HARD ANODIZING KJ ATTACHMENT NO.1 TO KJ-06

Transcription

1 KJ ATTACHMENT NO.1 TO KJ-06 KJ translated by: Justyna Kilian; Date: 02/22/2017 Compiled by: Leszek Karkosza Approved by: Dariusz Nykiel

2 Dział Techniczny DTT-8/S Page 2 of 7 Chief Process Engineer DTT 1. Purpose of document. The purpose of this document is to regulate rules for sulfuric acid hard anodizing process of aluminum alloys performed by supplier on parts delivered to Polskie Zakłady Lotnicze Sp. z o.o. 2. Subject of document. The subjects of this document are requirements of hard anodizing process and control of parts which are subject to hard anodizing process 3. Range of document. All requirements specified herein apply to all suppliers and should be met in scope specified in a purchase order / agreement / contract. 4. Related documents. Range of application of reference documents relates to their current issue. PN-EN 2536 ASTM B 244 PN-EN ISO 2360 PN-EN ISO 4516 PN-EN ISO 1463 ASTM B 487 AMS 2468 AMS 2469 MIL-A-8625 Hard anodizing of aluminum alloys Standard test method for measurement of thickness of anodic coatings on aluminum and of other nonconductive coatings on nonmagnetic basis metals with eddy-current instruments Coating thickness measurement. Eddy current method. Metal coatings and non organic coatings. Micro hardness tests with method of Vickers and Knopp Metal and oxide coatings. Coating thickness measurement. Microscopic method. Standard test method for measurement of metal and oxide coating thickness by microscopical examination of cross section Hard coating of aluminum alloys. Hard anodic coating on aluminum and aluminum alloys. Requirements for process and coatings. Anodic coatings for aluminum and aluminum alloys. 5. Additional information Coating classification. Instruction applied inspection on hard anodized coating per types and categories in accordance with PN-EN TYPE A: hard anodizing without sealing. TYPE B: hard anodizing with sealing. If in documentation type of coating is not listed, type A shall be applied. Categories of aluminum alloys, subjected to hard anodizing are as follows: Category 1 alloys containing less than 1 % of copper Category 2 alloys containing 1% to 5 % of copper Types of anodizing per MIL-A-8625 are TYPE III hard anodizing General notices. a) For every part, detail technology should be prepared.

3 Page 3 of 7 b) Parts for anodizing should be free from foreign substances, oxides and dirt s like greases, oils, paint, welding flux. Apply preparation process in order to getting entirely wettable surface before anodizing. Using abrasive materials contained iron for mechanical cleaning is forbidden, it could be in effect increased aluminum alloys corrosion. c) The parts shall be anodized after complete machining, heat treatment, welding, and penetrant inspection. The surface of anodized parts shall be free from surface defects which may cause the produced anodic coating not meet the requirements of this specification. The surface defects may be caused by machining, cutting, scratching, polishing, bending, stretching, etching, alloy chemistry imbalance and inclusions. d) Following process operations per form without excessive intervals in order to avoid parts drying. e) Avoid parts handling after deoxidizing, if necessary touch wet parts only in clean latex or rubber gloves. f) Before anodizing non- metal elements should be removed or protect before contact with sulfuric acid. g) Use additional internal cathodes to anodizing parts with deep cavities or to internal surface of pipes, when length- to internal diameter ratio is bigger than 10:1. h) It is allowed to handle wet parts only in rubber gloves, while dry parts only in clean cotton gloves. i) Cathode and anode bars maintain in cleanness. j) Anodizing parts should be totally immersed in bath. k) On every hard anodized parts where coat microhardness test is required, witness test sample should be anodized with the load. Witness sample should be made of the same material as anodized part and should possess the same roughness class as a part. Sample dimensions: minimum 30x30x5mm. Sample should be used for coat thickness measurement, if shape or dimensions not allow to measure coat thickness on the part. l) Hard anodic coat can be machined up to removal maximum 50% of thickness in order to fit part dimension Non-conforming parts. Follow in accordance with requirements defined in KJ-06 para Proceeding description Process qualification procedure. Hard anodizing process is one of special processes and requires preliminary and periodical qualification in production conditions. In the case when special process realized in accordance with defined requirements at supplier was approved by one from the companies of corporation to which Polskie Zakłady Lotnicze Sp. z o.o. belongs, this qualification can be automatically recognized. It is allowed to approve the special process at supplier basing on its manufacturing/ technological process, if previously approved by design engineer of Polskie Zakłady Lotnicze Sp. z o.o. Then such special process has a status of frozen process at supplier. Every change in the approved process requires repeated acceptance of the design engineer.

