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Surface protection Guidelines for Welding joints in Powder coating / Liquid Painting process

CQ / FF / 004 dt 03.05. 2012

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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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Surface protection guidelines for Welded areas

REF: CQ / FF / 004 DATE: 03.05.2012

Annexure A: Recommended Cleaning method of Welded portion / joints.

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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Surface protection guidelines for Welded areas

REF: CQ / FF / 004 DATE: 03.05.2012

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

Primer on Welding portions / Joints

Primer on Welding portions / Joints

Flash off (20 min)

Flash off (20 min)

Powder Coating

Powder Coating

Curing

Curing

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Surface protection guidelines for Welded areas

REF: CQ / FF / 004 DATE: 03.05.2012

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

Option 3: > 2mm Thk material


Shot Blasting

Dry off

Phosphating

Cleaning

Primer on Welding portions / Joints

Dry off

Primer on Welding portions / Joints

Flash off (20 min)

Flash off (20 min)

Flash off (20 min)

Powder Coating

Powder Coating

Powder Coating

Curing

Curing

Curing

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Surface protection guidelines for Welded areas

REF: CQ / FF / 004 DATE: 03.05.2012

Annexure D: Approved List of Primers for Touch up in Welding portions / joints.


Supplier Name Product Name Product Code PDS

Faber Berger

2k Epoxy primer grey Epoxy Primer

26-611 Autowash Primer

Application recommendations.
Properties 26 - 611 Auto Wash Primer

Application viscosity by FC B4 @ 30 deg C Recommended Thinner

32 2 32 - 006

40 5 Nil

Mixing ratio by volume Part A : Part B


Maturation after mixing Application thru DFT Minimum Flash off time before powder coating Pot Life Application temperature

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

VISION To be among Global Top 10 in Trucks & Top 5 in Buses.

1, Sardar Patel Road, Guindy, Chennai 600 032.

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