空客公司抗腐蚀钢的钝化流程规范AIPS(共38页)

1、Airbus Process Specification Passivation of Corrosion Resistant Steel Published and distributed by : AIRBUS S.A.S. ENGINEERING DIRECTORATE 31707 BLAGNAC Cedex FRANCE Copyright reserved Ref. no. AIPS02-05-005空客公司抗腐蚀钢的钝化流程规范出版、发行:空客工程指挥部31707 BLAGNAC Cedex法国著作权所有参考编号。AIPS02 - 05 - 005Contents 1 Scope

2、2 Normative references 3 Definition, applicability and limitations 4 Engineering requirements 5 Technical qualification 6 First part qualification 7 Series production inspection 8 Rework 9 Environment, health and safety内容1范围2引用标准3定义、适用性和局限性4工程需求5技术资格6第一部分资格7系列的生产检验8返工9环境、健康和安全1 Scope This Airbus Pro

3、cess Specification defines the Engineering requirements for Passivation of Corrosion Resistant Steel . This specification does not give detailed instructions; these are given in the Process Instructions (PI) / Airbus Process Instruction (AIPI) and the Work Instructions. This specification shall not

4、be used as an inspection document. It shall be applied when mentioned in the relevant standard, material specification or Definition Dossier. 2 Normative references Only normative references cited in the text are listed hereafter. The latest issue of the publication referenced shall be used. AIMS 09

5、-00-003Water Quality. AIPS 04-03-001Heat treatment of steels. EN 2832 Hydrogen embrittlement of steels Notched specimen test. ASTMF519 Mechanical Hydrogen Embrittlement Evaluation of Plating/Coating Processes and Service Environments. EN 6072 Constant amplitude fatigue testing. EN 10020Definition an

6、d classification of grades of steel ISO 1463 Metallic and oxide coatings - Measurement of coating thickness: Microscopic method. ISO 2409 Paints and Varnishes - Cross-cut test ISO 2812 Paints and Varnishes - Determination of resistance to liquids - Part 2: Water immersion method ISO 4287GPS - Surfac

7、e Texture: Profile method ISO 6270 Paints and varnishes Determination of resistance to humidity Part 2: Procedure for exposing test specimens in condensation-water atmospheres ISO 9227 Corrosion tests in artificial atmospheres - Salt Spray Tests. ISO 18118Surfacechemical analysis Auger electron spec

8、troscopy and X-ray photoelectron spectroscopy ISO 25178 GPS - Surface Texture: Part 601, Part 602, Part 701: Nominal characteristics of instruments EN 9103 Quality management systems Variation management of key characteristics1范围空客过程规范定义了抗腐蚀钢钝化的工艺要求。此规范并未给出详细说明；这些都在过程指示 (PI)/空客过程指令(AIPI)和工作指令中给予说明。这

9、个规范不得作为一个检查文档。它适用在相关标准中提到时,材料规格或定义档案。2引用标准只有在本文中引用的标准才在下文中列出来。应该使用引用版本的最新版本。AIMS09 - 00 003 水质。AIPS 04 - 03 001 钢的热处理。EN 2832 钢的氢脆,切口试样测试。ASTM F519 机械氢脆电镀评价/涂层工艺和服务环境。EN 6072 恒幅疲劳测试。EN 10020 钢种的定义和分类ISO 1463 金属和氧化物涂层,涂层厚度的测量:显微镜法ISO 2409漆和清漆-横切测试ISO 2812漆和清漆-抗液体测定-第2部分:水浸法ISO 4287 GPS -表面纹理:剖面方法ISO

10、6270漆和清漆,抗湿度的测定第2部分:在冷凝空气中暴露测试样的程序 ISO 9227 人工范围中的腐蚀测试-盐雾测试。ISO 18118 表面化学分析俄歇电子能谱和X射线光电子能谱ISO 25178 GPS -表面纹理: 零件 601,零件602,零件701:名义工具特征EN 9103质量管理系统关键特征的多样管理3Definition, applicability and limitations 3.1 Definitions Batch/lot: A batch consists of parts of a similar alloys/steel grade and configura

11、tion, treated sequentially in the bath setup using the same set of bath make-up solutions and process parameters within a defined period of 24h or within a time frame that will ensure consistent passivation results. Corrosion Resistant Steel (CRES)According to EN 10020 stainless steel is defined as

12、steel with at least 10.5% Cr and max :1.2% C. Stainless steel is subdivided by main propery into Corrosion Resisting Steel, heat resisting steel and creep resisting steel. CRES as defined in this AIPS is considered as Corrosion Resisting Steel which fulfils the corrosion resistance requirments accor

