DIN 6701-4-2015 Adhesive bonding of railway vehicles and parts - Part 4 Manufacturing controls and quality assurance《轨道车辆和车辆零件的胶粘剂粘结 第4部分 生产控制和质量保证》.pdf

1、December 2015DEUTSCHE NORM English price group 13No part of this translation may be reproduced without prior permission ofDIN Deutsches Institut fr Normung e. V., Berlin. Beuth Verlag GmbH, 10772 Berlin, Germany,has the exclusive right of sale for German Standards (DIN-Normen).ICS 45.040; 83.180!%V7

2、2“2512015www.din.deDIN 6701-4Adhesive bonding of railway vehicles and parts Part 4: Manufacturing controls and quality assurance,English translation of DIN 6701-4:2015-12Kleben von Schienenfahrzeugen und -fahrzeugteilen Teil 4: Ausfhrungsregeln und Qualittssicherung,Englische bersetzung von DIN 6701

3、-4:2015-12Collage des vhicules ferroviaires et ses composants Partie 4: Contrle de la fabrication et assurance de la qualit,Traduction anglaise de DIN 6701-4:2015-12www.beuth.deDocument comprises 28 pagesDDIN-Normenausschuss Fahrweg und Schienenfahrzeuge (FSF)DIN-Sprachendienst08.17 DIN 6701-4:2015-

4、12 2 A comma is used as the decimal marker. Contents Page Foreword . 4 Introduction 5 1 Scope 6 2 Normative references 6 3 Terms and definitions 7 4 Workmanship . 7 4.1 General 7 4.2 General process requirements . 8 4.2.1 Transport and storage of adhesives, auxiliary materials and adherends 8 4.2.2

5、Manufacturing environment . 8 4.2.3 Preparation of work stations and conditioning . 8 4.2.4 Occupational health and safety, environmental protection 9 4.2.5 Checking for fitting accuracy . 9 4.2.6 Checks prior to start of production . 9 4.2.7 Treatment of bonding surfaces 9 4.2.8 Batching, blending,

6、 application 11 4.2.9 Joining the adherends 11 4.2.10 Clamping . 11 4.2.11 Curing . 12 4.2.12 Packaging and transport of bonded components 12 4.2.13 Disassembly of bonds . 12 4.3 Specific processing requirements . 12 4.3.1 Adhesives 12 4.3.2 Adherend materials and surfaces 14 4.4 Work instructions .

7、 17 4.5 Manufacturing documentation . 18 5 Mock-ups prepared for new production to demonstrate consistency . 19 6 Adhesive bonding as repair and touching-up work on rail vehicles 20 6.1 General 20 6.2 Workmanship . 20 6.3 Maintenance programme . 20 6.4 Repair instructions . 20 6.5 Subcontracting 21

8、7 Quality assurance 21 7.1 General 21 7.2 Quality planning . 21 7.2.1 General 21 7.2.2 Testing plan . 21 7.2.3 Test instructions 22 7.2.4 Test report . 22 7.3 Quality inspection . 22 7.3.1 General 22 DIN 6701-4:2015-12 3 7.3.2 Test methods . 22 7.3.3 Verifying production consistency . 23 7.4 Correct

9、ive action . 23 7.5 Imperfections in adhesive bonds 23 7.5.1 Application-related imperfections 23 7.5.2 Decorative imperfections . 23 Annex A (informative) Non-destructive testing . 24 A.1 General 24 A.2 Dye penetrant testing 24 A.3 Test for adhesion at flanks . 24 A.4 Suction cup test 24 A.5 Test u

10、sing a feeler gauge . 24 Annex B (informative) Examples of imperfections of bonds 25 Annex C (informative) Examples of decorative imperfections . 26 Bibliography . 27 DIN 6701-4:2015-12 4 Foreword This standard has been prepared by Working Group NA 087 00-12 AA Werkstoffe, Fge- und Verbindungstechni

11、k of DIN-Normenausschuss Fahrweg und Schienenfahrzeuge (FSF) (DIN Standards Committee Railway). Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. DIN and/or DKE shall not be held responsible for identifying any or all such patent ri

12、ghts. DIN 6701 Adhesive bonding of railway vehicles and parts consists of the following parts: Part 1: Basic terms, basic rules Part 2: Qualification of manufacturers of adhesive bonded materials Part 3: Guideline for construction, design and verification of bonds on railway vehicles Part 4: Manufac

13、turing controls and quality assurance DIN 6701-4:2015-12 5 Introduction Adhesive bonding is a process essential to the production of railway vehicles and their components. Railway vehicles within the meaning of this standard are defined in DIN 25003. The DIN 6701 series of standards gives specificat

