SUNPOWER规格书SPEC.docx

Specification,Hot Dip Galvanized SteelDocument Number: 507140 Rev AREV.EC #DESCRIPTIONDATEAUTHORAECR-001984First Release8/6/2013Chelsea Teall &Gelo JuanDocument Number: 507140 Rev A26PROPERTY OF SUNPOWER CORPORATION FILE-021203CONFIDENTIAL INFORMATIONFORM # 001-63005 Rev ATable of Contents1.0Scope3范围2.0Inspection33.0Non-Visual Requirements33.1Adhesion33.1.1Stout Knife Test33.1.1Bend Test (Referee Test)33.2Thickness54.0Visual Requirements64.1General Visual Requirements74.1.1ASTM A123 Excerpts74.1.2SunPowers Interpretation of the ASTM A123 Excerpts84.1.3Mating Surfaces84.2Specific Visual Requirements94.2.1 Desired Surface Conditions104.2.2 Dross Inclusions114.2.3 Flux Deposits/Inclusions124.2.4 Excess Zinc134.2.5 Bare or Thin Spots144.2.6 Other Anomalies151.0 Scope1.0范围This procedure describes and further defines the requirements for SunPower parts that are hot dip galvanized per ASTM A123The Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Productsor ISO 1461Hot Dip Galvanized Coatings on Fabricated Iron and Steel Articles, Specifications and Test Methods. The galvanizer must meet the requirements given within this document. 这个程序描述和进一步定义了SUNPOWER热浸锌零件的镀锌要求 ASTMA123铁和钢产品热浸锌涂层的标准规范。或者ISO1461关于钢和铁装配件的热浸锌涂层的规范和测试方法。镀锌必须满足该文件资料中给出的要求。2.0 Inspection检查In accordance with Section 9.3 of ASTM A123, the material shall be inspected at the galvanizers plant prior to shipment. SunPower may also inspect and test the materials and accept or reject the material after shipment from the galvanizers plant. 与ASTMA123，9.3部分相一致，材料应该在发运到镀锌厂之前进行检查。SUNPOWER也许也监督和测试材料和接收或者材料在从镀锌厂装运发出之后。Frequency of inspection will be determined by SunPower Supplier Quality.检查的频率将由SUNPOWER供应商质量部决定。2.0 Non-Visual Requirements2.0 非可视的要求3.1Adhesion3.1附着力If a part exhibits poor adhesion, then the full replacement cost will be borne by the supplier. “Poor adhesion” includes flaking that occurs while driving piles into the ground; however, damage restricted to the top 4” of the pile during driving is not considered “poor adhesion.”如果一个件的附着力较差，然后，全部的替代成本将由供应商承担。较差的附着力包括锌层脱落发生当把桩管打入地里面；然而，桩管的损坏限制到等级4在打桩过程中不被视为附着力较差。3.1.1Stout Knife Test3.1.1坚实小刀测试法The stout knife is an inadequate test for measuring the adhesion of a coating because it gives false passes to inadequate coatings; however, this is the test suggested by ASTM A123. If the stout knife test is performed and the coating fails, then the part is rejected. If the stout knife test is performed and the coating passes, then a referee test must be done. It is permissible to skip the stout knife entirely and just do the bend test. l 坚实小刀不是一个不充分的测试对于涂层附着力的测量因为它对不充分的涂层给了一个错误的通过；但是，这是被标准ASTMA123建议的测试。如果小刀测试执行了并且涂层是失败的，这个零件将被拒收。如果小刀测试执行了并且涂层通过了，然后一个仲裁测试将被执行。完全跳过小刀测试直接做压扁试验是被允许的。3.1.2Bend Test3.1.2压扁试验The bend test is the referee test for adhesion. The bend test is a destructive test. The bend test may be performed on galvanized components or “samples” described below. 压扁试验是针对附着力的仲裁测试。压扁试验是一个破坏性测试。压扁试验也许被执行在下面描述的镀锌零件或者样品上面。Samples: Before galvanizing, take at least one component from each heat and cut it into smaller pieces. One piece shall be included in each batch of hot-dip galvanized parts. It shall be hung off the rack at the lowest point of the rack. The pieces to be tested shall be cut into 6” x 1” samples (either before or after galvanizing).样品：在镀锌之前，从每个压力下选取至少一个零件并且切成更小的零件片，一片零件将应该包括热浸锌零件的每一批。它应该被从支架上取下在支架的最低点。待测试的零件片应该被切成“6*1”样品。