QUALITY CONTROL

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Alubond U.S.A PRODUCT QUALITY CONTROL TOP COIL, PROTECTIVE AND ADHESIVE FILMS: Thickness measurement Standard Test for Thickness Measurement of Aluminum Coils, Protective and Adhesive films (pre-process testing) Thickness measurement of: Painted aluminum coils (top and bottom): 0.2 to 0.5mm Adhesive film: 50-60µm Protective film: 80µm THICKNESS TEST: - THICKNESS MEASURED WITH MICROMETER LEAST COUNT AT 0.01mm. - DEVEATION SHOULD BE ±0.02mm

Micrometer


Alubond U.S.A PRODUCT QUALITY CONTROL TOP COIL: Coating thickness measurement ASTM B 244 Standard Test Method for Measurement of Thickness of Coatings on Aluminum with Eddy-Current Instruments (pre-process testing) With this method, coating thickness on aluminum substrate is measured. Coating thickness measuring is performed with ultrasonic thickness measuring device. Measuring unit is µm. For PVDF colors, ≥ 25 µm For PE colors, ≥ 16 µm COATING THICKNESS TEST - ASTM B244-79 - COATING THICKNESS MEASURED WITH NON FERRUS COATING THICKNESS GAUGE . - CLEAN THE SPECIMEN WITH CLOTH. - ENSURE THE INSTRUMENT AT TARE (0) POSITION WITH PLAIN ALUMINIUM OR MATCH WITH CALIBERATION PAD READING. - MEASURE THE COATING THICKNESS (µm) Coating thickness measurement with ultrasonic instrument


Alubond U.S.A PRODUCT QUALITY CONTROL TOP COIL: Color difference ASTM E 1347-06 Standard Test Method for Color and Color-Difference Measurement by Tristimulus Colorimetry (pre-process testing) The most direct and accessible methods for obtaining the color differences and color coordinates of object colors are by instrumental measurement using colorimeters or spectrophotometers with either hemispherical or bidirectional optical measuring systems. This test method provides procedures for such measurement by use of a colorimeter with either a bidirectional or a hemispherical optical measuring system. This test method is suitable for measurement of color differences of nonmetameric, nonparameric pairs of object-color specimens, or color coordinates of most such specimens. A further limitation to the use of colorimeters having hemispherical geometry is the existence of a chromatic integrating-sphere error that prevents accurate measurement of color coordinates when the colorimeter is standardized by use of a white standard. COLOR DIFFERENCE BETWEEN TOP COIL COLOR AND MASTER BATCH COLOR IS TESTED. THE COLOR DIFFERENCE OF METALLIC COLORS SHOULD BE ∆ E* ≤1, AND THE DIFFERENCE OF SOLID COLORS SHOULD BE ∆ E ≤0.6.

Visual comparison to be done using Visual Color Comparator.


Alubond U.S.A PRODUCT QUALITY CONTROL TOP COIL: Gloss measurement ASTM D 523 standard test method for specular gloss (pre-process testing) Gloss is related to surface capacity to radiate more light in particular directions than in other directions. Gloss measuring of particular color is done with glossmeter, which can have “geometry” of incident light 20⁰, 60 ⁰ and 85⁰. Single angle measurement (60⁰) is the most often used method for gloss measuring as it covers the widest range of values. Single angle measurement (20⁰) is used for measuring of gloss of very shiny surfaces, which has a gloss value, measured by single angle measurement of (60⁰) is greater than 70%. Single angle measurement (85⁰) is used for gloss measuring of surfaces, which possesses very low gloss and has a gloss value, measured by single angle measurement of (60⁰) is less than 10%. The gloss value is often determined by the customer requirement. Gloss value of the top coil should not be different from the gloss value of master batch. 60º GLOSS TEST- ASTM D 523-89 - GLOSS MEASURED BY 60º GLOSS METER - CLEAN THE SPECIMEN WITH CLOTH - CALIBERATE THE METER WITH EXISTING CALIBERATION PAD - MEASURE THE SPECIMEN GLOSS(%) Gloss measurement with gloss meter