14、ions relating to this process, which are based on the generic standards for adhesive bonding and take the requirements specifically relevant to rail vehicle construction into account. DIN 6701-4:2015-12 6 1 Scope This standard applies to the adhesive bonding and sealing of adherends in the manufactu

15、re and repair of railway vehicles (rail vehicles, for short) and their components. It specifies general definitions and basic requirements for any bonding and sealing work involved. It also specifies requirements to be met by contractors. It applies specifically to the manufacture, repair and qualit

16、y assurance of rail vehicles and their components. It also applies to: the manufacture of insulated glazing units using adhesives and sealing materials; the manufacture of bonded assemblies using adhesives and sealing materials (e.g. bonded sandwich panels). This standard does not apply to: the manu

17、facture of laminated safety glass; the securing of fasteners by means of adhesives; the manufacture of vulcanizates; the manufacture of plywood; the manufacture of fibre reinforced plastic components and the lamination of components (e.g. CFRPs, GFRPs); the manufacture of electronic component assemb

18、lies using adhesive without any mechanical requirements on bond strength. 2 Normative references The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated refe

19、rences, the latest edition of the referenced document (including any amendments) applies. DIN 25003, Railway applications Classification of rail vehicles Survey, terminology and definitions E DIN 6701-1, Adhesive bonding of railway vehicles and parts Part 1: Basic terms, basic rules DIN 6701-2, Adhe

20、sive bonding of railway vehicles and parts Part 2: Qualification of manufacturers of adhesive bonded materials DIN 6701-3, Adhesive bonding of railway vehicles and parts Part 3: Guideline for construction design and verification of bonds on railway vehicles DIN 25043 (all parts), Railway application

21、s Measuring of new railway vehicles DIN 6701-4:2015-12 7 DIN 27200, State of railway vehicles Terms and definitions for the reliable state of railway vehicles DIN 27201-1, State of railway vehicles Basic principles and production technology Part 1: Procedures for preparation and modification of main

22、tenance programmes DIN 27201-2, State of railway vehicles Basic principles and production technology Part 2: Proof of maintenance DIN 27201-9, State of railway vehicles Basic principles and production technology Part 9: Measuring DIN 54457, Structural adhesives Testing of adhesively bonded joints Be

23、ad peel test DIN EN 1464, Adhesives Determination of peel resistance of adhesive bonds Floating roller method (ISO 4578:1990, modified) DIN EN 1465, Adhesives Determination of tensile lap-shear strength of bonded assemblies DIN EN 571-1, Non-destructive testing Penetrant testing Part 1: General prin

24、ciples DIN EN 13775, Railway applications Measuring of new and modified freight wagons DIN ISO 7619-1, Rubber, vulcanized or thermoplastic Determination of indentation hardness Part 1: Durometer method (Shore hardness) DVS-EWF 3301, Europische Klebfachkraft Ausbildung, Prfung und Qualifizierung (The

25、 European Adhesive Specialist Professional education, examination and training) DVSEWF 3309, DVS-EWF-Lehrgang European Adhesive Engineer EAE (Klebfachingenieur/in) (DVS-EWF training course The European Adhesive Engineer (EAE) 3 Terms and definitions For the purposes of this standard, the terms and d

26、efinitions in E DIN 6701-1 and DIN 27200 apply. 4 Workmanship 4.1 General All bonds (classes A1 to A3 as in DIN 6701-3) shall be designed and manufactured in accordance with the following requirements where they are relevant for the process and the particular class. The process shall be planned and

27、performed so as to ensure a safe and reproducible working procedure. Some major criteria for designing and performing the bonding process are given in the following. Care shall be taken to ensure that bonding is adequately integrated into the overall manufacturing process, due consideration being gi

28、ven to the operational conditions and the particular requirements of the bonding process. Minimum technical requirements in the process, such as temperature and humidity, shall be established, specified, maintained and documented. Any necessary documents shall be prepared with the involvement of the

29、 bonding supervisor in charge. DIN 6701-4:2015-12 8 4.2 General process requirements 4.2.1 Transport and storage of adhesives, auxiliary materials and adherends The technologically necessary transport and storage conditions (such as temperature and humidity) shall be established and maintained. Depe

30、nding on the size, form and mass of adherends, transport devices (lifting crossheads, vacuum lifters, etc.) shall be specified and used. 4.2.2 Manufacturing environment The manufacturing environment shall be designed to suit the bonding system in question, as follows. a) The work station for bonding

31、 shall be identified and protected. b) Temperature limits for bonding work specified for technical reasons shall be observed. c) Inadmissible variations in temperature shall be prevented. d) Inadmissible draughts shall be prevented. e) Humidity limits specified for technical reasons shall be observe

