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1、制造单位WORKSHOP中航飞机起落架有限责任公司燎原分公司ZhonghangAircraft1.andingGearCorp.1.td,1.iaoyuanDivision编号SERIA1.版次REV转包厂MD-I.Y-(X)3D聚氨酯漆双层漆涂覆工艺PO1.YURETHANEPAINT-TWO-COATPRGENERA1.MANUFACTURINGOPERATIONPROCEDURE（编制依据PCS2500版次3）(PREPAREDTOPCS2500ISSUE3)总页数（含封面）：29TOTA1.PAGE(INC1.UDINGCOVER):29APPROVEDBY:校对:PREPAREDBY
2、:CHECKEDBY:审定:REVIEWEDBY:APPROVEDBY:中国陕西城固张寒路】8号No18.ZhiUMQidnRoadChCnKGu,ShanXi,China分发路线表第位份数单位份数单位份数胞位份数总位份数111厂15F21F技术处原成管理处质fit检验处理化计量检测中心管埋推进办人力资源处生产方案处供给处技安保卫处设备处总经理技术副总经理1电生产副总羟理质量副总经理1电人事劭总羟理财务审计处计算机站市场部故原跟产办设计研究所档案处空军代表海军代表精包生产事业部燎原机电燎原国际俄原实业标资存档制造单位WORKSHOP转包厂更改记录MODIFICATIONRECORD笫I页PAG
3、ENO.共1页TOTA1.PAGEA初版INITIA1.RE1.EASEApprova1.onfi1.e20060410B重新格式化RE-FORMAT许风章Xufcngzhang20070423C全部升版REV1SA1.1.1.THECONTENTS李涛1.OD更改底漆的配比Changethemakingupofprimer.更改面漆的粘度值，CHANGEVISCOSITYVA1.UEFORTOPCO.更改同化时间和温度要求.REVISECURINGTIMEANDTEMPERATUREREQUIREMENTS.万亭WANING版次REV.NO更改说明DESCRIPTION更改者Changedb
4、y11期DATE目次1.IST序号NO内容CONTENT页次PAGE备注Descripiton1范围Scope42引用标准Referencestandard43要求Requirements54待喷涂零件的外表准备PreparationoftheSurfacestobePainted95漆料的技术条件Technica1.Requirementsforpaints126喷漆说明Instructionsofpaint197质量控制QuaIityContro1.208漆层的返修ReworktoPainting249喷漆前和喷漆后的检查InspectionBeforeandAfterPainting26
5、1.范围Scope本工艺规程规定了聚氨酯双层漆涂覆工艺方法和质量控制的要求。Thisdocumentdefinestheapp1.icationcharacteristicsandqua1.itycontro1.forprotectivetreatmentbytwocoatPo1.yurethanepiant.本工艺规程按照PCS2500,版次3编制。ThisspecificationpreparedinaccordancewithPCS25OO,Issue302.引用标准ReferenceSpecifications以下文件的最新版次包含的条文在本标准指定的范围内构成了本标准的一局部。The
6、currentissueofthefo1.1.owingdocumentssha1.1.beconsideredapartofthisspecificationtotheextenthereinindicated.PCS25OO聚氨酯漆双层漆涂覆工艺.PCS25OOPo1.yurethanePaint-TwoCoatProcess.ISO2409漆和清漆的划格试验ISO2409PaintsandVarnishes-Cross-CutTest.MI1.-A-8625铝和铝合金阳极化涂层.MI1.-A-8625anodiccoatingfora1.uminiumanda1.uminiuma1.1.
