铝及铝合金化学转化膜质量要求.doc

目 录 1工艺鉴定要求工艺鉴定要求 6 1 1总则 6 1 2对生产设备及原材料的要求 6 1 2 1生产线 6 1 2 2水质要求 6 1 2 3化工原材料要求 6 1 2 4质量检验手段 6 1 3工艺鉴定程序 6 1 4试验及试片要求 6 1 4 1试片要求 6 1 4 2试验项目及试片数量 7 1 5试验方法及质量指标 7 1 5 1外观 7 1 5 2耐蚀性 7 1 5 3表面接触电阻 7 1 5 4无色转化膜中的六价铬含量 7 1 6鉴定状态的保持 7 2批生产过程中零件质量检验要求批生产过程中零件质量检验要求 7 2 1外观 7 2 2耐蚀性 8 2 3表面接触电阻 8 2 4六价铬含量 8 表目录 表表1 试验项目与试片试验项目与试片 7 密级 秘密 Error Reference source not found 2012 03 20Total14 Error Reference source not found 范范 围围 本规范规定了铝及铝合金无色化学转化处理的工艺要求及其质量要求 本规范适用于铝及铝合金无色化学转化处理的工艺鉴定 首样鉴定和批生产质量检验 可用于指导产品设计 采购和生产 以及用于生产者在零件化学转化处理过程中的质量检验 供应商来料验收的抽检比例可按其它相关文件执行 简简 介 介 铝合金化学转化处理是一种化学加工工艺 用此工艺所得到的表面膜层可作为有机涂层的底层 也可单独作为 防腐蚀层应用 本规范明确规定了处理工艺为无色化学转化工艺 并制定了此种表面膜层的外观 耐蚀性 表面接 触电阻等质量指标 作为华为对生产方进行工艺鉴定和生产者对零件生产质量进行控制的依据 关键词 关键词 铝 化学转化 膜 防腐蚀 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 2423 17 ASTM B117 2ISO 3613锌 镉 铝 锌合金和锌 铝合金的铬酸盐转化膜 试验方 法 GB T 9791 3ISO 4288触针式仪器测量表面粗糙度的规则和方法GB 10610 4GB 5749生活饮用水卫生标准 5DKBA0 450 0011 铝及铝合金阳极氧化质量要求 6YB010标准样板 喷砂光亮阳极化 7YB019标准样板 拉丝 术语和定义术语和定义 术语术语 定义定义 化学转化通过化学处理使金属参与化学反应而在其表面形成不溶性盐类膜的处理 过程 当所形成的膜层是氧化膜时 则称作 化学氧化 当形成的膜 层是铬酸盐膜时又称作 铬酸盐处理 或 铬化 无色化学转化指铝材表面转化膜呈无色状 即铝本色 的化学转化工艺 喷砂光亮无色化学转化指经喷砂处理后再进行化学抛光和无色化学转化的表面处理工艺 阳极氧化在电流作用下 位于阳极的工件表面在电解液中形成氧化膜的处理过程 简称 阳极化 局部氧化指在一个铝零件上 一部分表面是阳极氧化 另一部分表面是化学转化 的表面处理工艺方法 全自动 或半自动 氧化 生产线 全自动线 指零件的氧化处理过程均没有手工介入 全部由设备自动控 制完成的生产线 半自动线 指零件的氧化处理过程中除吊装设备由手工控制运动外 其 它过程参数全部由设备自动控制完成的生产线 表面接触电阻是指接触件在进行机械接触时如通过电流 则在接触面处形成电压降 这个电压降和通过的电流求出的电阻称为表面接触电阻 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 密级 秘密 Error Reference source not found 2012 03 20Total14 术语术语 定义定义 丝印即丝网印刷 一种印刷工艺方法 密级 秘密 Error Reference source not found 2012 03 20Total14 1 工艺鉴定要求工艺鉴定要求 1 1总则 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 节的要求 1 2对生产设备及原材料的要求 1 2 1 生产线 生产方必须具备半自动 或全自动氧化生产线 不允许用手工线生产 每个槽位都必须有温度 时间的控制显示器 并在有效校验周期内 烘干设备能自动控制温度和时间 1 2 2 水质要求 所有工艺槽的配制用水必须用去离子水或蒸馏水 化学转化处理前后的清洗用水必须用去离子水或蒸馏水 其它清洗用水必须达到 GB 5749 饮用水要求 清洗槽中水流方式应采用逆流 或者定时更换 注 去离子水或蒸馏水的水质要求达到 PH 5 0 7 5 电导率不大于 10 S cm 1 2 3 化工原材料要求 化学转化处理前各工艺槽所用化工原材料必须不低于相应工业级材料的国家标准要求 化学转化及以后所用化工原材料必须不低于相应化学纯级材料的国家标准要求 1 2 4 质量检验手段 生产方必须具有以下检测仪器 盐雾试验箱 粗糙度检测仪 表面接触电阻测量仪器 以及常规化学分析仪器 并能进行合格的试验操作 所有检测仪器设备都必须具有有效的校验合格证 注 盐雾试验也可委托外部进行 但其试验单位必须得到华为技术有限公司认可并备案 1 3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 试片加工 注1 表面处理 注2 试片检查及测试 提供试验报告 注3 及试片给华为技术有限公司以便复验 注注 1 鉴定用试片可由华为技术有限公司完成并提供给被鉴定工厂 2 所有试片必须同时进行处理 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机构 1 4试验及试片要求 1 4 1 试片要求 材料 6063 裸铝板 尺寸 80 125 1 4 mm 表面粗糙度 Ra 1 m 密级 秘密 Error Reference source not found 2012 03 20Total14 表面处理 无色化学转化 若需要局部氧化时 应在试片的同一面保持一半是阳极氧化膜 一半是化学 转化膜 1 4 2 试验项目及试片数量 下表给出了工艺鉴定所需的试验项目和试片数量要求 表表1 试验项目与试片试验项目与试片 试验项目试片数量 片 外观2 耐蚀性6 表面接触电阻2 膜层中的六价铬含量2 注注 其中一半试样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 1 5 1 外观 所有试片应进行外观检查 转化膜应是无色透明膜 表现为铝基底颜色 膜层必须连续 均匀 完整 无划伤 污染和腐蚀现象 要求 光亮 化处理的外观应与 YB015 保持一致 局部氧化的表面 两种膜层的分界整齐 无溶液渗漏现象 每种膜层外观均符合其对应的质量标准 1 5 2 耐蚀性 按 IEC 60068 2 11 进行 100 小时的中性盐雾试验 试验后 在每一试片边缘5mm以外的表面上直径不大于 0 8 mm 的腐蚀点不能多于三个 1 5 3 表面接触电阻 按下面所述方法在试片上的化学转化区域测试接触电阻 利用微欧计 两个电极与被测表面接触 电极面积为 1cm2 电极压强为 1 4MPa 即压力 14kgf 在试样 表面上任取两点进行测量 共测五次 其平均值应不大于10m 1 5 4 无色转化膜中的六价铬含量 按 ISO3613 中的六价铬存在试验方法检测转化膜中是否存在六价铬 如果发现存在六价铬 则应利用ISO3613中的比色法定量检测六价铬含量 