Application Manual: Zinc Flake

APPLICATION MANUAL
ZINC FLAKE
• INFORMATION AND NOTES ON OUR ZINC FLAKE PRODUCT PORTFOLIO

• OVERVIEW OF THE DIFFERENT POSSIBILITIES OF THE APPLICATION
• MINIMUM DOCUMENTATION REQUIREMENT
• NOTES ON THE QUALITY CONTROL OF THE SYSTEMS
CONTENT LIST
INTRODUCTION 4
GUIDE 5
1. 1. PRODUCT INFORMATION 6
1.1. Product groups 6
1.1.1. Basecoats 6
1.1.2. Topcoats 7
1.2. Naming 7
1.3. Product lines 8
1.4. Form of delivery 10
1.5. Labelling 11
1.6. Storage conditions 12
2. SURFACE PRE-TREATMENT 13
2.1. Uncoated metals 13
2.1.1. Degreasing 13
2.1.2. Blasting 13
2.1.3. Phosphating 16
2.1.4. Rinsing/passivation 16
2.2. Galvanically coated metals 16
3. PREPARING THE PAINT 17

3.1. Starting 17
3.2. Stirring 18
3.3. Viscosity 18
3.4. Filtering 19
4. GENERAL SAFETY NOTICES 20
5. COATING 21
5.1. Dip spinning 21
5.2. Rack dip spinning 25
5.3. Dip drawing 25
5.4. Spraying 27
2 - CONTENTS
6. CURING 28
6.1. Curing process 28
6.2. Drying process 29
6.3. Cooling 29
6.4. Exhaust air cleaning 29
7. IN-PROCESS INSPECTIONS 30
7.1. Tests on paint and environment 30
7.1.1. Viscosity 30
7.1.2. Solid content 31
7.1.3. Dew point 32
7.2. Tests on component 32
7.2.1. Cleanliness 33
7.2.2. Corrosion resistance 36
7.2.3. Friction coefficient 36
7.2.4. Pre-dimension and accuracy to gauge 37
7.2.5. Determination of layer weight 38
7.2.6. Layer thickness 38
7.2.7. Adhesion 40
7.2.8. Evidence of sealing 41
8. IN-PROCESS MAINTENANCE INTERVALS 42

8.1. Influences to be avoided within the process 42
9. DOCUMENTATION 44
9.1. General Information 47

10. CONTROL PLANS 48
ANNEX 49
Annex A: 49
Suppliers of auxiliary materials and equipment
Annex B: 53
Specialist literature standards for testing coatings/corrosion resistance
Annex C: 54
Recommended measuring instruments and testing equipment
Annex D: 55
Detailed description of work and test instructions
Preparation of a salt batch for DIN EN ISO 9227
Control of salt spray chamber
Annual check of the corrosiveness of the salt spray chamber
Suspension and evaluation of samples in the salt spray test
Test for sealing (procedure dot test)
Annex E : 60
Basin protocol
Annex F: 61
Dew point table
Annex G: 62
1. Causal diagram for reduced corrosion protection or reduced adhesion
2. Causal diagram for deviating coefficients of friction
INHALTSVERZEICHNIS - 3
INTRODUCTION
For more than 30 years Dörken MKS-Systeme GmbH & Co. KG has been developing micro-layer
corrosion protection systems and is today the European market and technology leader in the field of
chromium(VI)-free zinc flake systems. Behind this is a sustainable corporate strategy, which is based
on several success factors from a technological point of view:
• constantly monitored high quality of the coating systems developed and manufactured
exclusively in Germany;
• many years of proven reliability in use in the automotive industry and other industries;
• global availability;
• Use of modern management systems;
• a global network of highly committed and qualified coating companies, whose high quality
standards are not only guaranteed by regular audits, but constantly improved;
An essential part of these audits is this application manual. The manual contains:
• information and notes on our zinc flake product portfolio;

• an overview of the various application possibilities;
• a minimum documentation requirement;
• notes on the quality testing of the systems;
The focus is on our zinc flake systems. Current technical data on our products can be found in the
respective technical data sheets and safety data sheets.
The technical data sheets, safety data sheets and other downloads for the application manual
referred to here can be found in the login area of our homepage. Registration on the Dörken MKS
homepage is required here (Login >> Sign-up). The electro-deposition paint (DELTA-eLACK®) and
the DELTA-PROZINC® system are not part of this manual.
If you have any questions about the contents of this manual or about other Dörken MKS-Systeme
products, please do not hesitate to contact us!
CONTACT INFORMATION:
Dörken MKS-Systeme GmbH & Co. KG
Wetterstraße 58
D-58313 Herdecke
Telephone: +49 2330, 63243

Fax: +49 2330, 63354
Email: mks@doerken.de
Internet: www.doerken-mks.de
4 - INTRODUCTION
GUIDE
Dörken MKS-Systeme GmbH & Co. KG supplies its customers worldwide with products for the
production of micro-corrosion protection layers.
In order to ensure consistent quality in application and handling as well as the actual protective
effect and functions of the coating systems, users must have a certified management system. The
minimum requirement here is DIN EN ISO 9001 in the currently valid version.
With regard to the handling and application of Dörken MKS products, a review of the coating process
and all preparatory or involved processes is necessary in accordance with the QM system (quality
management).
The "control plans" contained in this manual form the basis for the coating process with Dörken MKS
products and for continuous improvement processes in accordance with the QM specifications.
The specified characteristics, methods and random samples can be adapted taking into account a
statistical evaluation and validation. A corresponding decision must be visible in the control plans.
In addition to these control plans, the CQI-12 audit also provides useful information for checking
the processes.
In the course of the Quality Development (Audit), Dörken MKS will examine the coating operations
at regular intervals with regard to the quality and performance of the Dörken MKS coating (in
accordance with the licence agreement).
In the event of anomalies in the audit or complaints from the supply chain, Dörken MKS will review
the control plans together with the customer and define measures.
The control plans described in this manual and the adjustments made as part of the CIP (continuous
improvement process) are also used for assessment purposes.
GUIDE - 5
1. 1. PRODUCT INFORMATION
1.1. Product groups
The product portfolio is divided into three groups: basecoats, topcoats and thinners.
1.1.1. Basecoats
The main task of basecoats is to actively protect the coated steel surface against corrosion. This
protective effect is based on the sacrificial property of the zinc contained in all basecoats.
The less noble a metal is, the greater its tendency to corrode ("rust"). Zinc is very base compared to
iron and steel, therefore it will corrode first in unfavourable environmental conditions.
Corrosion is an electrochemical process in which the metal involved in the reaction oxidises. If the
oxidising metal is electrically connected to another metal, the electrons released during oxida-
tion flow from the base metal (here zinc) into the more noble metal (here steel). Hence the terms
"sacrificial anode" (zinc corrodes) and "cathodic corrosion protection" (steel is protected)
Element Mg Al Zn Fe Ni Cu Ag Pt Au
Standard potential E° (V) -2,37 -1,66 -0,76 -0,44 -0,25 0,34 0,80 1,20 1,50
non-noble corrosion resistance noble
Fig 1: Dependence of corrosion resistance on standard potential.
Our basecoats are electrochemically very conductive due to their high zinc flake content. The
flakes are in electrochemical contact with each other. If the coating is damaged, the zinc sacrifices
itself to protect the steel surface. The small size of the flakes allows a micro-coating with corrosion
protection from 5 µm
Zinc flake coatings are aviable as curing and air-drying systems. The advantage of Dörken MKS-Base-
coats is the low curing temperature. The lower the temperature, the higher the energy savings and
the lower the load on the base material. The ideal cure temperature ranges for the basecoats are
listed in the respective technical data sheet.
Advantages of Dörken MKS basecoats:

They are free of harmful heavy metals such as chromium, lead or cadmium and comply
with the EU directives on end-of-life vehicles 2000/53/EC and the Waste Electrical and
Electronic Equipment Directive 2002/95/EC.
6 - PRODUCT INFORMATION
All Dörken MKS zinc flake basecoats can be combined with Dörken MKS topcoats.
Since no release of hydrogen in the material is to be expected during the application of zinc flake
systems (hydrogen embrittlement!), this is a very material-friendly corrosion protection process.
1.1.2. Topcoats
Various properties of the coating system can be achieved with a topcoat:
• Setting of a defined coefficient of friction;

• Sealing of the surface;
• Resistance to chemicals;
• Abrasion resistance:
• Colour:
The application of a topcoat can significantly increase the service life of the underlying basecoat.
1.2. Naming
The protected product names DELTA®-TONE, DELTA®-SEAL, DELTA-LUBE® and DELTACOLL® are
supplemented by numbers and lubricant specifications for precise product identification.
The products of the DELTA-PROTEKT® series are clearly described by letter combinations and
a sequence of numbers:
The first two letters have the following meaning:

K: cathodic corrosion protection
V: Sealing
M: modifier
E: electrodeposition paint
L: solvent based/solvent
H: water based
The numbers that follow indicate the functional system to which the product belongs. If the product
contains a lubricant additive, the letters "GZ" are added.
EXAMPLES OF SOME PRODUCTS
DELTA-PROTEKT® KL 120: Zinc flake basecoat with cathodic protection on solvent basis.
DELTA-PROTEKT® VH 300: Inorganic water-based sealant.
DELTA-PROTEKT® VH 301.1 GZ: Inorganic water-based sealant with lubricant additive.
DELTA®-SEAL GZ SILBER: Organic silver topcoat with lubricant additive.
DELTACOLL® 80 SCHWARZ: Black sealant for galvanised surfaces.
PRODUCT INFORMATION - 7
1.3. Product lines
Basecoats
The basecoat is the layer chiefly responsible for cathodic corrosion protection.
DELTA®- DELTA- DELTA- DELTA- DELTA- DELTA-

TONE PROTEKT® PROTEKT® PROTEKT® PROTEKT® PROTEKT®
9000 KL 100 KL 105 KL 130 KL 120 KL 170 RT
Excellent combination Ideally tailored Integrated lubricant Dark grey basecoat Suitable for coating Room temperature
with DELTA®-SEAL- for threaded parts additive for a defined of many different curing zinc flake
Series coefficient of friction Ideally suited for components
Temperature- black topcoats For industrial coating
Frequently used for resistant Ideally tailored (avoids silver shimmer) Excellent adhesion in the low temperature
springs, hose clamps for threaded parts range
and stamping Especially high
parts Resource efficiency temperature resistance Coating of tempera-
ture-sensitive compo-
Very good adhesion and Good protection against Very good protection nents possible
ductility white rust against white rust
High temperature Very good ductility

resistance
Topcoats
The various topcoats act as a further layer of corrosion protection and are responsible for
additional properties such as the coefficient of friction and chemical resistance.
DELTA®- DELTA- DELTA- DELTACOLL®- SPECIAL

SEAL-Series PROTEKT® PROTEKT® Series PRODUCTS
VL-Series VH-Series
Solvent-based topcoats Solvent-based topcoats Water-based sealings Solvent-based Bonding agents

sealings
For universal application For universal application Extremely thin layers Lubricants
on various substrates on various substrates of 1–5 μm Extremely thin layers
of 1–5 μm Sliding lacquer
Available in a range Developed for special Suitable for zinc
of colours applications requiring colorless or black High temperature
flake, galvanic zinc
UV- and chemical protection
Chemical resistance resistance
coatings and zinc Ideally suited for
alloys galvanic zinc coatings ... and more
Partly with lubricant Partly with lubricant and zinc alloys
additive in order to additive in order to Partly with lubricant
fulfill requirements fulfill requirements additive in order to Partly with lubricant
for friction coefficient for friction coefficient fulfill requirements additive in order to
for friction coefficient fulfill requirements
for friction coefficient
Thinners
To adjust the coating to its ideal application viscosity, or to subsequently dilute it, each coating has specific
Dörken MKS thinners. Each coating is exclusively compatible with these specific thinners.
The use of unauthorised thinners results in voiding of the product warranty.
The following thinners are approved for products from Dörken MKS-Systeme:
DELTA- DELTA®-SEAL DELTACOLL® DELTACOLL®

