熱噴涂鋁涂層質(zhì)量要求

1、目 錄1工藝鑒定要求工藝鑒定要求 .61.1總則.61.2工藝過程要求 .61.3工藝鑒定程序 .61.4工藝鑒定試驗(yàn)及試樣要求.61.4.1試樣要求.61.4.2試驗(yàn)項(xiàng)目及試樣數(shù)量.71.5試驗(yàn)方法及質(zhì)量指標(biāo) .71.5.1外觀.71.5.2鋁涂層的表面粗糙度.71.5.3鋁涂層厚度.71.5.4結(jié)合強(qiáng)度.71.5.5耐蝕性.71.6鑒定狀態(tài)的保持 .72批生產(chǎn)中工件檢驗(yàn)要求批生產(chǎn)中工件檢驗(yàn)要求 .82.1外觀.82.2鋁涂層的表面粗糙度 .82.3鋁涂層厚度 .82.4結(jié)合強(qiáng)度.82.5耐蝕性.83參考文獻(xiàn)參考文獻(xiàn).8confidentiality level: confidentialR

2、EV.B2012-03-23表目錄表表1.鑒定試驗(yàn)項(xiàng)目及試樣數(shù)量鑒定試驗(yàn)項(xiàng)目及試樣數(shù)量.7圖目錄圖圖1 工藝鑒定用試樣制作圖形工藝鑒定用試樣制作圖形.6圖圖2 過渡區(qū)示意圖過渡區(qū)示意圖 .82012-03-23Error! Reference source not found.范范 圍圍本規(guī)范規(guī)定了熱噴涂鋁涂層的工藝和質(zhì)量要求。本規(guī)范適用于對鋼板材料或鋁材表面進(jìn)行局部修復(fù)而進(jìn)行的處理。簡簡 介介本規(guī)范對熱噴涂鋁的適用場合、基材對象、加工工藝流程及其后處理限制以及鋁涂層的質(zhì)量要求作出了明確規(guī)定。其中質(zhì)量要求包括外觀、膜厚、表面粗糙度、耐蝕性、結(jié)合力等。 關(guān)鍵詞關(guān)鍵詞熱噴涂，鋁，修復(fù)引用文件引用文

3、件下列文件中的條款通過本規(guī)范的引用而成為本規(guī)范的條款。凡是注日期的引用文件，其隨后所有的修改單（不包括勘誤的內(nèi)容）或修訂版均不適用于本規(guī)范，然而，鼓勵(lì)根據(jù)本規(guī)范達(dá)成協(xié)議的各方研究是否可使用這些文件的最新版本。凡是不注日期的引用文件，其最新版本適用于本規(guī)范。序號(hào)序號(hào)文件編號(hào)文件編號(hào)文件名稱文件名稱等效標(biāo)準(zhǔn)等效標(biāo)準(zhǔn)1IEC 60068-2-11基本環(huán)境試驗(yàn)程序.第2部分:試驗(yàn).試驗(yàn)Ka:鹽霧GB 10125ASTM B1172ISO 1463金屬和氧化物鍍層.鍍層厚度的測定.顯微鏡法GB/T 64623ISO 2178磁性基質(zhì)的非磁性鍍層.鍍層厚度的測量.磁性法GB/T 49564ISO 2409

4、涂料和清漆 交叉切割試驗(yàn)GB/T 92865DKBA0.450.0012 鋁及鋁合金化學(xué)轉(zhuǎn)化膜質(zhì)量要求術(shù)語和定義術(shù)語和定義 術(shù)語術(shù)語 定義定義生產(chǎn)批指同一天在相同條件下處理的、材料和形狀相似的零件的總和。2012-03-231 工藝鑒定要求工藝鑒定要求1.1總則總則熱噴涂鋁工藝只適用于對鋼板基材或鋁材所進(jìn)行的局部修復(fù)處理、或者表面局部導(dǎo)電化處理。生產(chǎn)者的工藝設(shè)備、工藝流程、質(zhì)量保證措施應(yīng)在其主要的工藝文件中加以說明。生產(chǎn)者的工藝質(zhì)量必須滿足第 1.2 至 1.6節(jié)的要求。1.2工藝過程要求工藝過程要求1）熱噴涂鋁處理必須在工件噴涂有機(jī)涂層后進(jìn)行。2）熱噴涂鋁涂層進(jìn)行化學(xué)轉(zhuǎn)化的后處理，可以采用刷