Alubond U.S.A PRODUCT QUALITY CONTROL TOP COIL: Pencil hardness testing ASTM D 3363 standard test method for film hardness by pencil test (pre-process testing) The purpose is to provide a rapid, inexpensive method for determination of comparative scratch resistance and hardness of a coating on aluminum substrate. Pencil hardness is in range from very soft to very hard: Min HB And Max 2H For pencil hardness testing of the coating in ACP production, HB pencil is used. PENCIL HARDNESS TEST- ASTM D3363-92A : - STRIP THE WOOD FROM PENCIL GRADE HB MIN HARDNESS LEAVING A FULL DIAMETER OF LEAD EXPOSED TO A LENGTH OF 6cm. - FLATTEN THE END OF THE LEAD 90ยบTO PENCIL AXIS - HOLD THE PENCIL AT 45ยบWITH ROLLER TESTER AND PUSH FORWARD ABOUT 6cm USING AS MUCH DOWNWARD PRESSURE AS CAN BE APPLIED WITHOUT BREAKING THE LEAD. - NO SCRATCH MARK OR DE PAINTING ALLOWED Pencil hardness testing with HB pencil


Alubond U.S.A PRODUCT QUALITY CONTROL TOP/BOTTOM COIL: Coating flexibility Testing ASTM D 4145 Standard Test Method for Coating Flexibility of Prepainted Sheet (pre-process testing) This test method describes a procedure for determining the flexibility and adhesion of coatings (paints) on metallic substrates that are deformed by bending when the sheet is fabricated into building panels or other products. The metal substrate must be capable of passing this test without fracturing and with no excessive grain development. A sample of coil is folded to 180⁰, and after that, no cracks or coating peel-off should be visible. Coated coil is folded couple of times at the same side (temper). It is counted, when crack or peel-off has occurred. T-BEND TEST IN WHICH THE COATED SPECIMEN IS BENT AROUND ITSELF: - BEND THE TEST SAMPLE IN 180º - REPEAT THE TEST UNTIL 3 –TIMES - THERE SHOULD BE NO CRACK/NO ADHESION LOSS ON PAINT

T-Bend Test in Which the Coated Specimen is Bent Around Itself


Alubond U.S.A PRODUCT QUALITY CONTROL TOP COIL: Coating adhesion Testing ASTM D 3359 Standard Test Methods for Measuring Adhesion by Tape Test (pre-process testing) These test methods cover procedures for assessing the adhesion of coating films to metallic substrates by applying and removing pressure-sensitive tape over cuts made in the film. Aim is to establish whether the adhesion of a coating to a substrate is at a generally adequate level. If a coating is to fulfill its function of protecting or decorating a substrate, it must adhere to it for the expected service life. Because the substrate and its surface preparation (or lack of it) have a drastic effect on the adhesion of coatings, a method to evaluate adhesion of a coating to different substrates or surface treatments, or of different coatings to the same substrate and treatment, is of considerable usefulness in the industry. The limitations of all adhesion methods and the specific limitation of this test method to lower levels of adhesion should be recognized before using it. DRY ADHESION TEST- ASTM D 3359-02 - MAKE 11 PARALLEL CUTS ,1mm APART THROUGH FILM - MAKE SIMILAR CUTS AT 90ยบ TO AND CROSSING THE FIRST 11 CUTS (USE CROSS HATCH TOOL) - APPLY TAPE 20mm WIDE OVER AREA OF CUTS BY PRESSING DOWN FIRMLY AGAINST THE COATING - SHARPLY PULL THE TAPE OFF AT RIGHT ANGLE TO PLAN OF THE SURFACE BEING TESTED

Dry adhesion Test


Alubond U.S.A PRODUCT QUALITY CONTROL TOP COIL: Impact testing ASTM D 2794 Standard Test Method for Resistance of Organic Coatings to the Effects of Rapid Deformation (Impact) (pre-process testing) This test method covers a procedure for rapidly deforming by impact a coating film and its substrate and for evaluating the effect of such deformation. The purpose is to determine color resistance to impact. After impact, no cracks or peel-off should be visible. Coatings attached to substrates are subjected to damaging impacts during the manufacture of articles and their use in service. In its use over many years, this test method for impact resistance has been found to be useful in predicting the performance of organic coatings for their ability to resist cracking caused by impacts. IMPACT TEST: - PLACE THE 1 KG LOAD AT HEIGHT 50CM - PLACE THE SPECIMEN TO BE TESTED AT BOTTOM OF THE IMPACT TESTER - DROP THE LOAD - THERE SHOULD BE NO CRACK/ NO PAINT PEEL OFF Coating impact resistance testing