7、oys.1.G033DUA1.SCOPEMP40测厚仪操作程序.1.G033operationprocedureforDUA1.SCOPEMP40thicknessmeasureinsrument.PCS2620溶剂热除油Hotdegreasingwithso1.vents.PCS-2622冷除油co1.dso1.ventdegreasing.PCS-2621零件的碱性除油a1.ka1.inedegreasing.PCS-27(X)褪漆paintstripping.PCS-2141低氢脆刷镀镉PCS-21411.owembritt1.ementcadmiumbrushp1.ating.PCS-
8、2220铝合金防护性化学处理.PCS-2220protectivechemica1.treatmentofa1.uminiuma1.1.oys.PCD-341封闭的加工工艺(“AFA零件”)PCD-341manufacturingsea1.edprocess(*AFAparts).3.要求Requirements3.1 设备Equipment喷漆间应有良好的通风和除尘装置。Theshopsha1.1.beanenc1.osedarea,butonewhichiswe1.1.venti1.atedanddus1.free.（八）压缩空气装置应配备有过滤器，用来过滤水，油和固体颗粒。Thecomp
9、ressedairinsta1.1.ationsha1.1.beequippedwithfi1.terstortheretentionofmoisture,oi1.andso1.idpartic1.es.3.2 喷漆间PaintingRoom应保证喷漆间的清洁，用来吊挂，喷涂，转运零件的设备应无灰尘。Dustremova1.sha1.1.bebysuction.Thebeams,conso1.es,supportsandtransferequipmentsha1.1.befreeofanydus1.,whichcou1.dfa1.1.ontopreparedornew1.ypaintedpar
10、ts.3.3 环境条件COnditiOnS（八）必须在以下环境条件下工作:Thefo1.1.owingambientconditionsha1.1.bemaintainedwhi1.eworkisinprogress:1温度：15C35CTemperature:15*C35C2相对湿度：35%75%Re1.ativeHumidity:35%75%(b)喷漆间必须配备nJ记录的温度计和湿度计，应保持记录，确保零件的喷漆条件有可追溯性。且要定期进行校验。Theshopsha1.1.beequippedwitharecordinghygrometerandarecordingtemperaturei
11、ndicator.therecordssha1.1.bekepttoensuretraceabi1.ityofthePain1.ingconditions.(c)在漆层开始枯燥和固化时，必须保证喷漆环境的相对稳定。Theshopsha1.1.bemaintainedtore1.ativityconstantconditionsduringthepaintingandcuringofa1.1.coats.3.4烘箱OVCn用于枯燥固化漆层的烘箱必须符合以下要求oTheovenusedforcuringthepaintingmustbemetthefo1.1.owingrequirements:(
12、1)设备工作区内任意一点的实际温度与控制点的温度最大允许温差应为14*C(25F)oThemaximuma1.1.owab1.edifferencebetweenthecontro1.setpointandtheactua1.airtemperatureatanypointwithintheworkzoneoftheequipmentsha1.1.be14C(25f)(2)工艺仪表的温度读数与校验仪表的温度读数按可追踪标准所知的偏差进行校准，其最大允许温差应为2.8C(5F)oThemaximuma1.1.owab1.edifterencebetweentheprocessinstrument
13、ationtemperaturereadingsandca1.ibrationinstrumentationtemperaturereadings,correctedfora1.1.knowndeviationsf11)11atraceab1.estandardsha1.1.be+/-2.8(+/-5FJ备注1：除上述要求外，烘箱也应符合AMS-27505级烘箱规定。Note):exceptaboverequirements,ovensha1.1.bemettherequirementsofAMS-2750,c1.ass5.备注2：合成橡胶的装配件,底漆和面漆的强制枯燥温度不能超过71,零件底
14、漆和面漆的强制枯燥温度不能超过U2C.(涂抹密封胶的装配件不属于合成橡胶零件)。Note2:forcedr),ingofprimerandfinishingcoatisnotPermiSSibIeatatemperatureover7Conassemb1.iesincoporatinge1.astomerandisnotpe11nissib1.eatatemperatureover1.!2,Condetai1.p*rts(T1.ieassemb1.edpartswhichsea1.antapp1.iedarenotassemb1.iesincorporatingekstomerparts)3.
