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Iso 2063 2005

ISO 2063-2005 Thermal Spraying - Metallic and other inorganic coatings - Zinc, Aluminium and their alloys

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Mehmet Turaylar
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254 views20 pages

Iso 2063 2005

ISO 2063-2005 Thermal Spraying - Metallic and other inorganic coatings - Zinc, Aluminium and their alloys

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Mehmet Turaylar
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INTERNATIONAL ISO STANDARD 2063 Third edition 2005-03-01 re Thermal spraying — Metallic and other inorganic coatings — Zinc, aluminium and their alloys Projection thermique — Revétements métalliques of autres revétements inorganiques — Zinc, aluminium et alliages de ces métaux Reforonce number 180 2063:2005(E) © 180 2005 ISO 2063:2005(E) PDF disclaimer ‘This PDF fle may contain embedded typefaces. In accordance with Adobe's lensing policy, this fle may be printed or viewed but hall not be edted unless the typetaces which are embedded are leensed to and installed onthe computer performing the eating. In dowloading ths fle parties accept therein the responsibly of not infinging Adobe's loansing potcy. The ISO Contra Secretariat ‘accepts no lablity in ts ares [Adobe is a trademark of Adobe Systems Incorporated DDetals of the software products used to cxeeto this POF fle can ba found in the Gonoral Info relaive to the fle; the PDF-creation parameters were optimized for printing Every care has been taken to ensure that the files suitable for use by ISO member bodies. In ‘he unlikely event thal a problem relating to tis found please inform the Central Secretariat at the adcross given Dolow. 180 2005 All rights reserved. Unless otherwise specitied, no part ofthis publication may be reproduced of utlized in any form or by any means, tectonic oF mechanical, Including photocopying and microfilm without permission in wating ftom either ISO at the adaress below oF {50's member body inthe country ofthe requester 180 copyright office ‘Case postale 56 » CH-1211 Geneva 20 Tel +81 2274901 11 Fax +41 22 74909 47 Exmai copyrignt@iso org Web wr iso.org Published in Switzeriand ii © 150 2005 ~ Alights reserved ISO 2063:2005(E) Foreword SO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies) The work of preparing International Standards is normally carried out through ISO technical committees. Each member body interested in a subject for which a technical committee has boon established has the right to be represented on that committee. Intemational organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. [SO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization Intemational Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2 The main task of technical committees is to prepare Intemational Standards, Draft inteational Standards adopted by the technical committees are circulated to the member bodies for voting. Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote. ‘Attention is drawn to the possiblity that some of the elements of this document may be the subject of patent Tights. ISO shall not be helé responsible for identifying any or all such patent rights 1SO 2063 was prepared by the European Committee for Standardization (CEN) in collaboration with Technical Committee ISO/TC 107, Metallic and other inorganic coatings, in accordance with the Agreement on technical cooperation between ISO and CEN (Vienna Agreement). Throughout the text of this document, read “.this European Standard.." to mean “. this Intemational Standard...” This third edition cancels and replaces the second edition (ISO 2063:1991), which has been technically revised For the purposes of this International Standard, the CEN annex giving a list of EN documents corresponding to ISO documents mentioned as normative references has been removed (© 150 2008 ~ Attrights reserves ii Contents Scop Normative references ... Terms and definitions Manner of specifying requirements... Classification... 6 —— Manufacture... i See 641 Preparation of surfaces to be coated by thermal spraying .... 62 Coating metal... 63 Thermal spraying, 64 — Sealing 65 Painting 7 oR 74 Thickness . 7.2 Appearance 73 Adhesion. B Test methods..rsmrwnnnn 8.1 Measurement of thickness. 82 Adhesion test Annex A (informative) Adhesion test methods ....... Al Grid test... A2 Tensile test method Annex B (informative) Recommendations for US@ ..u...ninne Bibliography sso: msiinsmnns iv {© 180 2005 ~ All rights reserved ISO 2063:2005(E) Foreword This document (EN ISO 2063:2005) has been prepared by Technical Committee CEN/TC 240 “Thermal spraying and thermally sprayed coatings”, the secretariat of which is held by DIN, in collaboration with Technical Committee ISO/TC 107 "Metallic and other inorganic coatings”, This European Standard shal be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by September 2005, and conflicting national standards shall be withdrawn at the latest by September 2005 This document supersedes EN 22063:1993, ‘Annex A and B are informative. ‘This document includes a Bibliography