Ebook Powder Coating

PQ-7002-0
ASHOK LEYLAND LIMITED ALS.268.03

STANDARD Issue No: 04
Date: 10.12.2013
SURFACE PROTECTION
REQUIREMENTS Sheet: 1 of 27
` CONTENTS
1.0 Purpose 2
2.0 Scope 2
3.0 Component Classification 3
4.0 Coating Technologies 8
5.0 Testing
5.1 General Test Conditions 17
5.2 Sampling 17
5.3 Test Methods
5.3.1 Coated Surface Appearance 18
5.3.2 Dry Film Thickness 18
5.3.3 Adhesion 18
5.3.4 Resistance to Solvents 19
5.3.5 Resistance to UV Light Alternating with Humidity 20
5.3.6 Resistance to Humidity 22
5.3.7 Surface Flow / DOI 23
5.3.8 Erichsen Cupping Resistance 24
5.3.9 Impact Resistance 25
5.3.10 Acid Resistance 26
5.3.11 Alkali Resistance 26
5.3.12 Water Resistance 27
6.0 Agreement of Inspection 27
7.0 References 27
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SURFACE PROTECTION
1. PURPOSE:`
This standard is to provide comprehensive corrosion protection requirements for all the
components that require surface protection to meet the performance and aesthetic
requirements.
This standard classifies the components based on location, functionality and degree of
corrosion protection required.
This standard also provides guidelines for acceptance test for different coating
processes and indicative processes that can be used for protecting surfaces from
deteriorating effects of environment (corrosion and weathering).
2. SCOPE:
The standard classifies the corrosion protection requirements based on location,
functional and aesthetic requirements.
The standard is applicable to all bought out components, components manufactured in

house and surface treated at vendor locations.
Scope of this standard includes all metallic parts covered in section 3 of this standard.
Special requirements not covered in the standard will be mentioned in the respective
part drawing.
Scope of this standard is to specify corrosion protection requirements and acceptance

test requirements. The standard provides guidelines on possible processes that can meet
the end requirements. The process recommendations outlined in standard are indicative
in nature
Zinc Aluminum Flake (ZAC) coating technology is referenced with the appropriate
ALS Number.
The Coatings used should be free from Hazardous substances and must contain less
than 0.1% lead (Pb), mercury (Hg), hexavalent chromium (Cr6+), polybrominated
biphenyls (PBB), and polybrominated diphenylethers (PBDE), and less than 0.01%
cadmium (Cd).
The process shall be validated by CQE / CQ - TPH for process approval. At the time of
production part approval, the AL approved surface coating vendor has to submit
detailed Control plan & other validation reports to CQE / CQ - TPH.
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3. COMPONENT CLASSIFICATION:
Based on the position and degree of corrosivity, the components / parts comprising the
truck are classified as under.
Degree of
Degree of corrosion
S.No. Level Position Weathering List of Parts
protection required
Resistance required
High (Min 250h – Cab BIW
Directly Exposed
High (Min 1000h as Gloss Retention ≥ panels &
1 CLASS A & Aesthetically
per ASTM B117) 85%, No Chalking, Exterior Parts,
appealing
No film cracking) Loadbody
Interior parts that
Cab Interior
will be visible to
Surface items,
customers after High (Min 800h as Low (Min 200h –
2 CLASS B Cab Threaded
opening of per ASTM B117) No Chalking, No
parts &
closures. Eg. film Cracking)
metallic trims
Glove Box
Moderate (Min Medium (Min 200h
Direct Exposure & Chassis FSM,
300h / 336hrs**as – Gloss Retention ≥
3 *CLASS C aesthetically less Underbody
per ASTM B117) 85%, No Chalking,
appealing Parts
No film cracking)
Pipings,
Adaptors,
Indirect Exposure
Moderate (Min Low (Min 200h – Clamps,
& No UV
4 CLASS D 300h / 336hrs**) as No Chalking, No Chassis & Cab
resistance
per ASTM B117 film Cracking) Fasteners,
requirement
Exhaust Pipes
Engine Parts
* - Unless Otherwise Specified, Color of Class C Components: Black to RAL 9005

Individual & Specific Color Requirements if any will be provided in drawing.
(eg: Scamic Green for Army Vehicles)
** - Class C& D components to meet min 336hrs of SSR for products covered by
Urban Bus Spec-II (Apr 2013) of Ministry of Urban development, Govt. of India
The Indicative part list for each of the above class is given here.
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SURFACE PROTECTION
CLASS A – CAB EXTERIOR PARTS – INDICATIVE PART LIST
S.No Description Type

