静电涂装作业指导书.docx

Shanghai Nautilus General Equipment Manufacturing Co Ltd文件种类Doc. TypeISO 品质文件ISO Quality Control Document文件编号S. No.修订日期Date制定部门Dept版本VersionA106.10.27页数文件标题静电涂装作业指导书HeadingEpoxy Coating Operation Manual品管部 QCs 机密等级Confidential Level1 OF 6管制Controlled1. 目的 Purpose:作为涂装作业之标准。This document provides standards for coating inspection and acceptance.2. 范围 Scope of application:适用于本厂的全部的进货物品。This document covers the general requirements for surface preparation, environmental control, and the inspection of powder coating to metal substrates.3. 参考文件 References:GB9286 GB1732 GB67424. 操作条件 General Requirements:4.1 涂装产品外表温度至少要高出露点 5或 3。在操作开头时及操作过程中每4 小时要测量一次。The surface temperature shall be at least 5 or 3above the dew point. Readings are required at the start of work and approximately every 4 hours.4.2 操作环境不得有污染、不适当或被损坏的涂料存在。Areas where contaminate, defective, or damaged coatings have been found are not allowed.4.3 供给商需在工作开头前对涂装产品外表进展彻底检查。The supplier shall thoroughly examine metal surfaces to be coated prior to commencement of work.4.4 供给商必需对每一个步骤进展检查和测试前方可进展下一个步骤。假设觉察有缺点和缺乏，必需马上进展补 救工作，否则不得进入下一步骤操作。The supplier shall inspect and test each step of the coating work operation before proceeding with the next phase. Defects and deficiencies in surface preparation and coating work that may adversely affect completed work shall be corrected before proceeding with the next step.5. 静电涂装工艺流程图Coating Process Flow Diagram:Y-W-027 A文件种类Doc. TypeISO 品质文件ISO Quality Control Document文件编号S. No.修订日期Date制定部门Dept版本VersionA106.10.27页数文件标题静电涂装作业指导书HeadingEpoxy Coating Operation Manual品管部 QCs 机密等级Confidential Level2 OF 6管制Controlled(1)(2)(3)*(4)(5)除油 Grease removing清洗Washing酸洗Pickling清洗Washing表调Surface adjustment(1) 用脱脂剂加温,除去工件外表油污.Use heated Degreasing solvent to quickly remove grease, oil and other contaminants of the metal surface(2) 用自来水清洗.Use freshwater rinse to clean the soluble chemicals.(3) 用盐酸除去工件外表各种锈及氧化皮.Use Hydrochloric acid to remove rust and oxide of the metal surface*假设是镀锌工艺,则由第 2 步直接进入第 5 步表调.For galvanizing process, transfer from 2nd Step directly into 5th step(4) 用自来水清洗Use freshwater rinse to clean the soluble chemicals.(5) 用专用表调剂磷化前进展处理.Use special surface adjustment solution for surface treatment before phosphating(6) 磷化Phosphating(6) 用加温磷化液进展磷化.Use heated phosphate solvent for phosphating(7)清洗Washing(7) 自来水常温, 如天气阴冷承受加高温清洗.Use freshwater rinse or high-temperature cleaning for cold weather to clean the soluble chemicals .(8) 枯燥Drying(8)自干或烘干.Bake or Dry in the air(9)(10)(11)(12)(13)刮腻子Putty Shaving烘干或凉干Drying磨平 Grinding喷涂Coating烘干Drying(9) 用专用导电腻子垫平外表凹面Use special conductive putty to smooth out the concave surface(10) 烘干或凉干. Bake or Dry in the air(11) 用砂皮打磨.Use sand paper to burnish the surface(12) 用纯聚脂粉末喷涂，颜色由客户指定Use polyester powder with customer appointed color scheme to coat(13) 进烘箱,温度把握于 180190,升温 3045 分钟保温依据工件厚度进展把握文件种类Doc. TypeISO 品质文件ISO Quality Control Document文件编号S. No.