According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, ireland, italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom 180 2008 ~ Al nghis reserved 180 2063:2005(E) Introduction Thermal-sprayed metallic coatings are produced by heating the coating metal to its molten stage and projecting it in a stream of gas onto the prepared surface to be coated It is essential that the purchaser specifies the coating metal or alloy and the thickness of the coating required: merely to ask for thermal metal spraying to be carried out in accordance with this standard, without this information, Is insufficient. Itis essential that the design of the article is such that it may be coated properly vi © 180 2008 ~All rights reserved 1SO 2063:2005(E) 1 Scope This standard applies to thermal-sprayed metallic coatings for the protection of iron and steel against corrosion by applying zinc or aluminium or their alloys to uncoated surface to be protected This standard deals with characteristic properties and gives test methods for coatings obtained by the spraying of Zinc and aluminium and their alloys for the general purpose of corrosion protection It gives firstly the definition, classification and symbols for these coatings in relation to their thickness It then deals with the preparation of surfaces, application of coatings and their characteristic properties: namely, thickness, appearance and adhesion Finally it gives test methods for checking these properties For other metals some of the provisions ere valid and can be adopted by agreement between the interested parties 2 Normative references The following referenced documents are indispensable for the application of this document For dated references, ‘only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN ISO 1463, Metallic and oxide coatings — Measurement of coating thickness — Microscopical method (iSO 1463 1982) EN ISO 2064:2000, Metallic_and other inorganic coatings — Definitions and conventions concerning the ‘measurement of thicknoss (ISO 2064 1996) EN ISO 2178, Non-magnetic coatings on magnotic substrates — Measurement of coating thickness — Magnetic method (ISO 21781982), EN ISO 8501-1, Preparation of steel substrates before application of paints and related products— Visual assessment of surface cleanliness — Part 1: Rust grades and preparation grades of uncoated stee! substrates and of steel substrates after overall removal of previous coatings (ISO 8501-1: 1988). EN ISO 1124-2, Proparation of stee! substrates before application of paints and related products — Specifications for metallic biast-cleaning abrasives — Part 2: Chilled-iron gn (ISO 11124-2:1993). EN ISO 11126-3, Preperation of stee! substrates before application of paints and related products — Specifications for non-metallic blast-cleaning abrasives — Part 3. Copper refinery slag (ISO 11126-3 1993}. EN ISO 11126-4, Preparation of stee! substrates before application of paints and related products — Specifications for non-metallic blast-cleaning abrasives — Part 4: Coal furnace slag (ISO 11126-4 1993) EN ISO 11126-7, Preparation of steel substrates before application of paints and related products — Specifications for non-metallic blast-cleaning abrasives — Part 7. Fused aluminium oxide (ISO 11126-7 1995) EN ISO 1294-1, Paints and varnishes — Corrosion protection of steel structures by protective paint systems — Part 1: General introduction (ISO 12944-11998) EN ISO 12944-2, Paints and varnishes — Corrosion protection of stee! structures by protective paint systems — Part 2: Classification of environments (ISO 12944-21998) EN ISO 12944-3, Paints and varnishes — Corrosion protection of stee! structures by protective paint systems — Part 3 Design considerations (ISO 12944-3:1998). {© 180 2008 ~All rights reserved 1 180 2063:2005(E) EN 180 12944-4, Paints and vamishes — Corrosion protection of steel structures by protective paint systems @ Part 4: Types of surface and surface preparation (ISO 1294-4: 1998). EN ISO 12944-5:1998, Paints and varnishes — Corrosion protection of steel structures by protective paint systems — Part 5: Protective paint systems (ISO 1294-5 1998) EN ISO 12944.6, Paints and varnishes — Corrosion protection of steel structures by protective paint systems — Part 6. Laboratory performance test methods (ISO 12944-6:1998) EN ISO 12944-7, Paints and vamishes — Corrosion protection of steel structures by protective paint systems — Part 7: Execution and supervision of paint work (ISO 12944-71998) EN ISO 12944-8, Paints and vamishes — Corrosion protection of steel structures by protective paint systems — Part 8: Development of specifications for new work and maintenance (ISO 12944- 8:1998) EN ISO 14919:2001, Thermal spraying — Wires, rods and cords for flame and arc spraying ~ Classification — Technical supply conditions (ISO 14919 2001) 3 Terms and definitions e For the purposes of this European Standard, the terms and definitions given in EN ISO 2064:2000 and the following apply. 