Abstract: An improved process for applying a coating by means other than electrodeposition to an untreated ferrous metal substrate is disclosed. The substrate need not be phosphated prior to treatment. The process includes contacting the substrate surface with a Group IIIB and/or IVB metal-containing compound in a medium that is essentially free of accelerators, phosphate, zinc, and polymeric material, and coating the substrate by non-electrolytic means. This composition is then cured by conventional means. Substrates treated by the process of the present invention demonstrate excellent corrosion resistance and are also disclosed herein.

Abstract: The present invention provides a metal substrate coated with a first pretreatment composition including a transition element-containing material having one or more Group IIIB elements, Group IVB elements, lanthanide series elements or mixtures thereof; and a second pretreatment composition including a reaction product of at least one epoxy-functional material or derivative thereof and at least phosphorus-containing material, amine-containing material and/or sulfur-containing material deposited upon the first pretreatment composition. If desired, the first and second pretreatment compositions can be combined into a single pretreatment.

Abstract: A composition for passivating a metal substrate is provided. The composition is prepared by mixing together: a) Group IIIB or IVB metal compound; and b) a reaction product of an epoxy group-containing polymer or oligomer, a hydroxy functional acid and a dialkanolamine. The compositions, which are substantially free of chrome, are used to treat metal substrates prior to the application of a protective or decorative coating.

Abstract: An improved process for applying a lead-free coating by electrodeposition to an untreated ferrous metal substrate is provided. The substrate need not be phosphated prior to treatment. The process includes the following steps: a) contacting the substrate surface with a group IIIB or IVB metal compound in a medium that is essentially free of accelerators needed to form phosphate conversion coatings; followed by b) electrocoating the substrate with a substantially lead-free, curable electrodepositable composition; and c) curing the electrodepositable composition. The group IIIB or IVB metal compound is preferably a zirconium compound and is typically in an aqueous medium. The process may further include initial steps of cleaning the substrate with an alkaline cleaner and rinsing with an acidic rinse. Substrates treated by the process of the present invention demonstrate excellent corrosion resistance.