13、ding to this AIPS. Delay/Storage/Open time: Maximum allowed period of time between one process step and its subsequent step. Process Instruction:Document (e.g. AIPI: Airbus Process Instruction) that describes the detailed process, parameters, detailed steps, etc., which enable the process to meet th

14、e requirements of this process specification. Process Specification:Document that describes the requirements of a process (e. g. AIPS: Airbus Process Specification) Production relevant alloys: All alloys treated with the passivation process acc. to this AIPS at the processor in the specific shop. Rm

15、 (max):Maximum specified Ultimate Tensile Strength (UTS). Steel grade: Alloys from a defined group: e.g. austenitic, ferritic, martensitic or precipitation hardening (PH) steel Surface preparation/ conditioning Process steps prior to passivation to produce a surface free from contaminations. Sample：

16、 A sample can be a serial part or a accompanying specimen , which is processed with the serial parts and appropriate for the prescribed test method3 定义、适用性和局限性3.1定义批/批次:一批由相似的合金/钢级和配置构成,按顺序处理在槽子安装使用同一套槽液组成溶液和工艺参数在一个定义的段24小时或在一个时间框架,确保一致的钝化效果。耐腐蚀钢(CRES)根据EN 10020，不锈钢的定义是钢至少10.5% Cr以及最大1.2% C.不锈钢是通过主要

17、特性细分成不锈钢、耐热钢和抗蠕变的钢。在AIPS中定义的CRES被认为是耐腐蚀钢，这个可以按照AIPS完成抗腐蚀的要求。 延迟/存储/开放时间：一个工序之间及其后续步骤最大允许时间。过程指令:文档(如 AIPI:空客过程指令),描述了详细的过程,参数,详细的步骤等,这使得过程能够满足这种需求流程规范。工艺说明书:该文档描述了工艺的需求(比如AIPS:空客过程规范)生产相关合金:所有合金的钝化过程根据AIPS在特定车间的处理程序Rm(最大):指定最大极限抗拉强度(极限抗拉强度)。钢的等级:合金定义组:如奥氏体、铁素体、马氏体或沉淀硬化(PH)钢表面处理/调节钝化前的生产步骤产生一个无污染的表面样

18、品:一个样品可以是一个连续的零件或一个附随的样品,这是处理串行部分和适合规定的测试方法3.2 General description of the process The complete passivation process consists of a sequence of operations: a surface preparation step. The passivation process is only effective if surface contaminants that may accelerate corrosion are removed by applicab

19、le means. a passivation step. The passivation process itself consists of subjecting the items to a solution that reinforces the natural surface oxide film upon which the corrosion resistance of the material largely depends. a post-treatment step (if required). Following the passivation process a pos

20、t treatment operation such as a conversion coating, paint application, or resin- based coating can be performed, to improve the corrosion resistance. This applies particularly to corrosion sensitive steel grades (i.e. some martensitic or precipitation hardening corrosion resistant steels) The extent

21、 of the passivation and post-treatment (coating) will be defined on the drawing. The passivation process itself is a chemical process used to remove surface contaminations and to generate a stable superficial oxide layer to increase the corrosion resistance. Surface preparation steps, as required, s

22、uch as descaling, cleaning, pickling, desmutting and subsequent steps such as rinsing and post treatment are integral to the passivation process.3.2过程的一般描述完整的钝化过程由一系列作业程序构成:一个表面处理步骤。当加速表面腐蚀的污染物以合适的方法移除掉，钝化过程才是有效的。一个钝化步骤。钝化过程本身包括把物品放在溶液里，这个加强了抗腐蚀材料主要依赖的自然面氧化膜。一个后处理步骤(如果有需要的话)。钝化处理后的后处理操作如转换涂料、油漆的应用,或

23、树脂为基础的涂层可以执行,提高耐蚀性。这特别适用于腐蚀敏感钢等级(即一些马氏体或沉淀硬化耐蚀钢)钝化的程度和后处理(涂料)将在图纸中得到定义。钝化过程本身是一个化学过程用于去除表面污染和产生一个稳定的表面氧化层来提高耐蚀性。表面处理的步骤,如有需要,如除锈、清洁、酸洗、除污和后续步骤如清洗和后处理对钝化过程来说是不可或缺的。3.3 Applicability and limitations This Airbus specification is applicable when invoked by the drawing directly or through another documen

