En çok kullanılan ön işlem "fosfat kaplama" veya "fosfatlama" olarak bilinir.
Fosfat kaplama, bir metal ile bir kimyasal çözeltinin reaksiyonu sonucunda oluşur. Fosfat, boyanacak yüzeydeki demir, çinko ve mangan kristallerinin oluşturduğu tabaka şeklindeki formdur. Demir fosfat, çinko fosfat,mangan fosfat ve zirkonyum fosfat olarak değişik uygulamaları vardır.
Genel olarak boya altı uygulandığı gibi koruyucu yağlar öncesinde kullanılabilir. Demir, çelik ve bazı durumlarda da alüminyum ve çinko yüzeyleri kaplamak içinde kullanılabilir. Daldırma ve sprey kullanımı yaygındır.
Sıcaklık, konsantrasyon, zaman, pH ve toplam-serbest asit dikkat edilmesi gereken noktalardır.
Fosfatlama işlemi 35-98ºC sıcaklıkta 5-10 dakika ve %3-20 konsantrasyonlarda yapılabilmesinin nedeni fosfat türü ve proses şeklidir. Genelde bir metal fosforik asitle reaksiyona girerse, fosfat kaplanacağı anlamı çıkartılabilir. Fosfat kaplama reaksiyonu metal yüzeyin fosforik asit ile eritilmesi sonucu, asit-baz reaksiyonu olarak kabul edilir. Bu erime gerçekleşirken pH artışı gözlenir. Metalik fosfat metal üzerinde çözünmez bir hal alır ve metalik renkli bir yapı oluşturur.
Bu kaplama sayesinde boya zerrelerinin metal yüzeyine yapışma kabiliyeti artar ve boya ömrü uzar. Malzeme korozyona karşı daha dirençli hale gelir ve dolayısı ile garanti süresi artmış olur.
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