1 Cab Exterior Panels / Cab BIW shell Sheet Metal
2 Grille Sheet Metal
3 Bumper Sheet Metal
4 FES Sheet Metal
5 Bracket – Pedal Support Sheet Metal
6 Pedals Sheet Metal
7 Foot Step Sheet Metal
8 * Loadbody Sheet Metal
Possible Process Recommendations for Class A:
1. Pretreatment followed by Cathodic Electrodeposition (CED) & Topcoat as per

4.2
2. Pretreatment followed by Autophoretic Coating followed by Powder Topcoat as
per 4.4
3. * - Pretreatment followed by Painting as per 4.6 – Coating Loadbody Interiors
with Polyurea coating is optional for Superior Abrasion Resistance.
CLASS B – CAB INTERIOR & METALLIC TRIM – INDICATIVE LIST

1 Cab Threaded parts Steel
2 Front Panel – Instrument Cluster Sheet Metal
3 Steering Column
4 Steering Mounting U Clamp
5 Fog lamp Mounting Bracket
6 DAT Cap, Fuel Tank Cap
Possible Process Recommendations for Class B:

1. Pretreatment followed by Cathodic Electrodeposition (CED) as per 4.1
2. Zinc Aluminum Flake Coating (ZAC) as per ALS.268.02
3. Pretreatment followed by Autophoretic Coating as per 4.4
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CLASS C – CHASSIS PARTS – INDICATIVE LIST
S.No DESCRIPTION Type

1 Frame Side Member Sheet Metal
2 Passenger Cowl Sheet Metal
3 Bumper Mounting Bracket Sheet Metal
4 Warning Triangle Mounting Bracket Sheet Metal
5 Air cleaner mounting Bracket Sheet Metal
6 Battery Carrier Sheet Metal
7 Cross member Sheet Metal
8 Antisag member Sheet Metal
9 CSO mounting Bracket Sheet Metal
10 Fuel Filter mounting Bracket Sheet Metal
11 Radiator side mounting Bracket Sheet Metal
12 RUPD, SUPD & FUPD Sheet Metal
13 Spare Wheel Carrier Sheet Metal
14 Tie bar Sheet Metal
15 Tail Pipe mounting Bracket Sheet Metal
16 Shock absorber mounting Bracket Sheet Metal
17 Tail lamp Mounting Bracket Sheet Metal
18 Fuel tank Sheet Metal
19 Fuel Tank Strap, Chassis straps Sheet Metal
20 Silencer Mounting Bracket Sheet Metal
21 Control tube Sheet Metal
22 Flick valve Mounting Bracket Sheet Metal
23 Water Separator Mounting Bracket Sheet Metal
24 DDU Mounting Bracket Sheet Metal
25 Helper spring Bracket Sheet Metal
26 Wheel Disc Sheet Metal
27 * Rear Axle Casing Sheet Metal
28 * Propellor Shaft Tube Sheet Metal
29 * Leaf Springs Sheet Metal
30 Radius Rod Tube Sheet Metal
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31 `
Drag Link Sheet Metal
32 Metal Adblue Tank Sheet Metal
33 Adblue Tank Bracket Sheet Metal
34 Flitch Sheet Metal
35 Hub Cap Sheet Metal
36 5th Wheel Coupling Sheet Metal
37 Wheel Arch Mounting Bracket Sheet Metal
38 Axle Arm Forging
39 Control Lever Forging
40 CSO Knuckle Forging
41 Spring Top seat Forging
42 Steering Lever Forging
43 Track Rod Lever Forging
44 Bell Crank Lever Forging
45 Axle Beam Forging
46 Propellor Shaft Joints Forging
47 Drop Arm Forging
48 * Radius Rod Eye End Forging
49 Cab Mounting Bracket Casting
50 Engine Mounting Bracket Casting
51 Spring Bracket Casting
52 Spring Shackle Casting
53 Thermostat Housing Casting
54 Wheel Hub Casting
55 Torque Plate Casting
56 Steering Gear Box Casing Casting
57 Bus Structures(visible areas) Sheet metal
Possible Process Recommendations for Class C:

1. Pretreatment followed by Cathodic Electrodeposition (CED) & Topcoat as per
4.2
2. Pretreatment followed by Autophoretic Coating & Powder Topcoat as per 4.4
3. Pretreatment followed by Powder Coating as per 4.5
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4. Pretreatment followed by Painting as per 4.6
* - For Proprietary parts, suitable coating to be selected by the part vendor to

meet this specification for class C in concurrence with PD – MED.
Machined surfaces are excluded and they need to be protected against Rust
using Rust preventive oil or other suitable method.
CLASS – D – INDICATIVE LIST

