热浸锌检修作业指导书

文件编号DocumentNO.热浸锌检修作业指导书InspectionandrepairinginstructionforHGD页次page6/61.目的Purpose规范热浸锌修补作业过程。RegulatethereparingworkprocedureforHGD使用范围Scope所有热浸锌产品修补作业。AllHGDproductsareincludedforrepairingwork.3.职责Responsibility生产部负责本文件的制定，批准，发布，修改，废止。Theproductiondepartmenthastheresponsibilitytoconduct,approve,issue,reviseandannulthisdocument.车间热浸锌修补人员负责遵循本文件。TherepairingpersonnelinHGDworkshophastheresponsibilitytofollowthisdocument.车间本工序直接负责人负责检查本文件的执行。Thedirectownerofthisprocessinworkshophastheresponsibilitytochecktheexcutionofthisdocument.4.作业过程workingprocedure4.0作业前：beforeworking检查下列内容，确保软硬件齐全，状态良好，计量合格：Checkbelowcontenttosecureallhardwareandsoftwareiscompleteandingoodconditionswithqualifiedmeasurement.人员：人员要被培训合格，熟知热浸锌不良问题，人员的防护用品穿戴齐全，口罩、安全鞋、手套。Personnel:personnelhastobetrainedasqualifiedandfullyknowthedefectsforHGD.Theprotectivearticlesforpersonnelhastobewaredproperlylikemasks,saftyshoesandgloves.工具：木锤、铲刀、砂纸、各型号锉刀。Tool:hammer,blade,sandpaperandallkindsoffiles.物料：检查待修补加工的零件，修补用的Hempel16490富锌底漆，使用时间在2H内，清洗剂99350。Materials:checkthosecomponentsneedtoberepairedandmachined,Hempel16490primercoatedforrepairing,withinusingtime2hours,cleaningagent99350.文件：引用ZPS1009606。Document:RefertoZPS1009606环境：作业场所的光照能满足检修要求，配有强光电筒。Enviroment:lightsforworkingareahastofullfilltherequirementofinspectionwithhighlightflash.补漆环境:paintrepairingenvironment：基体表面温度高于露点温度3℃Substratesufacetemperatureis3℃higherthandew-pointtemperature.构件温度≥10℃constructiontemperature≥10℃环境温度≥10℃environmemnttemperature≥10℃RH≤85%4.1检修作业过程：Inspectionandrepairingworkingprocedure4.1.1检查产品：按客户指定的“封样样品”要求，检查产品表面外观。Inspectproducts:Inspecttheappearanceofproductsaccordingtothespecifiedrequirementof“samplingsample”对比样件检查，可通过目测和触摸方式对比样件检查。ComparethethesampleinspectionbyVTandtouch4.1.2热浸修常规缺陷如下：commondefectsforHGDasbelow:【不良面积>100平方厘米】需退回热浸锌厂返工，【defectsarea>100m2】,needtobereturnedtoHGDfactorytorework【锌层开裂】不允许，【Zinclayercrack】isnotallowed【总面积>2㎡，不良>10%】需退回热浸锌厂返工，【Totalarea>2㎡,defects>10%】needtobereturedtoHGDfactorytorework,【局部生锈】不允许，【partinrusted】isnotallowed.【总面积<2㎡，不良>5%】需退回热浸锌厂返工，【Totalarea>2㎡,defects>5%】needtobereturedtoHGDfactorytorework,【局部锌灰】不允许，【partinZincash】isnotallowed.【碰伤、划痕】见样件【bruise,scratch】seesample【焊渣】不允许【dross】notallowed【气孔】不允许【pores】notallowed【流挂】见样件【sag】seesample【露底】不允许【exposure】notallowed【气泡】不允许【bubbles】notallowed【锌瘤】见样件【listedge】seesamples【毛刺】见样件【burrs】seesamples锌瘤listedge凸起、流痕、发白buldges,flowmarks,blanch生锈rusted毛刺burrs锌层开裂Zinclayercrack锌灰、锌瘤Zincash、listedge锌瘤listedge漏镀面missinggalvanizingsurface露底exposure孔内堵锌zincpluginhole4.1.3不良修补：defectsrepair【工具】适用合适的打磨工具（如下图）；【tool】isapplicableforpropergrindingtool.修磨工具gringdingtool修补工具repairtool【打磨】生锈、锌瘤、粗糙和锐点、毛刺及残留焊剂需使用平锉刀、砂纸、圆锉刀平行去除（注意：不可倾斜），不允许划伤完好面。如下图所示：【Grinding】rusted,listedge,coarseandsharppoint,burrsandremainedfluxneedtoberemovedparallely(note:notlean)byfiles,sandpaperandroundfiles,notallowtoscratchthehperfectsurface.Shownasbelowpicture:【检验】针对热浸锌修膜区域，修膜后用膜厚仪测量涂层的厚度；【Inspection】ForrepairingareaforHGD,measurethethicknessofcoatingbyfilmthicknessgauge.对部份无法用膜厚仪确认涂层是否合格的修膜区域，按ZPS1009606要求的修补方式涂油漆。ForpartofthoserepairingareawhichcannotbeconfirmedasqualifiedbyfilmthicknessgaugeispaintedasthewayaccordingtoZPS1009606【补漆】步骤一，使用Hempel清洗剂99350清洗补漆区域，再用清水擦洗，使表面清洁。最后用干净布擦干（清洗剂配比：1：20体积比）【paintreparing】step1,useHEMPELcleaningagent99350tocleantherepairingarea,andcleanitwiththewatertokeepthesurfaceclean.Finallydryitbycleancloth(cleaningagentratio:1:20involumn)步骤二，气动抛光机用120#砂纸打磨距不良区域外围5mm内的面积，使锌层表面圆滑过渡，使其达到ISO8501-1St3级别。Step2,Grindtheoutsidearea5mmawayfromthedefectsareaby#120sandpaperwithPneumaticpolishertomakethesurfacesmoothandroundandmeettheclassISO8501-1ST3.步骤三，使用Hempel16490富锌底漆进行修补，颜色与干膜厚度按照下表。Step3:RepairbyHEMPEL16490primercoated,itscolorsandfilmthicknessisaccordingtobelowsheet.在可能的情况下，所有用油漆修补形状均以方形修补。Wherepossible,allpaintingrepairformissqaure.等级classPaintsystem油漆Color颜色NDFT(µm)C3HEMPEL’SZINCPRIMER16490Grayish浅灰色的90C4HEMPEL’SZINCPRIMER16490Grayish浅灰色的110C5HEMPEL’SZINCPRIMER16490Grayish浅灰色的185步骤四，固化时间step4:curingtime指触干touchabletry20℃，30Min完全固化（RH70%）totallycuring10℃，14天10℃，14days20℃，7天20℃，7days30℃，5天30℃，5days4.2检验Inspection自检：自检频率100%。Self-inspection:frequencyofself-inspectionis100%专检：专检频率100%。Specialinspection:frequencyofspecialinspectionis100%4.3产品防护转序：Productprotectiveflowprocess防护：产品补漆部不可触碰。Protection:thereparingareaoftheproductsisnottouchable.堆放：选用适合的转载箱存放产成型后的零件，托盘选择合适，垒高合适，搬运中不掉落，产品不变形，不碰伤、压伤。Stackup:Storeformedcomponentsinpropercontainer,selectproperpallettopileupcorrectly,nofall-offduringremovals,producthasnodeformation,bruiseandcrush.搬运：搬运注意产品和人员的防护。Transport:noticetheprotectionforproductsandpersonnels.4.4记录Records填写《车间温湿度点检表》。Fill<humidityandtemp