（无论是在镀锌前还是镀锌后）Procedure: Bend the sample over a mandrel until its two legs are parallel (180) or until the coating fails. If the coating fails before the sample is bent 180, then note the degrees of bending at which failure occurred. The mandrel diameter shall be four times the thickness of the sample. 程序：压扁样品在轴胎上直到它的两条腿是平行的（180）或者直到涂层失败。如果在样品被压弯到180度之前涂层已经失败了，然后，标记失效发生时的压扁程度。轴胎直径应该是样品厚度的4倍。Pass/Fail Criteria: The outside surface of the sample shall be evaluated for whether the sample passes/fails the adhesion test. The inside surface (in contact with the mandrel during bending) shall be disregarded.通过/失败标准：样品的外表面应该被评估是否该样品通过/了附着力测试Fail: The galvanization peels or flakes away from the steel with any single fracture in the coating going across the entire width of the sample. Often times, a failing sample will fail before the sample is bent the full 180. The following photos are examples of failing samples. 失败：镀锌脱落或者脱落从钢件伴随着任何单一的断裂在涂层穿越整个样件的宽度。通常次数下，一个失效的样品将失败在样品被完全弯曲到180度。下面的图片是失效样品的照片。Pass: The sample is bent 180 and the galvanization does not peel or flake away from the steel with any single fracture in the coating going across the entire width of the sample. Coating fractures that do not go across the entire width of the sample are not considered failures. The following photos are examples of passing samples. 通过：样品被弯曲到180度并且镀锌层不从钢件上脱落在穿越整个样件的宽度。穿越整个样品宽度的涂层断裂不被认为是失败的。下面是通过样品的照片。3.2Thickness3.2 厚度The thickness of the galvanization on steel shall be measured in accordance with ASTM A123 or ISO 1461. For clarification, the definitions of terms used in this section are provided:钢件镀锌的厚度测量时应该与ASTM123或者ISO1461相一致。对于澄清，提供了条款的定义在下面的部分。ASTM A123 specific (using the magnetic thickness measurement):ASTMA123规格（使用磁性厚度仪来测量）large articlea single component whose surface area is greater than 160 in2. 大件单一零件表面区域高于160英尺。small articlea single component whose surface area is less than or equal to 160 in2.小件-单一零件表面区域小于或者等于160英尺。specimenfor large articles, a single specimen is one third of the large article; in other words, there are three specimens per large article. For small articles, a specimen and a small article are equivalent. 样本对于大件，单一样本是大件的三分之一；换句话说，每个大件有3个样本。对于小件而言，一个样本和一个小件是等价的。average thicknessthe average thickness of three specimens (15 individual measurements). For large articles, this is the average thickness of a single large article. For small articles, this is the average thickness of three small articles. 平均厚度三个测量区域的平均厚度（15个个人的测量）。对于大件而言，这是单一大件的平均厚度。对于小件而言，这是三个小件的平均厚度。minimum average thicknessthe minimum requirement for the average thickness. When expressed in microns, the minimum average thickness is equivalent to the coating thickness grade given in ASTM A123.最小平均厚度平均厚度的最小要求。当用微米 时，最小的平均厚度对于在ASTMA123中给定的涂层厚度等级是等价的。maximum average thicknessthe maximum requirement for the average thickness.最大平均厚度平均厚度的最大要求Average specimen thicknessthe average thickness from no less than five individual measurements on a specimen.平均样品厚度平均厚度在一个样品上从不少于5个个人的测量范围。minimum average specimen thicknessthe minimum requirement for the average specimen thickness. When expressed in microns, the minimum average specimen thickness is equivalent to one coating grade less than the coating grade equivalent to the minimum average thickness (when expressed in microns). 最小平均样品厚度平均样品厚度的最小要求。当用微米表述时，最小平均样本厚度是和小于一个涂层等级的下一个涂层等级等价的（当用微米表述时）Maximum average specimen thicknessthe maximum requirement for the average specimen thickness.最小平均样本厚度平均样本厚度的最大要求。