34 significant surface part of the article covered or to be covered by the coating and for which the coating is essential for serviceability andlor appearance 32 minimum local thickness lowest value of the local thickness found on the significant surface of a single article 4 Manner of specifying requirements When specifying the coating of articles by thermal spraying in accordance with this standard, the purchaser shall state, in addition to the number of the standard, the significant surface of the metal coating and its thickness in accordance vith the symbols indeated in Tablet e 2 (© 150 2005 ~ Al rights reserved ISO 2063:2005(E) 5 Classification Tho zinc, aluminium or Zn-Al alloy coatings considered in this standard are classified in a scale according to their thickness, in conformity with the indications in Table 1 Table 1 — Classification of sprayed metal coatings Thermal spray material according to EN ISO 14919 Minimum local thickness (ume 50° 100 180 200 250 300° 299,99 199.5 AlMgS Znalt5 ——_—_1_ This classification gives a series of thickness values applicable to zino, aluminium and Zn-Al alloy coatings Intermediate values may be specified by agreement between the parties concerned. The symbol corresponding to each coating shall be composed of the symbol according to EN ISO 14919 followed by the minimum local thickness! In conformity with EN 150 2084 > Thicknesses requiring an agreement between the Interested partes notably on the spraying technique used to achieve uniformity of thickness, the use of paints or sealers and the test memods. © By special agreement between the interested parles, oreator minimum thicknesses may be Used ifthe coating cbtainad remains in ‘confonnity wih this stand }$ To speaty an alloy coating, te chemical symbol corresponding to EN ISO 14919 shall be followed by the minimum local thickness © @. a coating of 120 um consisting of thermal spray material sccorsing to ZnANTS alloy shall De speciied as (EN ISO 14919 ZnA\15) 120, he parentheses being essontal forthe denicaion ofthe alloy terms 6 Manufacture 6.1 Preparation of surfaces to be coated by thermal spraying’) ‘The surface shall be thoroughly cleaned and roughened by blasting using a suitable abrasive grit. Blasting shall be continued until the surface has a metallic appearance and uniform texture according to EN [SO 8501-1, grade Sa3 Immediately before spraying, the surface shall be dry and free from dust, grease, scale, rust and any contaminants In all cases, the roughness of the surface shall be verified by comparison with a reference surface having similar properties to the workpiece, prepared according to specifications agreed between the interested parties. Unless otherwise specified, one of the following abrasives shall be used in the preparation of the surface: — hematitc chilled cast iron grit according to EN ISO 11124-2; — copper refinery slag according to EN ISO 11126-3; 41) This subclause specifies the most important elements of surface preparation before thermal spraying of zine, aluminium and their alloys For more detailed specifications, itis facommonded to refer to EN 13507 {2 ISO 2008 - All rights reserved 3 Iso 2063:2005(E) — coal furnace slag according to EN ISO 11126-4; — aluminium oxide grit according to EN ISO 11126-7. In certain cases”, other abrasives may be used, by agreement between the interested parties, but with special precautions to achieve sufficient cleaniiness and roughness to ensure the adhesion of the sprayed material ‘The grit size of the abrasive is generally between 0,5 mm and 1,5 mm. The abrasive used, whatever its type, shall be clean, dry and not contaminated. In the case of abrasive blasting using compressed air, the air shall be sufficiently clean and dry to prevent contamination of the abrasive or the surface to be sprayed with metal 62 Coating metal ‘The thermal spray material of zine and zinc alloys or aluminium and aluminium alloys shall comply with EN ISO 14919, especially — 2m 99,99 according to EN ISO 14919:2001, 24; — 21 ANS according to EN ISO 14919:2001, 2.3; — A199,5 according to EN ISO 14919:2001, 3.2; — _AIMg8 according to EN ISO 14919:2001, 33 63. Thermal spraying ‘The thermal spraying shall be carried out after the surface has been prepared by abrasive blasting, within a period that ensures that the prepared surface is still clean, dry and not visibly oxidized, when spraying commences This time delay shall be as short as possible and typically less than 4 h, depending on local conditions. ‘Spraying shall not be carried out under conditions leading to condensation of humidity on the surface to be sprayed and the surface shall be maintained at a temperature of at least 3 °C above the dew-point to avoid blistering If deterioration of the surface to be coated is observed, any affected areas shall be prepared again to bring them to the required quality (see 61) 6.4. Sealing ‘The purpose of sealing is to reduce inherent porosity of the sprayed coating. Natural sealing can be achieved by oxidation of the metallic coating under normal environmental exposure conditions when resulting oxides, hydroxides endfor basic salts are not soluble in this environment. Artificial sealing can be achieved either by chemical conversion of the metallic coating surface (by phosphating, reactive painting, etc) or by applying an appropriate sealant to seal any porosity The sealant shall be applied before the coating can take up any moisture. 