24、t for the purpose given in the scope. When processing to AIPS02-05-005 is required, it shall be invoked on the drawing by the words “Passivation of Corrosion Resistant Steel” or AIPS02-05-005. Process instructions shall not be called on drawing. This specification is applicable for -corrosion resist

25、ant austenitic steel -corrosion resistant martensitic and precipitation hardening and maraging steel This specification may be used surface preparation prior to dye-penetrant inspection. However, the requirement for this process is not stated in this AIPS and shall be defined in corresponding docume

26、nts. Note: Passivation is not to be regarded as a coating, nor should it be regarded as offering protection against galvanic corrosion to mating materials. This specification is not applicable for -unalloyed or low-alloyed carbon steel -cast steel -powder metallurgy steel -surface modified steel i.e

27、. with case-hardened, carburized or nitrided surfaces -soldered or brazed steel All operations (machining, heat treatment, welding, punching, drilling, forming, trimming, deburring, dimpling, etc.) influencing the effectiveness of the surface treatment or leaving untreated surfaces shall be complete

28、d prior to the surface treatment process. This process shall not be used on items containing joints and cavities where it is not possible to mask prior to passivation or to ensure complete removal of the passivation solution. If needed, hollow items shall be sealed to to prevent ingress of electroly

29、te to the internal surfaces. Only passivation solutions based on nitric acid or citric acid shall be used unless process qualification shows the fullfillment of this specification including surface analysis as per paragraph 4.2.4. Chromate loaded products (e.g. chromic acid or sodium dichromate) sha

30、ll not be used within the whole process chain. The material removal due to abrasive blasting, wire brushing or intensive pickling processes may influence the dimensions of the part and shall be considered so that final dimensional accuracy and surface roughness requirements of the design are met. Re

31、work of passivated parts is only acceptable if the design requirements according to the drawing and to this AIPS are met after the process. Parts shall only be submitted to rework a maximum of two times. The passivation process may have influence on fatigue properties. Components which are subject t

32、o fatigue requirements shall not be treated according to this specification unless the fatigue requirements are considered by the relevant design authority.3.3适用性和局限性空客规范适用于，为了范围中给出的目的，图纸直接或者通过另一个文件。当需要根据AIPS02-05-005处理的时候,应当调用图上的字“耐蚀钢的钝化”或AIPS02 - 05 - 005。过程说明不得要求图。本规范适用于耐蚀钢耐蚀马氏体奥氏体沉淀硬化和马氏体时效钢这个规范

33、在着色渗透检验前可用于表面处理。然而,这一过程的要求中没有在AIPS规定出来和应被定义于相应的文档。注意:钝化不被视为一个涂层,也不应该被视为提供防止电化学腐蚀交配的材料。本规范不适用于非合金的或者低合金的碳钢铸钢粉末冶金钢表面修饰钢 比如表面硬化的，涂炭的或者氮化的表面焊接或钎焊的钢所有影响表面处理或者留下未处理表面的操作(机械加工、热处理、焊接、冲压、钻孔、成型、剪线、去毛刺、压痕等)，应该在表面处理步骤前完成。 这个过程不得用于包含接头和腔的项目,这些在钝化之前不可能掩饰或确保完整移除钝化溶液。如果需要,凹陷的产品应密封,以防止电解质进入内部表面只有当钝化溶液基于硝酸或柠檬酸才能使用除非

34、过程认证展示规范的完成包括按照段落4.2.4的表面分析。铬酸盐加载产品(如铬酸、重铬酸钠)在整个过程链不得使用。用喷砂,钢丝刷清理或密集的酸洗过程用来去除材料可能影响部分的尺寸,并应考虑,以便能够满足最终尺寸精度和设计的表面粗糙度。如果设计的要求是根据图纸和AIPS并且在过程后得到满足，钝化零件的返工过程才是可以接受的。零件最多提交返工两次。钝化过程可能影响疲劳性能。受支配于疲劳性要求的组件不得根据本规范对待除非疲劳性要求由相关设计权威考虑的。4 Engineering requirements Engineering requirements are minimum requirements

35、 specified by Responsible Engineering to ensure optimal performance of the manufacturing process. All Engineering requirements have to be met and controlled in production. 4.1 Technical requirements Substrate Material: The condition of the material/parts to be treated shall be as described in the re

36、levant material specification. The parts shall be free from surface defects or damages like scratches, furrows, pores, cracks and foreign matter. Material of Process Equipment: Tanks, racks, baskets, electrical equipment etc. used for the treatments shall be made of material resistant to the bath li