检测机构必须得到华为技术有限公 司认可 要求转化膜中的六价铬含量不能高于900ppm 1 6鉴定状态的保持 生产者应保持并遵守经华为技术有限公司正式批准的工艺和检验文件 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 2 批生产过程中零件质量检验要求批生产过程中零件质量检验要求 2 1外观 1 所有零件都应进行外观检查 2 处理后的零件应呈现铝基底颜色 转化膜必须连续 均匀 完整 零件表面不允许有划伤 污染 腐蚀 痕迹或疏松粉末 但允许有轻微的夹具印 焊缝及焊点处不允许膜层发黑 盲孔周围允许有轻微的 孔 密级 秘密 Error Reference source not found 2012 03 20Total14 口半径方向外延不超过2mm 水印痕迹 3 喷砂表面外观应与标准样板 YB010 一致 拉丝外观应与 YB019 一致 当有争议时 按 ISO4288 方法 测试其粗糙度 Ra 应分别为 喷砂在1 4 2 0 m 拉丝在1 7 2 7 m 4 对局部氧化的零件 阳极氧化膜可以向化学转化膜区域扩展 允许扩展的深度最多2mm 而化学转化膜不能向阳极氧化膜区 域扩展 两种膜层的分界线应清晰 整齐 不能呈锯齿状 不能有溶液渗漏现象 2 2耐蚀性 1 耐蚀性检查在与零件同时处理的试片 材料为6063裸铝 尺寸为80 125 或压铸 型材零件上进行 生 产零件为铝板材时用试片 生产零件是型材或压铸件时用零件或零件上的截取部分 2 试验应在化学转化处理完成 24H 以后 三天之内进行 每生产批至少检查一件 3 按 IEC 60068 2 11进行中性盐雾试验 除铝压铸件进行 48 小时的试验外 其它铝零件要求进行100 小 时的试验 试验后 在试样距边缘5mm以外的表面上 每 1dm2表面上的腐蚀点不能多于 3个 直径不 大于 0 8 mm 零件上的孔周边作为边缘对待 4 当生产的零件尺寸太大 不能放入试验箱 时 可以用该零件上的典型结构部分作替代试样 5 对于化学转化处理后进行了局部喷涂处理的零件 不要求检测耐蚀性 6 对于化学转化后只进行丝印 不再进行其它处理的零件 耐蚀性要求与上面第3 点一致 2 3表面接触电阻 1 检测在零件上的无色化学转化处理区域进行 2 每生产批零件至少检查一件 按 1 5 3 节的描述进行检测 要求零件上任意两点间的电阻不大于 20 m 3 若零件面积小于 1cm2 允许用常规万用表的 声音 档进行检测 即将其测量电极平放 与零件表面接 触 施以轻压 小于140g 当有蜂鸣声 显示导电 时则认为合格 2 4六价铬含量 1 属于华为指定的氧化加工商 由氧化者每年提供一次零件上的膜层环保检测报告 检测单位必须是华为认 可的机构 2 其它氧化商按以下要求进行试验测试 3 每周试验一次 有新调整化学转化处理溶液后也必须试验一次 试验样件必须从批生产零件中抽取至少一 件 检测在零件上的无色化学转化处理区域进行 4 按 ISO3613 中的六价铬存在试验方法检测钝化膜中是否存在六价铬 5 如果发现存在六价铬 则应利用ISO3613中的比色法定量检测六价铬含量 检测机构必须得到华为技术有 限公司认可 要求转化膜中的六价铬含量不能高于900ppm TABLE OF CONTENTS 1 REQUIREMENTS FOR PROCESS AUTHENTICATION 12 1 1 GENERAL REQUIREMENTS 12 1 2 REQUIREMENTS FOR PRODUCTION EQUIPMENT AND MATERIALS 12 1 2 1 Production Line 12 1 2 2 Requirements for Water Quality 12 1 2 3 Requirements for Chemical Materials 12 1 2 4 Quality Control Method 12 1 3 PROCESS AUTHENTICATION PROCEDURE 13 1 4 REQUIREMENTS FOR TESTS AND TEST PIECES 13 1 4 1 Requirements for Test Pieces 13 1 4 2 Test Items and Piece Quantities 13 1 5 TEST METHOD AND QUALITY INDEXES 14 1 5 1 Appearance 14 1 5 2 Corrosion Resistance 14 1 5 3 Surface Contact Resistance 14 1 5 4 Chromium VI Content in Colorless Conversion Films 14 1 6 KEEPING OF AUTHENTICATION STATUS 14 2 QUALITY CONTROL OF BATCH PRODUCTION 15 2 1 APPEARANCE 15 2 2 CORROSION RESISTANCE 15 2 3 SURFACE CONTACT RESISTANCE 15 2 4 CHROMIUM VI CONTENT 16 3 REFERENCES 16 LIST OF TABLES TABLE 1 TEST ITEMS AND NUMBER OF TEST SPECIMENS 13 confidentiality level confidential Error Reference source not found ential 第8页 共14页Page 8 Total14 Error Reference source not found Scope This Specification describes the process and quality requirements for colorless chemical conversion treatment on aluminum and its alloys It applies to the process authentication first article authentication and batch production quality control of colorless chemical conversion treatment on aluminum and its alloys It aims to guide product design purchase production and quality control over parts chemical conversion treatment by producers The acceptance sampling rate of vendors deliveries is determined according to other related documents Brief introduction Chemical conversion treatment on aluminum alloys is a chemical process to produce surface films either as the base of powder coatings paint films or independently as