静电涂装作业指导书
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Degreasingsolventpreparation:Thinning2~3%ZC-IIDegreasingsolventwithfreshwater.
6.1.4温度：50~65℃
Temperature:50~65℃(122~149℉)
6.1.5方法：浸法。浸制时间：10~15分钟。根据脱脂的实际情况确定，也可延长。
3.参考文件References:
GB9286 GB1732 GB6742
4.操作条件GeneralRequirements:
4.1涂装产品表面温度至少要高出露点5℉或3℃。在操作开始时及操作过程中每4小时要测量一次。
Thesurfacetemperatureshall be at least5℉or3℃above the dew point.Readingsare required at the start of work and approximately every 4 hours.
Total Acid level: 16~20; Educt Acid: 0.8~1.2; Catalyzer: 2~3;Alkalinity: 10~15.
6.4.2磷化温度：45℃±5℃
PhosphateTemperature:45℃±5℃
6.4.3处理方法：浸制法，将待处理工件浸没于磷化槽内。
Method: Immersing.
6.4.4磷化时间：≥8分钟
PhosphateTime:≥8minutes.
6.4.5磷化液的管理：每天测定一次总酸度和游离酸度，及促进剂和碱度，并使之符合要求。
Phosphate solventmanagement:InspectTotal Acid level,Educt Acid,CatalyzerandAlkalinityevery day to meet the requirements.
4.4供应商必须对每一个步骤进行检查和测试后方可进行下一个步骤。若发现有缺点和不足，必须立即进行补救工作，否则不得进入下一步骤操作。
The supplier shall inspect and test each step of the coating work operation before proceeding with the next phase.Defects and deficiencies in surface preparation and coating work that may adversely affect completed work shall be corrected before proceeding with the next step.
Use sandpapertoburnishthe surface
(12)(12)用纯聚脂粉末喷涂，颜色由客户指定
Use polyester powderwithcustomer appointed color schemeto coat
(13)(13)进烘箱,温度控制于180℃~190℃,升温30~45分钟
6.2酸洗Pickling
6.2.1经脱脂、清洗并滴干后的工件放酸洗槽中进行酸洗，以除去工件表面的锈斑、氧化皮等。
Purpose:Useacid to remove rust,oxideandother contaminantsofthemetalsurface.
6.2.2酸洗液：工业盐酸，浓度≥20%。
Method:Immersing for 10~15 minutes according toactualcircumstances.
6.1.6清洗：脱脂后的工件应放入常温清水池内流水漂洗。
Washing:Usefreshwater rinse toclean thesoluble chemicalsof component units.
6.4磷化处理Phosphating
6.4.1磷化液：用锌系磷化液（ZL-II）按3%的重量比与自来水配制。
总酸度：16~20（点）；游离酸：0.8~1.2（点）；促进剂：2~3（点）；碱度：10~15
Solventpreparation:Thinning3%ZL-IIzinc-phosphatesolvent with freshwater according to weight.
6.1.2脱脂：用脱脂液加温，以加速去除待酸洗工件表面的油垢，润滑脂，加工液等污物。
Grease removing:UseheatedDegreasingsolventtoquicklyremovegrease,oilandother contaminantsofthemetalsurface
6.1.3脱脂液的配制：ZC-II中温脱脂剂（2~3）%+自来水余量。
6.5磷化膜的质量要求Phosphatefilmrequirements
6.5.1轻量级2~3g/M²
Lightweight: 2~3g/m2
6.5.2磷化膜的外观应结晶致密、连续和均匀，颜色应为浅灰色。不允许有疏松的膜层，不允许局部无膜（焊缝的气孔和夹渣除外）。不允许有锈蚀和严重的挂灰
Surface:Crystallizationshall bedense, continuous,uniform andlight grey.Looseadhering coating,exposed metalsurface(except weldstomata and slag), rust and serious dust arenot allowed.
6.2.4酸洗时间：视工件板材的厚度、锈蚀程度以及氧化皮的状况确定，以达到除锈的目的。
Time: According toactualthickness, rust and oxideofcomponent units.
6.2.5漂洗：为减少带入漂洗槽的酸量，工件从酸洗槽中提出后应在酸洗槽上方稍作停留，滴去工件上的大部分酸液后浸入清水槽，用常温下流动水漂洗。经漂洗后的工件放入中和槽中和，中和槽PH值9~10。
6.详ቤተ መጻሕፍቲ ባይዱ作业内容DetailedOperation:
6.1脱脂Grease removing
6.1.1擦洗：当工件有严重油垢时，需用汽油人工擦洗。
Scrubbing:Usegasolinetoscrubthecomponent unitssurface ifgreaseor oilisserious.
