Asking for e-coat inspection plan

X

xn58xn58

#1
Dear all,
I first time work with e-coating process. I hope anyone to provide me a process inspection plan, such as when to inspect, what stage to inspect, how frequent to inspect, what need to be inspected.etc.

Also, if you know the common drfects and root reasons, please also advise.

thank you very much.
 
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Jen Kirley

Quality and Auditing Expert
Staff member
Admin
#2
Hi xn58, welcome to The Cove! :bigwave:

An inspection process for e-coating is spelled out as a part of the overall quality control plan in manufacturing trailers in this document. Look in Section 4:

http://contracting.tacom.army.mil/comveh/ltt/ATPD 2171 R16Sep.doc

I am referencing you to a comprehensive example that you may find way too complex for your needs. That's fine, you can examine the document to see how the process is called out and apply the concept to your own needs.

Notice the plan identifies defect types and their criticality. It outlines, among other things: how many will be sampled, at what process points and to what standard (it points to tables within the document where MIL-specs are not called out) the output will be comforming to.

To some degree the coating's acceptance criteria are specifically called out in this sample document, but I also like to see samples of acceptance/rejectability at inspection stations. They can increase consistency in the inspection process and work to ensure the customer's wishes are conformed to precisely.

In the end, a document must be designed to fit your organization's QMS, product needs and design, extent of regulation and other considerations that you know and I do not. I hope this example gives you what you need to develop your own effective process plan.
 

Miner

Forum Moderator
Staff member
Admin
#3
xn58xn58 said:
Dear all,
I first time work with e-coating process. I hope anyone to provide me a process inspection plan, such as when to inspect, what stage to inspect, how frequent to inspect, what need to be inspected.etc.

Also, if you know the common drfects and root reasons, please also advise.

thank you very much.
If you have any contacts in automotive, they may be able to help. In a former life, I worked for a Tier 1 supplier to automotive. We first purchased, then e-coated internally weldments to automotive. Mazda had an excellent specification for e-coat testing.

I don't have access to a control plan anymore, but I can provide some from memory. First, your cleaning operations are critical. Temperature, dwell time, concentration of cleaner, cleanliness (conductivity) of rinse are a few.

In the coating process, total surface area to be coated, voltage (based on surface area), concentration, temperature, dwell time.

Bake process is basically time and temperature.

Some quality tests are salt spray corrosion, scratch test (test in heat zone areas if welded; use tape to test adhesion), visual (orange peel, color), thickness.

Coat rack design is critical. You need good conductivity to coat the correct thickness. If your parts are heavy, they can hang on the edge of a triangular cross-section hook. If they are light, there is atendency to float off when submerged, so you will need a springlike retainer. The hook/retainer will leave a mark, so these need to be located in a non-critical/visible area.
 
R

Randy Stewart

#4
Appearance was the biggest issue I can remember. Looking for drips, runs, even coverage, misses, etc. We also tested for coating thickness and adhesion.
 
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