热喷涂铝涂层质量要求.docVIP

目 录 1工艺鉴定要求工艺鉴定要求 6 1 1总则 6 1 2工艺过程要求 6 1 3工艺鉴定程序 6 1 4工艺鉴定试验及试样要求 6 1 4 1试样要求 6 1 4 2试验项目及试样数量 7 1 5试验方法及质量指标 7 1 5 1外观 7 1 5 2铝涂层的表面粗糙度 7 1 5 3铝涂层厚度 7 1 5 4结合强度 7 1 5 5耐蚀性 7 1 6鉴定状态的保持 7 2批生产中工件检验要求批生产中工件检验要求 8 2 1外观 8 2 2铝涂层的表面粗糙度 8 2 3铝涂层厚度 8 2 4结合强度 8 2 5耐蚀性 8 3参考文献参考文献 8 confidentiality level confidential REV B 2012 03 23 表目录 表表1 鉴定试验项目及试样数量鉴定试验项目及试样数量 7 图目录 图图1 工艺鉴定用试样制作图形工艺鉴定用试样制作图形 6 图图2 过渡区示意图过渡区示意图 8 2012 03 23 Error Reference source not found 范范 围围 本规范规定了热喷涂铝涂层的工艺和质量要求 本规范适用于对钢板材料或铝材表面进行局部修复而进行的处理 简简 介介 本规范对热喷涂铝的适用场合 基材对象 加工工艺流程及其后处理限制以及铝涂层的质量要求作出了明确规定 其 中质量要求包括外观 膜厚 表面粗糙度 耐蚀性 结合力等 关键词关键词 热喷涂 铝 修复 引用文件引用文件 下列文件中的条款通过本规范的引用而成为本规范的条款 凡是注日期的引用文件 其随后所有的修改单 不包括勘 误的内容 或修订版均不适用于本规范 然而 鼓励根据本规范达成协议的各方研究是否可使用这些文件的最新版本 凡 是不注日期的引用文件 其最新版本适用于本规范 序号序号文件编号文件编号文件名称文件名称等效标准等效标准 1IEC 60068 2 11基本环境试验程序 第2部分 试验 试验Ka 盐雾GB 10125 ASTM B117 2ISO 1463金属和氧化物镀层 镀层厚度的测定 显微镜法GB T 6462 3ISO 2178磁性基质的非磁性镀层 镀层厚度的测量 磁性法GB T 4956 4ISO 2409涂料和清漆 交叉切割试验GB T 9286 5DKBA0 450 0012 铝及铝合金化学转化膜质量要求 术语和定义术语和定义 术语术语 定义定义 生产批指同一天在相同条件下处理的 材料和形状相似的零件的总和 2012 03 23 1 工艺鉴定要求工艺鉴定要求 1 1总则总则 热喷涂铝工艺只适用于对钢板基材或铝材所进行的局部修复处理 或者表面局部导电化处理 生产者的工艺设备 工艺流程 质量保证措施应在其主要的工艺文件中加以说明 生产者的工艺质量必须满足第 1 2 至 1 6节的要求 1 2工艺过程要求工艺过程要求 1 热喷涂铝处理必须在工件喷涂有机涂层后进行 2 热喷涂铝涂层进行化学转化的后处理 可以采用刷涂 喷涂或浸涂等各种方式 1 3工艺鉴定程序工艺鉴定程序 被鉴定的工厂必须完成以下全部试验工作 这些试验必须在零件批生产所用的条件下完成 1 试样加工 注1 2 表面处理 注2 3 试样检查及测试 按1 4节 4 提供试验报告 注3 及试片给华为技术有限公司以便复验 注 1 鉴定用试样也可由华为技术有限公司完成并提供给被鉴定工厂 2 所有试样必须同时进行处理 3 试验报告的发出者必须是华为技术有限公司认可的试验室或单位 1 4工艺鉴定试验及试样要求工艺鉴定试验及试样要求 1 4 1试样要求 材料 冷轧钢板 尺寸 80 125 1 4 mm 表面粗糙度 Ra 1 mm 表面处理 先局部喷粉后再进行热喷涂铝处理 喷涂范围见图1 粉末涂层区域 蓝色部分 热喷涂铝涂层区域 面积不小于50 100 图1 工艺鉴定用试样制作图形 2012 03 23 1 4 2试验项目及试样数量 表1给出了工艺鉴定所需的试验项目和试样数量要求 表1 鉴定试验项目及试样数量鉴定试验项目及试样数量 试验项目试验项目试样数量 件 试样数量 件 外观所有试样 铝涂层厚度所有试样 表面粗糙度所有试样 结合强度3 耐蚀性 3 3 注 其中三件为提供华为技术有限公司进行复验用 1 5试验方法及质量指标试验方法及质量指标 1 5 1外观 所有试样均应进行外观检查 铝涂层应结晶均匀 致密 连续 经化学转化后外观符合转化膜相关要求 不允许 起皮 鼓泡 大熔滴 裂纹 掉块和严重水纹印 1 5 2铝涂层的表面粗糙度 所有试样均应进行粗糙度检测 用粗糙度测量仪器在每个试样上取至少5个点进行测试 其值必须符合以下要求 平均Ra低于12 5 m 1 5 3铝涂层厚度 所有试样均应进行厚度检测 按 ISO 2178 进行非破坏性测试 或采用其它等效的方法 每一试样上测取 10 个点 其值均应在 80 m以上 1 5 4结合强度 在三件试样上进行结合强度试验 按 ISO 2409 的试验方法 在试样上划出 2mm 见方的小格 然后用标准胶带 3M公司的Scotch 250 拉扯 应无 任何涂层脱落现象 1 5 5 耐蚀性 在三件试样上进行耐蚀性试验 经化学转化处理后的铝涂层应符合 DKBA0 450 0012 的要求 即按IEC 60068 2 11进行盐雾试验应通过100H 1 6鉴定状态的保持鉴定状态的保持 经过华为技术有限公司鉴定的工艺 在未得到华为技术有限公司的同意之前 不能改变任何可影响性能质量的工艺参 数 否则将重新进行鉴定 2012 03 23 2 批生产中工件检验要求批生产中工件检验要求 2 1外观外观 所所有工件都应进行外观检查 铝涂层应呈哑白色 结晶均匀 致密 连续 无起皮 鼓泡 大熔滴 裂纹 掉块和严重水纹印等缺陷 与粉末涂层的交界边缘应整齐 无疏松颗粒 不露底材金属 而且铝层应覆盖一些粉末层形成过渡 过渡区宽度为 1 3mm左右 如下图所示 铝涂层 有机涂层 有机涂层 钢基材 1 3mm 图2 过渡区示意图 2 2铝涂层的表面粗糙度铝涂层的表面粗糙度 每生产批工件抽检至少一件 每个表面上取至少5个点进行测试 其值必须符合以下要求 平均Ra值低于12 5 m 2 3铝涂层厚度铝涂层厚度 所有工件均应进行厚度检测 按 ISO 2178 进行检测 在零件表面 凡能被直径为 20 mm 的球接触到的区域 厚度均应在 60 150 m范围内 凡直径为 20 mm 的球不能接触到的区域 其厚度不作要求 2 4结合强度结合强度 每生产批至少检查一件工件或样件 按 ISO 2409 的试验方法 在试样上划出 2mm 见方的小格 然后用标准胶带 3M公司的Scotch 250 拉扯 应无 任何涂层脱落现象 2 5 耐蚀性耐蚀性 在试样上进行耐蚀性试验 每生产批至少检测三件 经化学转化处理后的铝涂层应符合DKBA0 450 0012 的要求 即应通过100H的盐雾试验 按IEC 60068 2 11进行 3 参考文献参考文献 制定本规范参考的文献 但没有直接引用里面的内容 序号序号文献编号或出处文献编号或出处 文献名称文献名称 1GB 9795热喷涂铝及铝合金涂层 2实用新型专利说明书 CN 2676567Y导电屏蔽机柜机箱的构件 2012 03 23 TABLE OF CONTENTS 1REQUIREMENTS FOR PROCESS AUTHENTICATION 11 1 1GENERAL PRINCIPLE 11 1 2REQUIREMENTS FOR PROCESS 11 1 3PROCEDURE OF PROCESS AUTHENTICATION 11 1 4REQUIREMENTS FOR THE SAMPLE OF PROCESS AUTHENTICATION 11 1 4 1Requirements for Samples 11 1 4 2Test Items and Quantity of Samples 12 1 5TEST METHODS AND QUALITY INDEXES 12 1 5 1Appearance 12 1 5 2Surface Roughness of Aluminum Coating 12 1 5 3Thickness of Aluminum Coating 12 1 5 4Binding Strength 13 1 5 5Corrosion Resistance 13 1 6RETENTION OF AUTHENTICATION STATUS 13 2INSPECTION REQUIREMENTS FOR PARTS DURING BATCH PRODUCTION 13 2 1APPEARANCE 13 2 2SURFACE