating adhesion and corrosion resistance across multiple sheet metal substrates.

The programme also had to fit ACE Malaysia's existing immersion line, preserve production control during process changeover, and provide objective evidence before mass-production approval.

The solution

Zirconium nano-conversion coating.

Replaces conventional phosphate conversion with a phosphate-free zirconium film.
Removes surface-conditioning and accelerator-management stages.
Runs the conversion stage without the conventional heated phosphating bath.
Uses final deionised-water control to protect film quality before dry-off and powder coating.
Supports multi-metal production on one controlled line.

Controlled process

From incoming part to coated product

Critical process stages are controlled through documented checks, reaction plans and traceable inspection records.

1LoadPart & hanger check

2DegreaseClean surface

3RinseCarry-over control

4Zr conversionControlled immersion

5DI rinseFinal water control

6InspectFilm & coating weight

7Powder coatProtected transfer

Quality assurance

Three layers of control

Shift-level process checks

Bath condition, rinse performance, timing and exit appearance are checked against controlled work instructions. Any critical excursion stops the line and holds affected work.

Laboratory verification

Bath analysis, instrument calibration and trend monitoring provide an independent check on line control and trigger corrective action when required.

Performance validation

Coating-weight measurement, cross-cut adhesion and neutral salt-spray testing verify that the complete pretreatment and coating system meets the agreed specification.

Expected impact

Better environmental performance, built for regional production.

The zirconium route reduces chemical stages, sludge generation, heating demand and wastewater loading while maintaining the disciplined verification expected for semiconductor-industry products.

Qualification is being completed through coupon trials, first-article verification, salt-spray testing and customer approval before mass-production release at ACE Malaysia.

Controlled production area at ACE Malaysia

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