37、quids. Water Quality: The necessary quality of the water (see AIMS 09-00-003) used for preparation of the baths as well as for the rinsing and drying (hot water) processes shall be defined in the Process Instruction. Rinsing and Drying: In between the surface treatment steps rinsing may be necessary

38、 to avoid contamination of the following bath. Processes paramters (i.e. process temperature) used for rinsing and drying shall not influence the material properties or further processing. Air used for drying or any other operation shall be dry and free from oil. Heat treatment: Prior to any heat tr

39、eatment the item shall be cleaned to remove all contaminants. Stress relief: Mechanical surface treatments like grinding operations may induce material embrittlement. CRES treated to a ultimate tensile strength Rm (max)higher than 1100MPa shall receive a stress relief heat treatment. The heat treatm

40、ent parameters shall be defined in the process instruction. De-hydrogenation: Bath operations may induce hydrogen permeation followed by material hydrogen embrittlement. CRES treated to a ultimate tensile strength Rm (max) higher than 1100 MPa shall receive a de-hydrogenation heat treatment within 1

41、h after the passivation treatment. The de-hydrogenation heat treatment shall be performed as indicated in the process instruction When the last tempering prior to de-hydrogenation is performed at a temperature lower than 200C, the part shall be de-hydrogenated at (135 5)C. In this case, twice the ti

42、me indicated in the table above shall be applied. If two or more processes leading to hydrogen embrittlement are performed within a 1h time span, de-hydrogenation needs only be performed once at the end of those processes. Handling of Items: During all process operations the parts shall not be subje

43、cted to any tensile, flexure, torsion or other stresses. All items/components shall be handled in such a way that any type of contamination or damage is avoided. If necessary, within all surface treatment steps components shall only be touched with adequate gloves. All parts shall be fully immersed

44、in the bath, not touching or covering one another. Parts with cavities shall be attached in such a way that gas bubbles can escape and proper bath circulation is ensured. The jigging of the components shall be adequate. Masking: Areas not to be subjected to the process shall be masked with masking v

45、arnish, plastic plugs or other approved auxiliary materials. It shall be demonstrated that the use of the masking materials is without detrimental effects on further processing (e.g. paint application) or the requested surface condition. If exposure to the surface treatment process is prevented by m

46、asking the corrosion resistance requirements may not be reached and must be achieved by other means. Delay/Open Times: Unless otherwise specified, parts shall be treated from one step to the next without delay (e.g. wet in wet between pickling treatment, rinsing and passivation treatment). Maximum a

47、llowed open/delay times shall be indicated in the Process Instruction. The time span for transfer / transportation / storage between different steps and/or sub-steps shall not be exceeded.4工程需求工程要求是责任工程部门规定的最小要求,确保生产过程的最优性能。所有技术要求必须得到满足并且在生产中得到控制。4.1技术要求基材：材料/零件的条件应得到处理并且在相关材料规范中描述出来。这个部件应该没有表面缺陷或损害

48、如划痕、皱纹、毛孔、裂纹和杂质。工艺设备的材料:用于处理的槽子、货架、篮子、电气设备的材料应该对槽液的溶液有抵抗力。水质量:用于槽液，洗涤和干燥(热水)的水的必要质量(见AIMS09-00-003)应在过程指令中明确出来。洗涤和干燥:表面处理步骤冲洗之间的对避免接下来槽液的污染可能是必要的。用于清洗和干燥的过程参数（比如过程温度）不应该影响材料特性或者深加工。用于干燥或任何其他操作的空气应干燥,无油。热处理:在进行任何热处理项目前，应清洗去除所有污染物。去应力:机械表面处理如磨削操作可能引起材料脆化。耐蚀钢得到极限抗拉强度Rm(max)高于1100 mpa,应当受到一个去应力的热处理。热处理参

49、数应该在过程规范中定义出来。去除氢:槽液操作可能诱发氢渗透接而引起材料氢脆。当耐蚀钢得到极限抗拉强度Rm(max)高于1100 Mpa，在钝化处理后应该收到去除氢热处理1小时。这个去除氢热处理均应按照过程指令在去除氢化作用之前，在温度低于200执行最后的回火。零件应在温度为(1355)C去除氢化。在这种情况下,应该应用表格中指示时间的两倍。如果导致氢脆的两个或者更多的程序是在一个1小时的时间跨度执行，在这些过程的结束仅仅需要执行去除氢化。处理事项:在所有过程操作中，零件不应受到任何拉伸、弯曲、扭转或其他压力。所有物品/组件应以这样一种方式来处理，应避免任何类型的污染或损坏。如果有必要,在所有表