PROTEKT® 2000- 80 80
Thinner
KL-T- Series Thinner for GZ
Series SCHWARZ
Standard thinners for Standard thinners for Standard thinner for Standard thinner for
solvent-based base coats solvent-based top coats solvent-based sealing DELTACOLL® 80 GZ
of the DELTACOLL® SCHWARZ
Special thinners on Special thinners on 80 series, except for
request request DELTACOLL® 80 GZ
SCHWARZ
1.4. Form of delivery
Depending on the type of product, different containers are used to ensure optimum delivery quality
and processability.
Each order confirmation is accompanied by a factory test certificate.
Zinc flake basecoats are supplied in

the blue sheet steel buckets; topcoats
and DELTACOLL® 80 GZ SCHWARZ
are supplied in the grey buckets.
The water-based, colourless topcoats

of the VH series and Lubricants
(DELTA-LUBE®) are supplied in
white plastic containers; coloured,
water-based topcoats in blue plastic
containers.
Thinners and some paints such as

DELTACOLL® 80 are supplied in metal
cans with easy-to-dose screw caps.
Table 1: Delivery form of the products
1.5.Labelling
1.5. Etikettierung
Labels are attached to each material container. The security labels and contents are subject to
continuous changes and revisions. They contain important information for the user prescribed by law:
Auf jedem Materialbehälter sind Etiketten angebracht. Sie enthalten wichtige, vom Gesetzgeber
vorgeschriebene Informationen für den Anwender:
• product number
• batch number
• Produktnummer
• content quantity
• Chargennummer
• Suitability for storage
• Inhaltsmenge
• Safety instructions
• Lagerfähigkeit
• Safety notices
• Gefahrensymbol
• Contact information
• Sicherheisthinweise
• Kontaktdaten
Fig 2: Sample labelling Abbildung 2: Sicherheitsetikett mit Gefahrensymbolen
1.6. Storage conditions
For water-based products such as the VH series, a minimum storage temperature of 5 °C is recom-
mended, but not below freezing.
Increased temperatures – as with all paints – shorten the service life.

They act like a premature, slow curing process. The rise in temperature leads to a slight but steady
polymerisation of the binder contained in the paint. The higher the temperature, the faster the process.
It is therefore recommended not to store the paints above 35 °C. In general, a storage temperature of
about 20–25 °C is considered ideal. In individual cases, the specifications in the technical data sheet
must be taken into account.
Since basecoats containing zinc flakes are highly sensitive to moisture, the containers must always
be stored tightly closed. During longer breaks it is advisable to close the paint container airtight or
to fill the material back into the original container.
If the temperature of the stored paints is in the range of the application temperature e. g. 20–28 °C
(note dew point temperature at the application location!), the paint can be refilled quickly as no
temperature adjustment is required.
2. SURFACE PRE-TREATMENT
The term pre-treatment refers to various processes used to prepare the surface for coating. The
quality of a coating depends to a very high degree on the quality of the surface pre-treatment.
The better the pre-treatment, the higher the quality of the coating.
"Pre-treatment is the be-all and end-all!"

Different surface pre-treatment methods are described below. The processes are aimed at the treat-
ment of uncoated metals and metallic surfaces which have already been provided with a galvanic
coating.
2.1. Uncoated metals
In order to achieve a high-quality coating, the surface of the component to be coated must be clean,
dry and free of dust and grease.
Depending on the material, intended use and component geometry, different pre-treatment processes
are used.
2.1.1. Degreasing
Cleaning of the surface to be coated usually begins with degreasing. There are different methods
for this.
One of the most common methods for degreasing industrial surfaces is water-based, hot alkaline
degreasing. The most common degreasing processes operate at a temperature of about 60–70 °C
and a pH value in the range of 11–14. In this process, oils, fats and waxes are dissolved or saponified
and washed off during the subsequent rinsing cycles. Ultrasonic cleaning equipment can support the
cleaning process.
Residues of removed oil, grease or wax must be removed from the washing system at regular
intervals!
2.1.2. Blasting
Blasting is a very effective process for removing firmly adhering residues such as scale or rust
and often follows degreasing. Depending on the material and degree of contamination, abrasives
made of steel, glass, ceramics or other hard mineral materials are typically used in various
geometries. The blasting process must be adapted to the components and their requirements.
SURFACE PRE-TREATMENT - 13
For steel surfaces, stainless abrasives with a hardness of about 450 HV and an average grain size
distribution of 0.2 to 0.6 mm (depending on component size) are recommended. Roughnesses of
Rz 10–25 µm, Ra 2–6 µm are usually achieved.
A degree of purity (e. g. according to ISO 8501/1+2) of Sa 2 ½ should be sought:
"When viewed without magnification, the surface must be free of visible oil, grease and dirt and
free of scale, rust, coatings and impurities of other types to the extent that any remaining traces
are still visible as slight, spotty or streaky shades."
In order to ensure constant quality in the blasted surface, a regular inspection of the blasting material
is necessary. These controls are necessary because the blasting material changes over time:
• Blasting grains become smaller;

• the blasting material is enriched with dust;
• the blasting material is contaminated by surface dirt (fats and oils);
The size distribution of the blasting grains is determined by means of a sieve analysis. Unwanted
dust can be removed with regularly maintained filters.
Impurities introduced, such as grease and oil, not removed by the filter, can often only be removed
by replacing the abrasive.
Fig 3:
Depending on the desired surface quality,
different blasting media are used.
14 - SURFACE PRE-TREATMENT
The loading of the blasting machine is ideally matched to the capacity of the coating machine(s).
An average load is about 100–200 kg with a blasting time of 6–12 minutes. In order to remove the
blasting dust produced during the blasting curtain, the blasting unit ventilation usually continues
for 2–4 minutes. Only then can the blasted material be removed from the blasting chamber.
Check the cleanliness of the surface after blasting! It is essential to avoid dust or abrasives being
carried over into the coating bath!
Fig 4:
Blasting aid DELTA®-SBA
Oil or grease residues from upstream processes have a negative effect on adhesion. DELTA®-SBA
separates oil and grease from blasting agents and blasting material and absorbs them, leaving
surfaces perfectly prepared for subsequent coating processes.
Product description:
• mineral blend (white granulate)
• defined grain (0.5 mm)
• defined porosity
• capillary action
• pronounced hydrophilic and lipophilic character (amphiphilic)
Dosage recommendation:
• automatic or manual addition after air separation
• theoretical volume added: approx. 50-70 g/t blasting material (in ongoing process)
SURFACE PRE-TREATMENT - 15
Tunnel with
compressed air blow-off
parts slide
air extraction air extraction parts container
Fig 5: Blast system
2.1.3. Phosphating
Phosphating is not generally recommended as a standard pre-treatment process, as it involves

some risks and in any case requires a technical adjustment. For some parts groups and geometries,
however, phosphating may be possible. Here, for example, fine-crystalline thin-film phosphating of
up to 3 g/m2 is common.
If the layer thickness is too high, inter-granular stress cracks can form in the phosphate layer.
Furthermore, the electrical connection of the zinc flakes to the steel substrate could be reduced. In
order to prevent residual water from entering the coating material, it is necessary to thoroughly dry
the phosphate layer at approx. > 70 °C. The phosphating must be adapted to the necessary baking
temperatures of Dörken MKS products.
2.1.4. Rinsing/passivation
Due to the wettability and chemical stability of the coating material, care must be taken to ensure
that any after-treatments used, in particular those containing amines, borates and/or silicates, are
washed off without leaving residues.
2.2. Galvanically coated metals
Normally, passivation takes place immediately after electroplating. Before coating the passivated
parts with suitable topcoats, they must be dried. If water from insufficiently dried parts gets into
the topcoats, their protective properties are weakened. Gloss formers and additives contained in
the galvanic layers can lead to wetting and adhesion problems. A technical comparison is therefore
necessary. Coating of surfaces which are not pre-coated with MKS systems is only permitted after
consultation and permission (licence agreement) from Dörken MKS-Systeme GmbH & Co. KG is
possible.
16 - SURFACE PRE-TREATMENT
3. PREPARING THE PAINT
3.1. Starting
All coating materials must be prepared or prepared before use. Make sure that the material has
reached ambient temperature before use. Otherwise there is a risk of condensation (moisture)
entering the paint. During transport and storage, the heavier particles settle at the bottom of the
container. Therefore, the contents must be homogenised before further use.
The stirrer is adapted to the respective

product. A mixer with a stirring disc is used
as standard. The rotational speed should be
such that there is no vortex through which
air is sucked into the material, because air
always brings a certain amount of moisture
into the material. In order to avoid
electrostatic charging, all stirring vessels
must be earthed.
In the case of solvent-containing base-coats,

a dissolver disc is used to stir the material
in the delivery container (see illustration).
The paint is mixed for approx. 10–20
minutes until it is fully homogenised. The
perfect mixing can be checked with a clean
stick to which no residues may adhere when
the contents are stirred. For safety reasons,
solvent emissions must be removed from
the room air.
In addition to this standard method, there

is also another method in which mixing
takes place automatically with the lid
closed. In this way, no solvent soaks away
and no moisture enters. This requires a
gyroscopic mixer which rotates the
container simultaneously around two
axes. This process also takes less time.
However, the process is only suitable
for full containers and only for some of
the products.
Table 2: Preparation of the paint with stirrer or mixer
PREPARATION OF THE PAINT - 17

3.2. Stirring
The paints in the coating process must continue to be kept homogeneous.

For this it is necessary to stir the paint slowly from time to time so that the solid does not settle at the
bottom or segregation does not take place. It is recommended to stir every hour for 10 minutes at
very low speed (10–20 rpm). Avoid stirring too fast, as this can affect the material.
The coating itself experiences a certain amount of movement during the coating process, which
contributes to its homogeneity. This works particularly well with a high throughput throughout the
process. But this movement alone is not enough to keep the material homogeneous over time.
On the other hand, it is essential to avoid large amounts of mechanical energy acting on the paint.
When using an agitator, it is therefore recommended to select a low rotational speed (10–20 rpm).
When using a pump, a diaphragm pump with a low flow rate is recommended. The pipes should have
a diameter of at least 2 inches (5.08 cm).
These supporting measures should be carried out regularly.
3.3. Viscosity
Viscosity is the measure of the flow behaviour of a coating and depends, among other things, on
temperature and solids content. The ideal viscosity of the coating material depends on the coating
process, the coating system and the geometry of the parts. The viscosity of the paints in the delivered
condition normally differs from the viscosity during processing. The viscosity must therefore be
brought to the processing state before the paint is transferred to the processing container. For this
purpose, the viscosity is adjusted with a suitable dilution.
There is a dependency between dilution addition and viscosity, as the solids content is reduced
during dilution.
100
90
80
Viscosity 3 mm [s]
0 % Diluent
70
3 % Diluent
60 4 % Diluent
6 % Diluent
50
40
30
5 10 15 20 25 30 35
Temperature [°C]
Fig 6: Dependence of viscosity on temperature and thinner addition for a base-coat as an example
18 - PREPARATION OF THE PAINT

Example solvent-borne base-coat:
It can be seen from the viscosity diagram that an addition of about 6 % of solvent is accompanied
by a reduction of the viscosity from 60 s to 40 s.
During the coating process, three phenomena have a decisive influence on the viscosity:
1. Evaporation of the solvent

2. Consumption of the solid
3. Temperature change
The viscosity must therefore be checked regularly and, if necessary, topped up with solvents or
fresh paint (to compensate for the used solids). When refilling, the temperature must always be
taken into account.
The rule of thumb for base-coat is:

The viscosity decreases by about 1 s per 1 °C temperature increase!
Temperature
Viscosity
Fig 7: Increased temperatures lead to a decrease in viscosity
3.4. Filtering
In order to remove impurities, dust, coarse metal particles or dried paint residues from the coating
bath, the paint must be filtered at intervals appropriate to the throughput.
The recommended filter sizes can be found in the technical data sheets.
PREPARATION OF THE PAINT - 19

