mb standards
TRANSCRIPT
-
7/30/2019 MB Standards
1/30
Surface Protection & Bonding Process
28.06.2012 Mercedes-Benz Trk, Istanbul
-
7/30/2019 MB Standards
2/30
Folie 2
Index
1. Accredited test scopes Corrosion Resistance Tests2. Paint Tests
3. Phosphating & E-Coating Tests
4. Bonding processes
-
7/30/2019 MB Standards
3/30
Folie 3
Accredited test scopes: Corrosion Resistance Tests
-
7/30/2019 MB Standards
4/30
Folie 4
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)
-
7/30/2019 MB Standards
5/30
Folie 5
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.
-
7/30/2019 MB Standards
6/30
Folie 6
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.
-
7/30/2019 MB Standards
7/30
-
7/30/2019 MB Standards
8/30
Folie 8
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
-
7/30/2019 MB Standards
9/30
Folie 9
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.
-
7/30/2019 MB Standards
10/30
-
7/30/2019 MB Standards
11/30
Folie 11
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
-
7/30/2019 MB Standards
12/30
Folie 12
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.
-
7/30/2019 MB Standards
13/30
-
7/30/2019 MB Standards
14/30
Folie 14
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
-
7/30/2019 MB Standards
15/30
Folie 15
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.
-
7/30/2019 MB Standards
16/30
Folie 16
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.
-
7/30/2019 MB Standards
17/30
Folie 17
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.
-
7/30/2019 MB Standards
18/30
Folie 18
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.
-
7/30/2019 MB Standards
19/30
Folie 19
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 .
-
7/30/2019 MB Standards
20/30
Folie 20
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
-
7/30/2019 MB Standards
21/30
Folie 21
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.
-
7/30/2019 MB Standards
22/30
Folie 22
Phosphating & E-Coating Tests
-
7/30/2019 MB Standards
23/30
Folie 23
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
-
7/30/2019 MB Standards
24/30
Folie 24
3. Phosphating & E-Coating Tests
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.
-
7/30/2019 MB Standards
25/30
Folie 25
3. Phosphating & E-Coating Tests
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.
-
7/30/2019 MB Standards
26/30
Folie 26
3. Phosphating & E-Coating Tests
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.
-
7/30/2019 MB Standards
27/30
Folie 27
3. Phosphating & E-Coating Tests
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.
-
7/30/2019 MB Standards
28/30
Folie 28
Bonding processes
-
7/30/2019 MB Standards
29/30
Folie 29
Index
4 Bonding processes4.1 Adhesion tests
4.2 Activities for bonding processes
-
7/30/2019 MB Standards
30/30
Folie 30
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.