6.5 Painting Painting of sealed metallic coatings may be done either for aesthetic reasons or to extend the service life of the protective system. In the case of corrosion protection of steel structures the system and the paint system shall apply according to EN ISO 12944-5:1998, Table A 10. 2) In some countries, the use of dry siceous material is subject to statutory regulations 4 © 180 2005 ~ At nights reserved j 1S 2063:2005(E) For the execution of painting EN ISO 12944-1 to EN ISO 12944-8 shall be considered. 7 Required characteristics 7.1 Thickness 7.1.1 General Metallic coatings deposited by thermal spraying are defined by their minimum local thickness (see 3.2) The method of measurement, the number and distribution of the measurements over the whole surface area treated shall be done in accordance with 7.1.2 and 7 1 3, 7.1.2 Coatings with a surface area of between 1 cm’ and 1m In the case of coatings with a surface area of between 1 cm’ and 1m”, the local thickness at any given point shall be the arithmetic mean of three measurements distributed within an area of t cm* (see Figure 1) If the geometry of the component does not allow this, an appropriate reference piece shall be agreed between the ‘contacting parties, which shall be sprayed at the same time, using the some conditions and shall be measured by ‘metallographic or mechanical means. 1cm Figure 1 ~ Distribution of measurement points in the reference square centimeter 7.1.3 Coatings with a surface area greater than 1m” In the case of coatings with a surface area greater than 1 m?, the local thickness at any given point isthe thickness of the coating measured on a reference surface which shail be approximately 1 dm’ in area. The local thickness shall be the arithmetic mean of 10 measurements distributed over the reference square ecimetre in accordance with Figure 2 {© 10 2006 ~ Al rights reserved 5 Peet 180 2063:2005(E) Figure 2 — Distribution of measurement points in the reference square decimetre 7.4.4 Location of thickness test points “The measurement ofthe local thickness forthe purpose of determining the minimum characteristic thickness of tho @ coating takes place in practice at points at which the thickness of the coating is presumed to be at its lowest. These points, and their number, may be defined by agreement between the parties concemed and stipulated at the time of placing the order. It is recommended that these points should, wherever possible, be those specified in the product standards. In the absence of any agreement between the parties concemed, the choice of these points is left to the discretion of the customer 7.4.5 Methods of measurement ‘The measurement of thickness shall be made by magnetic measuring methods (see 8.1.2) which can be used in all cases, provided that specifications are observed conceming the number of measurements which shall be used to ‘obtain the arithmetic mean, In the case of dispute, use the micrographic cross-section method if this possible (see 8 1.3) 7.2. Appearance The surface of the coating shall be of uniform appearance, without blisters or bare patches, and free from non- ahoring metal and defects wit can be detimerta tothe serie Me and expected use ofthe protective coaing 7.3 Adhesion If at the end of the test according to annex A no separation from the parent metal or within the metallic coating has ‘occurred, the coating should be deemed to be satistactory The tonsilo adhesive strength should be determined according to A2 The minimum values of tensile adhesive strength shall be agreed between the contracting parties, 8 Test methods 8.1 Measurement of thickness 8.4.1 Field of application of the methods 8.4.1.1 Magnetic measurements have the advantage of being non-destructive, rapid and capable of being carried out directly at any point on the surface to be controlled. Furthermore, the nature of the coating (zinc, aluminium) sprayed onto a ferrous metal, and the values of the standard thicknesses, contribute to the 6 (© 180 2008 Al rights reserved 1S 2063:2005(E) achievement of satisfactory accuracy As a result, in conformity with the specifications of this standard and by agreement between the interested parties on the correct calibration of magnetic instruments for a given sample, magnetic measurements make it possible to carry out effective and accurate acceptance checks 8.1.1.2 The micrographic cross-section method used as a reference method for sprayed metallic coatings, is lifficult to perform correctly. Therefore, this method shall be used only after prior agreement between the interested parties, the test being made according to the requirements of 81 3 81.2 Magnetic measuring method The tests shall be carried out according to EN ISO 2178 8.1.3 Micrographic cross-section 8.1.3.4 Principle Microscopic examination of a cross section taken from a sample coating in accordance with EN ISO 1463 81.32 Comments {In order fo prevent the separation of the coating from the substrate and rounding of the edges, the test piece shall be mounted in an appropriate mounting material such as plastic or low melting point alloy. The surface to be examined shall be carefully polished with @ suitable material. Ten measurements shall be made, uniformly distributed