4 Page 4 of 7 During preliminary Supplier qualification, Polskie Zakłady Lotnicze Sp. z o.o. reserve the right to participate in a process performed on parts and specimens at new Supplier facility and possibility to perform control quality inspections on processed parts or specimens. Polskie Zakłady Lotnicze Sp. z o.o. qualification team shall conduct process qualification, keeping the following steps: a) Inspection of devices and review of the metrological confirmation records. Verify if: devices have equipment to control parameters of special process work with required accuracy, the whole measuring equipment used to control the correct course of the process (or some parameters) is in proper place secured from aggressive weather conditions, used materials meet technical and quality requirements, there is a record regarding periodical review of the devices and metrological confirmation of used measuring equipment, process meets requirements of standards regarding environment protection and safety of the work. b) Review of the documents and special process instruction. Qualification team shall check if: technical documentation necessary to perform process is complete and current, process engineering and quality instruction regarding given process are accurate and intelligible taking into account included requirements; instructions shall be available on the work stand, products identification is ensured via their registering on the work stand. c) Knowledge and personnel practical abilities. Qualification team shall check if: personnel realizing process have required qualification documentation, personnel is authorized to perform special processes, all changes of the personnel are registered. Change of the personnel may cause necessity to perform repeated first article inspection. d) Realization of the special process on a specimen or product. Special process is performed on specimens or products in accordance with Polskie Zakłady Lotnicze Sp. z o.o. requirements. It is required to check the sequence of performed activities and correctness of process parameters determination. It is required also to verify if tests of specimens and products are performed on controlled and calibrated equipment. e) Results analysis. Qualification team heaving authorization of auditors prepares report from audit performed at supplier facilities. Documents prepared by supplier during internal qualification are attached Change in the special process. Every change regarding device, conditions, instruction or personnel at supplier facilities shall be reported by process owner to Supplier Quality Assurance Department Manager in Polskie Zakłady Lotnicze Sp. z o.o., who makes decision regarding needs of the new qualification. The change cannot be introduced until permission is obtained to applied the change.

5 Page 5 of 7 Audit performed by qualification team at supplier facilities is not necessary in the case, when special process conducted on a new equipment obtained qualification on equipment used up to now. In this case decision about qualification may be issued basing on inspection of internal qualification documents passed by process supplier Quality inspection of manufacturing series. a) Inspection processes and final acceptance of parts shall confirm conformity with parameters of qualification process. b) Conduct visual inspection of parts. c) Conduct register of records of quality acceptance. d) Time of keeping of quality records (test sheet, report of tests, registers, etc.) is 10 years or 40 years in case of critical parts. e) Periodically analysis of baths shall be conducted with frequency guarantee good quality of coating. Analysis results make up and bath change shall be registered. f) Control current and temperature parameters on measuring devices. g) Conduct thickness tests, microhardness and abrasion resistance of anodic coatings to steer the process. h) Conduct coating thickness inspection on parts. i) Control lack of pollution like water, oil, etc. in compressed air applied in inspection process Methods of inspection and requirements. a) Parts are subject to visual inspection, coating thickness and/or hardness. b) On specimens to approve and steer the process following tests are conducted: thickness inspection with microscopic method, micro hardness inspection. Results are compiled in form of reports from test. c) Defining the specimens. Specimens shall be processed with production parts. Specimens to test prior to anodizing shall be carefully looked round. Those shall not have visible contaminants, flaws as corrosion, inclusions and delaminations Parts inspection. Notes: Inspection carry out in clean cotton gloves Visual inspection of anodic coating. a) Visual inspection perform on 100% parts of every production batch. b) On parts not allowed are not anodized places (exception are places of contact with clamps of rack), deep scratches injuring anodic coating, etching (pitch), blisters, peeling off while rubbing, light stains being the sign of over etching of coating because of local overheating. c) Color of hard anodized coating depends on composition of alloy and parameters of anodizing. Coatings depending on type of material can be gray, green, black, brown, olive color, with different intensity of color and different hue. At the same coating thickness and different temperature of obtaining hue is usually different (darker at lower temperature) Thickness inspection of anodic coating.