修订日期Date制定部门Dept版本VersionA106.10.27页数文件标题静电涂装作业指导书HeadingEpoxy Coating Operation Manual品管部 QCs 机密等级Confidential Level3 OF 6管制ControlledPut the coated component units Into oven, the temperature shall be controlled at 180190 (356374) for 3045 minutes according to component units thickness6. 具体作业内容Detailed Operation:6.1 脱脂 Grease removing6.1.1 擦洗：当工件有严峻油垢时，需用汽油人工擦洗。Scrubbing: Use gasoline to scrub the component units surface if grease or oil is serious.6.1.2 脱脂：用脱脂液加温，以加速去除待酸洗工件外表的油垢，润滑脂，加工液等污物。Grease removing: Use heated Degreasing solvent to quickly remove grease, oil and other contaminants of the metal surface6.1.3 脱脂液的配制：ZC-II 中温脱脂剂23%+自来水余量。Degreasing solvent preparation: Thinning 23% ZC-II Degreasing solvent with freshwater.6.1.4 温度： 5065Temperature: 5065 (122149)6.1.5 方法： 浸法。浸制时间：1015 分钟。依据脱脂的实际状况确定，也可延长。Method: Immersing for 1015 minutes according to actual circumstances.6.1.6 清洗： 脱脂后的工件应放入常温清水池内流水漂洗。Washing: Use freshwater rinse to clean the soluble chemicals of component units.6.2 酸洗 Pickling6.2.1 经脱脂、清洗并滴干后的工件放酸洗槽中进展酸洗，以除去工件外表的锈斑、氧化皮等。Purpose: Use acid to remove rust, oxide and other contaminants of the metal surface.6.2.2 酸洗液： 工业盐酸，浓度20%。Pickling solvent: Industrial Hydrochloric acid with concentration 20%.6.2.3 方法：将工件浸没在酸洗液中，工件之间必需有间隙，不行板面紧贴，以免影响酸洗结果。Method: When multiple component units are immersed, there shall be space between the units, close to the tank are not allowed in case of influencing pickling result.6.2.4 酸洗时间： 视工件板材的厚度、锈蚀程度以及氧化皮的状况确定，以到达除锈的目的。Time: According to actual thickness, rust and oxide of component units.6.2.5 漂洗：为削减带入漂洗槽的酸量，工件从酸洗槽中提出后应在酸洗槽上方稍作停留，滴去工件上的大局部酸液后浸入清水槽，用常温下流淌水漂洗。经漂洗后的工件放入中和槽中和，中和槽PH 值 910。Washing: Use freshwater rinse to clean the soluble chemicals at room temperature, then put into neutralization sink with PH 910.文件种类Doc. TypeISO 品质文件ISO Quality Control Document文件编号S. No.修订日期Date制定部门Dept版本VersionA106.10.27页数文件标题静电涂装作业指导书HeadingEpoxy Coating Operation Manual品管部 QCs 机密等级Confidential Level4 OF 6管制Controlled6.3 外表调整Surface adjustment6.3.1 目标： 酸洗后的工件外表较粗糙，经外表调整后，能使金属外表形成细结晶的磷酸盐膜层。Purpose: The metal surface is rough after pickling and surface adjustment will form crystallization of phosphate film on metal surface.6.3.2 配制： 按重量比=胶体钛盐0.20.3% + 自来水余量。Solvent preparation: Thinning 0.20.3% colloidal titanium salt with freshwater according to weight.6.3.3 方法： 在常温下将工件浸入外表调整液槽内，浸制时间0.51 分钟。Method: Immersing for 0.51 minute at room temperature.6.4 磷化处理Phosphating6.4.1 磷化液： 用锌系磷化液ZL-II按 3%的重量比与自来水配制。总酸度 ：1620点； 游离酸： 0.81.2点； 促进剂：23点； 碱度：1015Solvent preparation: Thinning 3% ZL-II zinc-phosphate solvent with freshwater according to weight. Total Acid level: 1620; Educt Acid: 0.81.2; Catalyzer: 23; Alkalinity: 1015.6.4.2 磷化温度： 45±5Phosphate Temperature: 45±56.4.3 处理方法： 浸制法，将待处理工件浸没于磷化槽内。