along one of the sides of the test piece and covering approximately the 20mm length of the cross-section (object surface), and the arithmetic mean of these measurements shall be taken 8.2 Adhesion test The choice of the test method and its interpretation shall be carried out by agreement between the interested Parties. An explanation of the methods is given in annex A. (© 150 2005 All rights reserved 7 1S 2063:2005(E) eee Annex A e (informative) Adhesion test methods Al Grid test AA Principle Cutting through the coating to the parent metal to give a lattice pattem having squares of specified dimensions, No ‘separation of the coating should ocour. AA.2 Apparatus Couting ool with har point, fa type similar to that shown n Figure At ® A1.3 Procedure Using the tool (see A.1 2), cut a lattice with the dimensions given in Table A 1 Table A.1 — Lattice dimensions Thickness of coating verified um 16 mm x 15 mm $200 25 mm x 25 mm > 200 ‘The depth of the cuts should be such that the coating is cut through to the parent metal ‘Approximate surface covered by the lattice Wherever possible, after the lattice has baen cut, apply a sultable adhesive tape, agreed upon between the @ interested partes, to this part by means of a roller with a loading of 5 N. Then pul off the adhesive tape quickly and abruptly, ina direction perpendicular tothe surface If this is not possible, the method of scribing the coating should be agreed upon between the interested parties. 8 (© 180 2008 ~ All rights reserved ISO 2063:2005(E) Key a Side view b Front view Figure A.1 — Cutting tool A.2 Tensile test method A2.1 General requirements: Inconsistent results will be obtained unless a pneumatic or hydraulic tester, which ensure a pulling force truly normal to the surface, is obtained The coated substrate shall be sufficiently rigid to avoid flexing during testing. Choose a flat, level part of the test surface Remove any loose material from the test area A.2.2 Preparation of the Test Dolly The test dolly (pull stub) shall be cleaned either mechanicelly (abrasion) or chemically and degreased with clean Paper or textile moistened with an appropriate solvent such as alcohol. The face of the dolly shall be abraded or Toughened to improve the key. Epoxy-type adhesives require a coarse surface, acrylc-type adhesives work better with a smooth one, Place new silicon carbide paper on a flat and hard surface and rub the test surface of the test element firmly against the silicon carbide paper several times until the characteristic grey pure steel colour appears © ISO 2008 All rights reserves 9 ISO 2063:2005(E) With the micro-grooves the effective surface area is now many times larger than the nominal size of the test e ‘element, and this will strengthen the bond between the adhesive and the test element and reduce glue failure Unless there is reason to suspect new contamination such as from handling with bere hands, there is no need to degrease once more at this point A.2.3 Preparation of the coating ‘The inherent key in thermal sprayed coatings is normally sufficient to prevent glue failure without further pre- treatment. If required the metal coating could be slightly abraded with a grit paper to create more metal contact betwen dolly and coating and if contamination is suspected degreasing with clean paper or textile moistened with an appropriate solvent. A2.4 Applying adhesive The adhesive shall be able to form a stronger bond between the dolly and the coating than that at the coating substrale interface. It should be of high viscosity to prevent it seeping into the slightly porous metal spray. Otherwise, cover the coating with a wash primer to prevent the adhesive from penetrating to the substrate. Apply sufficient adhesive to the face of the dolly to cover it and also to fill the uneven surface of the sprayed metal Press the dolly by hand down onto the test surface and continue to apply pressure for about half a minute to expel ait and to even out the thickness of the adhesive Allow time for the adhesive to harden, A.2.8 Before stressing Unless specifically agreed between interested parties, carefully cut around the periphery of the dolly to remove excess adhesive and to penetrate to the substrate, Cutting eliminates the lateral bond within the coating but can introduce cracks, which then undermine the dolly, resulting in a lower breaking stress. A26 Stressing ‘Attach the adhesion tester carefully to avoid disturbing the adhesive under the dolly. Reset the indicator to zero Gradvally and smoothly increase the stress on the dolly (pull stub) until the bond breaks. This should be done no faster than 1 MPais [EN ISO 4624 < 90 s, < 1 MPals} A2.7 Assessment ‘Assess the area where the break in the coating occurred, ifit was adhesive or cohesive failure, if it was over the full or partial area Record the result, the thickness type of coating and if wash primer was used, the adhesive and adhesion tester, whether cut around the dolly or not, the name of the test operator. 10 © 150 2006 — Al rights reseed — ISO 2063:2005(E) oweD1dde OMSIOg ;apUOLUULOGEL YON = "YN os os oo oot 008 00h os os 13 uauiuosaua s00pUI ag oon ost

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