Alubond U.S.A PRODUCT QUALITY CONTROL TOP/BOTTOM COIL: Methyl Ethyl Ketone Testing ASTM D 4752 Standard Practice for Assessing the Solvent Resistance of Coatings Using Solvent Rubs (pre-process testing) Its purpose is to determine the resistance degree of coating on Methyl Ethyl Ketone, which presents the hardest solvent for organic colors. After a particular number of double rubs, the color should not be removed from aluminum substrate. PVDF colors should not be removed from the substrate after 100 double rubs PE colors should not be removed from the substrate after 50 double rubs SOLVENT RESISTANCE TEST -ASTM D 4752 - CLEAN THE SPECIMEN WITH CLOTH - RUB MEK WITH SPONGE AT EVEN PRESSURE TO FORWARD DIRECTION ABOVE THE PAINTED SURFACE. - REPEAT THE ABOVE AT REVERSE DIRECTION - REPEAT THE ABOVE PROCEDURE 100 TIMES. - THERE SHOULD BE NO ADHESION LOSS

Solvent Rub Tester


Alubond U.S.A PRODUCT QUALITY CONTROL LDPE: Melt index ASTM D 1238 Standard Test Method for Melt Flow Rates of Thermoplastics by Extrusion Plastometer (pre-process testing) Melt index is defined as polymer mass which flows through capillary at particular pressure and temperature, during 10min. (Capillary diameter, pressure and temperature are defined in the ASTM D 1238). Melt index of granules is determined in Melt flow index tester and the value of melt index should be within the following limits: 0.2-1.5 g/10 min MELT FLOW INDEX TEST - ASTM D 1238 - SET THE MFI MACHINE TEMP 190ยบC. - COLLECT & PUT THE LDPE SAMPLES IN TO THE EXTRUDER - APPLY THE LOAD 2.16 kg OVER THE PISTON - AFTER 10 min COLLECT THE LDPE & MEASURE THE WEIGHT - THE MFI SHOULD BE 0.1-2.0 g/10 mins Melt index determination

Balance


Alubond U.S.A PRODUCT QUALITY CONTROL ADHESIVE FILM/TOP/BOTTOM COIL: Peel strength testing ASTM D 903 Standard Test Method for Peel or Stripping Strength of Adhesive Bonds (process testing) Lamination test is performed in process every 30 min. Testing is performed with portable instrument. The load is measured then, in kg, and the adhesion force is calculated (N/mm) –Newton at mm of sample width (load (kg)*9.81 N/kg) : 25mm. Testing is performed at the sample of 25mm width and length equal to panel width. If skin thickness is 0.50mm, minimal peel strength have to be 7 N/mm with cohesive failure. If skin thickness is 0.30mm, minimal peel strength have to be 5 N/mm with cohesive failure. 180º PEEL OFF - ASTM D-903: - CUT 25 mm WIDE PANEL AS PER REQUIRED LENGTH - PEEL THE TOP SKIN FOR 1 cm LONG & HOLD WITH GRIP CLAMP FIRMLY - PEEL OFF THE SKIN WITH UTM AT 180º-152.4mm/ min RATED SPEED. - REPATED THE ABOVE PROCEDURE FOR BOTTOM SKIN ALSO - THERE SHOULD BE NO ADHESION LOSS Universal Peel off Tester

Peel strength test (180⁰)


Alubond U.S.A PRODUCT QUALITY CONTROL ADHESIVE FILM/TOP/BOTTOM COIL: Boiling water test ASTM D 3359 Standard Test Methods for Measuring Adhesion by Tape Test (final product testing) The purpose is to simulate the real environment, with boiling water during 2h. It is performed with each coil change. After 2h: no color change on the coating, checking adhesion with cross hatch cutter, and check lamination of all corners of both top and bottom coil. BOILING WATER TEST: - BOIL THE ACP SPECIMEN WITH DISTILLED WATER AT 100ยบC- 2 HRS - THERE SHOULD BE EVEN BONDING WHILE DELAMINATE THE SKIN - THERE SHOULD BE NO PAINT ADHESION LOSS WHILE CROSS HATCH