corrosion resistance films This Specification defines the colorless chemical conversion treatment and the appearance corrosion resistance and surface contact resistance requirements for films produced with this treatment process It can be used as the basis of producer process authentication by Huawei and part production quality control by producers Key words Aluminum chemical conversion film corrosion resistance Referenced Documents The following normative documents contain provisions which through reference in this text constitute provisions of this specification 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 Standard 1IEC 60068 2 11Corrosion Tests in Artificial Atmospheres Salt Spray TestsGB 2423 17 ASTM B117 2ISO3613Chromate Conversion Coatings on Zinc Cadmium Aluminum Zinc Alloys and Zinc Aluminum Alloys Test Methods GB9791 3ISO4288Rule and Method of Surface Roughness Measurement with Probe Instruments GB10610 4DKBA0 450 0011Requirements for Anodization of Aluminum and Its Alloys confidentiality level confidential Error Reference source not found ential 第9页 共14页Page 9 Total14 No Document No Document TitleEquivalent Standard 5YB010Sandblasting and Polishing Anodization Huawei Standard Sample Material 6YB019Belt Grinding Huawei Standard Sample Material Term Definition Term Definition Chemical conversionA chemical treatment process to form an insoluble salt film on metallic surfaces called chemical oxidization when forming an oxide film and chromatizng or chromaking when forming a chromate film Transparent chemical conversion A chemical conversion process to form colorless showing the color of aluminum films on aluminum surfaces Sandblasting and polishing chemical conversion A transparent chemical conversion process that comprises sandblasting and polishing Anodizing The process of coating the anodic part surfaces electrolytically with an oxide Local anodizingA surface treatment process in which the surface of an aluminum part is partly anodized and partly chemically converted Fully automatic or semi automatic anodizing production line Fully automatic line fully automatic part anodizing by equipment Semi automatic line all anodizing process parameters except lifting equipment parameters are controlled by equipment Surface contact resistanceVoltage on the contact surface of contact parts divided by the current through the part Batch The collection of parts in similar shapes made of similar materials treated under identical conditions on the same day SilkscreenA printing technology also called silkscreen printing confidentiality level confidential Error Reference source not found ential 第10页 共14页Page 10 Total14 1 Requirements for Process Authentication 1 1 General Requirements Producer shall explain the equipment used the process flow and the quality control measures in the main process documents Producer shall ensure that their quality meet the requirements in section 1 1 2 Requirements for Production Equipment and Materials 1 2 1 Production Line Producer should have a semi automatic or fully automatic anodizing production line instead of a manual line Each tank is equipped with temperature and time