NAVISTAR MPAPS GT-24-2015 Phosphate System Compatibility.pdf

1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 1 of 7 NAVISTAR, INC. Material, Parts, and Process Specification

2、s (MPAPS) NUMBER: MPAPS GT-24 Former Designation: CEMS GT-24 TITLE: Phosphate System Compatibility CURRENT REV No.: 1510 DATE: OCT. 2015 WRITTEN/EDITED BY: S. Brailey APPROVED BY: R. Goluch SUPERSEDES: CEMS GT-24 April 2009 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This s

3、pecification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regulatory limits

4、 prior to use. Change Notice: Updated to new format, editorial changes 1.0 APPLICATION This is a method for determining the effect of contaminants (mill oils, drawing compounds, corrosion preventatives, adhesives, sealers, etc.) on the cleaning stages of the phosphate coating system and on the phosp

5、hate coating developed by the system. 2.0 SCOPE This specification covers test methods for high volume contaminants, low volume contaminants, and adhesives and sealers. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must c

6、omply with the requirements of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 o

7、r TS-16949 CFR Title 29, Part 1910 NAVISTAR MPAPS B-50 NAVISTAR MPAPS G-5 NAVISTAR MPAPS GT-Paint NAVISTAR MPAPS P-9543 4.0 APPARATUS 1. A water bath with capabilities of both heating and agitation suitable to simulate the cleaning stage(s) of the phosphate coating system. 2. Draw bars capable of le

8、aving 0.014 mm (0.54 mil) and 0.019 mm (0.75 mil) wet films - RDS Specialties Rods #6 only the bottom half of each panel is to be topcoated. Use Grade 56 primer and Grade 18 topcoat as per MPAPS G-5. 18. Determine the paint adhesion on both the primer and topcoat on one panel from each group in acco

9、rdance with the method described in MPAPS GT-Paint, method 5A. 19. Perform a humidity test in accordance with MPAPS GT-Paint, method 7E on one panel from each group. 20. Perform a salt spray test in accordance with MPAPS GT-Paint, method 7D on one panel from each group. Report Report the following i

10、nformation: 1. The percent of processing lubricant and water separation at 5 minute, 60 minute, and 24 hour intervals. 2. The percent of water break-free (% WBF) for each metal at each contaminant level and that of the controls. 3. The change in amount of foaming at each contaminant level. 4. The ph

11、osphate coating weight and coating appearance for each control and test panel of each metal at each contaminant level. 5. The minimum percent adhesion observed on each control and test panel of each metal for each of the contaminant levels. 6. Humidity test results for each control and test panel of

12、 each metal for each of the contaminant levels. 7. Salt spray test results for each control and test panel of each metal for each of the contaminant levels. LOW VOLUME CONTAMINANTS Low volume contaminants include but are not limited to miscellaneous lubricants and solvents used to maintain the phosp

13、hate system. Panel Preparation For each metal substrate (CR steel, galvanized steel, 5052-H32 aluminum) to be used in the processing lubricant evaluation: 1. Prepare 4 control panels and 12 test panels for each metal as described High Volume Contaminants, preparation, steps 1 thru 3. 2. Allow the sp

14、ecimens to equilibrate at atmospheric conditions for 2 hrs. prior to testing. Procedure 1. Test for cleanability as described in High Volume Contaminants, procedure, steps 6 thru 13. 2. Test for phosphatability as described in High Volume Contaminants, procedure, steps 14 thru 15. Report 1. The perc

15、ent of water break-free (%WBF) for each metal at each contaminant level and that of the controls. 2. The phosphate coating weight and coating appearance for each control and test panel of each metal at each contaminant level. NUMBER: MPAPS GT-24 TITLE: Phosphate System Compatibility REVISION: 1510 T

16、his document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 4 of 7 SEALERS AND ADHESIVES This procedure is intended for all s

17、ealers and adhesives that will enter the phosphate system. Panel Preparation Prepare 8 control panels, 8 test panels, and 8 sandwich test panels for each material to be evaluated. 1. Apply the sealer bead of adhesive patch to oiled panels representative of the production conditions. 2. Prepare a set

18、 of sandwich panels with a 6 mm gaps used oiled panels representative of production conditions. 3. Allow the specimens to equilibrate at atmospheric conditions for 2 hours prior to testing. Procedure Re-use the solution for each different set of samples. 1. Record the weight of all the test panels a

19、nd sandwich test panels. 2. Run 4 test panels and 4 sandwich test panels in all the stages of the phosphate system at the times and temperatures representative of production conditions. 3. Run 4 test panels and 4 sandwich test panels in all the stages of the phosphate system allowing the panels to r

20、emain at each bath for 24hrs. 4. Run 4 control panels in all the stages of the phosphate system at the times and temperatures representative of production conditions. 5. Record the weight of all the test panels and sandwich test panels. Calculate % weight loss. 6. Bake all test panels and sandwich t