ROUGHNESS OF ALUMINUM COATING 14 2 3THICKNESS OF ALUMINUM COATING 14 2 4BINDING STRENGTH 14 2 5CORROSION RESISTANCE 14 3REFERENCE DOCUMENT 14 LIST OF TABLES TABLE 1 TEST ITEMS AND QUANTITY OF SAMPLES 12 LIST OF FIGURES FIGURE 1 SAMPLE FOR PROCESS APPRAISAL 12 FIGURE 2 THE TRANSITIONAL AREA 13 2012 03 23 Error Reference source not found Scope The technical specifications herein stipulate the process requirements and quality requirements for the thermal spray aluminum coating The technical specifications are applicable to the local repair of the surface of the steel plates or aluminum material Brief Introduction The technical specifications expressly stipulate the applicable scenarios matrix materials process flow and after treatment restrictions of thermal aluminum spraying as well as the quality requirements for the aluminum coating The quality requirements cover its appearance film thickness surface roughness corrosion resistance and binding strength Keywords Thermal spraying aluminum and repair Normative references The following normative documents contain provisions which through reference in this text constitute provisions of the specifications For dated references subsequent amendments excluding corrections to or revisions of any of these publications do not apply However parties to agreements based on this specification are encouraged to investigate the possibility of applying the most recent editions of the normative documents For undated references the latest edition of the normative document referred to applies No Document No Document TitleEquivalent 1IEC 60068 2 11Basic environmental testing procedures Part 2 Tests Test Ka Salt mistGB 2423 17 ASTM B117 2ISO 1463Metallic and oxide coatings Measurement of coating thickness Microscopical method GB T 6462 3ISO 2178Non magnetic Coating on Magnetic substrates Measurement of coating Thickness Magnetic Method GB T 4956 4ISO 2409Paint and Varnish Cross Cut Test GB T 9286 5 DKBA0 450 0012 Requirements for Chemical Conversion Coating on Aluminum and Its Alloys Term Definition Term Definition Explanation BatchThe sum of the parts with the similar materials and shape that are processed in the same conditions on the same day 2012 03 23 1 Requirements for Process Authentication 1 1General Principle The process of thermal aluminum spraying is only applicable to local repair of the steel plate matrix or aluminum material or local conductive treatment on the surface The producer s processing equipment process flow and quality assurance measures should be described in its main process documents The producer s process quality should come up to the requirements as stipulated in sections 1 2to 1 6 1 2Requirements for Process The process of thermal aluminum spraying cannot be implemented unless an organic coating is sprayed to the part The thermal sprayed coating of aluminum must undergo the chemical conversion after treatment by means of brushing spraying or dip coating 1 3Procedure of Process Authentication The factory to be appraised should complete all the following tests upon condition that the parts are produced in batches Sample processing Note 1 Surface treatment Note 2 Sample inspection and test for details see section 1 4 The test report for details see Note 3 and test pieces should be provided to Huawei for the purpose of re inspection 1 The test pieces can be arranged and provided by Huawei for the factory 2 All samples must be processed at a time 3 The test report must be released by a laboratory or institution recognized by Huawei 1 4Requirements for the Sample of Process Authentication 1 4 1 Requirements for Samples Material Cold rolled steel