32、d. f) Inadmissible contamination (e.g. due to silicones, dust, aerosols, etc.) shall be precluded. g) Adequate lighting conditions shall be ensured. h) Sufficient space shall be provided. 4.2.3 Preparation of work stations and conditioning a) The conditioning of adherends, adhesives, primers and oth

33、er materials in a suitable area under adequate ambient conditions shall be ensured. b) Technically allowed temperature tolerances shall be maintained. c) Where necessary, component temperatures shall be measured using suitable equipment. d) Any required materials shall be made available at the work

34、station. e) Materials and auxiliary materials shall comply with the data given in the work instructions. f) The following materials and auxiliary materials shall be selected to suit the process and shall be provided in adequate quantity, e.g.: documentation forms, pens; tools, equipment, platforms,

35、lifting appliances; personal protective equipment (e.g. suitable gloves which are free of silicone and powder); warning tape, warning notices, labels (e.g. “Keep out”, “Do not enter”, “Do not move vehicle”); adherends; DIN 6701-4:2015-12 9 cleaning wipes (disposable cloths, dust-free and low lint, u

36、ncontaminated); cleaning agents; adhesives, primers, adhesive tape, sealing materials, smoothing agents; batching and application equipment, tools such as filling knifes, spatulas, spray guns, beakers, etc. measuring equipment such as scales, tape measures, vernier calipers, dial gauges, etc.; clamp

37、ing devices, templates; spacers; silicone-free skin protecting products, cleansers and care products. 4.2.4 Occupational health and safety, environmental protection When bonding, the applicable regulations shall be complied with. 4.2.5 Checking for fitting accuracy a) Suitable test and measurement m

38、ethods shall be used for checking fitting accuracy after the conditioning of adherends prior to the application of adhesive. b) Any specified tolerances shall not be exceeded. 4.2.6 Checks prior to start of production a) Adhesives and auxiliary materials shall be identified. b) In the case of reclos

39、able containers, the date at which the container was opened for the first time or the expiry date shall be marked on the container. c) The maximum shelf life shall be established, recorded and maintained. NOTE After the container has been opened, the maximum shelf life may deviate from the expiry da

40、te. d) After removal from the container, adhesive and auxiliary materials shall be checked for any abnormal appearance, odour or consistency, taking the regulations for occupational health and safety into account. e) Adherends shall be identified and checked for usability, damage and any dimensional

41、 deviations. f) Temperature, and where necessary humidity, shall be measured using suitable equipment. 4.2.7 Treatment of bonding surfaces Agents for, and methods of surface treatment (cleaners, abrasives, adhesion promoters, etc.) shall be qualified and specified in the work instructions (see 4.4).

42、 a) Cleaning: 1) Only use cleaning agents and methods that suit the contamination. 2) Flash-off times shall be specified and maintained (e.g. taking into account any diffusion and porosity). 3) Cleaning wipes shall be replaced by new ones as often as necessary. DIN 6701-4:2015-12 10 4) Care shall be

43、 taken to ensure that any contamination of cleaning agents is precluded. 5) Where aqueous cleaners are used, sufficient subsequent rinsing and drying is required. 6) Where solvent-based cleaners are used, an adequate flash-off time is to be provided. 7) The result of the cleaning work shall be check

44、ed, e.g. by inspection, rubbing with clean white paper tissue, wetting test. 8) Where cleaning baths or vapour degreasing units are used, the cleaning agents shall be monitored and replaced or recovered. 9) It is to be ensured that bonding surfaces are not touched after cleaning so as to preclude re

45、newed contamination. b) Surface preparation: 1) Only abrasives that are fairly free from contamination shall be used; they shall be replaced by new material where necessary. 2) Where baths are used, any abnormal process parameters and composition and any unacceptable pollution of the bath shall be d

46、etected in due time. The bath substance shall be exchanged sufficiently often. 3) After any pickling, adherends shall be adequately rinsed and dried. 4) When using methods such as flame treatment, fluorination or plasma activation, the specified process parameters shall be complied with and monitore

47、d. 5) The result of surface preparation shall be checked, e.g. by inspection, a wetting test or by trial bonding. c) Post-treatment of surfaces: 1) As opposed to adhesives, primers mostly have a particularly high content of highly reactive components which also tend to easily react with humid air. I

48、n order to prevent any deactivation of the material prior to application, it shall be protected against the admission of moisture during storage or stockpiling. 2) Primers shall be homogenized by shaking prior to use. 3) For material that becomes fully effective only if applied as a thin film (so th

49、at molecules ensure the adhesion of the adhesive on the surface), a thick film is to be prevented in all cases (e.g. by using the wipe-on wipe-off technique if permitted for the material in question) for reasons of inadequate cohesion. 4) Primers tend to be highly sensitive if the processing time (which depends on the temperature and humidity) is longer or shorter than designed. It is