(2)(2)用自来水清洗.
Usefreshwater rinse toclean thesoluble chemicals.
(3)(3)用盐酸除去工件表面各种锈及氧化皮.
UseHydrochloric acid to remove rust andoxideofthemetalsurface
**如果是镀锌工艺,则由第2步直接进入第5步表调.
(6)(6)用加温磷化液进行磷化.
Use heatedphosphatesolventfor phosphating
(7)(7)自来水常温,如天气阴冷采用加高温清洗.
Usefreshwater rinseorhigh-temperature cleaningforcoldweathertoclean thesoluble chemicals.
Solventpreparation: Thinning 0.2~0.3% colloidal titanium saltwith freshwater according to weight.
6.3.3方法：在常温下将工件浸入表面调整液槽内，浸制时间0.5~1分钟。
Method:Immersing for 0.5~1 minute at room temperature.
Purpose: Themetalsurfaceisroughafterpicklingand surface adjustment willformcrystallization ofphosphatefilmonmetal surface.
6.3.2配制：按重量比=胶体钛盐（0.2~0.3）%+自来水余量。
5.静电涂装工艺流程图Coating Process Flow Diagram:
(1)(1)用脱脂剂加温,除去工件表面油污.
UseheatedDegreasingsolventtoquicklyremovegrease,oilandother contaminantsofthemetalsurface
(8)(8)自干或烘干.
Bake orDryin the air
(9)(9)用专用导电腻子垫平表面凹面
Use special conductiveputtyto smooth out theconcavesurface
(10)(10)烘干或凉干.
Bake or Dry in the air
(11)(11)用砂皮打磨.
Picklingsolvent: IndustrialHydrochloric acidwithconcentration≥20%.
6.2.3方法：将工件浸没在酸洗液中，工件之间必须有间隙，不可板面紧贴，以免影响酸洗结果。
Method:When multiple component units are immersed,there shall bespacebetween theunits,close to thetankare not allowed in case ofinfluencingpicklingresult.
4.2操作环境不得有污染、不适当或被损坏的涂料存在。
Areas where contaminate, defective, or damaged coatings have been found are not allowed.
4.3供应商需在工作开始前对涂装产品表面进行彻底检查。
6.1.4温度：50~65℃
Temperature:50~65℃(122~149℉)
6.1.5方法：浸法。浸制时间：10~15分钟。根据脱脂的实际情况确定，也可延长。
3.参考文件References:
GB9286 GB1732 GB6742
4.操作条件GeneralRequirements:
4.1涂装产品表面温度至少要高出露点5℉或3℃。在操作开始时及操作过程中每4小时要测量一次。
Thesurfacetemperatureshall be at least5℉or3℃above the dew point.Readingsare required at the start of work and approximately every 4 hours.
Total Acid level: 16~20; Educt Acid: 0.8~1.2; Catalyzer: 2~3;Alkalinity: 10~15.
6.4.2磷化温度：45℃±5℃
PhosphateTemperature:45℃±5℃
6.4.3处理方法：浸制法，将待处理工件浸没于磷化槽内。
Method: Immersing.
6.4.4磷化时间：≥8分钟
PhosphateTime:≥8minutes.
6.4.5磷化液的管理：每天测定一次总酸度和游离酸度，及促进剂和碱度，并使之符合要求。
Phosphate solventmanagement:InspectTotal Acid level,Educt Acid,CatalyzerandAlkalinityevery day to meet the requirements.
4.4供应商必须对每一个步骤进行检查和测试后方可进行下一个步骤。若发现有缺点和不足，必须立即进行补救工作，否则不得进入下一步骤操作。
The supplier shall inspect and test each step of the coating work operation before proceeding with the next phase.Defects and deficiencies in surface preparation and coating work that may adversely affect completed work shall be corrected before proceeding with the next step.
Use sandpapertoburnishthe surface
(12)(12)用纯聚脂粉末喷涂，颜色由客户指定
Use polyester powderwithcustomer appointed color schemeto coat
(13)(13)进烘箱,温度控制于180℃~190℃,升温30~45分钟
6.2酸洗Pickling
6.2.1经脱脂、清洗并滴干后的工件放酸洗槽中进行酸洗，以除去工件表面的锈斑、氧化皮等。
Purpose:Useacid to remove rust,oxideandother contaminantsofthemetalsurface.
