Thermal spraying—Quality requirements of thermally sprayed structures—Part 2:Comprehensive quality requirements
Some standard content:
GB/T19352.2—2003/IS014922-2:1999 GB/T19352 "Quality requirements for thermal sprayed structures" is divided into the following four parts: Part 1: Selection and use guidelines; Part 2: Comprehensive quality requirements; Part 3: Standard quality requirements; Part 4: Basic quality requirements. This part is Part 2 of GB/T19352. This part is equivalent to ISO14922-2:1999 "Quality requirements for thermal sprayed structures" (English version). The following editorial changes have been made to this part: a) The term "this standard" is changed to "this part"; b) The decimal point "" is replaced by the comma "," as a decimal point; c) The foreword of the international standard is deleted; d) The appendix of the international standard is deleted. This part was proposed by the China Machinery Industry Federation. This part is under the jurisdiction of the National Technical Committee for Standardization of Metallic and Non-metallic Coatings. Drafting organizations of this part: Wuhan Institute of Materials Protection, General Iron and Steel Research Institute, Shanghai Ruifa Spraying Machinery Co., Ltd., 703 Institute of China Aerospace Science and Technology Corporation.
Main drafters of this part: Wang Hongsheng, Wu Zijian, Chen Huiguo, Wu Jianhua, Wu Chaojun, Liu Zigang. 1
1 Scope
GB/T 19352.2—2003/ISO 14922-2:1999 Thermal spraying Quality requirements for thermally sprayed structures
Part 2: Comprehensive quality requirements
This part of GB/T 19352 specifies the quality requirements as follows: — It is independent of the type of thermal sprayed structure. It defines the quality requirements for thermal spraying not only in the workshop but also in the field. — It provides a guide to describe the manufacturer's ability to produce thermally sprayed components that meet the specified requirements. It can also serve as a basis for evaluating the manufacturer's thermal spraying capabilities. This standard applies when the manufacturer's ability to produce thermal sprayed components to the promised quality requirements is detailed in one or more of the following documents:
- a contract signed by the parties concerned;
an adopted standard;
- regulatory requirements.
The requirements in this standard may be adopted in their entirety, or the manufacturer may selectively delete some if the relevant component is not applicable. These requirements provide an adaptable framework for thermal spray control in the following circumstances: - Situation -
When the contract requires the manufacturer to have a quality system that complies with GB/T 19001-1994 or GB/T 19002-1994, the thermal spraying requirements in the contract are clearly provided.
- Situation II
When the contract requires the manufacturer to have a quality system that is different from GB/T 19001-1994 or GB/T 19002-1994, the thermal spraying requirements in the contract are clearly provided. Case 3
When the contract requires the manufacturer to establish a quality system, clearly provide the thermal spraying requirements in the contract. - Case 4
When the adopted standard includes thermal spraying as part of its requirements, clearly provide the thermal spraying requirements in the adopted standard: or clearly specify the thermal spraying requirements in the contract signed by the parties concerned. In this case, Part 3 or Part 4 of this standard may be more applicable.
2 Normative references
The clauses in the following documents become the clauses of this part through reference to this part of GB/T 19352. For any dated referenced document, all subsequent amendments (excluding errata) or revisions are not applicable to this part, however, the parties to the agreement based on this part are encouraged to study whether the latest versions of these documents can be used. For any undated referenced document, the latest version applies to this part.