15、5调漆设备Equipmentforpreparingthemixtures（八）调漆时，操作者必须使用带刻度的容器量取混合物的体积。如果需要并用天平称混合物的重量。Forpreparingthepaint,(heoperatorssha1.1.usegraduatedcontainersformixturesbyvo1.umeandaba1.anceformixturesbyweight(ifnecessarjf).(b)喷漆间应有自动搅拌装置。Theshopforpreparingthemixturessha1.1.beequippedwithanautomaticmixer.3.6压缩空气
16、CompressedirIa)每次工作开始和第一次使用前，以及每周至少检查一次压缩空气的清洁度。Checkthec1.ean1.inessofhccompressedaira1.1.eastonceperweek,atthestartofworkandbe1.orethefirstapp1.ication.(b)检查方法Methodofchecking1.拿一块玻璃样板或抛光的金属样板，除油，并且用干净的抹布擦干。Degreaseag1.ussorpo1.ishedmeta1.p1.ateandwipeitwithac1.eanrag2 .保持空气喷出口应距离样板2025Cm远，垂直对着样板吹
17、至少15秒。Ho1.dtheairout1.etperpendicu1.ar1.y1.ohcp1.ate,atadistanceof20to25cn，andb1.owatthefu1.1.rateforat1.east15seconds.3 .吹的过程中或吹完后，看看样板上是否有油滴或水滴。Duringandaftertheb1.owing,1.ookfortheappearanceofdrop1.etsofoi1.orwatero4 .试验后，样板应与开始时同样干净。Afterthetest,thep1.ateshou1.dappearasc1.eanasatthebeginning(c)如
18、果必要，调整压缩空气的过滤条件，直至到达要求的结果。Ifnecessary,adjusttheconditionsforthefi1.trationofthecompressedairunti1.thedesiredresu1.tisobtained.5 .7操作者的资格认证qua1.ificationoftheoperatorsA.负责喷漆的操作人员应在当地得到有效的质量程序资格认证后，还要事先接受该工艺标准操作的培训。Theoperatorsresponsib1.efortheapp1.icationofthepaintsha1.1.havereceivedpriortrainingint
19、hestandardpracticeforthisprocesssucceedingtotheirqua1.ificationaccordingtothequa1.ityprocedureinforceonthesite.6 .8.漆料的接收检验AcceptanceinspectionofthepaintsA.漆料必须有合格证，合格证必须注明产品的有效期。如果没有注明，必须在容器标签上增加有效期(此有效期以标准要求为准Checkthepresenceofcertificateofconformanceforthepainting.andmustbeinexpirydate.theexpiryd
20、atesha1.1.beaddedtothecontainer1.abe1.ifitisnota1.readyshown(expirymustbeinaccordancewithIhcspecification)B.标识IdentifiCatiOn(I)检查容器上是否有以卜标识内容：Checkthatthefo1.1.owinginformationisshownonthecontainers：（八）厂商名称Manufacturersname(b)产品(稀释剂、光饰漆等)名称Descriptionoftheproduct(thinner,topcoatetc)(C)产品颜色(面漆)Co1.ou
21、roftheproduct(topcoat)(d)容量(升)或净重Con1.en1.sin1.itersorndweight(e)批次Batchnumber(f)生产日期DateofInanuiacture(g)有效期ExpirydateC.如果货物运送不合格，或交货时至有效期已少于9个月的时间，那么该批货物拒收。Consignmentswhichareunsatisfactory,orwhichhave1.essthan9monthstotheirexpirydate,sha1.1.berejected.3.9材料的贮存StorageoftheproductsA.贮存漆料的房间温度应保持在1
22、5C25C。Thetemperatureofthestorageroomforpaintingsha1.1.beInaintiancd15C25C。4.待喷涂零件的外表准备Preparationofthesurfacestobepainted4.1 喷漆前零件的验收InspectionbeforepaintingA.保证待喷漆的零件外表没有油污，磕碰伤以及影响喷涂质量的缺陷。Ensurethatthesurfacetobepaintedisnotcontaminated,scatheandotherdefectsaffectedthequa1.ityofpainting.B.要喷涂零件的外表防
