Surface Protection & Bonding Process

28.06.2012 Mercedes-Benz Trk, Istanbul

Index
1. 2. 3. 4. Accredited test scopes Corrosion Resistance Tests Paint Tests Phosphating & E-Coating Tests Bonding processes

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Accredited test scopes: Corrosion Resistance Tests

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Index
1 Corrosion Resistance Tests 1.1 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

1.1 Salt spray tests (NSS & CASS) Corrosion resistance of painted and coated materials is evaluated according to DIN EN ISO 9227 in Erichsen salt spray cabinet.

1.2 Condensation-water test with constant humidity Humidity resistance and adhesion performance of paints and coatings are determined in Erichsen humidity test cabinet according to DIN EN ISO 6270-2.

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1. Corrosion Resistance Tests

1.3 Sulfur dioxide test with general condensation of moisture Corrosion resistance of Zn-coated materials is evaluated according to DIN EN ISO 6988 in corrosion test cabinet.

1.4 Corrodkode corrosion test (CORR-test) Corrosion resistance of CrNi-coated parts is determined with a special abrasive slurry according to DIN 50 958.

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Paint Tests

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Index
2 Paint Tests 2.1 Film thickness measurement 2.2 Coating thickness measurement with XRay spectrometer 2.3 Tests for coating adhesion 2.3.1 Scratch Test 2.3.2 Cross-Cut Test 2.4 Measurement elasticity of coated films 2.5 Gloss determination of painted films 2.6 Determination of colour and match 2.6.1 Colour match measurement with Spectrophotometer 2.6.2 Visual control with Spectralight III 2.7 Measurement of surface roughness 2.8 Measurement of paint hardness 2.9 Thickness measurement wedge cut 2.10 Measurement of stone impact resistance 2.11 2.12 2.13 2.14 Weathering tests Endoscopic examination Measurement of viscosity Measurement of high viscosity Brookfield viscosimeter 2.15 Determination of non-volatile matter content 2.16 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 test 2.21 Measurement of refractive index 2.22 Measurement of orange peel of the surfaces 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 is measured with Erichsen Minitest 4100 testing instrument according to DIN EN ISO 2064/3882.

2.2 Coating thickness measurement with X-Ray spectrometer Thickness of Cr, Ni, Ag, Zn, Zn/Ni, Zn/Fe coatings on ferric substrates is measured with Fischerscope X-RAY spectrometer according to EN ISO 3497.

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2. Paint Tests
2.3 Tests for coating adhesion 2.3.1 Scratch test Scratch test is used to measure the adhesion performance of paint/coatings on substrates and other coatings in the multicoat system according to Daimler standards.

2.3.2 Cross-cut test Cross cut test is used for assesing the resistance of paint/coatings to separation from substrate. Tests are done with tools according to DIN EN ISO 2409.

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2. Paint Tests
2.4 Measurement elasticity of coated films Bending and elongation degrees of paint, filler and clear coat are measured with Erichsen cylindrical or conical bend test apparatus according to DIN EN ISO 1519 .

2.5 Gloss determination of painted films Gloss of surface which coated with paint, filler and clear coat is measured with Haze-Gloss instrument in accordance with EN ISO 2813.

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2. Paint Tests
2.6 Determination of a matching colour variant Colour difference value is a diagonal of L, a, b values in the 3 dimensional cartesian coordinate system. It determines the location of the test plate in the colour space.

2.6.1 Colour match measurement with spectrophotometer Matching colour of paints with reference samples due to color scale is done with X-Rite Spectrophotometer. 2.6.2 Visual control with Spectralight III Visual assessment of paint colour is performed with Gretagmacbeth Spectralight III according to DIN EN ISO 4628-1.

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2. Paint Tests
2.7 Measurement of surface roughness Measurement of surface roughness Ra, Rz, Rv, Rp, Rt values are measured on coated and metal surfaces according to DIN EN ISO 8503-2.

2.8 Measurement of paint hardness Hardness of paints on test panel is evaluated with Erichsen Knig Albert instrument in accordance with DIN EN 1522.