4. GENERAL SAFETY NOTICES
Safety instructions for handling chemicals, potential hazards and protective measures must be
observed in accordance with the product safety data sheets for the products.
Fig 8: Before starting work, observe the safety instructions in the safety data sheets!
The production plants must be designed in accordance with the applicable local regulations and in
consultation with the plant manufacturers. In particular, the regulations on explosion protection
must be observed.
The maximum solvent mass to be applied in ovens must be agreed with the manufacturers. The
accumulation of dusts containing zinc in plants can also lead to a metal fire or explosion. Cleaning
intervals must be agreed with the plant manufacturer.
20 - GENERAL SAFETY NOTICES

5. COATING
There are general framework parameters that influence the coating result – independent of the
application method. These include the processing temperature and the dew point.
5.1. Dip spinning
The coating of mass articles (bulk material) is usually carried out by dip spinning. The basket or
dipping drum with a diameter of 400–900 mm is the most important tool. The bulk material is
loaded into the basket. The filling level depends on the bulk density of the parts. Depending on the
dip spinning parameters and paint setting, an average layer thickness of 3–6 µm can be applied per
coating process.
In the case of some special component geometries (internal forces, small parts, undercuts), it is ad-
visable to tilt the basket for complete surface wetting. The same applies to centrifuging off excess
coating material after wetting.
An inclination angle of ≥ 75° at a speed of approx. 5–20 rpm enables improved leakage of excess coat-
ing material. This can be combined with pre-spinning before the tilting process.
The basket is then dipped into the dipping container. The paint wets the entire surface of the parts. A
mechanical movement by slowly rotating the basket improves the wetting process by removing bub-
bles and changing the contact surfaces.
After the dipping process, the basket is lifted out of the dipping bath and quickly turned or centred
so that the coated parts are centrifuged against the outer wall of the basket. The centrifugal force
causes the superfluous paint to drip back through the holes in the basket into the dip tank. After
coating, the parts must be dried in the oven. When emptying the drum, it is recommended to
distribute the parts as far as possible from each other on a conveyor belt or in a crate (tray). This
results in a better baking process, less adhesion and a more uniform quality of the coating.
The dip spinning process is influenced by several parameters. The most important parameters
are immersion time, spinning speed, spinning time and loading as well as viscosity of the coating.
In addition, there are other parameters that affect the process. These depend on the coating
technique, such as the rotation of the spinning unit and/or the change of direction, which can lead
to an improvement in quality.
Recommended parameters:
The basket must be immersed in the paint for at least 30 seconds. A low rotation speed of about
10–20 rpm and an oscillating immersion improves the wetting, so that adhering bubbles can be
removed.
Fig 9: Dip spinning process
COATING - 21
An important parameter is the centrifugal speed or centrifugal force (F), which results from the
rotational speed and the drum diameter. The centrifugal force should be constant when using
different basket diameters in order to obtain comparable results.
The centrifugal force is calculated as follows: F = mω²d/2
m = mass of a drop of paint (almost constant)

d = diameter
ω = angular velocity (ω2πn/t)
Formel
n/t Fliehkraft und
= revolutions Umrechnung
per time unit (e. g.der Drehzahl in Abhängigkeit vom Korbdurchmesser
rpm/60)
( 60 ) ( 60 )
n1 2 d1 n2 2 d2
!F = m × 2π × × = m × 2π × ×
2 2
! = > n12 × d1 = n2 2 × d2
d1
! =Formel
> n2 Fliehkraft
= n1 × und Umrechnung der Drehzahl in Abhängigkeit vom Korbdurchmesser
d2
( × 60 ) r p(m 60 )
n1 2 d1 n2 2 d2
!F = m × 2π × 900 m×m = m × 2π × ×
!n 2 = 219 U/min
rpm 2= 294 U/min 2
500 m m
! = > n12 × d1 = n 2 2 × d 2 Fig 10
Sample calculation:
Formel Festkörper d
! = > n 2d1==n900
Basket diameter × mm,1rotation speed n1 = 219 rpm
1
m = Masse
conversion d2d2 = 500 mm , rotation speed (n2)?
to basket diameter
mnach Einbrennen mit Probe − mleer
% Festkörper
! = *100%
m vor Einbrennen mit Probe
900 m m − mleer
!n 2 = 219 U/min
rpm × = 294 U/min
rpm
500 m m
Tabelle 1: Beispiel Korbdurchmesser vs. Drehzahl Fig 11
Formel
In order Festkörper
to achieve an approximately comparable coating result with a small basket, the rotation
Korbdurchmess Drehzahl
speed must be increased. For a basket with a diameter of[rpm]
500 mm, the rotational speed must be in-
m = Masse
creased to 294 rpm,
er
for example. For a basket with 500 mm diameter, for example, the rotation speed
must be increased to 294 rpm. mnach Einbrennen mit Probe − mleer
% Festkörper
! = [mm] *100%
m vor Einbrennen mit Probe − mleer
Basket diameter [mm] 300
Speed [rpm] 380
300 380
400 329
Tabelle400
1: Beispiel Korbdurchmesser vs. Drehzahl
329
500 294
500 294
Korbdurchmess
600 Drehzahl
268
600 268
er [rpm]
700 248
700 248
800 232 [mm]
800 232
900 219 300 380
1000 900
208 219
400 329
Table 3: Sample basket diameter vs. speed 1000 208
500 294
600 268
22 - COATING
700 248
800 232
The layer thickness depends on the spinning speed and the basket diameter: the higher the spinning
speed and the larger the basket diameter, the lower the layer weight for the same viscosity.
The spinning time is about 10-20 seconds per spinning direction. Usually the spinning is to the right
and to the left. Depending on the geometry of the parts to be coated, this process can be repeated.
In addition to the basket diameter, the construction (geometry) of the basket also has an influence.
For example, closed designs with a lower hole density or double walls must be centrifuged with
adapted parameters.
In addition, the quantity of parts and the acceleration of the spinning process lead to different flow
geometry (see Figure 12). An ideal material flow is achieved in the drums a) and b).
Both drums have similar properties, becasue the distance between the parts, through which the
paint must flow is the same. If the load is too high or the acceleration is too low basket fillings will
result when spinning as with c) and d). It is obvious that the paint in drum c) must cover the longest
distance (see blue arrow). Here it is probable that the parts will stick to each other due to the
adhesive effect of the paint. In addition, uneven coating weights result in drums c) and d). Parts lying
in the middle have a higher layer weight (due to the lower acceleration) than parts lying at the edge.
Basket diameter
large small
high
Rotation speed
middle
Fig 12:
Dependence of the distribution
of the bulk material in the basket
on the basket diameter and the
rotational speed
COATING - 23
In addition, the coating weight can be influenced by the viscosity of the coating.
The lower the viscosity, the less paint adheres to the component surface. The viscosity must be
adapted to the component geometry and the plant concept. For solvent-based base-coats, a starting
value between 40 and 42 seconds is recommended (see technical data sheet for guide values).
First, a test coating is applied to assess the layer weight and to check whether it meets the customer's
requirements.
If the requirements are not met, the spinning parameters must be adjusted: Spinning speed, spinning
time, viscosity and filling quantity in the basket.
As described in chapter "3.3. Viscosity" on page 18, the viscosity of paint is influenced by the temper-
ature, solvent evaporation and the solid. Therefore, a constant temperature of the paint container
must be ensured in order to ensure consistent quality. The following circumstances can influence
the bath temperature: changing day and night temperatures, radiated oven heat, warm components
and climate fluctuations.
This results in the definition, control and maintenance of a constant viscosity window (defined
processing viscosity ± 2 seconds).
In general, a system consists of several layers. Between the individual layering cycles, the parts are
transported from the basket into the oven and back again. Loading and transport processes damage
the coating. This process must therefore be limited to a minimum
Corrosion protection reduction (%)
0 2 4 6 8 10 12 14 16 18 20
0
Total drop
-10
-20
Individual drop height (cm)
-30
-40
-50
-60
-70
Fig 13: Influence of total drop height on corrosion protection, source: DSV
24 - COATING
The parts should be gently unloaded onto the pre-drying belt from the oven or into the tray. Mechanical
loads can cause significant damage to the coatings and thus reduce the corrosion protection effect.
The larger the parts and the greater the drop height, the greater the damage.
A rubber or plastic coating on the floor or reducing the drop height by sliding with a corresponding
inclination can therefore be helpful.
Beschichtung
Additional stress or damage to the components can be caused by vibration chutes or a discharge
of the components after each coating process.
An important aspect of parts to be re-coated is their temperature. The parts must be cooled down
to ≤ 30 °C, but still above the dew point temperature, before they are coated again.
Basecoats and topcoats contain different solvents, so separate baskets and dipping containers
must be used. If the wrong solvents are mixed into the paint, it can be damaged.
Regular cleaning (paint stripping) of the coating baskets at sufficiently short intervals is absolutely
necessary, as paint build-up and clogging (sticking) of the baskets can have a decisive influence on
the quality of the coating, layer thickness and its distribution.
5.2. Rack dip spinning
In the rack dip-spinning process, the parts to be coated are fixed to a frame at one or more small
support points or alternatively individually placed in compartments (basket with grid). The unit thus
equipped is immersed, centrifuged and moved through the oven together with the frame. The racks
must be cleaned regularly.
5.3. Dip drawing
Dipping into the paint and pulling it out under defined conditions is particularly suitable for parts
with special geometries, such as tubes, plates or more complex parts. This makes it possible to
coat the inside and outside of tubes in a single process step. The most important parameters in the
dipping process are size and geometry. The parts should have enough openings from which the paint
can run off when being pulled out. If there are accumulations of paint at points – e. g. if the solvent
is boiled up, for example in corners, bubbles will form during baking and a flawless coating will not
be achieved at this point.
A venting of the components to prevent air inclusions must be ensured, otherwise uncoated
defects will occur.
COATING - 25
The dip drawing process is influenced by several parameters. The most important are:
• Immersion time
• Extraction speed
• Viscosity
• Paint and part temperature
During the immersion period, it must be ensured that the components are completely wetted and
vented.
The extraction speed is the determining factor for the layer weight or the layer thickness.
Fig 14: Schematic structure of a dip drawing system
If the extraction takes place at a constant speed, the result is a wedge-shaped layer thickness
distribution. In order to achieve an even layer thickness, the extraction must be carried out with a
slight acceleration.
Thus it is also possible to change the total layer thickness by the extraction speed. For example, the
following relationship between layer thickness and speed was observed for solvent-borne base-coats
(at 40s viscosity and 20 °C coating temperature):
Speed [mm/min] Layer density [μm]

60 7
70 8
80 9 Table 4.
Example dependence of the layer thick-
100 11 ness on the extraction speed
The wetting of the component depends to a large extent on the substrate (roughness and surface
tension). Possible droplet formation can be avoided by means of an air sword or by blowing off.
26 - COATING
5.4. Spraying
The spray application is used for parts that are unsuitable for other application methods or require
a particularly uniform layer structure. A special advantage of the spray application is the variation of
the layer thickness. The application can be done automatically or manually. The coating material is
atomised into fine droplets – either with compressed air or in a high rotation process.
During spraying, all parts are usually coated on supports or racks adapted to the specific component.
In order to achieve optimum layer thickness distribution, the component and spray nozzle move
relative to each other. Paint that does not hit the component is referred to as overspray. The static
charging of the component makes it possible to reduce the overspray. The paint droplets are thus
statically attracted by the component. In order to protect the environment and not to pollute the
environment unnecessarily, the overspray is removed by suction, filter or water wall.
The paint is fed through hoses with a pressure or pump system. This results in only a small amount of
air and moisture being introduced; however, the homogeneity of the coating must always be ensured
here as well. Depending on the continuity of the coating process, it may be necessary to stir in the
storage tank and/or to install a ring line with continuous material flow until the paint is sprayed. This
prevents solids from settling in the hoses. Suitable filter devices must be integrated into the paint
supply. If different paints are used continuously, independent supply lines should be used. If only
one line is used for several lacquers, the respective dilutions must be rinsed with each paint change
or work interruption.
The compressed air supply for spraying systems must always be dry and oil-free.
The spraying process is influenced

by several parameters.
• Viscosity
• Paint temperature
(see technical data sheet)
• Air pressure
• Material pressure
• Atomiser nozzle/disc
• Ambient temperature
• Relative humidity
• Distance of the part to the pistol
• Tension
• Leakage current Fig 15: Spray process
The process of spraying is however also influenced by the equipment.