1 Hose Clamps Sheet Metal
2 Hose / Tube End Fittings Sheet Metal
3 Adaptors Sheet Metal
4 Clips Sheet Metal
5 Jaw End Bar Machining
6 U Bolt Bar Machining
7 Exhaust Pipes Aluminized Steel
8 Exhaust Flange Sheet Metal
9 Cab, Engine, Chassis- Fasteners Steel
Compressor, steering, Radiator &
10 CAC pipes etc, (ID & OD) both sides Steel
11 Tailpipe Sheet Metal
12 Radiator Piping Steel
13 CP Lever Forging
14 * Engine Parts (includes Proprietary)
15 Spacer, Distance Piece, Wedge Plate Sheet Metal
16 Anchor Bracket Sheet Metal
17 Bus structures (not visible parts) Sheet Metal
18 Bracket in Buses(not visible parts) Sheet Metal
Possible Process Recommendations for Class D:

1. Pretreatment followed by Cathodic Electrodeposition (CED) as per 4.1
2. Pretreatment followed by Autophoretic Coating as per 4.3
3. Zinc Aluminum Flake Coating (ZAC) as per ALS.268.02
4. Pretreatment followed by Powder Coating as per 4.5
5. Pretreatment followed by Painting as per 4.6
* - For Proprietary parts, suitable coating to be selected by the part vendor to

meet this specification for class D in concurrence with PD – MED.
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Machined` surfaces are excluded and they need to be protected against Rust
using Rust preventive oil or other suitable method.
4. COATING TECHNOLOGIES:
4.1 PRETREATMENT FOLLOWED BY CATHODIC
ELECTRODEPOSITION CED)
PROCESS OVERVIEW:
The process starts with a Pretreatment phase followed by dipping in Cathodic
Electrodeposition bath and baking. In case of HR material, Offline Acid Pickling / Shot
blasting may be done to remove mill scale
TEST PARAMETERS TO BE CHECKED ON FINISHED PART:
S.No Property Test Acceptance Criteria Test Method

1 Coated Surface Appearance The coated surface shall be free from 5.3.1
running, crawling, solvent popping, pin
holes and water drop traces
2 Dry Film Thickness (DFT) As agreed between AL & Vendor 5.3.2
3 Gloss As per master sample Visual
Observation
4 Color Difference As per master sample Visual
Observation
5 Adhesion In a 10 x 10 square lattice 5.3.3
• No Exfoliation along a straight
line
• No Square broken upto 50% of
the area.
6 Resistance to Solvents (30% No Surface Alterations are allowed 5.3.4
Toluene & 70% Isooctane)
7 Corrosion Resistance (Hrs as Edge Masked & Dent Free Panel ASTM
per Component - No Corrosion / Red Rust B117
Classification) - No Blistering
- Underpellicular Corrosion ≤
2mm
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` Edge masked and damage free

component, the following are not
allowed:
- Corrosion focuses on weld
junctions and surfaces in general
- Blistering.
- Underpellicular corrosion ≤
2mm
On Box-type surfaces:
- No ferrous corrosion focuses on
the walls.
8 Resistance to UV light Chalking & Film Cracking not allowed. 5.3.5

alternating with Humidity
(Hrs as per Component
Classification)
Irradiance: 0.47 Watt/m2/nm
9 Resistance to Humidity No Film removal and blistering is 5.3.6
(800h at 40°C) allowed. Min 80% of Adhesion should
be retained
10 Impact Resistance (Ball Dia No Paint Film Crack & Exfoliation. 5.3.9
– ½”, Weight – 500g
Height – 50 cm)
11 Acid Resistance (0.1N No Surface defect on the film after 5.3.10
H2SO4 Soln.) – 20±2ºC / 8h washing with DM water
12 Alkali Resistance (0.1N No Surface defect on the film after 5.3.11
NaOH Soln.) – 20±2ºC / 8h washing with DM water
13 Water Resistance (40ºC / No Surface defect on the film. Shall 5.3.12
240h) pass Adhesion at 2mm Square
4.2 PRETREATMENT FOLLOWED BY CED & TOPCOAT
PROCESS OVERVIEW:
The process starts with a Pretreatment phase (that includes Phosphating) followed by
dipping in Cathodic Electrodeposition bath, baking and followed by topcoat application
& baking. The topcoat could be a Polyester or Polyurethane system. In case of HR
material Offline Acid Pickling / Shot blasting may be done to remove mill scale
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The topcoat is`provided so as to provide Weathering Resistance, Scratch Resistance for

Aesthetic surfaces.

running, crawling, solvent popping, pin
holes and water drop traces
Observation
4 * Instrumented Gloss @ 60° Mutual agreement between AL & Glossmeter
Customer
Observation
6 *Instrumented Color dE < 1 SAE J1545
Difference
7 Adhesion No film notches or liftings in the square 5.3.3
(10 x 10 squares) lattice are allowed
8 Resistance to Solvents (30% No Surface Alterations are allowed 5.3.4
9 Corrosion Resistance (Hrs as Edge Masked & Dent Free Panel ASTM
per Component - No Corrosion / Red Rust B117
2mm
Edge masked and damage free

allowed:
- Slight Corrosion focuses on weld
junctions and surfaces in general
- Slight Blistering.
2mm
No ferrous corrosion focuses on the
walls.
10 Resistance to UV light - Chalking & Film Cracking not 5.3.5
alternating with Humidity allowed.
PQ-7002-0
Date: 10.12.2013
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(Hrs` as per Component - Gloss Variation ≤ 15%