23、护层应完整。Ensurethesurfacetreatmenttothesurfacetobepaintedisintegrity.4.2 除油degreasingA.按照PCS2620进行蒸汽除油或使用MEK(酮)丁工除油，对于几何形状复杂的零件,也可以按PCS2621碱除油.保证待喷涂的零件外表无水，油污和其它脏物。如果进行了两次除油，必须使用MEK.VaporedegreasinginaccordancewithPCS2620ormanua1.degreasingwithMEK.A1.ka1.ic1.eana1.socanbeusedForspecia1.shapePartsperPCS
24、2621.Ensuerthesurfacetobepaintedbefreeofwater.oi1.andothercontaminations.Adoub1.edegreasing.usingMEK.mayhavetobecarriedout.B.手工清洗使用的抹布的质量必须符合以下规定：Manua1.c1.eaningusing1.intfreec1.oth,1.hcqua1.ityofwhichsha1.1.confo11ntothatdefinedbe1.ow:（八）抹布必须不掉绒毛Theysha1.1.benonf1.uff(b)抹布必须是100%的纯棉Theysha1.1.bema
25、deof100%cotton(C)抹布不能上浆或用硅的处理Theysha1.1.nothavebeentreatedwitheitherstarchorsi1.icones(d)不能有任何污物(有油脂、墨迹等)Theysha1.1.notcontainanystains(suchasgrease,ink.etc)（e）必须完全枯燥Theysha1.1.becomp1.ete1.ydry注：在非常特殊的情况下，如果在外表处理之后立刻喷漆，或采取了防护措施防止零件被污染（外表处理后的零件采用了干净的牛皮纸进行了正确的防护，使零件没有受到污染），此时可以进行除油，也nJ以不进行除油，任意选择。Inv
26、eryspecificeases,wherethesurfacetreatmentandhcpaintingarecarriedoutwithoutinterruptionandwhereprecautionistakentoprotectthepartsformanycontamination（protectedwithkraftpaperaftersurfacestreatedandthepartsnotbecontaminated）.thedegreasingmaybemadeoptiona1.4.3屏蔽Masking（1）必须非常小心的进行屏蔽，防止喷漆外表有任何粘性物在外表沉积。Th
27、emaskingsha1.1.beapp1.iedverycarefu1.1.y,avoidinganydepositofadhesiveonsurfacestobepainted.（2）可以用金属覆盖保护，或用适当的保护胶带保护。Themaskingsha1.1.consisteitherofmeta1.covers,oranysuitab1.emaskingtape.（3）绝对禁止在零件上使用无法粘贴的材料，如PTFE（聚四氟乙烯）喷雾和硅树脂产品。Theuseofanti-adherentproductsontheparts,suchasPTFEspraysandsi1.icone-ba
28、sedproducts,istota1.1.yprohibited.（4）屏蔽后，如果有必要，使用MEK清洗保护后受污染的区域。Aftermasking,ifnecessary,c1.eaningthemaskingareawithMEK.4. 5检查inspection（1）按以下方法，对所有.的不同产品的除油效果进行每日检查：carryoutadai1.ycheckoftheeffectivenessofthedegreasingwiththedifferentproductsused,inthefo1.1.owingmanners:（八）用纯洁水或蒸谭水雾喷淋清洗零件或试片(和零件同批C
29、heckthepan,orthetestpane1.s,withamistofpuredc-mincra1.iscd,ordisti1.1.edwater.(b)检杳水膜应没有破裂。如果水膜别离成水滴或有任何破裂迹象，那么说明除油不充分。Checkthatthefi1.mofwaterisunbroken,anyseparationintodrop1.ets,oranybreakinthefi1.mwi1.1.beasignofinadequatedegreasing.(c)改良除油条件，直至得到连续不破裂的水膜。Amendthedegreasingconditionsunti1.anunbr
30、okenfi1.misobtained.5漆料的技术条件technica1.requirementsforpainting5. 146372-8型底漆463-12-8primerA底漆的调配Makeupforprimer组分composition配比(体积)makeup(vo1.ume)463-12-8(基料)base1CAI16(固化剂)hardener1C25/90S(稀释剂)thinner0.25(max)最大B熟化时间：30分钟Standofftime:3()minutesC粘度值：2634s(IS03#杯，在202C温度卜.测量)Viscosityva1.ue:2634S(ISO3#