Example: If the minimum average thickness is 85 m, then the coating thickness grade is 85 and the minimum average specimen thickness is 80 m (80 is one coating thickness grade less than 85).举例：如果最小平均厚度是85微米，然后，涂层厚度等级是85并且最小平均样本厚度是80微米（80是小于85的一个涂层厚度等级）ISO 1461 specific: ISO1461规范reference areathe area within which a specific number of single measurements has to be made.参考区域单一测量的具体数区域应该制作：local coating thicknessthe mean value of coating thickness obtained from the specified number of measurements within a reference area for a magnetic test or the single value from a gravimetric test.本地涂层厚度涂层厚度的最小值 从测量的样品数量在一个参考区域从磁性测试 或者单一值从定量分析的测试。mean coating thicknessthe average value of the local thicknesses either on one large article or on all the articles in the control sample.最小涂层厚度本地厚度的平均值或者MINIMUM: 最小 In ASTM A123 language, the minimum average thickness(and therefore the minimum average specimen thickness) shall be the default given in ASTM A123, unless otherwise called out on the drawing. In ISO 1461 language, the mean coating thickness (and therefore the local coating thickness) shall be the default given in ISO 1461, unless otherwise called out on the drawing. 在ASTMA123语言，最小平均厚度（而且因此最小平均样本厚度）将缺少给定在ASTMA123,除非后者在图纸上说出） 在ISO1461语言中，最小涂层厚度（和因此本地涂层厚度）将缺少给定在ISO1461中，除非或者在图纸上说出MAXIMUM: 最大 In ASTM A123 language, the maximum average thickness on the article shall be 8 mils, and the maximum average specimen thickness shall be 10 mils. In ISO 1461 language, the maximum mean coating thickness shall be 8 mils, and the maximum local coating thickness shall be 10 mils. 在ASTMA123语言中，最大平均厚度关于物料应该8毫英寸，而且最大平均样本厚度应该10毫英寸。 在ISO1461语言中，最小涂层厚度将是8英寸，而且最大本地涂层厚度将10毫英寸。3.0 Visual Requirements4.0 可视要求Hot dip galvanized parts shall conform with ASTM A123 or ISO 1461 and the requirements given in this document.Each subsection of Section 4.2has pictures that show different galvanization anomalies that can be categorized as the following:热浸锌零件应该符合ASTMA123或者ISO1461和文件中给定的要求。4.2中的每个XX有图片显示不同的镀锌可以像下面分类： Category 1 Accept. No rework required. 分类1-接受 无返修要求 Category 2 Accept with rework. The galvanization anomaly requires reparation. Once properly repaired, then article is acceptable. 分类2返修后接受。镀锌XX要求返修。一旦被正确的返修，然后该物件就被接收。o Reparation shall be in accordance with ASTM A780 and the zinc-rich paint manufacturers written instructions with a minimum average DFT (dry film thickness) of 3 mils. As per ASTM A780 Annex A2 the thickness measurements shall be taken in accordance with SSPC-PA2. Every repaired part shall have the DFT recorded until it is well established that the zinc-rich paint may be consistently applied at the appropriate thickness (100% over 25 parts), after which the sampling frequency may be reduced to three parts per bundle or another frequency set by SunPower Supplier Quality.If the DFT is too thin, then remediation per the zinc-rich paint manufacturers written instructions must be taken to provide a coating with thick enough DFT; also, the inspection frequency should be increased to 100% for 25 parts before reduced back to the normal rate). o 维修应该符合ASTMA780并且富锌涂层制造被写在说明有最小平均DFT（干膜厚度）为3毫英尺。正如ASTMA780 厚度测量应该符合SSPC-PA2 (measurement of dry paint thickness with magnetic gauges). 每个被修复的零件应该有干膜厚度记录直到它完全建立富锌涂层一致地应用在合适的厚度（100%over 25parts）,在样品频率每捆缩减到3件或者SUNPOWER供应商质量设置的其他的频率。如果干膜厚度太薄，然后修补提供较厚的涂层，检查频率应该增加到100%25个件在缩减到正常比率范围内。o Each area subject to renovation shall be 1 in. 25 mm or less in its narrowest dimension. If the area is greater, then it is Category 3.o 每个面积受控于翻修应该在或者小于它的最窄的尺寸范围。