Classification) - No Color Variations are allowed.
Irradiance: 0.47 Watt/m2/nm
(168h at 40°C) allowed. Min 80% of Adhesion should
be retained
12 Pencil Hardness Min HB Pencil
Hardness
Tester
13 *Surface Flow (DOI) ≥ 0.6 5.3.7
measured on vertical
surfaces
14 *Erichsen Cupping No cracks upto 5mm indentation. 5.3.8
* - Tests Applicable for Cab parts / panels
4.3 PRETREATMENT FOLLOWED BY AUTOPHORETIC COATING
PROCESS OVERVIEW:
The process starts with a pretreatment phase that may include Alkaline Spray &
Immersion Cleaning followed by Plant & DI Water Rinsing and is followed by Auto
deposition with Autophoretic 800 series Coating Chemical followed by Plant Water &
Reaction Rinsing followed by Curing in Oven. Autophoretic 800 series Coating
Chemical isn’t over-coatable.
Autophoretic coating is a proprietary technology from M/s Henkel and as such the
above process overview is indicative. In case of HR material, Offline Acid Pickling /
Shot blasting may be done to remove mill scale.

1 Coated Surface Appearance The coated surface shall be free 5.3.1
from running, crawling, solvent
popping, pin holes and water
drop traces
2 Dry Film Thickness (DFT) As agreed between AL & 5.3.2
Vendor
Observation
Observation
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5 `
Adhesion In a 10 x 10 square lattice 5.3.3
• No Exfoliation along a
straight line
• No Square broken upto
50% of the area.
6 Resistance to Solvents (30% No Surface Alterations are 5.3.4
Toluene & 70% Isooctane) allowed
7 Corrosion Resistance as per Edge Masked & Dent Free Panel ASTM B117
(Hrs as per Component - No Corrosion / Red Rust
- Underpellicular
Corrosion ≤ 2mm

allowed:
- Corrosion focuses on
weld junctions and
surfaces in general
- Blistering.
- Underpellicular corrosion
≤ 2mm
- No ferrous corrosion
focuses on the walls.
8 Resistance to UV light Chalking & Film Cracking not 5.3.5

alternating with Humidity allowed.
(Hrs as per Component
Classification)
9 Resistance to Humidity No Film removal and blistering 5.3.6

(168h at 40°C) is allowed. Min 80% of
Adhesion should be retained
4.4 PRETREATMENT FOLLOWED BY AUTOPHORETIC COATING &

POWDER TOP COAT
PROCESS OVERVIEW:
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The process starts with a pretreatment phase that may include Alkaline Spray &
Immersion Cleaning followed by Water Rinsing and is followed by Autodeposition
with Autophoretic 900 series Coating Chemical followed by Plant Water & Reaction
Rinsing followed by Curing in Oven. After Autophoretic coating, the part to be powder
coated with Pure Polyester based powder.
Autophoretic coating is a proprietary technology from M/s Henkel and as such the
above process overview is indicative. In case of HR material, Offline Acid Pickling /
Shot blasting may be done to remove mill scale.
The topcoat is provided so as to provide Weathering Resistance, Scratch Resistance for

Aesthetic surfaces.

from running, crawling, solvent
popping, pin holes and water
drop traces
2 Dry Film Thickness (DFT) As agreed between AL & 5.3.2
Vendor
Observation
4 Instrumented Gloss @ 60° Mutual Agreement between AL Glossmeter
and Customer
Observation
6 Instrumented Color dE < 1 SAE J1545
Difference
straight line.
50% of the area.
9 Corrosion Resistance (Hrs as Edge Masked & Dent Free Panel ASTM B117
per Component - No Corrosion / Red Rust
- Underpellicular
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` Corrosion ≤ 2mm

allowed:
weld junctions and
surfaces in general
- Blistering.
≤ 2mm
10 Resistance to UV light - Chalking & Film 5.3.5

alternating with Humidity Cracking not allowed.
(Hrs as per Component - Gloss Variation ≤ 15%
Classification) - No Color Variations are
Irradiance: 0.47 Watt/m2/nm allowed.

