热喷涂铝涂层质量要求

1、目 录1工艺鉴定要求61.1总则61.2工艺过程要求61.3工艺鉴定程序61.4工艺鉴定试验及试样要求6试样要求6试验项目及试样数量71.5试验方法及质量指标7外观7铝涂层的表面粗糙度7铝涂层厚度7结合强度7耐蚀性71.6鉴定状态的保持72批生产中工件检验要求82.1外观82.2铝涂层的表面粗糙度82.3铝涂层厚度82.4结合强度82.5耐蚀性83参考文献8表目录表1.鉴定试验项目及试样数量7图目录图1 工艺鉴定用试样制作图形6图2 过渡区示意图8Error! Reference source not found.范 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

2、进行局部修复而进行的处理。简 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。 关键词热喷涂，铝，修复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。序号文件编号文件名称等效标准1IEC 60068-2-11基本环境试验程序.第2部分:试验.试验Ka:盐雾GB 10125A

3、STM B1172ISO 1463金属和氧化物镀层.镀层厚度的测定.显微镜法GB/T 64623ISO 2178磁性基质的非磁性镀层.镀层厚度的测量.磁性法GB/T 49564ISO 2409涂料和清漆 交叉切割试验GB/T 92865DKBA0.450.0012 铝及铝合金化学转化膜质量要求术语和定义 术语 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。1 工艺鉴定要求1.1 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

4、1.6节的要求。1.2 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1.4.1 试样要求材料

5、： 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试验项目试样数量（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

6、、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12.5m。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 80m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

7、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 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 批生产中工件检验要求2.1 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13mm左右（如下图所示）。铝涂层有机

8、涂层有机涂层钢基材13mm图2 过渡区示意图2.2 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12.5m。2.3 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 60150m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

9、.5 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 的要求，即应通过100H的盐雾试验（按IEC 60068-2-11进行）。3 参考文献制定本规范参考的文献，但没有直接引用里面的内容序号文献编号或出处 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TABLE OF CONTENTS1REQUIREMENTS FOR PROCESS AUTHENTICATION111.1General Principle111.2Requirements for Process111.3Procedure

10、of Process Authentication111.4Requirements for the Sample of Process Authentication11Requirements for Samples11Test Items and Quantity of Samples121.5Test Methods and Quality Indexes12Appearance12Surface Roughness of Aluminum Coating12Thickness of Aluminum Coating12Binding Strength13Corrosion Resist

11、ance131.6Retention of Authentication Status132INSPECTION REQUIREMENTS FOR PARTS DURING BATCH PRODUCTION132.1Appearance132.2Surface Roughness of Aluminum Coating142.3Thickness of Aluminum Coating142.4Binding Strength142.5Corrosion Resistance143REFERENCE DOCUMENT14 LIST OF TABLES TABLE 1.TEST ITEMS AN

12、D QUANTITY OF SAMPLES12LIST OF FIGURESFIGURE 1.SAMPLE FOR PROCESS APPRAISAL12FIGURE 2.THE TRANSITIONAL AREA13Error! Reference source not found.ScopeThe technical specifications herein stipulate the process requirements and quality requirements for the thermal spray aluminum coating. The technical sp

13、ecifications are applicable to the local repair of the surface of the steel plates or aluminum material. Brief IntroductionThe technical specifications expressly stipulate the applicable scenarios, matrix materials, process flow, and after-treatment restrictions of thermal aluminum spraying, as well

14、 as the quality requirements for the aluminum coating. The quality requirements cover its appearance, film thickness, surface roughness, corrosion resistance, and binding strength. KeywordsThermal spraying, aluminum, and repair Normative referencesThe following normative documents contain provisions

15、 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 investiga

16、te 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 TitleEquivalent1IEC 60068-2-11Basic environmental testing procedures. Part 2 : Tests. Test Ka: Salt mis

17、tGB 2423.17ASTM B1172ISO 1463Metallic and oxide coatings Measurement of coating thickness Microscopical methodGB/T 64623ISO 2178Non-magnetic Coating on Magnetic substrates- Measurement of coating Thickness - Magnetic MethodGB/T 49564ISO 2409Paint and Varnish-Cross-Cut Test GB/T 92865DKBA0.450.0012 R

18、equirements for Chemical Conversion Coating on Aluminum and Its AlloysTerm & DefinitionTerm & Definition ExplanationBatchThe sum of the parts with the similar materials and shape that are processed in the same conditions on the same day 1 Requirements for Process Authentication1.1 General Pr

19、inciple 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 producers processing equipment, process flow, and quality assurance measures should be described in its main process d

20、ocuments. The producers process quality should come up to the requirements as stipulated in sections 1.2to 1.6. 1.2 Requirements 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 u

21、ndergo the chemical conversion after-treatment by means of brushing, spraying, or dip-coating. 1.3 Procedure of Process AuthenticationThe 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

22、 (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

23、time. 3: The test report must be released by a laboratory or institution recognized by Huawei. 1.4 Requirements for the Sample of Process Authentication1.4.1 Requirements for Samples Material: Cold rolled steel sheet Size: 80 × 125 × 1 to 4 (mm) Surface roughness: Ra 1 mSurface treatment:

24、Spray powders locally first and then implement thermal aluminum spraying. Error! Reference source not found. describes the spraying range. 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

25、of samples. Table 1. Test items and quantity of samplesTest 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.1.5 Test

26、 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 defe

27、cts 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 shou

28、ld 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 sa

29、mple. The average value should be at least 80 m. 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).

30、 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 , that is, pass the 100H salt fog test in accordance with IEC 60068-2-11. 1.6 Retentio

31、n 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 2.1 Appearance

32、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 alumi

33、num 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. Figur

34、e 2. The transitional area2.2 Surface Roughness of Aluminum Coating Among every batch of workpieces, at least one workpiece should be tested. 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. 2.3 Thickness 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 coating thickness should be within the range of 60 to 150 m if t