50、面处理步骤中，组件只能套上手套才能触摸。所有部件应完全浸在槽液里,不要触摸或覆盖另一个。有腔的零件应该以这样一种方式连接起来，这样可以避免气泡也能确保正确的槽液循环。组件的振动应该是充分的。保护:不经过这个过程的区域应用清漆、塑料塞或其他批准的辅助材料进行保护。它应当证明使用掩蔽材料对深加工(如油漆应用程序)或要求表面条件是没有有害影响的。如果暴露在表面处理过程受到保护的阻止，抗腐蚀要求可能无法达到,必须通过其他手段获得。延迟/开放的时间:除非另有说明,零件处理从一个步骤到下一个步骤应该没有延迟(在酸洗、水洗和钝化处理间)。最大允许打开/延迟时间中应当在过程说明中写出来。不同步骤/或者子步骤之

51、间的转移/运输/储存不得超过时间跨度。4.1.1 Preparation prior to the passivation step After machining, all specimens with an ultimate tensile strength Rm (max) higher than 1100 MPa shall be submitted to stress relief heat treatment in order to relieve residual stresses. All parts shall be submitted to a surface prepar

52、ation process. The surface preparation process may include mechanical and/or chemical and/or electrochemical methods, singly or in combination. Necessary sub steps (e.g. cleaning, degreasing, descaling, abrasive blasting, activation, pickling, rinsing, drying, masking) depend on the degree of contam

53、ination. Although descaling or other steps may be necessary before passivation can be effective, these steps are not indicated explicitly in this AIPS but shall be indicated in the Process Instruction. The composition of appropriate surface preparation liquids may depend on the grade of the corrosio

54、n resistant steel to be treated. Alloying elements, contaminations and mechanical processing may influence the sensitivity of the CRES to corrosion. The result of the surface preparation treatment shall demonstrate a reproducible process and surface condition. Particularly, the resulting conditioned

55、 parts shall be substantially free of contaminants and other undesired organic and metallic residues from storage, transport and fabrication processes (e.g. oil, grease, forming compounds, lubricants, coolants, cutting fluids, rust, scale, foreign metal or other contaminations). Remaining contaminat

56、ion or damage shall lead to rejection or rework of the components. It is the responsibility of the processor to determine, by analysis or history, the condition of the surface prior to passivation treatment to assure conformance to the requirements of this AIPS. 4.1.2During the passivation step All

57、process parameters must be controlled an within the process window limits defined in the Process Instruction. 4.1.3After the passivation step / finish Parts must be adequately rinsed. Dependent on the requirements for corrosion resistance and/or galvanic compatibility the components treated by passi

58、vation may need a subsequent treatment or finish. The dimensional accuracy has to be checked. The relevant specifications for preservation and packaging shall be considered. The treated parts shall be protected by suitable covering so as to prelude contamination or mechanical damage during storage a

59、nd transportation. The overall process shall fulfil the requirements of this AIPS.4.4.1钝化步骤之前的准备加工后,所有标本的极限抗拉强度Rm(max)高于1100 MPa应当提交应力消除热处理为了缓解残留应力。所有零件应提交一个表面准备过程。表面制备过程可能包括机械和/或化学或电化学方法,单独的或组合在一起。必要的子步骤(如清洗、脱脂、除锈、喷砂、酸洗、活化、冲洗、干燥、掩蔽)取决于污染的程度。尽管在钝化有可能有效之前，除锈或其它步骤有可能是必要的,这些步骤在AIPS中没有明确的指示出来，但是应该在过程规范中

60、指示出来。适当的表面处理的组成液体的成分可能取决于处理的抗腐蚀钢的细节。合金元素、污染和机械处理可能会影响耐蚀钢的敏感性。表面处理的结果将证明一个可再生的过程和表面状况。特别是,由此导致的零件应当无污染和从存储、运输和加工过程产生的其它不受欢迎的有机和金属残留物(如石油、油脂、形成化合物、润滑剂、冷却剂、切削液、防锈、规模,异样金属或其它污染物)。剩余的污染或损坏将导致零件的拒收或返工。处理器的责任是通过分析或者历史在钝化处理前决定表面的条件，来确保符合AIPS的要求。4.1.2钝化步骤中所有的工艺参数必须控制在过程指令中定义限制的过程窗口。4.1.3钝化步骤之后/结束零件必须充分冲洗。依赖于