controllers within their effective verification periods The drying equipment has automatic temperature and time control 1 2 2 Requirements for Water Quality Distilled or de ionized water is used as make up water in all tanks Distilled or de ionized water is used for rinsing before and after chemical conversion The rinse water for other processes meets tap water Water flows in the opposite direction of the workflow in rinse tanks or is renewed regularly Distilled or de ionized water meets the following requirements PH 5 0 to 7 5 conductivity 10 S cm 1 2 3 Requirements for Chemical Materials The tanks for processes before chemical conversion are made of chemical materials up to national industrial material standards The tanks for chemical conversion and later processes are made of chemical materials up to national CP material standards 1 2 4 Quality Control Method Producer should have the following instruments and meters ready for tests salt spray test box roughmeter surface contact resistance meter and common chemical analyzers All the instruments and confidentiality level confidential Error Reference source not found ential 第11页 共14页Page 11 Total14 meters are available with effective marks of conformity The salt spray test can be made by a third party approved by Huawei which will keep a record of the party 1 3 Process Authentication Procedure The authenticated factory should complete all the following tests under batch production conditions Test piece manufacturing Note 1 Surface treatment Note 2 Test piece inspection and test Provide test reports Note 3 and pieces for Huawei Technologies Co Ltd for retest 1 Test pieces can be prepared by Huawei Technologies Co Ltd for authenticated factory 2 All test pieces must be treated at the same time 3 Test reports must be issued by labs or institutions approved by Huawei Technologies Co Ltd 1 4 Requirements for Tests and Test Pieces 1 4 1 Requirements for Test Pieces Material 6063 bare aluminum sheet Dimensions 80 mm x 125 mm x 1 mm 4 mm Surface roughness Ra 1 m Surface treatment colorless chemical conversion Local anodizing when necessary should be made to form half anodized and half chemical conversion film 1 4 2 Test Items and Piece Quantities The following table lists the test items and piece quantities for process authentication Table 1 Test items and number of test specimens Test ItemTest Piece Quantity Note 1 Appearance2 Corrosion resistance61 confidentiality level confidential Error Reference source not found ential 第12页 共14页Page 12 Total14 Surface contact resistance2 Chromium VI content in film2 Note 1 Half pieces are for retest by Huawei Technologies Co Ltd 1 5 Test Method and Quality Indexes 1 5 1 Appearance Check the appearance of all test pieces by visual observation Conversion films should be colorless transparent showing the color of the aluminum base material continuous even complete without scratches pollutions or corrosion The appearance of polished surfaces should be consistent with YB015 Locally anodized surfaces Two kinds of films form regular borders without solution leakage Each film meets its related appearance standard 1 5 2 Corrosion