4.5 PRETREATMENT FOLLOWED BY POWDER COATING
PROCESS OVERVIEW:
The process starts with the pretreatment phase that could either be Shotblasting and/ or
Degreasing, Acid Pickling (If necessary), Surface Activation and Phosphating,
Passivation and is followed by Powder coating with Pure Polyester powder and baking.
If Shotblasting is to be followed by Pretreatment process, Acid Pickling step could be
eliminated.

from sagging, crawling, pin
holes , blisters, uncoverage etc.
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2 Dry`Film Thickness (DFT) 60 ± 10µm 5.3.2

3 Gloss @ 60º 50 – 60 Gloss-o-meter
Observation
straight line.
50% of the area.
- Underpellicular
Corrosion ≤ 2mm

allowed:
weld junctions and
surfaces in general
- Blistering.
≤ 2mm
8 Resistance to UV light - Chalking & Film 5.3.5

alternating with Humidity Cracking not allowed.
allowed.

10 Erichsen Cupping No cracks upto 5mm 5.3.8
indentation.
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11 ` Resistance (Ball Dia

Impact No Film Crack & Exfoliation.
– ½”, Weight – 500g
Height – 50 cm)
12 Pencil Hardness Min HB Pencil Hardness
Tester
13 Acid Resistance (0.1N No Surface defect on the film 5.3.7
H2SO4 Soln.) – 20±2ºC / 8h after washing with DM water
14 Alkali Resistance (0.1N No Surface defect on the film 5.3.8
NaOH Soln.) – 20±2ºC / 8h after washing with DM water
15 Water Resistance (40ºC / No Surface defect on the film. 5.3.9
240h) Shall pass Adhesion at 2mm
Square
16 Scratch Hardness (Min No Film Peel-off ASTM D1474
3000g)
4.6 PRETREATMENT FOLLOWED BY PAINTING WITH PRIMER /

PRIMER & TOPCOAT
PROCESS OVERVIEW:
The process starts with the pretreatment phase that could either be Shotblasting and/ or
Degreasing, Acid Pickling (if necessary), Surface Activation and Phosphating,
Passivation and is followed by Epoxy or Polyurethane primer followed by Polyester /
Acrylated Alkyd / Polyurethane topcoat / Alkyd Amino application.
Any other painting system proposed will be included after validation by AL-MED /
TPH / CQE.

running, crawling, solvent popping,
pin holes and water drop traces
3 Gloss As per master sample Visual Observation
4 Color Difference As per master sample Visual Observation
straight line.
• No Square broken upto 50%
of the area.
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6 Resistance to` Solvents (30% No Surface Alterations are allowed 5.3.4

2mm

allowed:
- Corrosion focuses on weld
junctions and surfaces in
general
- Blistering.
2mm
- No ferrous corrosion focuses
on the walls.
8 Resistance to UV light - Chalking & Film Cracking 5.3.5

alternating with Humidity not allowed.
allowed.

(168h at 40°C) allowed. Min 80% of Adhesion
should be retained
10 Pencil Hardness Min HB Pencil Hardness Tester
5. TESTING
5.1 GENERAL TEST CONDITIONS
As a rule, the normal state of laboratory shall be at standard temperature (25 ± 3°C)
and at 65 ± 5% Relative Humidity. When the state of laboratory does not remain
constant at the normal state, the conditions at each test shall be reported.
5.2 SAMPLING
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The Part Supplier has to submit Components / Cross-cut section of the components
that undergo the same process as the part for each batch. The material for testing
should basically be free from rust, damage, grease and any other surface defects.
The edges shall be masked using a cellophane tape. Cross-cut is to be made in the
component face for subsequent under-pellicular corrosion evaluation.
* Proprietary components / cross-cut section of the components shall be tested in
NABL approved Lab facility and reports to be submitted to AL- MED / SS / CQE /
TPH.
5.3 TEST METHODS
5.3.1 COATED SURFACE APPEARANCE:
PURPOSE:
To examine the appearance of coated surfaces.
PROCEDURE:
Visually compare the coated surface of the specimen with that of standard plate under
the Lux level of 1500 or in diffused daylight*. Check the surface for any dust,
contamination, lint, sag, runs, orange peel appearance, non-uniformity, pinholes,
craters, cissings, blistering, water spots or any other surface defects.
* - Diffused Daylight means indirect sunlight entering through a north-facing window

from 3h after sunrise to 3h before sunset. The standard light D65 specified in 8 of JIS Z
8701 may be used as a substitute.
5.3.2 DRY FILM THICKNESS (DFT):