Boiling water test equipment


Alubond U.S.A PRODUCT QUALITY CONTROL PROTECTIVE FILM: Oven testing ASTM D 3359 Standard Test Methods for Measuring Adhesion of Protectiv film by Drying Oven (final product testing) Samples of the final product are tested in the oven during 2h, at 80⁰ and during 24h, at 50⁰. That is the way of simulating real environment, heat influence on the protective film and panel. Protective film should remain smooth, without waves, bubbles and wrinkles. No glue traces on coating are allowed. No print traces on coating are allowed. OVEN TEST: - SET THE OVEN TEMP TO 80ºC - PLACE THE SAMPLE ACP SPECIMEN IN THE OVEN - TEST UPTO 24 HRS AT SAME CONDITION - AFTER 24 HRS CHECK IF ANY DELAMINATION OR NOT - IF NOT THE PRODUCT GET QUALIFIED.

Drying Oven


Alubond U.S.A PRODUCT QUALITY CONTROL LDPE: T-bending test ASTM D 4145 Standard Test Method for Coating Flexibility (final product testing) Testing is performed on sample of final product. Sample is bended at both directions many times, and no breaking is allowed with LDPE core. T-BEND TEST: - BEND THE TEST SAMPLE IN 180º - REPEAT THE TEST UNTIL 3 –TIMES - THERE SHOULD BE NO CRACK/NO ADHESION LOSS ON PAINT


Alubond U.S.A PRODUCT QUALITY CONTROL TOP COIL AND FINAL COMPOSITE PANEL: Corrosion Resistance AAMA 620 Standard Test Method for Salt Spray Resistance (pre-process and final product testing) This Standard is related to test procedures and requirements for high performance coatings applied to metal (aluminum, stainless steel, bronze etc.) coil substrates for architectural use. It covers factory-applied coil coatings only. Its purpose is to assist the architect, owner and contractor to specify and obtain factory-applied coatings, which will provide and maintain a superior level of performance in terms of film integrity, exterior weather ability, and general appearance over a period of many years. SALT SPRAY RESISTANCE TEST: - SCORE THE FILM SUFFICIENTLY DEEP TO EXPOSE THE BASE METAL USING A SCRIBING TOOL - EXPOSE THE SAMPLE FOR 3,000 HOURS USING A FIVE PERCENT SALT SOLUTION - REMOVE AND WIPE SAMPLE DRY - IMMEDIATELY APPLY TAPE (PERMACEL 99 OR EQUIVALENT) 20 MM (3/4 IN) WIDE TAPE OF SUFFICIENT SIZE TO COVER THE SCORED AREA) BY PRESSING DOWN FIRMLY AGAINST THE COATING TO ELIMINATE VOIDS AND AIR POCKETS - SHARPLY PULL THE TAPE OFF AT A RIGHT ANGLE TO THE PLANE OF THE SURFACE BEING TESTED


Alubond U.S.A PRODUCT QUALITY CONTROL TOP COIL AND FINAL COMPOSITE PANEL: Weathering Resistance AAMA 620 Standard Test Method for Weathering Resistance (final product testing) This Standard is related to test procedures and requirements for high performance coatings applied to metal (aluminum, stainless steel, bronze etc.) coil substrates for architectural use. It covers factory-applied coil coatings only. Its purpose is to assist the architect, owner and contractor to specify and obtain factory-applied coatings, which will provide and maintain a superior level of performance in terms of exterior weather ability, and general appearance over a period of many years. The coating shall maintain its film integrity and as a minimum meet the following color retention (D 224489), chalk resistance (D 4214-89), gloss retention (D 523-89) properties. The architect, owner, or contractor should request data relative to the long-term durability of the color(s) selected. Exposure panels must be made available to the architect or owner upon request.

UV Accelerated Weathering Tester


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