Resistance Follow IEC 60068 2 11 to make 100 hour neutral salt spray tests There are at most three corrosion spots with a 0 8 mm or smaller diameter in the 5 mm margins of each test piece 1 5 3 Surface Contact Resistance Use the following method to test the contact resistance of the chemical conversion area of the test piece Put the two poles of a microhmmeter on any two points of the tested surface The area of each pole is 1 cm2 the pressure intensity is 1 4 MPa the pressure is 14 kgf Test five times and the average value should be not larger than 10 m 1 5 4 Chromium VI Content in Colorless Conversion Films Follow ISO3613 to check for chromium VI in conversion films If chromium VI is found follow ISO3613 to check its content with the colorimetric method the tester must be approved by Huawei Technologies Co Ltd The chromium VI threshold in conversion films is 900 ppm 1 6 Keeping of Authentication Status Producers shall maintain and follow the documents concerning process and inspection formally approved by Huawei Technologies Co Ltd When a process is authenticated by Huawei Technologies Co Ltd all the parameters that may affect the performance of finished parts shall be left as they are Otherwise re authentication is required confidentiality level confidential Error Reference source not found ential 第13页 共14页Page 13 Total14 2 Quality Control of Batch Production 2 1 Appearance 1 Check the appearance of all parts by visual observation 2 After treatment parts should be in the color of the aluminum base material Conversion films should be continuous even and complete There should be no scratches pollutions corrosion or loose powder on part surfaces Unobvious catcher marks are permitted Films should not turn black in welding seams and welding spots Unobvious water marks are permitted around blind holes within a 2 mm axial range 3 The appearance of sandblasted surfaces should be consistent with YB010 and belt grinded surfaces with YB019 In case of any disputes follow GB 10610 to test the roughness Ra is between 1 4 m and 2 0 m for sandblasting and between 1 7 m and 2 7 m for belt grinding 4 Locally anodized parts Anodized films can extend at most 2 mm to chemical conversion film areas while reverse extensions are unavailable Two kinds of films form clear and regular borders without solution leakage 2 2 Corrosion Resistance 1 This test is made on test pieces 80 mm x 125 mm 6063 bare aluminum sheets treated along with parts die casting parts or sectional parts Use test pieces for parts made of aluminum sheets and use parts or sections of parts for sectional parts and die casting parts 2 Make the test between 24 and 72 hours after chemical conversion Test at least one part for each batch 3 Follow GB T 10125 to make 48 hour neutral salt spray tests on aluminum die casting parts or 100 hour tests on other aluminum parts There are at most three corrosion spots with a 0 8 mm or smaller diameter per dm2 in the 5 mm margins of piece surfaces Areas around holes of parts are considered as margins 4 A large part than the test box can contain can be replaced by a section of the part in typical structure 5 This test does n