A calibrated Coating Thickness Gauge can be used for measuring the Dry Film
Thickness (DFT) of the panel / component.
5.3.3 ADHESION:
Purpose:
This standard covers procedures and equipment for cross-hatch adhesion tests on
inorganic and organic coatings.
CONDITIONS:
The test shall be performed at 25 ± 3°C and at least 72h after paint film polymerization.
Flat Surface in a component shall be considered for conducting the Adhesion Test. The
dimensions of the flat surface shall be as agreed between the buyer and seller.
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PROCEDURE:
1. Cut the coated surface of a flat, visible area of the component / cross cut
section of the component down to bare metal, applying constant pressure to
cross hatcher. If coating is particularly hard, use scriber.
2. Cross hatch the component / cross cut section of the component with the
spacing decided according to the DFT (Below 50µm – 1mm x 1mm; Above
50µm – 2mm x 2mm).
3. Repeat cutting operation at right angles to previous cut in such a way as to
produce a grid of as many squares as there are spaces between blades.
4. Apply adhesive tape (3M 898 Scotch tape or equivalent) to cut area
following the standard procedure for adhesion tests.
5. Remove tape from painted surface by hand with a quick upward motion.
INTERPRETATION OF RESULTS:
Inspect surface involved. Surface appearance shall comply with the specification listed
in this standard.
5.3.4 RESISTANCE TO SOLVENTS:
PURPOSE:
To check the Resistance of the coated surfaces to solvents.
PROCEDURE:
At an ambient temperature of 25° ± 3°C, soak an absorbent cotton wad with the solvent
mixture (30% Toluene & 70% Iso Octane) and wipe it, for approx 10secs on the panel
or component, provided that it is visible, pressing with the fingers with hand force.
Then examine the wad and note any possible traces of color.
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5.3.5 RESISTANCE TO UV LIGHT ALTERNATING WITH HUMIDITY:
PURPOSE:
This Standard covers equipment and procedures for the alternating ultraviolet radiation
/ humidity resistance test. This test provides an accelerated means of simulating
deterioration such as is caused by the UV component of sunlight both with and without
environmental humidity.
TEST EQUIPMENT:
Alternating ultraviolet radiation / humidity resistance test equipment with Solar Eye
control.
TEST CONDITIONS:
Temperature conditions for the alternating ultraviolet radiation / humidity resistance
test are as follows:
Temperature: 60 ± 2°C (during UV radiation exposure cycle) & 40 ± 2°C (during
humidity cycle).
Atmospheric pressure: 860 to 1060 mbar
Deionized water with conductivity below 6 to 7 µ/s shall also be used).
Irradiance: 0.47 Watt/m2/nm @ 313nm
SCOPE:
Method is commonly used for:
- Paint products for plastic or metal vehicle exterior components.
- Metal and nonmetal vehicle exterior components with organic coatings.
SPECIMEN PREPARATION:
1. Apply one or more coats of product under test using standard painting / powder
coating procedures.
2. Test panels shall measure 70 x 150 mm or 300 x 70 mm, and shall be constructed of
the material to which product under test is to be applied.
3. For testing of components, prepare one or more preferably flat specimens from
component. Dimensions shall be 70 x 150mm or 300 x 70mm.
4. For ferrous parts, mask die-cut edges (and backside where necessary) to prevent
rusting.
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TEST CYCLE: `
1. The following test cycle can be used.
- 8 consecutive hours of exposure to ultraviolet radiation (light cycle)
- 4 consecutive hours in humid, unlighted environment (dark humidity cycle)
2. Repeat cycle several times for the total exposure period indicated in this standard.
TEST EXECUTION:
1. Prepare specimens as per the Specimen preparation method outlined above.
2. Check that tank located underneath fluorescent lamps contains Demineralized
water.
3. Set test cycles and temperature.
4. Expose specimens for the test time mentioned in this standard.
5. Measure the gloss without polishing the surface to know the Gloss Reduction
%.
6. Also visually check the specimen for Chalking and Color variations.
RESULTS:
Specimens shall meet the requirements listed in this standard covering product or
component under test.
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5.3.6 RESISTANCE TO HUMIDITY:
PURPOSE:
To simulate, through the Humidity test, effect of the same nature as those encountered
during service on vehicle under various environmental conditions.
SCOPE:
This test method is commonly used to conduct tests serving to reveal any deterioration
in the physical and / or service characteristics of all types of paint products.
TEST PARAMETERS:
Test Temperature : +40° ± 2°C
Relative Humidity : 95 – 100%
TEST EQUIPMENT:
1. Equipment shall be capable of producing a humidity-saturated atmosphere with
continual condensation on test specimens.
2. Equipment consists of a chamber constructed of corrosion resistant material and
provided with hermetically sealable doors or hatches.
3. Means for exposing specimens shall be such that specimen faces are all exposed
and that condensed moisture does not drip thereon.
4. Thermostat-controlled heating shall be provided for Demineralized water in the
chamber, and temperature shall be monitored by means of immersion type
thermometers or indicating and recording instruments with 1°C scale divisions
and an accuracy of ± 1°C.
5. Equipment shall be provided with means for maintaining a constant water level
and with a filtered air source capable of maintaining a constant flow through the
chamber.
6. Flow shall be recorded by a flow meter.
TEST PROCEDURE:
1. Bring the Humidity chamber to the specified conditions and introduce the
specimen in chamber.
2. Exposure in the test chamber shall be continued uninterrupted for the specified
period.
3. Any water drops that have formed on test surface shall be dried-off after test
using the filter paper.
PQ-7002-0
Date: 10.12.2013
SURFACE PROTECTION
`
RESULT: Specimens shall meet the requirements listed in this standard covering
product or component under test.
5.3.7 SURFACE FLOW / DOI:
SCOPE:
This standard covers specification, method & equipment required for the determination
of DOI by using PGD meter –type IV.
PURPOSE:
To examine the outward appearance of coated surfaces
EQUIPMENT & RELATED ACCESSORIES:
PGD Meter Type IV
PROCEDURE:
1. Place the portable PGD meter type IV on the specimen and turn the power switch on.
Through the eyepiece, find the smallest readable figure on the test pattern reflected by
the mirror.
2. For 0.5 and higher scale points, take the value at which more than 50% of figures are
readable.
3 If for example, the figures at 0.5 and 0.3 scale points are readable while the figures at
0.4 point are not, then take the higher value 0.5.
4. Read the scale number on the left side of the figures that are readable, and record as
the measured value of the reflection sharpness of the painted surface.
Calculate to the first decimal place the average of three measurements taken at different
points.
PQ-7002-0
Date: 10.12.2013
SURFACE PROTECTION
5.3.8 ERICHSEN CUPPING RESISTANCE:
SCOPE:
This standard covers specification, method & equipment required for the determination
of paint film flexibility by using Erichsen drawing tester.
PURPOSE:
Flexibility is a measure of the paint film’s ability to undergo deformation under direct
load without any damage / defects in the paint film. It is also used to express the paint
film’s resistance to brittleness.
PRINCIPLE / METHOD:
In this method the paint film is subjected to gradual deformation by indentation under
standard conditions and assessing the resistance of the coating of paint or related
product to cracking and / or detachment of film from the base metal substrate.
EQUIPMENT & RELATED ACCESSORIES:
Erichsen drawing (cupping) tester
PROCEDURE:
1. Condition the test specimen at 23 ± 2º C for at least 2 hr
2. CLAMPING OF THE TEST PANEL:
Loosen the die holder and place the test specimen in to the instrument head.
Adjust the specimen so that the central axis of the indenter bisects the
specimen and gently tighten the die holder (The surface to be examined
should form the topside i.e., visible from top.
3. Reset the counter to zero by using the reset button.
4. Disengage the clutch lever with simultaneous turning of the test head in the
clockwise direction. The test has now started. The clutch lever can now be released.
5. Continue to turn the test head slowly at constant speed without any jerk. Watch the
topside of the test specimen continuously while turning the head.
6. Turn the test head until any crack / damage is observed or till the min. specified limit
(5mm).
PQ-7002-0
Date: 10.12.2013
SURFACE PROTECTION
`
7. After the observation of crack / damage to the test specimen, record the depth of
indentation indicated by the digital counter (the counter displays the value in terms of
1/10th of mm) and turn the test head in anti clockwise direction till the clutch lever gets
locked automatically.
8. Loosen the die holder and remove the test specimen and record the observations
made on the topside of the test specimen.
GUIDELINES:
1. It is recommended that the advance of the test head should be at a constant rate of 2
± 0.1 mm / sec. Also it is advisable to turn at half of the said speed towards the end of
the test to locate the point of crack more accurately.
Report the depth of indentation in mm, at which a crack is first observed on the surface
of the coating and / or the coating begins to become detached from the substrate.
5.3.9 IMPACT RESISTANCE

