靜電涂裝作業(yè)指導(dǎo)書

ShanghaiShanghaiNautilusGeneralEquipmentManufacturingCoLtdY-W-027Y-W-027A文件種類文件種類Doc.TypeISO品質(zhì)文件ISOQualityControlDocument文件編號S.No.修訂日期Date制定部門Dept版本VersionA106.10.27頁數(shù)文件標(biāo)題靜電涂裝作業(yè)指導(dǎo)書Heading EpoxyCoatingOperationManualQCs機(jī)密等級ConfidentialLevel1OF6管制ControlledPurpose:作為涂裝作業(yè)之標(biāo)準(zhǔn)。Thisdocumentprovidesstandardsforcoatinginspectionandacceptance.Scopeofapplication:適用于本廠的全部的進(jìn)貨物品。Thisdocumentcoversthegeneralrequirementsforsurfacepreparation,environmentalcontrol,andtheinspectionofpowdercoatingtometalsubstrates.References:GB9286GB1732GB6742GeneralRequirements:涂裝產(chǎn)品外表溫度至少要高出露點5℉或3℃。在操作開頭時及操作過程中每4小時要測量一次。Thesurfacetemperatureshallbeatleast5or3℃abovethedewpoint.Readingsarerequiredatthestartofworkandapproximatelyevery4hours.操作環(huán)境不得有污染、不適當(dāng)或被損壞的涂料存在。Areaswherecontaminate,defective,ordamagedcoatingshavebeenfoundarenotallowed.供給商需在工作開頭前對涂裝產(chǎn)品外表進(jìn)展徹底檢查。Thesuppliershallthoroughlyexaminemetalsurfacestobecoatedpriortocommencementofwork.救工作，否則不得進(jìn)入下一步驟操作。Thesuppliershallinspectandtesteachstepofthecoatingworkoperationbeforeproceedingwiththenextphase.Defectsanddeficienciesinsurfacepreparationandcoatingworkthatmayadverselyaffectcompletedworkshallbecorrectedbeforeproceedingwiththenextstep.靜電涂裝工藝流程圖CoatingProcessFlowDiagram:文件種類文件種類Doc.TypeISO品質(zhì)文件ISOQualityControlDocument文件編號S.No.修訂日期Date制定部門Dept版本VersionA106.10.27頁數(shù)文件標(biāo)題靜電涂裝作業(yè)指導(dǎo)書Heading EpoxyCoatingOperationManualQCs機(jī)密等級ConfidentialLevel2OF6管制Controlled(1)(2)(3)*(4)(5)

Greaseremoving清洗Washing酸洗Pickling清洗Washing表調(diào)Surfaceadjustment

用脫脂劑加溫,除去工件外表油污.UseheatedDegreasingsolventtoquicklyremovegrease,oilandothercontaminantsofthemetalsurface用自來水清洗.Usefreshwaterrinsetocleanthesolublechemicals.用鹽酸除去工件外表各種銹及氧化皮.UseHydrochloricacidtoremoverustandoxideofthemetalsurface*假設(shè)是鍍鋅工藝,25步表調(diào).Forgalvanizingprocess,transferfrom2ndStepdirectlyinto5thstep用自來水清洗Usefreshwaterrinsetocleanthesolublechemicals.用專用表調(diào)劑磷化前進(jìn)展處理.Usespecialsurfaceadjustmentsolutionforsurfacetreatmentbeforephosphating磷化Phosphating

用加溫磷化液進(jìn)展磷化.Useheatedphosphatesolventforphosphating(7)

清洗Washing

自來水常溫,如天氣陰冷承受加高溫清洗.Usefreshwaterrinseorhigh-temperaturecleaningforcoldweathertocleanthesolublechemicals.枯燥Drying (8) 自干或烘干.BakeorDryintheair