31、cup.measureat202C)D使用有效期:8小时(1822C)Pot1.ife:8hours(18-22*C)E喷涂厚度要求：2025Um(局部40Um)Thichness:2025口m(1.oca1.areamaybe40Hm)备注:在镀镉和孤度的凹半径处或形状特别起伏的区域,喷漆厚度难以控制,底漆厚度允许为:2040um.Oncadmiump1.atingandonareaswithconcaveradiiofcunratureorveryundu1.atingshapes.wherethepaintapp1.icationisdifficu1.ttocontro1.,primer
32、thicknessarea1.1.owed:2040m.F固化温度和时间要求：Temperatureandtimetorcuring外表喷有底漆随后要喷涂面漆：Ifat1.eastsomeofthesurfacespaintedwithprimerwi1.1.subsequent1.yhavefinishapp1.ied:(1)室温下至少448小时；或At1.east448hoursinambient,or;(2)室温卜放置1小时后，随后在规定的烘箱中，以下温度范围和时间内进行固化：（八）在5862C温度下，至少45分钟：或45minutesminimumbetween5862C,or(b)在
33、8090C温度卜，至少20分钟；或20minutesminimumbetween8()90C,or(c)在3236C温度下，至少2小时30分钟;2hours30minutesminimumbetween3236C.组分compositions配比(体积)makeup(vo1.ume)如果零件没有喷底漆，而宜接喷面漆Ifnoneofthesurfacespaintedwithprimerwi1.1.subsequent1.yhavetopcoatapp1.ied.(1)室温下至少8天：或at1.east8daysinambient,or;(2)室温下放置1小时后，随后在规定的烘箱中，以下温度范围
34、和时间内进行固化；Ovendryingaftermandatorypre-dryingfor1houratambienttemperature,p1.us:（八）在5862C温度下，至少3小时:或3hoursminimumbetween58-62C,or(b)在8090C温度下，至少1小时30分钟；或Ihourand30minutesminimumbetween80-90CG.漆的有效寿命：463-12-8Primer(底漆)1.5yearCA116Hardencr(固化剂)1.5ycarC2590SThinner(稀释剂)2years5.2面漆TopCoatA面漆的调配MakeUPforto
35、pcoa1.AerodurSG1.AIuminiumFinish1S6622R（固化剂）hardener1C2590S（稀释剂）thinner0.5（最小）0.75（最大）0.5ninto0.75maxB熟化时间：1530分钟Inductiontime:153OminutesC粘度值：3640s（ISO3#杯，在202C温度下测量）Viscosityva1.ue:3640S（ISO3#cup,measureat202C）D使用有效期：6小时（在202C温度卜.测量）Pot1.ife：6hours（at202C）E喷涂厚度要求：Thicknessrequirements厚度：4050mThick
36、ness:4050m.备注:在镀镉和弧度的凹半径处或形状特别起伏的区域,喷漆厚度难以控制,面漆厚度允许为:40-90n.Oncadmiump1.atingandonareaswihconcaveradiiofcurvatureorveryundu1.atingshapes,wherethepaintapp1.icationisdifficu1.ttocontro1.,topcoatthicknessarea1.1.owed:4090m.E固化温度和时间要求：TemperatureandtimeIbrcuring室温下至少72小时：或At1.east72hoursinambient,or;(2)
37、室温卜.放置.30分钟后，随后在规定的烘箱中，以卜温度范围和时间内进行固化：Ovendryingaftermandatorypre-dryingfor30minutesatambienttemperature.p1.us:（八）在80C温度下，至少1小时；或1 hourminimumat80COr(b)在60C温度下，至少2小时；2 hoursminimumat60C;G漆的有效寿命：AerodurSG1.A1.uminiumFinish(W)!yearS6622RHardener固化剂)IyearC2590SThinner(稀释剂)2years5.3涂覆前漆料的配制Preparationof
38、thepaintsbeforetheirapp1.ication(1)说明instruction（八）不允许将产自不同供给商的产品混合使用。ThCmixingofproductsobtainedfromdifferentmanufacturesisnotauthorised(2)喷涂前检查每种漆料：Checksoneachpaintbeforeapp1.ication:（八）有效期ExpirydateJ1.检查容器上标志的有效期是否已超期。如果已超期，那么拒收。Checkthattheexpirydatesmarkedonthecontainershavenotbeenexceeded.rej