This includes components such as:
• Spray gun/high rotation bell
• Manual or automated application (lifting, swivelling or robotic arm)
• Diaphragm pump or pressure vessel
• Shape and dimensions of the frames
• Inner hose diameter
• Dimensions and air flow of the spray booth
• Type of electrostatic charge
The parameters and equipment components must be coordinated with each other.
COATING - 27
6. CURING
Regardless of the application technique, the next step is the curing or drying process. The typical
process is convection drying; induction and infra-red drying can also be used for special applications.
6.1. Curing process
Different types of ovens are used for convection drying, and are described below. The time between
application and curing should never exceed 5 minutes for solvent-containing base-coats, as these
react sensitively to humidity (information on all products can be found in the respective technical
data sheet).
Large rack parts, i.e. particularly thick-walled components or those with large diameters or large
masses, require a particularly long time to heat up.
Excessively high fill heights on the oven belt or tray must be avoided. The higher the bulk density of
the components, the lower the bulk height of the components should be. In general, pouring heights
> 10 cm should be avoided.
Conveyor belt oven (continuous oven)

Here the parts are emptied from the basket onto a slowly moving conveyor belt. Damage should be
avoided by a low drop height.
The first section of the oven is the pre-drying area. Here the solvents or, in water-based systems, the
water are evaporated at approx. 80–120 °C. Behind this there is a cascade over which the parts
fall onto a second conveyor belt which runs faster than the first one. This results in a larger area
distribution of the parts and reduces sticking together during final curing.
Alternatively, it is also possible to use an un-tightened, slightly corrugated belt, which moves the
parts slightly up and down. The components are moved against each other permanently, but only
minimally and gently, during pre-drying or during the entire curing process. The next step is the
curing process at a product-specific temperature and curing time according to the technical data
sheet. This is not the oven temperature, but the temperature of the parts (object temperature). The
curing time is the time during which the parts must have the object temperature.
Tray oven (continuous oven)

Each basket load is placed in a tray and this is then pushed into the oven, whereby the trays already
in the oven are pushed one position further. The heating process is identical to that of the conveyor
belt oven. Vibrating stations can prevent sticking together.
In order to avoid too high a vibration intensity, the components can alternatively be pre-dried in a
belt dryer and then distributed to the trays by means of an adjusted speed. At the same time, this can
also eliminate the disadvantage that flat components in particular are very difficult to distribute
by vibration.
Chain conveyor oven (continuous oven)

The only difference between continuous ovens for racked goods is that the parts are moved through
the oven with the complete rack.
28 - CURING
Chamber oven
Another possibility is the use of chamber ovens. This type of oven is particularly suitable for small
batch quantities and small loading volumes, as it usually takes a very long time for all parts to reach
the required temperature when the chamber is opened. The pre-drying and curing process can take
place in separate chamber ovens.
Regardless of the type of oven used, a uniform temperature distribution must be maintained
throughout the oven. The deviation from the nominal value must not exceed 5 K at any point. This
must be verified and recorded at least every four weeks by means of a oven protocol (see chapter
"10. Control plans" on page 48). Heating is usually by gas combustion. Two principles are used: direct
and indirect heating.
Since direct heating can cause additional contamination of the parts due to the combustion products,
Dörken MKS recommends the use of indirect heating methods.
Special cases during drying and curing:

IR drying/curing (e. g. partial coating of screw heads)
Inductive drying/curing (e. g. gentle curing of grease-filled bearing housings)
These processes are very special, so the drying process must be adapted to the individual part.
6.2. Drying process
Some water-based coatings cure at room temperature. However, this process can be accelerated
by higher temperatures (forced drying) (see technical data sheet).
6.3. Cooling
After curing, the parts are cooled to room temperature (30°C or less). This cooling usually takes place
in the oven, where only cold air is blown onto the parts. It is important to ensure that the
dew point (at least 3 K above dew point temperature) is not reached during cooling, otherwise the
coated parts will attract moisture.
6.4. Exhaust air cleaning
Volatile organic compounds, often also referred to as VOC (volatile organic compound), are a
collective term for organic substances that evaporate easily or are already present as a gas at
low temperatures.
Organic solvents, which are used to dilute the coating material, have a very high VOC content. Since
these can have a negative effect on the health of the user and on the environment, the cleaning
of the exhaust air is of great importance.
There are three different principles for exhaust air purification:

1. Thermal: All resulting emissions are burned.
2. Biological: In this process environmentally harmful emissions of microorganisms are
decomposed.
3. Photocatalytic: Harmful emissions are broken down by UV light and then collected in
activated carbon filters.
CURING - 29
7. IN-PROCESS INSPECTIONS
In order to ensure the best possible quality of a coating, a large number of process-accompanying
tests are required before, during and after the coating process.
Paint Component Surrounding area

before Temperature, Cleanliness Temperature,
coating viscosity, humidity,
solids content, dew point
during the level
coating –
after wetting, layer weight

coating – (layer thickness), –
adhesion, friction
coefficient, corrosion
protection
Table 5. Subject and time of process-accompanying inspections
The following sections describe the procedure for these process-accompanying checks.
7.1. Tests on paint and environment
7.1.1. Viscosity
The viscosity indicated in this manual and in the technical data sheets always refers to a temperature
of 20 °C. The viscosity depends to a large extent on the temperature of the coating material itself,
so any viscosity measurement must be accompanied by temperature documentation. The usual
measuring procedure is carried out with a flow cup, which is available in various shapes (see
technical data sheet).
The material must first be homogenised by mixing before a sample is taken.
The second step is temperature measurement using a thermometer and subsequent documentation.
Third, measure the time it takes for the paint to flow out of the cup. Each measurement must be
verified by at least a second measurement.
When using a cup with a tripod:

• Cover the outlet hole with your fingertip.
• Fill the cup.
• Cover the filled cup with a glass plate.
• Remove your finger from the outlet hole.
• Quickly pull the glass plate aside and start the stopwatch.
• Stop the stopwatch as soon as the paint flow is interrupted.
30 - IN-PROCESS INSPECTIONS
When using a immersion flow cup, measurements are usually taken directly from the paint container:
• Dip the cup into the container.

• Pull it out quickly, hold it vertically and start the stopwatch.
• Stop the stopwatch as soon as the paint flow is interrupted.
In both cases, make sure that no bubbles form at the outlet. If this is the case, repeat the measure-
ment. The flow cup must be thoroughly cleaned after each measurement (with a brush and suitable
dilution, not mechanically).
Required materials: Flow cup, stopwatch, mixer, thermometer
7.1.2. Solid content
A quality characteristic of paints is the ratio of liquid to solid components. Solids include binders and
pigments (determined according to DIN EN ISO 3251). The drying times and temperatures can be
taken from the respective technical data sheet.
First, the material must be homogenised by mixing. This is followed by

1. Weighing the empty bowl (m empty).
2. Taking a paint sample (approx. 1 g) and filling the bowl.
3. Quickly weighing the bowl again (m before ), to avoid evaporation of the solvents.
4. Placing the tray in the hot oven.
5. Removing the bowl after the specified time and allowing it to cool down to room temperature
(preferably in a desiccator).
6. Weighing the bowl again (m after).
The solids content is determined using the following formula
m = Mass
m after curing with sample - m empty
% Solid content = *100 %
m before curing with sample - m empty
Equipment: light bowl (aluminium), laboratory scale (measuring tolerance: ± 0.001 g), oven, stop-
watch, pipette, desiccator
Fully automatic instruments are also available (see Appendix C "Recommended measuring instru-
ments and test equipment" on page 54). The results of these instruments may differ from the method
described above. It is crucial that the same method is always used for measurement in order to
obtain comparable results.
IN-PROCESS INSPECTIONS - 31
die Lacktemperatur in jedem Fall mindestens 3 °C
zum Ablesen der Taupunkttemperatur befindet sic
zinklamellenhaltige Beschichtungsmaterial, so wi
7.1.3. enthaltenen Bindemittel reagieren bei Wasserzug
7.1.3. Taupunkt
Taupunkt
zähflüssige Masse, welche nach einiger Zeit soga
Der
Der Taupunkt
Taupunkt istist die
die Temperatur,
Temperatur, bei welcher sich die Luftfeuchtigkeit auf einer Oberfläche Oberfläche
7.1.3. Dew
niederschlägt point
niederschlägt (kondensiert).
(kondensiert). Sie Sie ist abhängig von der Luftfeuchtigkeit und der Lufttemperatur.
Lufttemperatur.
Beträgt
Beträgt die Lufttemperatur
diepoint
Lufttemperatur beispielsweise
beispielsweise 30 °C und die Luftfeuchtigkeit 55 % so so wird sich
sich auf
auf einer
einer
The dew is the temperature at which the air humidity precipitates (condenses)wirdon a surface. It
Oberfläche,
depends ondessen
Oberfläche, dessen Temperatur
Temperatur
the air humidity and20the°Cairoder weniger beträgt, die Feuchtigkeit aus
temperature. aus der
der Luft
Luft
kondensieren
For example,(siehe
kondensieren (siehe Bild
Bild
if the air 8,
8, 9,
9, 10).
10). Da
temperature Zinklamellen-Basecoats
is 30 °C and the humidity is 55 extrem wasserempfindlich
wasserempfindlich
%, humidity sind,
will condensesind, muss
frommuss
die
die Lacktemperatur
the air on a surface in
Lacktemperatur in jedem
jedem
whose Fall
Fall mindestens
temperature is 20 °C3or°C über
less (seeder Taupunkttemperatur
Taupunkttemperatur
Figures liegen.
liegen.
16, 17 and 18). Since Eine
Eine
zinc fl Tabelle
Tabelle
ake ba-
secoats
zum
zum are extremely
Ablesen
Ablesen der sensitive to water,
der Taupunkttemperatur
Taupunkttemperatur the paint
befindet sichtemperature
im Anhang.must always
Gelangt be atin
Wasser
Wasser least
in das3 °C above
das
the dew point
zinklamellenhaltige temperature. A table
zinklamellenhaltige Beschichtungsmaterial, for reading the dew point temperature
Beschichtungsmaterial, so wird es irreparabel geschädigt. Die can be found
Die im in the ap-
im Lack
Lack
pendix. If water gets into the coating material containing zinc flakes, it will be irreparably damaged.
enthaltenen
enthaltenen Bindemittel
Bindemittel reagieren
reagieren bei Wasserzugabe ähnlich wie Zement. Es entsteht entsteht eine
eine
The binders contained in the paint react similarly to cement when water is added. A viscous mass
zähflüssige
zähflüssige Masse,
Masse, welche
welche nach
nach einiger Zeit sogar vollständig erstarren
is formed, which can even solidify completely after some time (see Figure 18). kann (Siehe
(Siehe Abbildung
Abbildung 10).
10).
Figures 16, 17 and 18: Moisture can also condense on the paint surface in theBild
tank.
8, 9, 10: Auch an der Lackoberfläche im Tank k
7.2. Tests on component Ein Video der Reaktion eines Zinklamellen-Basec

hinterlegt:
There are analytical methods for all surface properties. Since these are very complex, the tests
described here only serve as an aid in order to be able to carry out an evaluation in comparison
with optimal reference components. The procedure must always be standardised internally.
These checks do not describe any system-relevant release checks for the end customer.
Since the coating process is subject to a multitude of influences, the coating result must be
monitored regularly.
The necessary tests must be introduced and validated in accordance with the quality management
Bild 8,
guidelines.
Bild 8,The
9, 10:
9, 10:required
Auch an
Auch an der
der Lackoberfläche
inspection im Tank
intervals
Lackoberfläche im Tank kann
must Feuchtigkeit
beFeuchtigkeit
kann kondensieren.
defined. Each lot must be tested based on
kondensieren.
statistical guidelines.
Ein Video
Ein Video der
der Reaktion
Reaktion eines
eines Zinklamellen-Basecoats
Zinklamellen-Basecoats mit
mit Wasser
Wasser ist
ist unter
unter folgendem
folgendem QR-Code
QR-Code
hinterlegt:
hinterlegt: 7.2. Prüfungen am Bauteil
Für alle Eigenschaften von Oberflächen gibt es anal