刮膩子PuttyShaving烘干或涼干DryingGrinding噴涂Coating烘干Drying

用專用導(dǎo)電膩子墊平外表凹面Usespecialconductiveputtytosmoothouttheconcavesurface烘干或涼干.BakeorDryintheair用砂皮打磨.Usesandpapertoburnishthesurface用純聚脂粉末噴涂，顏色由客戶指定Usepolyesterpowderwithcustomerappointedcolorschemetocoat(13)進(jìn)烘箱,180℃~190℃,30~45分鐘保溫依據(jù)工件厚度進(jìn)展把握文件種類文件種類Doc.TypeISO品質(zhì)文件ISOQualityControlDocument文件編號S.No.修訂日期Date制定部門Dept版本VersionA106.10.27頁數(shù)文件標(biāo)題靜電涂裝作業(yè)指導(dǎo)書Heading EpoxyCoatingOperationManualQCs機(jī)密等級ConfidentialLevel3OF6管制ControlledPutthecoatedcomponentunitsIntooven,thetemperatureshallbecontrolledat180℃~190℃(356℉~374℉)for30~45minutesaccordingtocomponentunitsthickness具體作業(yè)內(nèi)容DetailedOperation:脫脂Greaseremoving擦洗：當(dāng)工件有嚴(yán)峻油垢時，需用汽油人工擦洗。Scrubbing:Usegasolinetoscrubthecomponentunitssurfaceifgreaseoroilisserious.脫脂：用脫脂液加溫，以加速去除待酸洗工件外表的油垢，潤滑脂，加工液等污物。Degreasingsolventtoquicklyremovegrease,oilandothercontaminantsofthemetalsurface脫脂液的配制：ZC-II中溫脫脂劑〔2~3〕%+自來水余量。Degreasingsolventpreparation:Thinning2~3%ZC-IIDegreasingsolventwithfreshwater.6.1.4溫度：50~65℃Temperature:50~65℃(122~149℉)方法：浸法。浸制時間：10~15分鐘。依據(jù)脫脂的實際狀況確定，也可延長。Method:Immersingfor10~15minutesaccordingtoactualcircumstances.清洗：脫脂后的工件應(yīng)放入常溫清水池內(nèi)流水漂洗。Washing:Usefreshwaterrinsetocleanthesolublechemicalsofcomponentunits.酸洗Pickling經(jīng)脫脂、清洗并滴干后的工件放酸洗槽中進(jìn)展酸洗，以除去工件外表的銹斑、氧化皮等。Purpose:Useacidtoremoverust,oxideandothercontaminantsofthemetalsurface.酸洗液：工業(yè)鹽酸，濃度≥20%。Picklingsolvent:IndustrialHydrochloricacidwithconcentration≥20%.方法：將工件浸沒在酸洗液中，工件之間必需有間隙，不行板面緊貼，以免影響酸洗結(jié)果。Method:Whenmultiplecomponentunitsareimmersed,thereshallbespacebetweentheunits,closetothetankarenotallowedincaseofinfluencingpicklingresult.酸洗時間：視工件板材的厚度、銹蝕程度以及氧化皮的狀況確定，以到達(dá)除銹的目的。Time:Accordingtoactualthickness,rustandoxideofcomponentunits. 漂洗：為削減帶入漂洗槽的酸量，工件從酸洗槽中提出后應(yīng)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，用常溫下流淌水漂洗。經(jīng)漂洗后的工件放入中和槽中和，中和槽PH9~10。Washing:Usefreshwaterrinsetocleanthesolublechemicalsatroomtemperature,thenputintoneutralizationsinkwithPH9~10.文件種類文件種類Doc.TypeISO品質(zhì)文件ISOQualityControlDocument文件編號S.No.修訂日期Date制定部門Dept版本VersionA106.10.27頁數(shù)文件標(biāo)題靜電涂裝作業(yè)指導(dǎo)書Heading EpoxyCoatingOperationManualQCs機(jī)密等級ConfidentialLevel4OF6管制Controlled外表調(diào)整Surfaceadjustment 目標(biāo)：酸洗后的工件外表較粗糙，經(jīng)外表調(diào)整后，能使金屬外表形成細(xì)結(jié)晶的磷酸鹽膜層。Purpose:Themetalsurfaceisroughafterpicklingandsurfaceadjustmentwillformcrystallizationofphosphatefilmonmetalsurface.=膠體鈦鹽〔0.2~0.3〕%+自來水余量。Solventpreparation:Thinning0.2~0.3%colloidaltitaniumsaltwithfreshwateraccordingtoweight. 方法：在常溫下將工件浸入外表調(diào)整液槽內(nèi)，浸制時間0.5~1分鐘。Method:Immersingfor0.5~1minuteatroomtemperature.磷化處理Phosphating磷化液：用鋅系磷化液〔ZL-II〕按3%的重量比與自來水配制?？偹岫?6~2〔點；游離酸：0.8~1.〔點；2~〔點；堿度：10~15Solventpreparation:Thinning3%ZL-IIzinc-phosphatesolventwithfreshwateraccordingtoweight.TotalAcidlevel:16~20;EductAcid:0.8~1.2;Catalyzer:2~3;Alkalinity:10~15.6.4.245℃±5℃PhosphateTemperature:45℃±5℃處理方法：浸制法，將待處理工件浸沒于磷化槽內(nèi)。Method:Immersing.8分鐘PhosphateTime:≥8minutes.磷化液的治理：每天測定一次總酸度和游離酸度，及促進(jìn)劑和堿度，并使之符合要求。Phosphatesolventmanagement:InspectTotalAcidlevel,EductAcid,CatalyzerandAlkalinityeverydaytomeettherequirements.磷化膜的質(zhì)量要求Phosphatefilmrequirements 輕量級2~3g/M2Lightweight:2~3g/m2磷化膜的外觀應(yīng)結(jié)晶致密、連續(xù)和均勻，顏色應(yīng)為淺灰色。不允許有疏松的膜層，不允許局部無膜〔焊縫的氣孔和夾渣除外。不允許有銹蝕和嚴(yán)峻的掛灰Surface:Crystallizationshallbedense,continuous,uniformandlightgrey.Looseadheringcoating,exposedmetalsurface(exceptweldstomataandslag),rustandseriousdustarenotallowed.清洗Washing水溫與方法：磷化處理后的工件從磷化槽內(nèi)取出滴干后，浸入清水槽內(nèi)清洗1~2分鐘。水溫≥65℃Method:Usefreshwaterrinsetocleanthesolublechemicalsfor1~2minutes.Temperature:≥65℃(149℉).清洗槽用水每天更換一次文件種類文件種類Doc.TypeISO品質(zhì)文件ISOQualityControlDocument文件編號S.No.修訂日期Date制定部門Dept版本VersionA106.10.27頁數(shù)文件標(biāo)題靜電涂裝作業(yè)指導(dǎo)書Heading EpoxyCoatingOperationManualQCs機(jī)密等級ConfidentialLevel5OF6管制ControlledFreshwatermanagement:Changeeveryday.枯燥方式：自干Dryingmethod:Dryintheair.PuttyShaving 當(dāng)工件有凹陷外表及制作時用砂輪打磨過的不平外表的缺陷而有不能用噴涂掩蓋時，用導(dǎo)電膩子填補刮平。Usespecialconductiveputtytosmoothouttheconcavesurface. 01號鐵砂布打磨平坦。Use#0or#1sandpapertoburnishthesurface.打磨膩子時應(yīng)盡量縮小打砂范圍，不要破壞非膩子填補局部的磷化膜。Minimizethescopeofputtyshavingsoasnottodestroynon-puttyfilledphosphatefilm.吹塵：經(jīng)打磨后的工件用壓縮空氣吹凈外表浮塵。Usecompressedairtoblowdustandlooseabrasiveparticles.不噴漆外表的處理：當(dāng)工件上有局部不噴漆要求時，用不干膠紙將該局部封蓋。Protection:Surfacesarenottobecoatedshallbesuitablyprotectedbydropclothsandmasking.Coating6.8.10.3~0.5MPa70~90KV，電流35~45AParameter:Pressure:0.3~0.5MPa,Voltage:70~90KV,Current35~45A.固化Solidifying 在流水線上噴涂時按工件大小，板材厚度調(diào)整流水線行走速度：0.6~0.8m/分鐘。Pipeliningspeed:0.6~0.8m/minaccordingtocomponentdimension.在箱式烘箱內(nèi)固化時，嚴(yán)格把握固化溫度和時間Temperatureandtimeshallbestrictlycontrolledwhilesolidifyinginsideoftheboxtypeoven.固化溫度和時間，按粉末供