5、涂、噴涂或浸涂等各種方式。1.3工藝鑒定程序工藝鑒定程序被鑒定的工廠必須完成以下全部試驗(yàn)工作，這些試驗(yàn)必須在零件批生產(chǎn)所用的條件下完成：1）試樣加工 （注1）2）表面處理 （注2）3）試樣檢查及測試（按1.4節(jié)）4）提供試驗(yàn)報(bào)告（注3）及試片給華為技術(shù)有限公司以便復(fù)驗(yàn)。注：1、鑒定用試樣也可由華為技術(shù)有限公司完成并提供給被鑒定工廠。2、所有試樣必須同時(shí)進(jìn)行處理。3、試驗(yàn)報(bào)告的發(fā)出者必須是華為技術(shù)有限公司認(rèn)可的試驗(yàn)室或單位。1.4工藝鑒定試驗(yàn)及試樣要求工藝鑒定試驗(yàn)及試樣要求1.4.1試樣要求材料： 冷軋鋼板尺寸： 801251 4 (mm)表面粗糙度：Ra 1 mm表面處理： 先局部噴粉后再進(jìn)行

6、熱噴涂鋁處理，噴涂范圍見圖1。粉末涂層區(qū)域（藍(lán)色部分）熱噴涂鋁涂層區(qū)域，面積不小于50100圖1 工藝鑒定用試樣制作圖形2012-03-231.4.2試驗(yàn)項(xiàng)目及試樣數(shù)量表1給出了工藝鑒定所需的試驗(yàn)項(xiàng)目和試樣數(shù)量要求：表1. 鑒定試驗(yàn)項(xiàng)目及試樣數(shù)量鑒定試驗(yàn)項(xiàng)目及試樣數(shù)量試驗(yàn)項(xiàng)目試驗(yàn)項(xiàng)目試樣數(shù)量（件）試樣數(shù)量（件）外觀所有試樣鋁涂層厚度所有試樣表面粗糙度所有試樣結(jié)合強(qiáng)度3耐蝕性3+3 注： 其中三件為提供華為技術(shù)有限公司進(jìn)行復(fù)驗(yàn)用。1.5試驗(yàn)方法及質(zhì)量指標(biāo)試驗(yàn)方法及質(zhì)量指標(biāo)1.5.1外觀 所有試樣均應(yīng)進(jìn)行外觀檢查。鋁涂層應(yīng)結(jié)晶均勻、致密、連續(xù)。經(jīng)化學(xué)轉(zhuǎn)化后外觀符合轉(zhuǎn)化膜相關(guān)要求。不允許：起皮、鼓泡

7、、大熔滴、裂紋、掉塊和嚴(yán)重水紋印。1.5.2鋁涂層的表面粗糙度所有試樣均應(yīng)進(jìn)行粗糙度檢測。用粗糙度測量儀器在每個(gè)試樣上取至少5個(gè)點(diǎn)進(jìn)行測試，其值必須符合以下要求：平均Ra低于12.5m。1.5.3鋁涂層厚度所有試樣均應(yīng)進(jìn)行厚度檢測。按 ISO 2178 進(jìn)行非破壞性測試（或采用其它等效的方法）。每一試樣上測取 10 個(gè)點(diǎn)，其值均應(yīng)在 80m以上。1.5.4結(jié)合強(qiáng)度在三件試樣上進(jìn)行結(jié)合強(qiáng)度試驗(yàn)。按 ISO 2409 的試驗(yàn)方法，在試樣上劃出 2mm 見方的小格，然后用標(biāo)準(zhǔn)膠帶（3M公司的Scotch 250#）拉扯，應(yīng)無任何涂層脫落現(xiàn)象。1.5.5 耐蝕性在三件試樣上進(jìn)行耐蝕性試驗(yàn)。經(jīng)化學(xué)轉(zhuǎn)化處