dienen die hier beschriebenen Prüfungen nur als Hil
Referenzbauteilen eine Bewertung vornehmen zu kö
standardisieren.
Diese Prüfungen beschreiben keine systemrelevante
7.2. Prüfungen
7.2. Prüfungen am
am Bauteil
Bauteil
Für alle
Für alle Eigenschaften
Eigenschaften von
von Oberflächen
Oberflächen gibt
gibt es
es analytische
analytische Verfahren.
Verfahren. Da
Da diese
diese sehr
sehr aufwendig
aufwendig sind,
sind,
dienen
dienen die hier beschriebenen Prüfungen nur als Hilfsmittel, um im Vergleich mit optimalen
32 die hier beschriebenen
- IN-PROCESS Prüfungen nur als Hilfsmittel, um im Vergleich mit optimalen
INSPECTIONS
Referenzbauteilen eine Bewertung vornehmen zu
Referenzbauteilen eine Bewertung vornehmen zu können.
können. Das
Das Vorgehen
Vorgehen ist
ist hierbei
hierbei immer
immer intern
intern zu
zu
standardisieren.
standardisieren.
7.2.1. Cleanliness
a. Copper sulphate test
This test can be used to check the cleanliness of the substrate surface. On a bare steel surface, a copper
sulphate solution produces a visible chemical interaction (firmly adhering copper precipitation),
which only takes place if the substrate is free of residues, e. g.
oil, grease or scale, (see also Annex D "Test for sealing – Procedure: Dot test" on page 59).
Fig 19:
Copper sulphate test:
above o.k. clean,
below n.o.k.
b. Surface tension with test inks
The higher the measured surface tension, the cleaner the substrate. The tension is determined using
several test inks. For a coating process, internal reference values can be determined that describe
a minimum level of cleanliness.
Fig 20:
Test inks 28–56 mN/m,
steel plate left half
with oil, right side clean
without oil
asserperltest
c. Water pearl test
esem Test werden Wassertropfen auf die Oberfläche aufgetragen. Je fettiger / öliger die
In this
läche ist, desto test, drops
prägnanter of water
steht are applied toauf
der Wassertropfen theder
surface. The more
Oberfläche. Einegreasy/oily
deutliche the surface is, the more
concise
enbildung lässt the water
auf eine drop
unreine is on the surface.
Oberfläche A clear drop formation indicates an impure surface.
schließen.
Surface cleanliness/wettability
waterdrop
substrate
surface
modest
best
Fig 21:
Spread of a drop of water on dirty
Abbildung 11: Ausbreitung eines Wassertropfend auf and cleaned surfaces.
verschmutzten und gereinigten Oberflächen.
d. Test for absence of oil and grease using small ceramic balls
st auf Öl- u. AFettfreiheit
previouslymittels
cleaned component
kleiner is then placed into a container with small ceramic beads (Zirblast®
Keramikkugeln
B60: 0.125-0.25 mm). The component is then carefully removed and lightly beaten twice against a
firm Bauteil
uvor gereinigtes surface.wird
Theniniteinen
is evaluated whether
mit kleinen ceramic beads
Keramikkugeln still adhere
(Zirblast® B60:to0,125-0,25
the surface of the component.
If ceramic beads still adhere, the result should be evaluated as n. ok. In the absence of ceramic beads
gefüllten Behälter getaucht. Danach wird das Bauteil vorsichtig entnommen und 2 mal leicht
on the surface of the component, the result is to be deemed ok. The test must always be carried out
n eine feste Oberfläche geklopft. Im Anschluss wird bewertet ob noch Keramikkugeln an der
with new, clean ceramic beads.
läche des Bauteiles anhaften. Bei noch anhaftenden Keramikkugeln ist das Ergebnis als n.i.O
werten. In Abwesenheit von Keramikkugeln auf der Oberfläche des Bauteiles ist das Ergebnis
O. zu bewerten. Der Test ist mit stets neuen sauberen Keramikkugeln durchzuführen.
Figures 22 and 23:

Bild 13: links Ergebnis n.i.O., rechts Ergebnis i.O. left result o.k., right result n. ok.
e. Wipe test
A white, lint-free cloth is rubbed over the surface. Visible residues on the cloth indicate an impure
surface.
Figures 24 and 25:

Wipe test left ok, right n. ok.
f. Test for freedom from oil and grease using fluorescence measurement
Residues such as oils, greases, cooling lubricants etc. can be detected using a method in which light
in the ultraviolet range is emitted onto a measuring point of the component by means of an LED
and the fluorescence is measured with a photodiode. The higher the measured value, the greater the
contamination of the component.
Fig 26:
Fluorescence measurement
with SITA Cleano Spector
7.2.2. Corrosion resistance
There are many ways to measure corrosion resistance. The salt spray test according to DIN EN ISO
9227 is usually used to determine how long it takes for white or red rust to form.
To perform the salt spray test, an appropriate atmosphere is required and the use of automatic
test equipment is recommended. The introduction of copper ions through copper and copper alloys
in one chamber should be avoided. A list of suppliers of measuring instruments can be found in
Appendix A "Suppliers of auxiliary materials and equipment" on page 49.
Fig 27:
Salt spray test according
to DIN EN ISO 9227
7.2.3. Friction coefficient
The coefficient of friction has a considerable influence on the tightening behaviour. It determines
how much torque is converted into pre-load force (which holds the two components together). If
the coefficient of friction is too high, the pre-load force will be too low and the connection will not
be properly preloaded. Conversely, too high a pre-load force (with too low friction) can cause the
bolt to break.
The mathematical and testing fundamentals are described in DIN EN ISO 16047. However, many
customers attach importance to their specific reference parts (nuts, washers, strips) and the
evaluation method, which can lead to different results.
Figures 28 and 29: Measurement of friction coefficients based on DIN EN ISO 16047
7.2.4. Vormaß und Lehrenhaltigkeit
7.2.4. Pre-dimension and accuracy to gauge
Eine Beschichtung braucht Platz, von daher sind schon bei der Gewindeherstellung die Schichtdicken
zu beachten und needs
Coating in entsprechende Toleranzklassen
space – therefore einzuordnen.
the layer thicknesses DietoDIN
have be EN
takenISO 10683
into hat diesen
account during thread
Platz in den Toleranzklassen berechnet (grafisch dargestellt in der Dörken MKS-Systeme
production and classified into corresponding tolerance classes. DIN EN ISO 10683 has calculated this
Anweisung).
spaceZur
in Überprüfung
the tolerancedient die (shown
classes Lehrunggraphically
mit Prüfmitteln
in thenach DINMKS
Dörken EN ISO 1502 (zuThe
instruction). beachten
gauging with
sind auchtest
dieequipment
Schlagstellen / Gewindebeschädigungen
in accordance with DIN EN ISOnach
1502DIN EN for
is used 26157. Diese(the
checking werden mitpoints/thread
impact den
gleichen damage
Prüfmittelin kontrolliert,
accordancesodass
with DINdasENFehlerbild genau
26157 must alsozubeüberprüfen
taken into ist).
account. These are checked with
the same test equipment so that the defect pattern can be checked exactly).
Das Vormaß für Kraftinnenangriffe ist in keiner Norm im Moment beschrieben.
The pre-dimension
Der Beschichter muss dieses formit
screw heads
seinem with internal drive
Vertragspartner is currently
gesondert regeln.not described in any standard.
The coater must regulate this separately with his contractual partner.
Hinweis: DSV Richtlinie „Verschraubbarkeitsprüfung von Muttern mit Zinklamellenüberzügen“
Note: DSV Guideline "Screwability test of nuts with zinc flake coatings" www.schraubenverband.de
www.schraubenverband.de
Figures 30 and 31: Gauging with test equipment based on DIN EN ISO 1502
Bild 19, 20: Lehrung mit Prüfmitteln nach DIN EN ISO 1502
Dimensions M…
Table 6. Layer thicknesses in µm for sizes 6g and 6e in accordance with ISO 10683.
Metric standard thread to ISO 965 tolerance positions 6g and 6e.
Abbildung 12:
7.2.5. Determination of layer weight
The average weight of the coating is very easy to determine. For this you take a suitable number of
parts (e. g. 5 screws) and weigh them before and after coating. The difference is the weight of the
coating for the corresponding number of parts.
Since the parts themselves show weight differences, it is recommended to mark the parts used for
weighing with markings that are also recognisable after coating. In this way you can weigh the same
parts and be sure that there will be no error due to the weight of the parts themselves. It is advisable
to wear gloves during the process.
Equipment: precise scales, gloves
7.2.6. Layer thickness
The layer thickness is very low, since our products are applied in the range of only a few µm. This
makes measurement more difficult.
a. Magnetic inductive/ eddy current measurement

Electronic measuring instruments based on induction are very often used here. A probe with a
magnetic field is placed on the surface. With steel substrates, the magnetic field induced under
the paint is measured. Eddy current testing is used for all other metals that have no ferromagnetic
effect (such as aluminium, copper, etc.). In most cases the same equipment can be used, but the
probes have to be replaced. The measured value depends on the distance between the substrate
(e. g. steel) and the probe. The reproducibility is usually around 10 %.
A new calibration must always be carried out before each measurement. Unless an application is
stored for this purpose (see back of instrument): Then press "Appl No" to select the application and
carry out a short check on the base material.
If the value is around 0 (+/- 2 µm), you can measure.
Measurement using Fischer MP40 as an example:

Switch on the instrument > ready for operation, it can be measured.
For a block evaluation (mean value, STD, etc.) of a certain number of measurements you should
start with n=0. After five measurements press "Block-Res". Press further to access the individual
evaluations. Deviations of up to +/- 3µm are normal.
How do I measure correctly?
With curvature:
Carry out calibration on the curved spot. Use auxiliary tripod and probe wedge.
Large measuring surface:

With a very small test part, the calibration and the measurement are always carried out at the
same position.
Field penetration depth:

Ensure that there are no variations in the base material thickness. Perform calibration on the
surface to be measured.
Fig 32:
Coating thickness measurement - Magnetic inductive
b. X-Ray
Another possibility is measurement with X-rays. The substrate of the sample emits characteristic
X-rays after excitation. The more of these waves are absorbed by the coating, the thicker the layer is.
With appropriate calibration, the measuring instrument outputs the layer thickness. Only base-coats
can be determined with this measuring method
Fig 33:
Measurement results
after X-rays
Figures 34 and 35:

Measurement
with X-rays
c. Cross section
c. Querschliﬀ: Die präziseste Methode zur Bestimmung der Schichtdicke ist das Anfertigen eines
The most precise
Querschliffes method for determining
mit anschließender the layer
mikroskopischer thickness Im
Auswertung. is the preparation
Schiedsfall of aincross section
gilt das
withEN
DIN subsequent microscopic mikroskopische
ISO 1463 beschriebene evaluation. In the case ofalsarbitration,
Verfahren the microscopic method
Referenzmethode.
described in DIN EN ISO 1463 is the reference method.
Figures 36 and 37:

Cross section with subsequent
microscopic evaluation
! !
Bild 25, 26: Querschliffes mit anschließender mikroskopischer Auswertung
7.2.7. Adhesion
7.2.7. Haftung
The adhesive strength is usually tested by an adhesive tape test. Sometimes it is combined with a
cross cut test. The adhesive tape is glued to the sample, rubbed firmly with the fingers or an eraser
Die Haftfestigkeit wird meist durch einen Klebebandtest geprüft. Manchmal erfolgt sie auch in
and then pulled off abruptly to see whether part of the coating adheres to the adhesive tape. Since it
Verbindung mit einer Gitterschnittprüfung. Das Klebeband wird auf die Probe aufgeklebt, mit den
is difficult to reproduce the pressure force, the speed of peeling and the evaluation of how much paint
Fingern
adheresbzw. einem
to the tape,Radiergummi fest tape
at least the same gerieben undalways
should dann be
ruckartig
used. abgezogen, um zu sehen, ob ein
Teil der Beschichtung am Klebeband haftet. Da die Anpresskraft, die Geschwindigkeit des Abziehens
und
When dietesting
Bewertung, wie viel of
the adhesion Lack am Klebeband
a base-coat, haftet,
it should nur schwer
not detach zu reproduzieren
completely sind, sollte
from the substrate so that
zumindest stets das gleiche Klebeband verwendet werden.
the bare steel can be seen. Small amounts of metal residues on the tape are normal.
Beim Prüfen der Haftung eines Basecoats sollte sich dieser nicht vollständig vom Substrat lösen, so
dass der blanke Stahl zu sehen ist. Kleine Mengen von Metallrückständen auf dem Klebeband sind
durchaus normal.
Für die Gitterschnittprüfung sind mit einem scharfen Messer 6 parallele Schnitte und dann dazu 6
senkrecht stehende Schnitte so anzubringen, dass 25 Quadrate entstehen. Eine detaillierte
Beschreibung der Gitterschnittprüfung und insbesondere der Bewertung finden Sie in der Norm DIN
EN ISO 2409.
Figures 38 and 39:

Tape test left ok, right n. ok.
! !
Bild 27, 28: Klebebandtest links i.O., rechts n.i.O.
For the cross cut test, 6 parallel cuts and then 6 vertical cuts shall be made with a sharp knife to form
25 squares. A detailed description of the cross cut test and in particular the evaluation can be found
in the Standard DIN EN ISO 2409.
Figures 40 and 41:

Cross cut test
Abbildung 13: Gitterschnittprüfung

(oben: Prüfblech; unten: Klebestreifen)
7.2.8. Evidence of sealing
In order to check whether a topcoat is present on a zinc-containing layer, a copper sulphate solution
is applied. A possible change is visible after only a few seconds. If too little or no topcoat is present,
ung der Adhäsion ist unter folgendem QR-Code hinterlegt:
the copper will precipitate as a brown to black sediment (see Appendix D "Test for sealing – Method:
Dot test" on page 59).
Abbildung 13: Gitterschnittprüfung
(oben: Prüfblech; unten: Klebestreifen)
sion ist unter folgendem QR-Code hinterlegt:
is einer Versiegelung
gelung
ob ein Topcoat auf einer zinkhaltigen Schicht vorhanden ist, wird eine
t auf einer zinkhaltigen Schicht vorhanden ist, wird eine
sung aufgebracht. Bereits nach wenigen Sekunden ist eine mögliche Verände
cht. Bereits nach wenigen Sekunden ist eine mögliche Veränderung
nr zu
gar wenig odervorhanden
kein Topcoat gar keinist,
Topcoat
wird sichvorhanden
das Kupfer alsist, wirdbis
braune sich das Kupfer als braun
mentation(siehe
derschlagen niederschlagen
Anhang D „Test(siehe Anhang –DVerfahren:
auf Versiegelung „Test auf Versiegelung – Verfahre
Seite <US>).
8. IN-PROCESS MAINTENANCE INTERVALS
Due to the different throughput, the respective environmental influences and the type of parts to be
coated, it is very difficult to give a general recommendation regarding maintenance. This section
should therefore only be regarded as a rough guideline, which you must adapt according to your op-
erating conditions.
Maintenance Interval
Viscosity + Temperature Every 2 hours
Solid content 1 x/work shift
Filtering 1 x/week
Define limit pattern, then
Cleaning the coating baskets
define intervals
Cleaning the coating frames
define intervals
Cleaning of all application components
define intervals
Oven temperature, profile 1 x/month
Define action limit,
Paint level
check every 2 hours
Table 7. Maintenance intervals
The following application components must be regularly compared with reference samples and
cleaned accordingly:
• Immersion tanks (centrifugal rings)
• Vibrating feeders
• Oven belts.
• Tray plates
• Application equipment for spray application
• Filters as well as racks and baskets and all components that come into direct contact
with the paint.
The residues remaining in the coating system must be removed by cleaning (once per working
shift, e. g. every 8 hours). This prevents small residues from sticking to the parts or getting into
the fresh paint
8.1. Influences to be avoided within the process
Humidity
In the case of water-sensitive paints, such as solvent-based zinc flake base-coats,

moisture being brought in may lead to gelation or thickening.
When using a wet pre-treatment such as phosphating or electroplating, the treated parts must not
allow any water to enter the paint.
This must be avoided at all costs with zinc flake base-coats. The treated parts must be dry before the
base-coat is applied.
42 - IN-PROCESS MAINTENANCE INTERVALS

a. The container must be clean and dry before filling. Remove dust, grease and water from the im-
mersion container if it is not clean.
b. Whenever possible, the container must be closed with a lid.
c. When filling the paint, put a whole bucket into the container. Do not store partially emptied buck-
ets for later use! The bucket could absorb moisture from the ambient air.
d. In order to avoid condensation formation in cold canisters, these must be brought to ambient
temperature before filling the container. Do not use a heater for this purpose!
When cold paint buckets are opened, water condenses in the bucket and the cold paint gels.
e. A similar behaviour occurs when the parts are cold during coating. If very cold screws, nuts or
pressed parts are brought into the coating area at ambient temperature, condensation may
form on the parts. To prevent this moisture from entering the immersion tank, wait until the
parts have warmed to ambient temperature.
f. The room in which the paint is prepared must have a maximum relative humidity of 65% to
prevent condensation on cold paint buckets.
Dew point
If the immersion tank or the parts to be coated have a temperature below the dew point, water
precipitates and damages the moisture-sensitive materials. This must be avoided at all costs! It
is therefore recommended to maintain a minimum temperature of Tmin = dew point + 3 K at all
important points.
A regular check of the dew point is therefore absolutely necessary.
Dust
After the blasting process or after a refilling process (by rubbing the parts together), dust can adhere
to the parts. The dust must be removed before the parts enter the coating unit. On the one hand, this
would otherwise lead to poor adhesion. On the other hand, steel or zinc dust can be embedded in
the dry layer and form rust spots before the substrate rust. In addition, steel and zinc dust can
dissolve in water-based lacquers and change their properties (see also "2. Surface pre-treatment"
and 3. Paint preparation" on page 13 and page 17).
Hydrogen embrittlement:
Hydrogen embrittlement can occur with certain pre-treatment methods such as pickling and
electrolytic degreasing. Hydrogen atoms can diffuse into the steel and under certain conditions
lead to a decrease in strength.
In the application of Dörken MKS paints, this can be ruled out due to the process.
Temporary corrosion protection

When temporary corrosion protection is used, chemicals containing amines, borates and silicates
must not be used, as they damage the base-coats.
IN-PROCESS MAINTENANCE INTERVALS - 43

9. DOCUMENTATION
Each company documents in its own way the quantities, properties, quality of incoming and outgoing
products, type of treatment and coating as well as the plant and equipment. Therefore, only a few
details should be mentioned in this chapter. In addition, it is necessary to keep additional records for
measuring instruments and auxiliaries, which are not dealt with here.
Material feed
During the coating process, new material (paint and solvent) must be replenished due to paint
consumption or evaporation of the solvent. The paint level must therefore be checked regularly.
The quantity of material added, date and time, type of material and lot number should be recorded.
In addition, the values for viscosity and solids content should also be noted on the same form.
It is also advisable to check and record the temperature and humidity (and dew point) of the
coating zone/booth
Tank number: 1 Last filtering: New filling
Coating material: Delta Protekt KL 120 Next filtering: 17.11.2018
Filling: 17.10.2018
Viscosity check
[3mm DIN flow cup] Material feed
(Every 2 hours)
Solids
Target Actual After Paint Air Relative Dew point content Carried
value value correction temperature Paint Batch Thinner Batch temperature humidity temperature (daily) out
Date Time [s] [s] [s] [°C] [kg] No. [L] No. [°C] [%] [°C] [%] person Remarks
18/10/2018 06:00 40-45 44 18 30 076567 2 3794032 21 35 5 Müller
08:00 40-45 43 19 Müller
10:00 40-45 42 20 21 40 7 Müller
12:00 40-45 43 22 Müller
14:00 40-45 43 22 23 65 16 56 Schmitz
16:00 40-45 45 41 22 8 3794032 Schmitz
18:00 40-45 42 21 23 50 12 Schmitz
Centrifugal
20:00 40-45 43 20 Schmitz funnel must be
cleaned.
Table 8. Sample documentation of the bath parameters (basin protocol in Annex E).
44 - DOCUMENTATION
On job card, which accompanies the products from goods receipt to dispatch, the special
properties of the parts are usually listed, such as:
• Type of part/part geometry
• Weight/volume/bulk density of the parts
• Delivery condition (oiled, heat-treated etc.)
• Pre-treatment
• Type and thickness of coating to be applied
In addition, the applied coating parameters (viscosity, programmes, loading, special drum geometry,
burn-in parameters, etc.) can also be determined.
Goods inward inspection

The delivery condition of the components must be contractually agreed and important criteria
must be checked. Important are surface quality (oil, stainless steel, scale), mixing of parts, gauge
accuracy – if required – and other component-specific features.
Outgoing goods inspection

The outgoing condition of the components must be contractually agreed and important criteria
must be checked.
Before shipping the products, the quality of the coating must be ensured by means of a suitable
test procedure.
Corrosion resistance, accuracy to gauge and coefficient of friction are particularly important.
DOCUMENTATION - 45
Job card for Dörken MKS coating
Tank No.
Customer
Item Article No.
Delivery docket No. Delivery docket date
Order No. Incoming date Schedule
Batch Total weight in KG Overall quantity Packaging
Standard Coating structure
Coating system
X Date Signature Comments

Goods inward check done
Degreasing done
Check after degreasing done
Blasting done
Check after blasting done
1. Coating done
Check after 1 Coating done
2. Coating done
3. Coating done
4. Coating done
Final inspection done
Packaging done
Fig 42: Job card
46 - DOCUMENTATION
9.1. General Information
Detection of solvent-containing coating systems. Titanates can be detected by a simple drop sample.
Add one drop of sulphuric acid (20-25%) to the base-coat. The acid attacks the zinc and the binder.
After a few seconds you will see gas bubbles. If there is a topcoat over the base-coat, remove it
carefully with a knife.
Now apply a drop of hydrogen peroxide solution (H2O2, 20-25 %) to the place of the first drop. If
titanates are present, the drops will turn yellowish to orange
Detection of chromium(VI)-free systems

Scratch the sample with a pointed needle to activate the surface. Rub a drop of test solution
thoroughly with a cotton swab. After 2 minutes, a red colour will appear if the coating contains
chromium(VI). Test solution: 6 ml deionised water + 5 ml acetone + 5 ml ethanol + 4 ml H3PO4 (86 %)
+ 0,1g diphenylcarbazide.
Checking the ovencurve

Standard test equipment is available (see Annex C "Recommended measuring instruments and test
equipment" on page 54). First, the data logger is to be placed in the oven together with a load
of coating parts. It is then connected to a computer to read out the temperature-time diagrams. The
test equipment itself is well insulated against heat. This technique is suitable for cassette ovens or
ovens with conveyor belts at the same height. However, if the conveyor belt has a cascade and
the device can be damaged by the fall, temperature probes with a long connecting cable are an
alternative. The probe should always be installed in a representative part. Dörken MKS uses an M10
screw, into which a small hole is drilled, to insert the probe. This ensures that the metal temperature
is actually measured and not just the hot air. Furthermore, it is advisable to measure at several points
with full loading of the oven in order to obtain values for the entire oven.
Testing for correct curing

After the curing process, there are several methods for testing the curing properties:
The most common, but also the most time-consuming, method is to subject the parts to a salt spray
test to determine whether they meet the customer's requirements.
Another possible method is the MEK test. This involves moistening a piece of cloth with MEK (methyl
ethyl ketone), applying a force of 1 kg to the flat surface with the thumb and rubbing it back and
forth over a short distance. Count the number of double strokes required to remove the coating. The
disadvantage of this method is that it is only suitable for objects with a flat surface and cannot be
used for base-coats either, as the silver sheen of the base-coats is very similar to the sheen of blasted
steel and therefore difficult to distinguish.
A very easy test to perform is the adhesive tape tear-off (tape test). For this purpose, a piece of
adhesive tape is stuck firmly onto the specimen with the help of fingers or an eraser. Subsequently,
it is pulled off jerkily and the amount of paint adhering to the adhesive tape is estimated. If
cured correctly, only small residues may adhere. For further details please refer to section
"7.2.7. Adhesion" on page 40
DOCUMENTATION - 47
10. Control plans
The specified characteristics, methods and samples must be adapted to the coating process under
consideration of a statistical evaluation and validation.
Adjustments must be traceable.
In the event of complaints from the supply chain, Dörken MKS-Systeme will review the control plans
together with the process owner and define measures.
The control plans and other downloads for the application manual referred to here can be found
in the login area of our homepage. Registration on the Dörken MKS homepage is required here
(Login >> sign-up)
1 CPLAN storage and paint preparation