GB/T6583—1994 Terminology of quality management and quality assurance (idtISO8402:1994) GB/T8642—2002 Determination of tensile bond strength of thermal spraying (idtISO14916:1999) GB/T9445--1999 Qualification and certification of non-destructive testing personnel (idtISO9712:1992) GB/T12608-2003 Technical conditions for the supply of wire, rod and core materials for thermal spraying flame and arc spraying (idtISO14919:2001)
GB/T 19352.2—2003/ISO 14922-2:1999 GB/T18719-2002 Thermal spraying terminology, classification (idt ISO14917:1999) GB/T19001-1994 Quality system Quality assurance model for design, development, production, installation and service (idt ISO9001:1994)
GB/T19002--1994
Quality system Quality assurance model for production, installation and service (idt ISO9001:1994) dtISO9002:1994) GB/T19352.1-2003 Thermal spraying Quality requirements for thermally sprayed structures Part 1: Guide to selection and use (idtISO14922-1:1999)
GB/T19356—2003 Thermal spraying powder composition and supply technical conditions (idtISO14232:2000) ISO14231:2000 Thermal spraying Inspection and acceptance of thermal spraying equipment ISO 14918:19993
Thermal spraying Qualification assessment of thermal spraying personnel
ISO/CD17833
Thermal spraying Thermal spraying coordination tasks and responsibilities
3 Definitions
This part adopts the definitions of GB/T6583-1994, GB/T18719-2002 and GB/T19352 Part 1. 4 Contract and Design Review
4.1 General
The manufacturer shall review the contract requirements and design data provided by the purchaser or the internal data of the components designed by the manufacturer. This ensures that the information necessary for the work to be carried out is available before the work is started. The manufacturer shall confirm that it is capable of meeting all requirements of the thermal spraying contract and that a comprehensive plan for all quality-related activities is in place. The manufacturer conducts a contract review to verify that the contract requirements are within its performance capabilities, that there are sufficient resources to support the delivery schedule, and that the content of the contract text is clear and unambiguous. The manufacturer shall confirm that any changes between the contract and the previous tender documents have been clarified and that the purchaser has informed it of any procedural, cost or quantity changes that may occur. The clauses in 4.2 are specifically considered during or before the contract review. The clauses in 4.3 are usually part of the design review; if the manufacturer does not undertake the design, these clauses should be considered during the contract review. It should be ensured that all relevant information is provided by the purchaser. When there is no contract or the contract terms are fixed, the manufacturer should consider the requirements of 4.2 when conducting its design review (4.3). 4.2 Contract Review
Contract requirements to be taken into account should include:
a) adopted standards, and any supplementary requirements;
process specifications for thermal spraying, non-destructive testing and heat treatment; approval of the thermal spraying process methods adopted;
approval of personnel;
post-processing;
inspection and testing;
selection, marking and/or traceability of materials, thermal spraying personnel and thermal spraying coatings (see 16);
quality control preparation, including any involvement of independent inspection agencies;
other requirements for thermal spraying, such as batch testing of consumables for particle size, particle size distribution, morphology and composition;
relevant environmental conditions at the thermal spraying site;
k)'Subcontracting;
1) Handling of non-conformities.
4.3 Design review
The design requirements to be considered shall include:
a) the location, accessibility and sequence of all coatings; b) the surface finish of the coatings;
c) the technical conditions of the substrate material and the properties of the coatings; GB/T19352.2-—2003/IS014922-2:1999 details and dimensions of the substrate surface preparation, details and dimensions of the sprayed coatings; d)
coating quality and acceptance requirements;
f) other special requirements, such as; acceptability of shot peening, heat treatment, cooling, masking, etc. 5 Subcontracting
When the manufacturer is to use subcontracting services (e.g., inspection, non-destructive testing, post-processing), the manufacturer shall provide all relevant technical conditions and requirements to the subcontractor. The subcontractor shall provide such documents and records of the subcontractor's performance as the manufacturer may require. Any subcontractor shall work under the instructions and responsibilities of the manufacturer and shall fully comply with the relevant requirements of this part. The manufacturer shall ensure that the subcontractor can comply with the quality requirements of the contract. The information provided by the manufacturer to the subcontractor shall include the contract review (see 4.2) and design review (see 4.3) all relevant data. If the structural design is to be subcontracted, additional requirements may be detailed. 6 Thermal spray personnel
6.1 General
The manufacturer shall arrange sufficient qualified personnel to plan, implement, supervise and inspect thermal spraying production in accordance with the specified requirements. 6.2 Thermal spray personnel assessment
All thermal spray personnel shall be approved through the corresponding qualification assessment in accordance with ISO14918:1999. All approval records shall be valid.
6.3 Thermal spray coordination personnel
The manufacturer shall assign appropriate thermal spray coordination personnel to provide thermal spray personnel with the necessary work and thermal spraying guidance so that the work can be smoothly implemented and controlled. These personnel responsible for quality activities shall have sufficient authority to take necessary actions. The responsibilities, interrelationships and scope of duties of these personnel shall be clearly defined, see ISO/CD17833.7 Quality testing personnel
7.1 General
The manufacturer shall have sufficient qualified personnel to plan and implement, supervise and inspect, test and accept thermal spraying production in accordance with the specified requirements.