39、ectanycontainerwhoseexpirydatehasbeenexceeded.(b)检查混合物的均匀性(调配过程中和在喷枪加满前)Homogeneityofthemix1.ures(duringthepreparationandpriortofi1.1.ingthespraygun)1将一根干净的杆浸入准备使用的混合物中；Dipac1.eanrodintothemixturedeemedtobereadytoruse2拿出杆，让漆流到混合物的外表：Withdrawther(x1.,a1.1.owinghcpainttorunontothesurfaceofthemixture.3
40、检查杆上流的漆和混合物外表的颜色的差异：Checkthatthereisnodifferenceintheco1.ourofthepaintrunningofftherodandthesurfaceofthemixture;4继续搅拌，使混合物均匀，宜至到达要求的结果。Continue1.ohomogenizethemixtureunti1.thedesiredresu1.tisobtained.备注：(1)基料必须搅拌1015分钟，使漆料混合均匀。(2)搅拌基料和固化剂混合物510分钟后，再在搅拌的同时缓慢的添加稀释剂。Note:(1) Thebasemustbeagitate10to15m
41、inutesinordertoobtainthehomogenizeofthemixture.(2) Agitatethemixtureofthebaseandhardenerfor5-IOminutes,thenduringtheagitating.addthethinners1.ow1.y.(C)粘度ViSCOSi1.y1使用相应的检查粘度。Checktheviscosityofeachpaint;a.使用流量杯和秒表Useaf1.owcupandastop-watchb.按使用工艺说明选择要求的量杯Choosehccupca1.1.edforbytheinstructionsforthe
42、processused.g检查出口孔是否完全清洗干净Checkthattheexitho1.eiscomp1.ete1.yc1.ean色用手指封住出口孔C1.osetheho1.eOffwithafinger勤灌满量杯Fi1.1.thecupcomp1.ete1.yf用刀片的直线边刮量杯的边，去除残留的漆；Removethemeniscusofthepaintbypassingthestraightedgeofab1.adeacrosstheedgeofthecup.g.松开手指，同时秒表开始计时：Removehefingerandstartthestopwatchatthesame1.ime
43、h当漆流不连续时，秒表停止计时；Stopthestopwatchwhenthestreamofpaintisinterruptedi.记录漆连续流动的时间；Notethedu11tionofthef1.owj.如果结果不合格，配备另一次混合样。如果这次仍不合格，请和制造商协商。Iftheresu1.tisnotsatisfactory,prepareanothermix,ifthisisnotsatisfactory,consu1.tthemanufacturer.备注.测试时的温度是1822(64T-72T)0Note:measureat1822C(64T72F)。6 喷漆说明app1.ic
44、ationinstructions(1)正常工作条件no11na1.operatingconditions（八）正常情况卜,用喷枪喷漆，让一层底漆枯燥后接着喷一层面漆。喷漆期间，零件和漆应与工作间处于同样稳定的温度，并在规定的环境下喷涂。Thepaintisnorma1.1.yapp1.iedbyspraygun,oneprimercoat,whichsha1.1.bea1.1.owedtodry,fo1.1.owedbyonetopcoat.duringspraying,partsandpaintssha1.1.beatthesamestabi1.isedtemperatureasthato
45、fworkshopandtheatmosphere.andsprayinthespecifiedconditions:(2)空心零件的喷漆paintingofhoi1.owparts（八）如果空心零件不适合用喷枪喷漆(由于零件的几何形状复杂，或内径小于35mm),允许用灌涂(填充和排干)或滚涂。在这种情况卜.，稀择剂的比例应根据操作人员的经验来定，而且必须小于工艺单上规定的数值。If,inthecaseofho1.1.owparts,app1.icationbysprayguninnotsuitab1.e(duetothepartscomp1.exgeometry,oraninterna1.diameterof1.essthan35nun),fi1.1.inganddraining,orro1.1.erapp1.ication,ise11nissib1.e.theproportionofthinnerisinthiscasedeterminedbytheexperie