6.2.2酸洗液：工业盐酸，浓度≥20%。
Method:Immersing for 10~15 minutes according toactualcircumstances.
6.1.6清洗：脱脂后的工件应放入常温清水池内流水漂洗。
Washing:Usefreshwater rinse toclean thesoluble chemicalsof component units.
6.4磷化处理Phosphating
6.4.1磷化液：用锌系磷化液（ZL-II）按3%的重量比与自来水配制。
总酸度：16~20（点）；游离酸：0.8~1.2（点）；促进剂：2~3（点）；碱度：10~15
Solventpreparation:Thinning3%ZL-IIzinc-phosphatesolvent with freshwater according to weight.
6.1.2脱脂：用脱脂液加温，以加速去除待酸洗工件表面的油垢，润滑脂，加工液等污物。
Grease removing:UseheatedDegreasingsolventtoquicklyremovegrease,oilandother contaminantsofthemetalsurface
6.1.3脱脂液的配制：ZC-II中温脱脂剂（2~3）%+自来水余量。
6.5磷化膜的质量要求Phosphatefilmrequirements
6.5.1轻量级2~3g/M²
Lightweight: 2~3g/m2
6.5.2磷化膜的外观应结晶致密、连续和均匀，颜色应为浅灰色。不允许有疏松的膜层，不允许局部无膜（焊缝的气孔和夹渣除外）。不允许有锈蚀和严重的挂灰
Surface:Crystallizationshall bedense, continuous,uniform andlight grey.Looseadhering coating,exposed metalsurface(except weldstomata and slag), rust and serious dust arenot allowed.
6.2.4酸洗时间：视工件板材的厚度、锈蚀程度以及氧化皮的状况确定，以达到除锈的目的。
Time: According toactualthickness, rust and oxideofcomponent units.
6.2.5漂洗：为减少带入漂洗槽的酸量，工件从酸洗槽中提出后应在酸洗槽上方稍作停留，滴去工件上的大部分酸液后浸入清水槽，用常温下流动水漂洗。经漂洗后的工件放入中和槽中和，中和槽PH值9~10。
6.详ቤተ መጻሕፍቲ ባይዱ作业内容DetailedOperation:
6.1脱脂Grease removing
6.1.1擦洗：当工件有严重油垢时，需用汽油人工擦洗。
Scrubbing:Usegasolinetoscrubthecomponent unitssurface ifgreaseor oilisserious.
(2)(2)用自来水清洗.
Usefreshwater rinse toclean thesoluble chemicals.
(3)(3)用盐酸除去工件表面各种锈及氧化皮.
UseHydrochloric acid to remove rust andoxideofthemetalsurface
**如果是镀锌工艺,则由第2步直接进入第5步表调.
(6)(6)用加温磷化液进行磷化.
Use heatedphosphatesolventfor phosphating
(7)(7)自来水常温,如天气阴冷采用加高温清洗.
Usefreshwater rinseorhigh-temperature cleaningforcoldweathertoclean thesoluble chemicals.
Solventpreparation: Thinning 0.2~0.3% colloidal titanium saltwith freshwater according to weight.
6.3.3方法：在常温下将工件浸入表面调整液槽内，浸制时间0.5~1分钟。
Method:Immersing for 0.5~1 minute at room temperature.
Purpose: Themetalsurfaceisroughafterpicklingand surface adjustment willformcrystallization ofphosphatefilmonmetal surface.
6.3.2配制：按重量比=胶体钛盐（0.2~0.3）%+自来水余量。
5.静电涂装工艺流程图Coating Process Flow Diagram:
(1)(1)用脱脂剂加温,除去工件表面油污.
UseheatedDegreasingsolventtoquicklyremovegrease,oilandother contaminantsofthemetalsurface
(8)(8)自干或烘干.
Bake orDryin the air
(9)(9)用专用导电腻子垫平表面凹面
Use special conductiveputtyto smooth out theconcavesurface
(10)(10)烘干或凉干.
Bake or Dry in the air
(11)(11)用砂皮打磨.
Picklingsolvent: IndustrialHydrochloric acidwithconcentration≥20%.
6.2.3方法：将工件浸没在酸洗液中，工件之间必须有间隙，不可板面紧贴，以免影响酸洗结果。
Method:When multiple component units are immersed,there shall bespacebetween theunits,close to thetankare not allowed in case ofinfluencingpicklingresult.
4.2操作环境不得有污染、不适当或被损坏的涂料存在。
Areas where contaminate, defective, or damaged coatings have been found are not allowed.
4.3供应商需在工作开始前对涂装产品表面进行彻底检查。