Method: Immersing.6.4.4 磷化时间： 8 分钟Phosphate Time: 8 minutes.6.4.5 磷化液的治理： 每天测定一次总酸度和游离酸度，及促进剂和碱度，并使之符合要求。Phosphate solvent management: Inspect Total Acid level, Educt Acid, Catalyzer and Alkalinity every day to meet the requirements.6.5 磷化膜的质量要求Phosphate film requirements6.5.1 轻量级 23g/M² Lightweight: 23g/m26.5.2 磷化膜的外观应结晶致密、连续和均匀，颜色应为浅灰色。不允许有疏松的膜层，不允许局部无膜焊缝的气孔和夹渣除外。不允许有锈蚀和严峻的挂灰Surface: Crystallization shall be dense, continuous, uniform and light grey. Loose adhering coating, exposed metal surface (except weld stomata and slag), rust and serious dust are not allowed.6.6 清洗Washing6.6.1 水温与方法：磷化处理后的工件从磷化槽内取出滴干后，浸入清水槽内清洗12 分钟。水温65Method: Use freshwater rinse to clean the soluble chemicals for 12 minutes. Temperature: 65(149).6.6.2 清洗槽用水每天更换一次文件种类Doc. TypeISO 品质文件ISO Quality Control Document文件编号S. No.修订日期Date制定部门Dept版本VersionA106.10.27页数文件标题静电涂装作业指导书HeadingEpoxy Coating Operation Manual品管部 QCs 机密等级Confidential Level5 OF 6管制ControlledFreshwater management: Change every day.6.6.3 枯燥方式： 自干Drying method: Dry in the air.6.7 刮腻子 Putty Shaving6.7.1 当工件有凹陷外表及制作时用砂轮打磨过的不平外表的缺陷而有不能用喷涂掩盖时，用导电腻子填补刮平。Use special conductive putty to smooth out the concave surface.6.7.2 待腻子枯燥后用 0 号或 1 号铁砂布打磨平坦。Use #0 or #1 sand paper to burnish the surface.6.7.3 打磨腻子时应尽量缩小打砂范围，不要破坏非腻子填补局部的磷化膜。Minimize the scope of putty shaving so as not to destroy non-putty filled phosphate film.6.7.4 吹尘：经打磨后的工件用压缩空气吹净外表浮尘。Use compressed air to blow dust and loose abrasive particles.6.7.5 不喷漆外表的处理： 当工件上有局部不喷漆要求时，用不干胶纸将该局部封盖。Protection: Surfaces are not to be coated shall be suitably protected by drop cloths and masking.6.8 喷涂 Coating6.8.1 工艺参数： 气压 0.30.5 MPa，电压 7090 KV，电流 3545 A Parameter: Pressure: 0.30. 5 MPa, Voltage: 7090 KV, Current 3545 A.6.9 固化 Solidifying6.9.1 在流水线上喷涂时按工件大小，板材厚度调整流水线行走速度： 0.60.8m/分钟。Pipelining speed: 0.60.8 m/min according to component dimension.6.9.2 在箱式烘箱内固化时，严格把握固化温度和时间Temperature and time shall be strictly controlled while solidifying inside of the box type oven.6.9.3 固化温度和时间，按粉末供给商供给的参数把握。常用粉末的固化温度为180，固化时间 20 分钟。Solidifying temperature: 180 (356). Solidifying time: 20 min.6.9.4 开箱： 固化完毕后开箱，待工件稍凉后取出工件，取出工件时应戴上干净手套。Oven opening: Open the oven and take out the components after they are cooler.6.9.5 去除：去除工件未喷涂外表掩盖的不干胶纸。Cleanup: Remove all protective film and masking from surfaces not being painted.7. 检验 Inspection7.1 各道工序完成后出烘房后进展出厂检验并作记录，合格前方可以出厂。All components can successfully pass after the completion of processes for inspection and record in the factory.文件种类Doc. TypeISO 品质文件ISO Quality Control Document文件编号S. No.修订日期Date制定部门Dept版本VersionA106.10.27页数文件标题静电涂装作业指导书HeadingEpoxy Coating Operation Manual品管部 QCs 机密等级Confidential Level6 OF 6管制Controlled制订Prepared by: 质量检验员Quality inspector审查Reviewed by:品控主管QC Supervisor核对Checked by:技术主管Technical Supervisor批准Approved by:厂长Plant Manager