2 CPLAN incoming and outgoing goods
3 CPLAN pre-treatment – degreasing
4 CPLAN pre-treatment – blasting
5 CPLAN tank monitoring
6 CPLAN machine data
7 CPLAN curing
48 - CONTROL PLANS
Annex
Annex A
Suppliers of auxiliary materials and equipment
Below you will find a selection of suppliers.
Blasting abrasive:
VULKAN INOX GmbH

vulkan-inox.de
WIWOX GmbH Surface Systems

wiwox.com
FROHN GmbH
frohn.com
Ervin Industries
ervinindustries.com
Solvent for cleaning:
ESSO
esso.de
EXXON
exxonmobil.com
Gyroscopic mixers:
Fluid Management
fluidman.com
Chameleon Colour Systems (e. g. RGM40)

chameleon.de
Fast & Fluid Management (e. g. Fast Galileo)

fast-fluid.com
Shunde Kedi
KD-30A automatic
kedi00.diytrade.com
Collomix Rühr- und Mischgeräte GmbH

collomix.de
ANNEX - 49
Stirrers:
Pendraulik GmbH (e. g. Pendraulik WR-V-25)

pendraulik.de
FluidSystems GmbH & Co. KG

fluidmix.de
ZANELLI S.r.l.
zanelli.com
Maver Milano S.r.l.

mavermilano.com
Measuring device:
Universal devices:
BYK-Gardner
bykgardner.com
Erichsen
erichsen.de
Weiss Umwelttechnik GmbH

wut.com
Gebr. Liebisch GmbH & Co. KG

liebisch.com
Elcometer
elcometer.com
VLM GmbH
vlm-labtec.com
Layer thickness:
Fischer (e. g. MP 40)

helmut-fischer.com
Winterthur Instruments
winterthurinstruments.de
Oxford Instruments
oxford-instruments.com
50 - ANNEX
Material analysis
Fischer
helmut-fischer.com
Roentgenanalytik GmbH & Co. KG

roentgenanalytik.de
Oven temperature measuring instruments:
Messtechnik-Vogel (e. g. Curve-X)

mtv-messtechnik.de
Datapaq
datapaq.com
Temperature and humidity measuring instruments:
Testo (e. g. Testo 615)

testo.de
Automatic devices for determining the solids content:
Sartorius (z.B. Sartorius MA 150)

sartorius.com
Mettler Toledo
mt.com
Surface cleanliness:
Arcotec
arcotest.de
LotarEnterprises
lotarenterprises.com
Sita Messtechnik GmbH

sita-messtechnik.de
ANNEX - 51
Friction coefficient test:
Schatz AG
schatz-germany.com
TesT GmbH
test-gmbh.com
Automatica
automatica.fr
REC® Engineering GmbH

rec-engineering.de
Plant construction
WMV Apparatebau GmbH & Co. KG

wmv.com
Ernst Reinhardt GmbH

ernst-reinhardt.com
SIDASA Engineering
sidasa.es
Forplan AG
forplan.ch
O.M.SA. Srl.
omsasrl.com
dh surfaces-solutions e.U.
dh-surfaces-solutions.com
J.Wagner GmbH
wagner-group.com
MAFAC Ernst Schwarz GmbH & Co. KG

mafac.com
Exel Industries
exel-industries.com
SLF Oberflächentechnik GmbH

slf.eu
52 - ANNEX
Annex B
Here you will find a selection of standards dealing with the testing of coatings and corrosion
resistance.
Standard Title
(year of publication
ISO 6270-2 (2005) "Coating materials – Determination of resistance to humidity –
Part 2: Methods for loading specimens in condensation water climates".
DIN 50018 "Tests in an alternating condensation-water climate with an atmosphere
(2013-05) containing sulphur dioxide"
ISO 9227 (2017) "Corrosion tests in artificial atmospheres – salt spray tests."
ISO 8044 (2015) "Corrosion of Metals and Alloys – Basic Terms"
DIN 50905-1 (2009-09) "Corrosion of metals – Corrosion investigations – Part 1: Principles"
DIN 50918 (1978-06) "Corrosion of metals; electrochemical corrosion tests"
ISO 4628-3 (2016) "Coating materials – Evaluation of coating damage – Evaluation of the amount
and size of damage and the intensity of uniform changes in appearance –
Part 3: Evaluation of the degree of rust"
ISO 2178 (2016) "Non-magnetic coatings on magnetic base metals – Layer thickness
measurement – Magnetic method"
ISO 2360 (2003) "Non-conductive coatings on non-magnetic metallic substrates –
Measurement of coating thickness – Eddy current method".
ISO 2409 (2013) "Coating materials – cross-cut test"
ISO 2431 (2011) "Paints and varnishes – Determination of the flow time with flow cups"
ISO 3231 (1993) "Coating materials – Determination of resistance to humid atmospheres
containing sulphur dioxide"
ISO 3497 (2000) "Metallic layers; film thickness measurement; X-ray fluorescence method"
ISO 4518 (1980) "Metallic coatings; Measuring film thickness; Profilometric method"
ISO 4624 (2016) "Coating materials – Tear test for assessment of adhesion"
ISO 6270-2 (2005) "Coating materials – Determination of resistance to humidity –
Part 2: Methods for loading specimens in condensation water climates".
ISO 8501-1 (2007) “Preparation of steel surfaces prior to the application of coating materials –
Visual evaluation of surface cleanliness – Part 1: Degrees of rust and surface
preparation of uncoated steel surfaces and steel surfaces after complete
removal of existing coatings".
ISO 8501-2 (2002) "Preparation of steel surfaces prior to the application of coating materials –
Visual evaluation of surface cleanliness – Part 2: Surface preparation degrees
of coated surfaces after local removal of existing coatings".
DSV Directive (2012-02) “Bolt tightness test of nuts with zinc flake coatings"
ASTM B117 (2016) Operating saltspray (fog) apparatus
ASTM B368 (2009) Copper-accelerated acetic acid-salt spray (fog) testing (CASS test)
ASTM B537-70 (2013) Rating of electroplated panels subjected to atmospharic exposure
ASTM D1654 (2008) Evaluation of painted or coated specimens subjected to corrosion environments
Table 9
ANNEX - 53
Annex C
Recommended measuring instruments and testing equipment
Viscosity:
• 3mm cup according to DIN 53211 on tripod with temperature control or
• 3mm cup according to DIN 53211 for manual control
• Stop watch
• Thermometer
Corrosion resistance:
• salt spray chamber (e. g. DIN EN ISO 9227 or comparable)
• Chamber for condensation water testing (e. g. . DIN EN ISO 6270-2)
• Kesternich chamber (e. g. DIN 50018)
Solid content:
Manual
• Laboratory scales (min. 4 decimal places!)
• Aluminium bowl
• Owen
• Stop watch
• Fully automatic
• Moisture Analyser (e. g. Sartorius MA 150)
Distribution of the oven temperature:

Temperature data logger, oven temperature probe
Dew point:
Manual
• Dew point table (see appendix)
Fully automatic
• Dew point meter (e. g. Testo 615)
Layer thickness
• Magnetic-inductive thickness measuring device (for coatings on steel)
• Eddy current thickness measuring device (for coatings on aluminium)
Adhesion:
• Adhesive tape (Tesa adhesive tape no. 4651 from Beiersdorf)
• Sharp knife (e. g. scalpel)
• Ruler for making parallel cuts
Gauge accuracy of bolts and nuts:

• Thread gauge for screws (6e, 6g and 6h for all diameters)
• Thread gauge for nuts (6G and 6H for all diameters, according to DIN EN ISO 10683)
• Gauges for testing the inner head drive (inner Torx, hexagon socket screws, cross recess)
Layer structure:
• Microscope
• Equipment for preparing metallographic cross-sections
(precision saw, polishing machine, embedding device)
54 - ANNEX
Annex D
Detailed description of work and test instructions
Adaptation to your own processes and procedures are indispensable.
Preparation of a salt batch for DIN EN ISO 9227:
Preparation of a salt batch:

Place 50 kg sodium chloride in the mixing container and
fill up to the measuring mark with 1,000 l water,
mix the mixture well with the existing whisk and leave to stand for 24 hours,
mix well again after 24 hours and leave to rest for 30 minutes,
Test the quality of the saline solution.
Attention: If mixing is poor, the concentration of the salt solution in the lower part of the tank
is higher than in the upper part.
Quality inspection of the saline solution:

Take the sample from the homogeneous solution using a 100 ml graduated cylinder.
1. pH-value (Calibrate pH electrode once a week to pH 4 and 6.8)

Remove the electrode from the KCl solution and rinse briefly with distilled water.
Place the electrode in the measuring cylinder with the sample and measure continuously for
15 min. After 15 minutes, read off the indicated value and enter it in the ready-made list.
The pH value should be 5.5-6.0 (internal target so that a pH value of 6.5–7.2 can be achieved
afterwards in the sample tank).
If the pH falls below this value, the preparation is adjusted with 1 mol/l sodium hydroxide (NaOH)
solution. If the values are exceeded, acidify the solution with 1 mol/l hydrochloric acid (HCl).
Attention (Corrosive liquids):

After use, rinse the pH electrode lightly and return it to the KCl solution.
2. Density determination with the refractometer

Device test: Measurement of distilled water; if the value exceeds 0.1 %, the measuring disc
must first be cleaned and calibrated after it has been exceeded again.
Calibration: Apply distilled water on the measuring plate and press the "zero" button.
Measurement:
Applying the sample from the measuring cylinder with a pipette
Start measurement with "Start
Density should be between 1.029-1.036 g/cm3 (internal specification to achieve the desired end
values). If the values deviate: Adjust the solution with salt or water.
After a successful quality check, the salt solution can be used!
Other applicable documents: DIN EN ISO 9227
ANNEX - 55
Control salt spray chamber:
Daily check:
• run test time
• Temperature in the test chamber (target 34–36 °C)
• Humidifier temperature (target 45–52 °C)
• Pressure (nominal 0.7–1.4 bar)
• Reading of the measuring cylinders embedded in the basin
(first from the left then from the right measuring cylinder)
Attention: The values in the left and right measuring cylinders must be the same up to 30%.
In the event of deviation the nozzle must be adjusted! Calculation of the average condensation
water quantity per hour.
Weekly check: (Calibrate pH electrode once a week to pH 4 and 6.8):

1. pH-value
Remove the electrode from the KCl solution and rinse briefly with distilled water.
Place the electrode in the measuring cylinder with the sample and measure continuously for 15 min.
Read off the value after 15 min (target 6.5–7.2).
After use, rinse the pH electrode lightly and return it to the KCl solution.
2. Density determination with the refractometer

Device test: Measurement of distilled water; if the value exceeds 0.1%, the measuring disc must
first be cleaned and calibrated after it has been exceeded again.
Calibration: Applying distilled water on the measuring plate and press the "zero" button.
Measurement:
• Applying the sample from the measuring cylinder with a pipette
• Start measurement with "Start"
• The density should be between 1.025–1.040 g/cm3.
• The density in g/cm³ is rounded to three decimal places.