6 Page 6 of 7 a) Anodic coat thickness should answer to technical documentation requirements. b) Nominal thickness of hard anodic coating is 50±10µm according to MIL A 8625, AMS 2468 and AMS c) Parts are approved on the basis of anodic coat thickness measurement on the part unless part shape or dimensions not allowed to perform measurement. In this case use the sample for the process. d) Measure anodic coat thickness on production parts or on the witness sample using eddy-current gauge or other approved by Polskie Zakłady Lotnicze Sp. z o.o. e) Coating thickness can be measured in Laboratory on lateral micro section using microscopic method. f) In order to process maintenance perform anodizing with the use of 3 samples of 2024 T3 AMS-QQ-A-250/4 material or alloy which provides majority of production in the month period. Nominal thickness of coating. Samples dimensions: minimum length x width x thickness = 3 x 3 x 0,032 cal (76 x 76 x 0,8 mm) Hardness inspection of anodic coating. Microhardness minimum 300 HV 0,05 (kg/mm 2 ) for category 1 alloys (PN-EN 2536), minimum 250 HV 0,05 (kg/mm 2 ) for category 2 alloys with anodic coat thickness from 25 to 42 micrometers. In case of other requirements, microhardness value should be determined in engineering documentation or agreed between orderer and contractor. Micro hardness of anodic coating is checked on specimen witness processed with a load. Micro hardness of coating shall be in alloys with high content of copper PA7, D16; PA6, D1; PA33, AK-8 minimum 250 HV0,05 (250 kg/mm 2 ), in alloys with low concentration of copper minimum 300 HV0,05 (300 kg/mm 2 ) unless the drawing or technology sheet defines different Specimens inspection. Compilation of tests on specimens witnesses of hard anodizing process for production batch and steering of process is listed below. Type of test Tests frequency Coating thickness Micro hardness Every load if Technology Sheet requires Every load if Technology Sheet requires Specimens dimensions [mm] minimum 30 x 30 x 5 minimum 30 x 30 x 5 Quantity 1 1 Material The same as made parts The same specimen as for thickness measurement Coating thickness inspection. Inspection of hard anodized coating thickness shall be done with microscopic method in accordance with PN-EN ISO 1463 or ASTM B 487. Thickness of hard anodized coating on specimen shall be in conformity with requirements of drawing or technical conditions of parts which were processes with.

7 Page 7 of Hardness inspection. Micro hardness measurement of anodic coating shall be conducted on lateral metallographic specimen in accordance with PN-EN ISO 4516 with method of Vickers and Knoop at load 0,490 N Abrasion resistance inspection Abrasion resistance inspection shall be done on samples with non- sealed anode, maximum weight loss (abrasion index) should consist:- alloys containing 2% copper or higher 3,5 mg/1000 cycles, for remaining aluminum alloys 1,5 mg/ 1000 cycles. Two samples weighted with 1 mg precision, shall be tested in accordance with ASTM D 4060 using CS-17 abrasive wheels with load 1000 g for cycles. Shield should rotate on anodized surface with speed 70 revolutions per minute, for cycles. The wheels shall be renewed at least after cycles. Abrasion index is defined after cycles, by dividing weight loss by Process inspection. Perform process control once a month. Additionally, when process is not carried out in 1 month period or longer, sample must be made at the beginning of production. Inspection contains tests below in conformity with following standards: 1. Control of process course parameters in accordance with MIL-A-8625, 2. Coat appearance in accordance with PN-EN Coat thickness in accordance with EN-PN 2536 and MIL-A Microhardness in accordance with EN-PN 2536.