8、理后的鋁涂層應(yīng)符合 DKBA0.450.0012 的要求，即按IEC 60068-2-11進(jìn)行鹽霧試驗(yàn)應(yīng)通過100H。1.6鑒定狀態(tài)的保持鑒定狀態(tài)的保持經(jīng)過華為技術(shù)有限公司鑒定的工藝，在未得到華為技術(shù)有限公司的同意之前，不能改變?nèi)魏慰捎绊懶阅苜|(zhì)量的工藝參數(shù)，否則將重新進(jìn)行鑒定.。2012-03-232 批生產(chǎn)中工件檢驗(yàn)要求批生產(chǎn)中工件檢驗(yàn)要求2.1外觀外觀所所有工件都應(yīng)進(jìn)行外觀檢查。鋁涂層應(yīng)呈啞白色，結(jié)晶均勻、致密、連續(xù)。無起皮、鼓泡、大熔滴、裂紋、掉塊和嚴(yán)重水紋印等缺陷。與粉末涂層的交界邊緣應(yīng)整齊，無疏松顆粒，不露底材金屬；而且鋁層應(yīng)覆蓋一些粉末層形成過渡，過渡區(qū)寬度為13mm左右（如下圖所

9、示）。鋁涂層有機(jī)涂層有機(jī)涂層鋼基材13mm圖2 過渡區(qū)示意圖2.2鋁涂層的表面粗糙度鋁涂層的表面粗糙度每生產(chǎn)批工件抽檢至少一件。每個(gè)表面上取至少5個(gè)點(diǎn)進(jìn)行測試，其值必須符合以下要求：平均Ra值低于12.5m。2.3鋁涂層厚度鋁涂層厚度所有工件均應(yīng)進(jìn)行厚度檢測。按 ISO 2178 進(jìn)行檢測。在零件表面，凡能被直徑為 20 mm 的球接觸到的區(qū)域，厚度均應(yīng)在 60150m范圍內(nèi) ；凡直徑為 20 mm 的球不能接觸到的區(qū)域，其厚度不作要求。 2.4結(jié)合強(qiáng)度結(jié)合強(qiáng)度每生產(chǎn)批至少檢查一件工件或樣件。按 ISO 2409 的試驗(yàn)方法，在試樣上劃出 2mm 見方的小格，然后用標(biāo)準(zhǔn)膠帶（3M公司的Scot

10、ch 250#）拉扯，應(yīng)無任何涂層脫落現(xiàn)象。2.5 耐蝕性耐蝕性在試樣上進(jìn)行耐蝕性試驗(yàn)；每生產(chǎn)批至少檢測三件。經(jīng)化學(xué)轉(zhuǎn)化處理后的鋁涂層應(yīng)符合DKBA0.450.0012 的要求，即應(yīng)通過100H的鹽霧試驗(yàn)（按IEC 60068-2-11進(jìn)行）。3 參考文獻(xiàn)參考文獻(xiàn)制定本規(guī)范參考的文獻(xiàn)，但沒有直接引用里面的內(nèi)容序號(hào)序號(hào)文獻(xiàn)編號(hào)或出處文獻(xiàn)編號(hào)或出處 文獻(xiàn)名稱文獻(xiàn)名稱 1GB 9795熱噴涂鋁及鋁合金涂層2實(shí)用新型專利說明書 CN 2676567Y導(dǎo)電屏蔽機(jī)柜機(jī)箱的構(gòu)件2012-03-23TABLE OF CONTENTS1REQUIREMENTS FOR PROCESS AUTHENTICATIO