如果面积比这个大，然后进入分类3.o The total area subject to renovation on each article shall be no more than of 1% of the accessible surface area to be coated on that article. If the area is greater, then it is Category 3.o 取决于每个物件上翻修得整个面积应该多于整个物件涂层上可接受面积的1%的一半以上。如果大于这个面积，然后进入分类3. Category 3 Reject. The part may be stripped, re-galvanized, and re-inspected. 分类3-拒收 零件可能脱落条状，重镀，重检。 If any other visual conditions exist that are not represented in the photos provided in this document or if it is questionable whether the part is acceptable or not, then please contact SunPower Supplier Quality. The part and condition will be evaluated through SunPowers MRB/NCR process. 如果存在任何其它的视觉缺陷没有在照片中展示在这份文件中或者不能确定该零件是接受还是拒收，然后请联系SUNPOWER供应商质量。零件和缺陷将通过SUNPOWER的MRB/NCR流程进行重新评估。4.1General Visual Requirements4.1.1ASTM A123 Excerpts4.1.1 ASTMA123摘录The following excerpts are from ASTM A123 and will be discussed in more detail in Section 4.1.2. 从ASTMA123中获取的摘录将在4.1.2中详细讨论。6 Coating Properties6涂层性质6.2“FinishThe coating shall be continuous (except as provided below), and as reasonably smooth and uniform in thickness as the weight, size, shape of the item, and necessary handling of the item during the dipping and draining operations as the galvanizing kettle will permit. Except for local excess coating thickness which would interfere with the use of the product, or make it dangerous to handle (edge tears or spikes), rejection for nonuniform coating shall be made only for plainly visible excess coating not related to design factors such as holes, joints, or special drainage problems (see Note 6). Since surface smoothness is a relative term, minor roughness that does not interfere with the intended use of the product, or roughness that is related to the as-received (un-galvanized) surface condition, steel chemistry, or steel reactivity to zinc shall not be grounds for rejection (see Note 7). Surface conditions related to deficiencies related to design, detailing, or fabrication as addressed by Practice A 385 shall not be grounds for rejection. The zinc coating on threaded components of articles galvanized under this specification shall conform to that required in Specification A 153/A 153M. Surfaces that remain uncoated after galvanizing shall be renovated in accordance with the methods in Practice A 780 unless directed by the purchaser to leave the uncoated areas untreated for subsequent renovation by the purchaser. 完成-涂层将是持续的（除了下面提供的），而且重量，尺寸，厚度和形状大致光滑和均一，而且这些项的必要处理在浸泡和XXX操作当镀锌壶允许的情形下，除了本身超过涂层厚度将和产品的使用产生干涉，或者使它很难去处理（边缘tears和spikes）,拒绝非均匀涂层应该进行 ，由于表面光滑是个相对项，小的粗糙度不会和产品的目的使用产生干涉，6.2.1Each area subject to renovation shall be 1 in. 25 mm or less in its narrowest dimension.每个区域受制于翻新将在25mm左右在更窄的尺寸。6.2.2The total area subject to renovation on each article shall be no more than of 1% of the accessible surface area to be coated on that article, or 36 in2 per short ton 256 cm2 per metric ton of piece weight, whichever is less.每个物件上翻新的总面积将不多于可接受面积的1%的一半在有涂层的那个物件上，或者每米顿25平方厘米，或者更少。6.2.3The thickness of renovation shall be that required by the thickness grade for the appropriate material category and thickness range in Table 1 in accordance with the requirements of 6.1, except that for renovation using zinc paints, the thickness ofg5 renovation shall be 50% higher than that required by Table 1, but not greater than 4.0 mils.