7.2 Non-destructive testing
The qualifications of non-destructive testing personnel shall be recognized in accordance with GB/T9445-1999. 8 Equipment
Equipment for manufacturing
The following equipment should be available when necessary:
Workshop, generally a roofed work area; a warehouse for properly storing base materials (parts to be coated), consumables and other auxiliary materials for thermal spraying; - Equipment for drying thermal spray powder; - Equipment and machine tools for handling and processing parts to be thermally sprayed (such as degreasing equipment, sandblasting room); - Spraying equipment, including feeding, adjustment and control equipment; operating system (such as turntable, rotating machinery, robot system); - exhaust system, dust collector, noise and radiation protection equipment, - Equipment for heat treatment of parts before and after spraying; ... - Cooling equipment,
GB/T 19352.2-2003/ISO 14922-2:1999-Machine tools, tools and equipment for post-processing of thermal spray coatings (such as grinding, turning); - Equipment and tools for testing thermal spray coatings and materials; - Appropriate conditions for on-site spraying. 8.2 Description of Equipment
The manufacturer shall maintain a list of the essential equipment used in thermal spraying operations. The list shall include details of the major equipment and key parameters used to assess the maximum production capacity and potential capacity of the workshop, such as the following: - Maximum capacity of the crane;
Size of the components that can be sprayed;
- Capacity of the blasting and spraying rooms.
8.3 Suitability of Equipment
The equipment capacity shall be sufficient for the purpose concerned. Unless otherwise specified in the contract (the requirements shall be in accordance with ISO 14231:2000), thermal spraying and pre-treatment and post-treatment equipment generally do not require approval. 8.4 New Equipment
After the installation of new equipment (or equipment after overhaul) (see 9.1), appropriate equipment tests shall be carried out in accordance with ISO 14231:2000. The tests shall demonstrate that the equipment is functioning properly. Whenever equipment tests are carried out, they shall be carried out in accordance with the appropriate standards. Records of the tests shall be retained. 8.5 Maintenance
The manufacturer shall have a documented plan for equipment maintenance. The plan should ensure that the equipment status fluctuations are controlled within the range specified by the relevant thermal spraying process technical specifications through inspection and maintenance. Such a plan may only cover those equipment conditions (fluctuations) that are indispensable to ensure the quality of thermal sprayed components.
For example, the following conditions:
The condition of the guide mechanism of mechanized thermal spraying equipment; the condition of ammeters, voltmeters and flow meters used for thermal spraying machine operation; the condition of cables, hoses, connectors,
The condition of control systems in mechanized and (or) automated thermal spraying; the condition of thermocouples and other temperature measuring instruments; the condition of powder feeders, wire feeders and guide tubes. Defective equipment should not be used.
8.6 Health, safety and environmental issues
Equipment necessary for the protection of health, safety and the environment must be applicable. All activities to implement health and safety standards and light and heat radiation protection standards must be ensured.
9 Implementation of thermal spraying
9.1 Production planwww.bzxz.net
The manufacturer shall prepare a complete production plan and deploy the appropriate equipment in 8.1 or on site. At least it shall include: - Specification of component manufacturing process, such as individual parts or components and the subsequent final assembly sequence; - Marking of special process requirements in component manufacturing; - Appropriate process specifications related to thermal spraying and related processes; - A coating production sequence, if this is meaningful; - The sequence and time of implementation of each process; - Specifications for inspection and testing, including the involvement of any independent inspection agency; - Environmental conditions, such as protection from wind and rain (spraying on site or in the workshop); 4
Provisions for batch, component or part identification. 9.2 Thermal spraying process specification
GB/T19352.2—2003/IS014922-2:1999The manufacturer shall prepare thermal spraying process specifications and ensure their correct implementation in production. Other processes, such as pre-treatment or post-treatment processes, only need to be approved in accordance with the contract. 9.3 Work instructions
The manufacturer can use the thermal spray process specification to explain the work to the thermal spray personnel directly in the workshop. It is also possible to use a demonstrative work instruction method. However, this demonstrative work instruction should be carried out using the approved thermal spray process specification without the need for separate approval. 9.4 Pre-treatment and post-treatment
The manufacturer shall be fully responsible for the specification and implementation of all pre-treatment and post-treatment. The treatment process shall be adapted to the substrate material, coating structure, etc. If necessary, process records shall be made during the treatment process. The records shall prove that the process specifications have been complied with and shall be traceable to the actual treatment process.