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2. Paint Tests
2.9 Thickness measurement with PIG instrument The indentation test is performed with PIG instrument for thickness measurement and cross-sectional analysis on painted surfaces according to DIN EN ISO 2815.

2.10 Measurement of stone impact resistance Stone impact resistance of painted surfaces are defined with Erichsen Stone Impact Test instrument in accordance with DIN EN ISO 20567-1.

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2. Paint Tests
2.11 Weathering test Light and weather fastness of painted surfaces are determined according to DIN EN ISO 11341 with Atlas Xeno Test instrument, thus revealing the colour fading value of the paint.

2.12 Endoscopic examination Visual examination of the profile inside is performed with Karl Storz Endoscope.

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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 viscometer according 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 measured with Brookfield viscosimeter.

2.15 Determination of non-volatile matter content Non-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 content Determination of ash content of e-coating in accordance with VDA 621-198.

2.17 Determination of fineness of grind Estimation of fineness/coarseness of paint pigments is determined with Erichsen Grindometer according to DIN EN ISO 1524.

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2. Paint Tests
2.18 Measurement of density Density of paint is measured with Erichsen Pyknometer according to DIN EN ISO 2811-1.

2.19 Tendency to running and floating The paint thickness when it starts running is determined according to VDA 621-114 .

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2. Paint Tests
2.20 Hiding power test Using the contrast ratio at a specified film thickness, hiding power of paint is determined in accordance with DIN 55601. 2.21 Test of crater on glass Change of surface tension ( crater )of paint is determined according to 4.1 at DBL 7399

2.22 Measurement of refractive index Refractive index of solvent, hardener etc. is determined with Atago Refractometer in accordance with DIN 53 169.

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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 is performed 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 analysis 3.2.1 pH measurement 3.2.2 Measurement of ionic composition 3.2.3 Conductivity measurement 3.3 Bacterial analysis 3.3.1 Bacteral incubator 3.3.2 Hy-Lite 2 3.4 REO Gert 3.5 Gardometer

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3. Phosphating & E-Coating Tests

3.1 Analytical Tests 3.1.1 Free acid, total acid test Free acid and total acid values of phosphate samples are determined with titration. 3.1.2 Total alkali Total alkali content of phosphate samples is determined with titration. 3.1.3 Determination of Zn, Mn, Ni content Zn-, Mn-, Ni-contents of phosphate samples are determined with titration.

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3. Phosphating & E-Coating Tests

3.2 Potentiometric analysis 3.2.1 pH measurement pH-values are measured in surface treatment lines with Orion Aplus instrument. 3.2.2 Measurement of ionic composition Fl and Cl concentrations in phosphating lines are measured with Orion Aplus instrument by means of an ion selective electrode. 3.2.3 Conductivity measurement Conductivity is measured in surface treatment lines with WTW Cond 330i instrument.

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3. Phosphating & E-Coating Tests

3.3 Bacterial analysis 3.3.1 Bacterial incubator Bacterial existence in surface treatment lines is detected by means of special test tubes contaminated with test solution which are stored in the incubator for a certain time.

3.3.2 Hy-Lite 2 Bacterial existence in e-coating line is rapidly detected with Hy-Lite 2 instrument based on ATP-decomposition method.

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3. Phosphating & E-Coating Tests

3.4 REO-Gert The e-coater REO-Gert allows for contamination and penetration controls in laboratory scale according to VDA 621-508 and Daimler standards.

3.5 Gardometer Mass per unit area of Zn- and Mn-phosphate coating is measured on blank steel, galvanized steel and aluminium substrates with Chemetall-Gardometer according to DBL 8422.

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Bonding processes

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Index
4 Bonding processes 4.1 Adhesion tests 4.2 Activities for bonding processes

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4. Bonding Processes
4.1 Adhesion tests Adhesion suitability is tested according to EVO 140.10 and Daimler standards. 4.2 Activities for bonding processes Description suitable bonding processes for different surfaces, research new material and application technics. Bonding process audits are being done. Organise bonding education for production employees. Giving consulting service for development and supporting of suppliers, description suitable bonding process or process failures analyse.

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