要求的翻新的厚度，除了翻新使用锌涂层，翻新的厚度应该比Table 1中要求的高，但是不大于4.0mils.6.2.4When areas requiring renovation exceed the criteria previously provided, or are inaccessible for repair, the coating shall be rejected.”6.4“AppearanceUpon shipment from the galvanizing facility, galvanized articles shall be free from uncoated areas, blisters, flux deposits, and gross dross inclusions. Lumps, projections, globules, or heavy deposits of zinc which will interfere with the intended use of the material will not be permitted. Plain holes of -in. 12.5-mm diameter or more shall be clean and reasonably free from excess zinc. Marks in the zinc coating caused by tongs or other items used in handling the article during the galvanizing operation shall not be cause for rejection unless such marks have exposed the base metal and the bare metal areas exceed allowable maximums from 6.2.1 and 6.2.2. The pieces shall be handled so that after galvanizing they will not freeze together on cooling.” 外观从镀锌设备出来装运前，镀锌物件应该没有未镀区域，起泡，XXX和总夹杂物。肿块，喷溅，小球状体或者干涉材料使用的富锌是不允许的。6.5“AdhesionThe zinc coating shall withstand handling consistent with the nature and thickness of the coating and the normal use of the article, without peeling or flaking.” 附着力镀锌层将抵抗操作始终与本质和涂层的厚度和物件的正常使用，没有剥落。4.1.2SunPowers Interpretation of the ASTM A123 Excerpts4.1.2 Sunpower对于ASTMA123概念的解释Conditions that are acceptable per ASTM A123:在ASTMA123中下列条件是可接受的： Continuous, smooth, and uniform coating. 连续，光滑和均匀的涂层 Shiny or matte surface. 光亮或者压光表面 Spangle. 亮片 Excess zinc in a local area that is not designated as mating surfaces, not in a hole/slot greater than -in diameter, and not an edge tear or spike. Other exclusions given in Section 3.3 may apply. 富含锌量在非指定的啮合表面区域，不在一个孔大于并且非边缘撕裂或者刺突，在3.3部分给定的其它除外条件可以应用.如下条件是可以接受的，虽然没有在ASTM123中强调： Small dross inclusions that are not at a mating surface and are tightly adherent to the part (if the dross inclusion can come off during installation, then that is unacceptable). 不在配合面且与零件粘合比较紧的小的废渣（如果废渣在安装中脱落，就是不可接受的） Zinc skimming or ash: Zinc skimming that deposit on the part as it is withdrawn from the bath. If zinc skimmings are shown to reduce the underlying coating thickness, then the article is unacceptable until repaired. 锌渣或者锌灰：从锌池中抽出时富集在零件表面上的锌渣锌灰。如果Conditions that are unacceptableper ASTM A123 (some are reparable, some are not):在ASTMA123中，下列条件是不可接受的（有些是可修复的，有些是不可以的）： Edge tears or spikes. 边缘撕裂或者脱落。 Excess zinc at mating surfaces or in holes/slots greater than -in diameter (interferes with the function of the part); includes lumps, projections, globules, or heavy deposits of zinc. 在配合面/孔/键槽区域富含锌 包括肿块，小球，凸起，附富锌 Uncoated areas. 未镀锌区域 Blisters. 水泡 Flux deposits/inclusions. 熔渣 Gross dross inclusions. Poor adhesion of galvanization to steel; no peeling or flaking is acceptable, whether it is upon shipment or during installation. Steel must meet the compositional requirements given in ASTM A385.Conditions that are unacceptable in addition to ASTM A123:在ASTMA123中以下情形是不可接受的： Deficiencies in galvanization related to metal, fabrication, and/or galvanizing manufacturing processes will be the responsibility of the supplier and suppliers subcontractor. 由金属，装配和镀锌制造流程造成的镀锌缺陷将由供应商或者供应商的分销商负责。Note: Both the supplier and the suppliers galvanizing subcontractor (if applicable) shall provide written notification to SunPower if the geometry or other design aspects will likely result in galvanizing defects, poor galvanizing quality, and/or manufacturing issues.注意：如果测量或者其它设计方面将有可能造成镀锌缺陷和锌层质量差或者制造问题，供应商和供应商的镀锌分包商（如适用）应该提供书面的告知书给Sunpower。More specific require