11、N .111.1GENERAL PRINCIPLE.111.2REQUIREMENTS FOR PROCESS.111.3PROCEDURE OF PROCESS AUTHENTICATION.111.4REQUIREMENTS FOR THE SAMPLE OF PROCESS AUTHENTICATION.111.4.1Requirements for Samples.111.4.2Test Items and Quantity of Samples.121.5TEST METHODS AND QUALITY INDEXES.121.5.1Appearance.121.5.2Surface

12、 Roughness of Aluminum Coating .121.5.3Thickness of Aluminum Coating.121.5.4Binding Strength.131.5.5Corrosion Resistance.131.6RETENTION OF AUTHENTICATION STATUS.132INSPECTION REQUIREMENTS FOR PARTS DURING BATCH PRODUCTION .132.1APPEARANCE.132.2SURFACE ROUGHNESS OF ALUMINUM COATING.142.3THICKNESS OF

13、ALUMINUM COATING.142.4BINDING STRENGTH.142.5CORROSION RESISTANCE.143REFERENCE DOCUMENT.14 LIST OF TABLES TABLE 1.TEST ITEMS AND QUANTITY OF SAMPLES.12LIST OF FIGURESFIGURE 1.SAMPLE FOR PROCESS APPRAISAL.12FIGURE 2.THE TRANSITIONAL AREA.132012-03-23Error! Reference source not found.ScopeThe technical

14、 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 IntroductionThe technical specifications expressly

15、 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, an

16、d binding strength. KeywordsThermal spraying, aluminum, and repair Normative referencesThe 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 r

17、evisions 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

18、 to applies.No.Document No.Document TitleEquivalent1IEC 60068-2-11Basic environmental testing procedures. Part 2 : Tests. Test Ka: Salt mistGB 2423.17ASTM B1172ISO 1463Metallic and oxide coatings Measurement of coating thickness Microscopical methodGB/T 64623ISO 2178Non-magnetic Coating on Magnetic

19、substrates- Measurement of coating Thickness - Magnetic MethodGB/T 49564ISO 2409Paint and Varnish-Cross-Cut Test GB/T 92865DKBA0.450.0012 Requirements for Chemical Conversion Coating on Aluminum and Its AlloysTerm & DefinitionTerm & Definition ExplanationBatchThe sum of the parts with the si

20、milar materials and shape that are processed in the same conditions on the same day 2012-03-231 Requirements for Process Authentication1.1General Principle The process of thermal aluminum spraying is only applicable to local repair of the steel plate matrix or aluminum material, or local conductive

21、treatment on the surface. The producers processing equipment, process flow, and quality assurance measures should be described in its main process documents. The producers process quality should come up to the requirements as stipulated in sections 1.2to 1.6. 1.2Requirements for Process The process

22、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 AuthenticationThe factory to be ap

23、praised 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 f

24、or 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 Authentication1.4

25、.1 Requirements for Samples Material: Cold rolled steel sheet Size: 80 125 1 to 4 (mm) Surface roughness: Ra 1 mSurface treatment: Spray powders locally first and then implement thermal aluminum spraying. Error! Reference source not found. describes the spraying range. 2012-03-23Powder coating (Blue

26、) Thermal spraying aluminum coating (the sprayed area is not smaller than 50100.Figure 1.Sample for process appraisal1.4.2 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 samplesTest

27、ItemQuantity of SamplesAppearanceAll samplesThickness of aluminum coatingAll samplesSurface roughness:All samplesBinding strength3Corrosion 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 sho

28、uld 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, crackl

29、e, 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 l

30、ower 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. 2012-03-231.

31、5.4 Binding Strength Test the binding strength for three samples. Scratch a small check (22 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 Resist

32、ance 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 con

33、sent 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 inspectio

34、n. 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

35、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 S

36、teel base 1 to 3 mm Figure 2.The transitional area2.2Surface Roughness of Aluminum Coating Among every batch of workpieces, at least one workpiece should be tested. 2012-03-23Test 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 the part, the coatin