21、est panels at the times and temperatures representative of the e-coat oven. 7. Record any visible loss of adhesion, dissolution and erosion on the adhesive/sealant surface. 8. Determine the phosphate coating weight in accordance with CEMS Test Method GT-23 on one panel from each group. 9. Use a scan

22、ning electron microscope (SEM) to describe the general appearance of the phosphate coating on the remaining three panels of each group. Report 1. % Weigh loss for each group. 2. Visible loss of adhesion, dissolution and erosion on the adhesive/sealant surface. 3. The phosphate coating weight and coa

23、ting appearance for each control and test panel of each group. 6.0 QUALITY Tests shall be performed by certified labs using good lab practices and conforming to all applicable standards and regulations. Traceable control samples shall be used as appropriate. Reports shall conform to good practice an

24、d MPAPS P-9543. Calibrations shall conform to applicable standards and show traceability to National Standards. Reports shall demonstrate compliance to appropriate standards and calibration records. 7.0 QUALIFICATION A sample report is shown in the Appendix as a guide in preparing the report for thi

25、s test method. NUMBER: MPAPS GT-24 TITLE: Phosphate System Compatibility REVISION: 1510 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar,

26、 Inc. OCTOBER 2015 Page 5 of 7 8.0 SOURCE APPROVAL AND QUALITY CONTROL 8.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Pr

27、oduction Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. 9.0 TECHNICAL INFORMATION For further information related to t

28、he technical content of this specification, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO

29、80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/ NUMBER: MPAPS GT-24 TITLE: Phosphate System Compatibility REVISION: 1510 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers ar

30、e required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 6 of 7 A.0 GENERAL INFORMATION SAMPLE REPORT FOR HIGH VOLUME CONTAMINANTS Report Number_ Date_ Processing Lubricant Identification _ Control Oil Identification: Cold rolled Steel _ Galvanized Steel _ 5052-H32 Aluminu

31、m _ EMULSIFICATION TEST RESULTS Cleaner Concentration Percent of Separation 5 Minutes 60 Minutes 24 Hours 0.25 oz./gal. 0.50 oz./gal. 1.00 oz./gal. 2.00 oz./gal 100% 100% 50% 0% - - 100% 50% - - - 100% PERCENT WATER BREAK-FREE (%WBF) TEST RESULTS Contamination Level % Weight % WBF - Area CR Steel Ga

32、lvanized Steel 5052-H32 Aluminum 0.0% (Control) 0.0% 0.10% 0.25% 90% 100% 90% 50% 80% 90% 90% 40% 90% 100% 90% 40% FOAM TEST RESULTS Contamination Level % Weight Increase in Amount of Foam Times more Foam 0.0% 0.10% 0.25% - 1 4 PHOSPHATE COATING WEIGHT AND APPEARANCE Contamination Level % Weight Coa

33、ting Weight, mg/ft.2 Appearance CR Steel Galvanized Steel 5052-H32 Aluminum 0.0% (Control) 140 180 160 Uniform on All 0.0% 150 160 160 Uniform on All 0.10% 180 180 180 Light Streak on Steel & Galvanized 0.25% 90 130 80 Streaked on All NUMBER: MPAPS GT-24 TITLE: Phosphate System Compatibility REVISIO

34、N: 1510 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 7 of 7 SAMPLE REPORT (Continued) ADHESION TEST RESULTS P

35、ER GT-PAINT, METHOD 5A Contamination Level, % Weight Adhesion, Minimum Percent Comment CR Steel Galvanized Steel 5052-H32 Aluminum 0.0% (Control) Primer Topcoat 100 100 100 100 100 100 - - 0.0% Primer Topcoat 100 95 100 95 100 100 - - 0.10% Primer Topcoat 95 90 95 90 85 80 Aluminum Samples Failed Mi

36、n % Adhesion HUMIDITY TEST RESULTS PER GT-PAINT, METHOD 7E Contamination Level, % Weight CR Steel Galvanized Steel 5052-H32 Aluminum Comment 0.0 (Control) Primer Topcoat Pass Pass Pass Pass Pass Pass - - 0.0% Primer Topcoat Pass Pass Pass Pass Pass Pass - - 0.10% Primer Topcoat Pass Pass Pass Pass P

37、ass Pass - - 0.25% Primer Topcoat Pass Pass Fail Fail Fail Fail Blisters on Galvanized and Aluminum SALT SPRAY TEST RESULTS PER GT-PAINT, METHOD 7D Contamination Level, % Weight CR Steel Galvanized Steel 5052-H32 Aluminum Comment 0.0 (Control) Primer Topcoat Pass Pass Pass Pass Pass Pass - - 0.0% Primer Topcoat Pass Pass Pass Pass Pass Pass 0.10% Primer Topcoat Pass Pass Pass Fail Pass Fail Galvanized & Aluminum Blisters to Prime 0.25% Primer Topcoat Pass Fail Fail Fail Fail Fail Topcoat 1/8 Inch Creepage on All Samples