sheet Size 80 125 1 to 4 mm Surface roughness Ra 1 m Surface treatment Spray powders locally first and then implement thermal aluminum spraying Error Reference source not found describes the spraying range 2012 03 23 Powder coating Blue Thermal spraying aluminum coating the sprayed area is not smaller than 50100 Figure 1 Sample for process appraisal 1 4 2 Test Items and Quantity of Samples Error Reference source not found describes the required test items and quantity of samples Table 1 Test items and quantity of samples Test ItemQuantity of Samples AppearanceAll samples Thickness of aluminum coatingAll samples Surface roughness All samples Binding strength3 Corrosion resistance3 3 Note Three samples are provided to Huawei for the purpose of re inspection 1 5Test Methods and Quality Indexes 1 5 1 Appearance All samples should undergo appearance inspection The aluminum coating should be crystallized evenly closely and continuously After chemical conversion the appearance should meet the related requirements for the conversion coating The following defects are not allowed peeling bubble big molten drop crackle block drop and striking watermark 1 5 2 Surface Roughness of Aluminum Coating All samples should undergo thickness the test of surface roughness Test at least five points in every sample by using a roughness meter The roughness should meet the following requirements The average value Ra is lower than 12 5 m 1 5 3 Thickness of Aluminum Coating All samples should undergo thickness measurement Conduct a non destructive test by using a method as described in ISO 2178 or by using an equivalent method Test ten points in each sample The average value should be at least 80 m 2012 03 23 1 5 4 Binding Strength Test the binding strength for three samples Scratch a small check 2 2 mm in the sample by using a method as described in ISO 2409 and then pull it by using a standard adhesive tape the Scotch 250 adhesive tape of 3M Ensure that no coating falls off 1 5 5 Corrosion Resistance Conduct the corrosion resistance test in the three samples After undergoing the chemical conversion treatment the aluminum coating should comply with DKBA0 450 0012 that is pass the 100H salt fog test in accordance with IEC 60068 2 11 1 6Retention of Authentication Status Without prior consent of Huawei do not modify the process parameters of any process appraised by Huawei which may affect its performance quality Otherwise the process has to be appraised again 2 Inspection Requirements for parts During Batch Production 2 1Appearance All parts should undergo appearance inspection The aluminum coating should be flat white in color and be crystallized evenly closely and continuously The following defects are not allowed peeling bubble big molten drop crackle block drop and striking watermark The border between the aluminum coating and the powder coating should be tidy No loose grains are allowed No substrate metal should be exposed The aluminum coating should be covered by a powder coating for forming a transitional area The transitional area should be 1 to 3 mm in width as shown in the following table Aluminum coating Organic coating Organic coating Steel base 1 to 3 mm Figure 2 The transitional area 2 2Surface Roughness of Aluminum Coating Among every batch of workpieces at least one workpiece should be tested 2012 03 23 Test at least five points in every surface The measured values should meet the following requirements The average Ra value is lower than 12 5 m 2 3Thickness of Aluminum Coating All workpieces should undergo thickness measurement Measure the coating thickness in accordance with ISO 2178 On the surface of t