PURPOSE:
The Purpose of this test is to evaluate the Impact Resistance of the paint film using
Dupont Impact tester.
TEST PROCEDURE:
1. Fix the panel onto the tester.
2. Impact the fixed panel using the ball as per the conditions specified (Ball Dia: – ½”,
Weight – 500g, Height – 50 cm)
in this standard.
PQ-7002-0
Date: 10.12.2013
SURFACE PROTECTION
5.3.10 ACID RESISTANCE

PURPOSE:
The Purpose of this test is to evaluate the Acid Resistance (0.1N H2SO4 in water)
TEST PROCEDURE:
1. Dip the panel in 0.1N H2SO4 in water soln and keep it at 20 ± 2°C for 8h.
2. Wash the panel after exposure with flowing water and after drying, inspect the
surface.
in this standard.
5.3.11 ALKALI RESISTANCE

PURPOSE:
The Purpose of this test is to evaluate the Acid Resistance (0.1N NaOH in water)
TEST PROCEDURE:
1. Dip the panel in 0.1N NaOH in water soln and keep it at 20 ± 2°C for 8h.
surface.
in this standard.
PQ-7002-0
Date: 10.12.2013
SURFACE PROTECTION
5.3.12 WATER RESISTANCE

PURPOSE:
The Purpose of this test is to evaluate the Water Resistance.
TEST PROCEDURE:
1. Immerse the panel in DI / DM water in a water bath maintained at 40 ± 2°C for 240h.
surface.
3. Perform the Adhesion test.
Inspect surface involved. Surface appearance & Adhesion Test results shall comply
with the specification listed in this standard.
6. AGREEMENT OF INSPECTION:
Vendors shall submit Components / Cross-cut sections of Component (representative of
the actual painting process adopted and processed in line with the component under
consideration) to the Unit Quality / CQE for testing as per the Agreement of Inspection
had with Unit Quality / CQE.
For Smaller components, the vendor may submit panels / components based on
agreement with Unit Quality / CQE.
7. REFERENCES:
ALS.268.02 – Zinc Aluminum Flake (ZAC) coating
ASTM B117 - Standard Practice for Operating Salt Spray (Fog) Apparatus

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PQ-7002-0

ASHOK LEYLAND LIMITED ALS.268.03

The standard is applicable to all bought out components, components manufactured in

Scope of this standard is to specify corrosion protection requirements and acceptance

* - Unless Otherwise Specified, Color of Class C Components: Black to RAL 9005

CLASS A – CAB EXTERIOR PARTS – INDICATIVE PART LIST

S.No Description Type

Possible Process Recommendations for Class A:

1. Pretreatment followed by Cathodic Electrodeposition (CED) & Topcoat as per

CLASS B – CAB INTERIOR & METALLIC TRIM – INDICATIVE LIST

S.No Description Type

Possible Process Recommendations for Class B:

S.No DESCRIPTION Type

Possible Process Recommendations for Class C:

* - For Proprietary parts, suitable coating to be selected by the part vendor to

CLASS – D – INDICATIVE LIST

S.No Description Type

Possible Process Recommendations for Class D:

* - For Proprietary parts, suitable coating to be selected by the part vendor to

TEST PARAMETERS TO BE CHECKED ON FINISHED PART:

S.No Property Test Acceptance Criteria Test Method

` Edge masked and damage free

8 Resistance to UV light Chalking & Film Cracking not allowed. 5.3.5

4.2 PRETREATMENT FOLLOWED BY CED & TOPCOAT

The topcoat is`provided so as to provide Weathering Resistance, Scratch Resistance for

TEST PARAMETERS TO BE CHECKED ON FINISHED PART:

S.No Property Test Acceptance Criteria Test Method

Edge masked and damage free

(Hrs` as per Component - Gloss Variation ≤ 15%

4.3 PRETREATMENT FOLLOWED BY AUTOPHORETIC COATING

TEST PARAMETERS TO BE CHECKED ON FINISHED PART:

S.No Property Test Acceptance Criteria Test Method

Edge masked and damage free

8 Resistance to UV light Chalking & Film Cracking not 5.3.5

9 Resistance to Humidity No Film removal and blistering 5.3.6

4.4 PRETREATMENT FOLLOWED BY AUTOPHORETIC COATING &

The topcoat is provided so as to provide Weathering Resistance, Scratch Resistance for

TEST PARAMETERS TO BE CHECKED ON FINISHED PART:

S.No Property Test Acceptance Criteria Test Method

Edge masked and damage free

10 Resistance to UV light - Chalking & Film 5.3.5

11 Resistance to Humidity No Film removal and blistering 5.3.6

4.5 PRETREATMENT FOLLOWED BY POWDER COATING

TEST PARAMETERS TO BE CHECKED ON FINISHED PART:

S.No Property Test Acceptance Criteria Test Method

2 Dry`Film Thickness (DFT) 60 ± 10µm 5.3.2

Edge masked and damage free

8 Resistance to UV light - Chalking & Film 5.3.5

9 Resistance to Humidity No Film removal and blistering 5.3.6

11 ` Resistance (Ball Dia

4.6 PRETREATMENT FOLLOWED BY PAINTING WITH PRIMER /

TEST PARAMETERS TO BE CHECKED ON FINISHED PART:

S.No Property Test Acceptance Criteria Test Method

6 Resistance to` Solvents (30% No Surface Alterations are allowed 5.3.4

Edge masked and damage free

8 Resistance to UV light - Chalking & Film Cracking 5.3.5

9 Resistance to Humidity No Film removal and blistering is 5.3.6

5.3 TEST METHODS

5.3.1 COATED SURFACE APPEARANCE:

* - Diffused Daylight means indirect sunlight entering through a north-facing window

5.3.2 DRY FILM THICKNESS (DFT):

5.3.4 RESISTANCE TO SOLVENTS:

5.3.5 RESISTANCE TO UV LIGHT ALTERNATING WITH HUMIDITY: