mb standards

7/30/2019 MB Standards

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Surface Protection & Bonding Process

28.06.2012 Mercedes-Benz Trk, Istanbul


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Index

1. Accredited test scopes Corrosion Resistance Tests2. Paint Tests

3. Phosphating & E-Coating Tests

4. Bonding processes


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Accredited test scopes: Corrosion Resistance Tests


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Index

1 Corrosion Resistance Tests1.1 Salt spray tests (NSS & CASS)

1.2 Condensation-water test with constant humidity

1.3 Sulfur dioxide test with general condensation of moisture

1.4 Corrodkode corrosion test (CORR-test)


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1. Corrosion Resistance Tests

1.2 Condensation-water test with constant humidityHumidity resistance and adhesion performance of paintsand coatings are determined in Erichsen humidity test

cabinet according to DIN EN ISO 6270-2.

1.1 Salt spray tests (NSS & CASS)

Corrosion resistance of painted and coated materials isevaluated according to DIN EN ISO 9227 in Erichsensalt spray cabinet.


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1. Corrosion Resistance Tests

1.3 Sulfur dioxide test with general condensation of moisture

Corrosion resistance of Zn-coatedmaterials is evaluated according toDIN EN ISO 6988 incorrosion test cabinet.

1.4 Corrodkode corrosion test (CORR-test)Corrosion resistance of CrNi-coated parts is

determined with a special abrasive slurry accordingto DIN 50 958.


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2 Paint Tests

2.1 Film thickness measurement

2.2 Coating thickness measurement with X-Ray spectrometer

2.3 Tests for coating adhesion2.3.1 Scratch Test2.3.2 Cross-Cut Test

2.4 Measurement elasticity of coated films2.5 Gloss determination of painted films

2.6 Determination of colour and match2.6.1 Colour match measurement withSpectrophotometer

2.6.2 Visual control with Spectralight III2.7 Measurement of surface roughness

2.8 Measurement of paint hardness

2.9 Thickness measurement wedge cut

2.10 Measurement of stone impact resistance

Index

2.11 Weathering tests

2.12 Endoscopic examination2.13 Measurement of viscosity

2.14 Measurement of high viscosityBrookfield viscosimeter

2.15 Determination of non-volatile matter

content2.16 Determination of ash content

2.17 Determination of fineness of grind

2.18 Measurement of density

2.19 Tendency to running and floating

2.20 Hiding power test2.21 Measurement of refractive index

2.22 Measurement of orange peel of thesurfaces

2.23 Measurement of orange peel of the

surfaces


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2. Paint Tests

2.1 Film thickness measurement with coating thickness gauge

Film thickness on painted and coated metal surfaces ismeasured with Erichsen Minitest 4100 testing instrumentaccording to DIN EN ISO 2064/3882.

2.2 Coating thickness measurement with X-Ray spectrometerThickness of Cr, Ni, Ag, Zn, Zn/Ni, Zn/Fe coatings onferric substrates is measured with Fischerscope X-RAY

spectrometer according to EN ISO 3497.


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2.4 Measurement elasticity of coated films

Bending and elongation degrees of paint, filler and clear coat aremeasured with Erichsen cylindrical or conical bend test apparatusaccording to DIN EN ISO 1519 .

2.5 Gloss determination of painted filmsGloss of surface which coated with paint, filler andclear coat is measured with Haze-Gloss instrument inaccordance with EN ISO 2813.

2. Paint Tests


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2.6 Determination of a matching colour variant

Colour difference value is a diagonal ofL, a, b values in the 3 dimensional cartesiancoordinate system. It determines thelocation of the test plate in the colour space.

2. Paint Tests

2.6.1 Colour match measurement with spectrophotometerMatching colour of paints with reference samples due tocolor scale is done with X-Rite Spectrophotometer.

2.6.2 Visual control with Spectralight IIIVisual assessment of paint colour isperformed with Gretagmacbeth Spectralight IIIaccording to DIN EN ISO 4628-1.


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2.9 Thickness measurement with PIG instrumentThe indentation test is performed with PIG instrument forthickness measurement and cross-sectional analysis on paintedsurfaces according to DIN EN ISO 2815.

2.10 Measurement of stone impact resistanceStone impact resistance of painted surfaces are definedwith Erichsen Stone Impact Test instrument in accordance

with DIN EN ISO 20567-1.

2. Paint Tests


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2. Paint Tests

2.12 Endoscopic examinationVisual examination of the profile inside is performedwith Karl Storz Endoscope.

2.11 Weathering test

Light and weather fastness of painted surfaces aredetermined according to DIN EN ISO 11341 withAtlas Xeno Test instrument, thus revealing the colour fadingvalue of the paint.


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2. Paint Tests

2.13 Measurement of viscosity

Viscosity of liquid materials (paint, filler, clear coat) are measured with DIN Cup 4 viscometeraccording to DIN EN ISO 2431. In order to provide constant temperature during measurements,thermosetted water bath is used.


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2. Paint Tests

2.14 Measurement of high viscosity fluids with Brookfield viscosimeter

Fluids with high viscosity e.g. paint, filler, wax, clear coat is measuredwith Brookfield viscosimeter.

2.15 Determination of non-volatile matter contentNon-volatile/solid content of primer, topcoat, e-coating,UBC etc. is determined according to EN ISO 3251.


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2. Paint Tests

2.16 Determination of ash contentDetermination of ash content of e-coating in accordance withVDA 621-198.

2.17 Determination of fineness of grindEstimation of fineness/coarseness of paint pigments isdetermined with Erichsen Grindometer according toDIN EN ISO 1524.


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2. Paint Tests

2.18 Measurement of densityDensity of paint is measured with Erichsen Pyknometeraccording to DIN EN ISO 2811-1.

2.19 Tendency to running and floatingThe paint thickness when it startsrunning is determined according to VDA 621-114 .


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2. Paint Tests

2.20 Hiding power testUsing the contrast ratio at a specified filmthickness, hiding power of paint is determinedin accordance with DIN 55601.

2.22 Measurement of refractive indexRefractive index of solvent, hardener etc.is determined with Atago Refractometer inaccordance with DIN 53 169.

2.21 Test of crater on glassChange of surface tension ( crater )of paint isdetermined according to 4.1 at DBL 7399


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2. Paint Tests

2.23 Measurement of orange peel of the surfaces

Orange peel measurement in terms of LW, SW and DOI on high to semi gloss surfaces isperformed with Wave- Scan Dual instrument.


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Phosphating & E-Coating Tests


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Index

3 Phosphating & E-Coating Tests

3.1 Analytical Tests

3.1.1 Free acid, total acid test

3.1.2 Total alkali

3.1.3 Determination of Zn, Mn, Ni content

3.2 Potentiometric analysis3.2.1 pH measurement

3.2.2 Measurement of ionic composition

3.2.3 Conductivity measurement

3.3 Bacterial analysis

3.3.1 Bacteral incubator3.3.2 Hy-Lite 2

3.4 REO Gert

3.5 Gardometer


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3.1 Analytical Tests

3.1.1 Free acid, total acid testFree acid and total acid values of phosphate samples aredetermined with titration.

3.1.2 Total alkaliTotal alkali content of phosphate samples is determined withtitration.

3.1.3 Determination of Zn, Mn, Ni contentZn-, Mn-, Ni-contents of phosphate samples are determined with

titration.


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3.2 Potentiometric analysis

3.2.1 pH measurementpH-values are measured in surface treatment lineswith Orion Aplus instrument.

3.2.2 Measurement of ionic compositionFl and Cl concentrations in phosphating lines aremeasured with Orion Aplus instrument by means of an ionselective electrode.

3.2.3 Conductivity measurement

Conductivity is measured in surface treatment lines with WTW Cond330i instrument.


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3.3 Bacterial analysis

3.3.1 Bacterial incubatorBacterial existence in surface treatment lines is detectedby means of special test tubes contaminated with test

solution which are stored in the incubator for a certain time.

3.3.2 Hy-Lite 2Bacterial existence in e-coating line is rapidly detected with

Hy-Lite 2 instrument based on ATP-decomposition method.


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3.4 REO-GertThe e-coater REO-Gert allows for contamination andpenetration controls in laboratory scale according toVDA 621-508 and Daimler standards.

3.5 GardometerMass per unit area of Zn- and Mn-phosphatecoating is measured on blank steel, galvanized

steel and aluminium substrates withChemetall-Gardometer according to DBL 8422.


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Bonding processes


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Index

4 Bonding processes4.1 Adhesion tests

4.2 Activities for bonding processes


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4. Bonding Processes

4.1 Adhesion testsAdhesion suitability is tested according to EVO 140.10and Daimler standards.

4.2 Activities for bonding processes

Description suitable bonding processes for differentsurfaces, research new material and applicationtechnics. Bonding process audits are being done.

Organise bonding education for production employees.

Giving consulting service for development and

supporting of suppliers, description suitable bondingprocess or process failures analyse.

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