9.5 Document basis
The manufacturer shall establish and maintain procedures for controlling relevant quality documents, such as thermal spray process specifications and thermal spray personnel certificates.
10 Thermal Spraying Consumables
10.1 General
The responsibilities and procedures for the control of thermal spraying consumables shall be specified by the manufacturer. 10.2 Batch Testing
Batch testing of consumables shall be carried out only when expressly specified in the contract. 10.3 Storage and Handling
The manufacturer shall develop and implement procedures for the storage, handling and use of consumables in accordance with the supplier's specifications to prevent moisture, caking, oxidation and damage.
11 Storage and Handling of Matrix Materials
Material shall not be damaged during storage. Identification shall be maintained during storage. 12 Inspection and Testing Related to Thermal Spraying
12.1 General
Inspections and tests shall be carried out at appropriate stages of the production process to ensure compliance with the contract requirements. The location and frequency of inspections and/or tests shall be determined according to the contract and/or the standards adopted, the thermal spraying process and the type of component (see 4.2 and 4.3). The manufacturer may carry out some informal tests without restriction. Such tests do not require a report. 12.2 Inspection and tests before thermal spraying
If necessary, the following checks should be carried out before thermal spraying begins: - the suitability and validity of the thermal sprayer's certification, see ISO 14918:1999; - the suitability of the thermal spraying process specification;
- identification of the substrate material;
- identification of consumables, for example, in accordance with GB/T 19356-2003 or GB/T 12608-2003; - surface preparation, shape and dimensions;
spraying should be carried out as soon as possible after surface preparation; mounting, clamping and positioning;
any special requirements in the GB/T 19352.2-2003/ISO 14922-2:1999 thermal spraying process specification, such as prevention of deformation; arrangements for any production tests;
suitability of the working conditions for thermal spraying, including the environment. 12.3 Inspection and testing during thermal spraying
If necessary, during the thermal spraying process, the following inspections should be carried out at appropriate intervals or continuously: basic thermal spraying parameters (such as gas flow, spraying current, spraying voltage, moving speed); surface temperature;
correct use and handling of consumables;
-control of distortion/deformation;
any intermediate inspections, such as dimensional inspections.
12.4 Inspection and testing after thermal spraying
If necessary, after thermal spraying, inspections should be carried out according to relevant acceptance standards: visual inspection;
non-destructive testing in accordance with relevant standards;
destructive testing in accordance with relevant standards, such as GB/T8642; appearance, shape and size of sprayed components; results and records of pre-treatment or post-treatment, such as grinding and subsequent heat treatment. 12.5 Status of inspection and testing
The status of inspection and testing of thermally sprayed components shall be marked by appropriate means, for example, by item marking or process cards. 13 Nonconformities and corrective actions
Methods shall be taken to control items that do not meet the specified requirements to prevent them from being used unintentionally. When reworked and/or resprayed by the manufacturer, the applicable process shall be effective at all work points where this work is performed. When reworked or resprayed, each item shall be re-inspected, tested and accepted in accordance with the original requirements. Measures shall also be taken to ensure that conditions that are detrimental to the quality of thermally sprayed components are promptly identified and corrected.
14 Calibration
The manufacturer shall be responsible for the proper calibration of inspection, measuring and test instruments. All instruments used to evaluate the quality of thermally sprayed components shall be properly controlled and shall be calibrated at the specified period. 5 Identification and traceability
Identification and traceability shall be properly maintained throughout the manufacturing process. If necessary, the document system to ensure the identification and traceability of thermal spraying operations should include: production plan;
records of spraying locations on components;
coating markings, labels, etc.;
traceability of special coatings (for fully mechanized and automated spraying equipment including sprayers);
approval of sprayers and processes;
- non-destructive testing methods and personnel;
spraying consumables, such as type, batch number, etc.;
- base material.
5 Quality records
If necessary, the quality records that meet the contract requirements shall include:6
-Contract/design review records;
Material certificates;
-Consumables certificates;
-Thermal spraying process specifications;
Thermal spraying process approval test records;
-Thermal spraying personnel approval certificate;
-Non-destructive testing personnel certificate;
-Pre-treatment, post-treatment and process specification records;-Non-destructive testing and destructive testing processes and reports;-Dimensional reports,
Repair and re-thermal spraying records.
If there are no other provisions, quality records shall be kept for at least 5 years. GB/T 19352.2—2003/ISO 14922-2: 1999
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