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Surface protection guidelines for Welding joints in Powder coating / REF: CQ / FF / 004 Liquid Painting process
DATE: 03.05.2012 Scope: This document is a guideline covering the additional surface protection care that should be exercised during the Powder coating process on the welded portions / joints of the components. This guideline is applicable to the Sheet Metal component suppliers & the approved powder coating suppliers (In-house / Job coating). Objective: To ensure that all the Surface coated components supplied to Ashok Leyland are completely free from rust & has the anti rusting property for the intended life including the weaker area of welding portions / joints. Guidelines: 1. Sheet Metal component suppliers of Ashok Leyland should adhere to the following guidelines after their Welding process: 1.1 The Welded portion shall be cleaned to have a smooth finished surface free from any burr, sharp edges, dust, scales etc. as per the guideline prescribed in Annexure A. 2. Surface coating suppliers (Powder / Liquid) should adhere to the following guideline for additional protection on Welding portions / joints. 2.1 Only the Powder coating process recommended in the Annexure B shall be adapted for components with Welding portions / joints for HR components. 2.2 Only the Powder coating process recommended in the Annexure C shall be adapted for components with Welding portions / joints for CR / HRPO components. 2.3 Only the AL approved Primers shall be used on Welded portion / joints as per the recommendation in the Annexure D. The coating supplier shall take complete responsibility for the paint raw material procured to assure the quality of the surface coating.
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Welded portion / joints shall be cleaned by a brushing action for surface finishing, cleaning and polishing, weld blending, de-burring, and removal of paint, rust, scale, or other contamination. Only the below mentioned brushing Tools shall be used for the purpose: Wheel brushes Appropriate for use with various types of hand-held grinders, bench grinders, robotic finishing equipment, or for mounting onto a driven arbor.
Wheel brush styles may be filled with crimped wire of steel or stainless steel in 0.014" and 0.020
Twisted knot wheels (2/3 twist, cable twist, or stringer bead) shall only be used to provide progressively higher levels of brushing action control and aggressiveness of cutting action.
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Annexure B: Recommended Powder coating process for HR components with Welding joints & concealed surface.
Option 1
Acid Pickling & Phosphating
Option 2
Shot Blasting
Dry off
Cleaning
Powder Coating
Powder Coating
Curing
Curing
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Annexure C: Recommended Powder coating process for CR / HRPO components with Welding joints & concealed surface.
Option 1
Phosphating
Option 2
Primer on Welding portions / Joints
Dry off
Phosphating
Cleaning
Dry off
Powder Coating
Powder Coating
Powder Coating
Curing
Curing
Curing
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Faber Berger
Application recommendations.
Properties 26 - 611 Auto Wash Primer
32 2 32 - 006
40 5 Nil
4:1
Min. 30 min
1:1
Min. 30 min
Paint brush / Spray gun / Dip process Min. 30 20 min Min 4 hrs 8 ~ 14 10 min 10 ~ 12 hrs
20 ~ 50 c
QUALITY POLICY Ashok Leyland is committed to achieve customer satisfaction, by anticipating and delivering superior value to the customers in relation to their own business, through the products and services offered by the Company and comply with statutory requirements. Towards this, the Quality Policy of Ashok Leyland is to make continual improvements in the processes that constitute the quality management system, to make them more robust and to enhance their effectiveness and efficiency in achieving stated objectives, leading to: Superior products manufactured as also services offered by the Company. Maximum use of employee potential to contribute to quality and environment, by progressive up gradation of their knowledge and skills as appropriate to their functions. Seamless involvement from vendors and dealers in the mission of the Company to address customers changing needs and protection of the environment. Managing Director January, 2007