D1_Qualicor Test specification Salt spray test Functional test
Annual check of the corrosiveness of the salt spray chamber:
Test preparation (1):

The salt spray chamber to be tested must be completely empty and able to run continuously for 48 hours.
Test material:
• 3 steel sheets CR4 according to ISO 3574 (150 mm x 70 mm)
• 3 zinc sheets (50 mm x 100 mm)
• Ethanol & Acetone
• Test solutions according to DIN 8407
Steel sheets: total 1.000 ml

500 ml distilled water
500 ml hydrochloric acid (HCL, ρ = 1,19 g/ml)
3.5 g hexamethylenetetraamine
56 - ANNEX
Zinc sheets: total 1.000 ml
250 g glycine in 1.000 ml distilled water (heat distilled water and dissolve glycine while constantly
heating and stirring).
Test preparation (2):

Thoroughly clean the sheets with acetone under a fume hood before testing.
Determine and note the mass of each sheet to within +/- 1 mg. Number the sheets from 1–3
and do not mix them up.
Set up at three positions of the chamber at an angle of 20 +/-5° to the vertical.
Length of test: 48h

In the event of an interruption or a technical problem, the attempt must be aborted and restarted.
Determination of mass loss:

Immerse the steel plates in the prepared test solution at 20–25 °C for 10 minutes.
Then clean with water, rinse with ethanol and allow to dry.
Immerse the zinc sheets in the prepared test solution at 20–25 °C for 5 minutes.
Then clean with water and light brushing, rinse with ethanol and allow to dry (repeat the
cleaning process for another 5 minutes if necessary). After drying, weigh all sheets exactly.
Always pay attention to the sequence.
Suspension and evaluation of samples in the salt spray test:
On the basis of DIN EN ISO 9227

Only samples that do not influence each other may be tested together. Select a suitable sample
holder depending on the type of sample. (For Ford: Screw holder with thread. Screw is screwed in
with 2 threads. Before testing, clean specimens with a phosphate-free, non-corrosive and slightly
alkaline washing solution, used here "deconex 21 CLF (liquid)" Dosage 3-10 ml/l water; see Figure 44).
20°¶
➝
Fig 43:
The screw head should run parallel to the
sample plate and thus have the same angle.
ANNEX - 57
The sample must be flat and inclined at an angle of 20° +/- 5° to the vertical if possible.
20°
➝
Fig 44:
Assembly according to Ford's requirement
No minimum distances are required, but the surfaces to be tested must be exposed to the spray
mist acting on them and must not touch each other or the walls of the container.
Irregular specimens such as pipe pieces must be placed at a slightly inclined angle in the sample
container so that condensation and rust can drain off and no liquid is present on the specimens.
If it is necessary to hang samples, the material used must not be metallic under any circumstances.
Samples must not be hit directly by the spray jet of the nozzle.
Evaluation:
The samples are examined in the chamber at regular intervals (as specified).
When the time has elapsed or changes become apparent, the sample is removed from
the test chamber and rinsed under running clear water and dried with compressed air.
When dry, the number and distribution of corrosion damage is described.
Documentation:
Take photographs, document red rust and/or white rust spots in lists.
Other applicable documents:

DIN EN ISO 9227
DIN EN ISO 10289
DIN 34804
DIN EN ISO 4628 part 1 to 10
Specific customer requirements:

Ford (WX 100)
GM (GMW 3355)
Daimler (DBL 9440)
58 - ANNEX
Test for sealing (procedure dot test):
Theoretical background:
The zinc flake coating (base-coat) reacts with copper sulphate to form elemental copper.
2-
Zn + CuSO4 → Cu + Zn 2++ SO4
If there is a topcoat on the zinc flake base-coat, it is protected against a reaction with the copper
sulphate solution.
Sequence:
Drop 1–2 drops of copper sulphate solution onto the surface to be tested. If the drop turns black
within 1–2 seconds or if a brownish red copper layer is deposited over time, there is no sealing on the
surface.
Fig 45: Dot test: left with sealing, right without
Preparation of the copper sulphate solution:

3 % copper sulphate solution adjusted to pH 1 with sulphuric acid
Recipe (for approx. 100 ml):

Weigh 4.69 g copper sulphate pentahydrate into a beaker glass
dissolve well in 100 g distilled water.
adjust to pH 1 with sulphuric acid (1:1) (approx. 0.2 g)
(Wear protective clothing when handling the copper sulphate solution!)
Attention:
Always use a zero sample for measurement!
Due to the small amount of acid in the copper sulphate solution, a thin sealing layer may quickly
dissolve and colouring may become visible.
ANNEX - 59
Tank number: Last filtering:
Coating material: Next filtering Annex E:
60 - ANNEX
Filling:
Basin protocol
Viscosity check
[3mm DIN flow cup] Material feed
(Every 2 hours)
Solids
Target Actual After Paint Air Relative Dew point content Carried
value value correction temperature Paint Batch Thinner Batch temperature humidity temperature (daily) out
Date Time [s] [s] [s] [°C] [kg] No. [L] No. [°C] [%] [°C] [%] person Remarks
Table 9
Anhang F: Taupunkttabelle (Temperatur Taupunkt in °C)
Relative humidity φ [%]
Annex F:
Dew point table (temperature dew point in °C)
Room temperature T [C°]
ANNEX - 61
Table 10
Seite 59
Material Method People
Annex G 1:
62 - ANNEX
Degreasing Shot blasting
Motivation
Pretreatment
Setting the Selection of the Qualification
Phosphatisation
coating coating process
parameters
Design of the
Stability of parts Coating
the coating Organisation
mechanism Parts for
coating Preparation Parts handling
of the coating
material
State of delivery Corrosion
protection/
adhesion
reduced
Inspection Cleaning
Storage conditions parts/
of process coating material
parameters
Maintenance
Centri- Paint
fuge tank Basket Conditions of
Inspection Machine production
Causal diagram for reduced corrosion protection or reduced adhesion
of the reliability
Coating
cleaned parts plant
equipment
Delivery conditions
Quality control Transport Oven Cooling of the parts/
of coated parts system zone coating material
Controls Machine Environment
Table 11
Material People Measurements Annex G 2:
Viscosity too
low/high
Wax Incorrect calibration

Lack of
Unsuitable proportion motivation
solvent Wrong reference type
High fluctuation (surface counter bearing)
Inhomogeneous
mixing of the material
Mix-up of mate- Defective measurement
rials (choice instrument
Concentration Effective diameter
of topcoat) material of counter bearing
too old
Qualification
Contamination/mixing
Deviating solids content Wrong specification
Deviation
of the coefficient
Causal diagram for deviating coefficients of friction
of friction
Method does not meet
the requirements Wrong technical
Storage specifications
Fig 7: Ishikawa diagram: Causes of deviations in the coefficient of friction

conditions parts/ Coating parameters
coating material Selection of the
bolting parameters Insufficient unsuitable
temperature
Equipment profile
inadequate
Air (standard)
temperature/ Selection of the Application method
humidity bolting method unsuitable
Viscosity
too low/
Temperature of the parts high
Operator
experience Insufficient
Test parameters (e.g. new parts) pre-treatment
unsuitable
Application
Environment Method
ANNEX - 63
Table 12
The construction of the Reinhardt systems reduces the coating material and energy consumption with the best possible coating
quality and throughput. This results in low operating costs and high quality of the coatings. The cleaning cycles of the baskets, and
especially the drums are very long, as they will not run into an oven. The transfer of the material takes place in the cold area to the
conveyor belt or to the material pallets of the tempering furnace.
Reinhardt systems have the highest safety concepts and a minimized EX area. From the material transfer, the coating, the pre-
drying zone, curing and the cooling zone, everything is built in-house - there is only one contact person for you. The optimized
continuous ovens with pallets reduce the space requirement and shorten a system up to 40%.
Drum lines Basket lines
T 301 T 602 K451/350 K801/600 K 802/600
Features
Number of drums/baskets in the coating cell 1 2 1 1 2
Tilting up to 85° while spinning - - Yes Yes Yes
Ø drum / basket mm Ø 800 Ø 800 Ø 450 Ø 800 Ø 800
Width drum / height basket mm B 300 B 600 H 350 H 600 H 600
max. batch load kg 100 200 100 200 200
max. batch volume Liter 60 120 35 135 135
toal volume Liter 90 180 55 350 350
Reference part
hexagon head screw 3/8“ x 1 ½“ perfect for allen head etc. universal application
min. cycle time min 4 2 3 2 1,5
max. throughput rate (1 Layer) kg/h 1500 6000 2000 6000 8000
Approx. paint volume Liter 100 160 100 250 250
Range of parts Ø 3/16“ – 5/8“ 3/16“ – 3/4“ 3/16“ – 3/4“ 3/16“ – 1“ 3/16“ – 1“
Length min / max mm 3/8“ – 6“ 3/8“ – 6“ 1/4“ – 6“ 1/4“ – 8“ 1/4“ – 8“
Suitable for single- or program controlled multiple coatings
Both varieties of that coating lines can be equipped with our belt type or the
Reinhardt Continuous ovens and cooling zones:
space saving pallet type continuous ovens
Advantages of the Reinhardt drum system:
• Especially suitable for „paint scooping“ parts.

• Higher quality standard of coated parts due to more even paint application.
• As a result, a consistent torque curve for automated screwing and assembly processes.
• No accumulation of unwanted residual amounts in wells such as e.g. the Allen head of the
screws.
• Cleaning the drums only every 6-10 weeks necessary. Savings up to 50,000.- per year / plant
possible.
• Closed coating booth, to minimize the exhaust air volume these parameters are adapted to the
needing‘s of the process.
• Coating booth optionally with air conditioning.
• In relation to the throughput we have a small paint reservoir volume, thus lowers paint provision.
Advantages of the Reinhardt basket system:
• The baskets are suitable for a diverse range of parts, with tilting device up to 85 ° even with
paint scooping parts.
• No processing of baskets in warm ambient air.
• Less build-up of paint on the baskets, thus reducing soiling on the parts.
• Signiﬁcantly longer cleaning cycles compared to conventional systems.
Reinhardt GmbH Güterbahnhofstraße 1 Tel.: +49(0)7721 8441 0 info@reinhardt.gmbh

BECAUSE HEAT WORKS. 78048 Villingen-Schwenningen Fax: +49(0)7721 8441 44 www.reinhardt.gmbh
64 - PARTNER COMPANIES
Blasting – Painting – Conveying
For company Dörken MKS-Systeme GmbH
& Co. KG in Herdecke we delivered equipment
suitable to treat the surface of up to 2 m long
profiles. The fully automated production line
consists of one booth for cleaning by dry-ice
blasting, one booth for wet painting as well
as two paint dryers. Drying can either be perfor-
med by using shortwave infrared radiation
or a combination of longwave infrared radiation
and circulating air or just circulating air.
The combination of longwave infrared radiation
and circulating air is an essential part of our
innovative “DARC®” technology and reduces Total view of the
the drying time by up to 70 % compared to installation
conventional drying methods.
SLF stands for Strahlen (Blasting), Lackieren (Painting), Fördern (Conveying). Our company offers equipment for
surface treatment, especially for large components, for example high-pressure cleaning systems, blasting and
paint spraying machinery for rail vehicles or for the wind power industry.
This is our range of products in detail:
Blasting and pre-treatment systems Paint spraying systems Conveyor technique

• Blastrooms • Open-space paint spraying • Lifting platforms
• Media blast robot “ReCo-Blaster®” systems • Overhead conveying
• Pressure blast cabinets / automated blasting • (Telescopic) paint spraying systems
machines booths • Roller conveyor systems
• (Telescopic) high-pressure cleaning booths • Powder coating systems • Rail-bound trolleys
• Process water treatment systems • Powder enamelling furnaces
• Passage-type pre-treatment systems • (Telescopic) dryers
Retrofitting is also possible.

You already have an installation, but would like
to benefit from energy, time and cost savings?
SLF Oberflächentechnik GmbH
Gutenbergstr. 10 · 48282 Emsdetten · Germany
136-11/17-4c
It would be our pleasure Tel.: +49(0)2572 1537-0 · Fax: -169

to advise you! info@slf.eu · www.slf.eu
PARTNER COMPANIES - 65
TULZ- coating-system
WMV Apparatebau, a manufacturer of equipment since The TULZ dip-spin-tilt coating module enables coating
1970 for the treatment of mass produced parts has the applicators to process a full range of fasteners, recess
TULZ coating system in its modular manufacturing program. headed parts, stampings and flat parts with superior quality
The TULZ coating system is already accepted and in use by at a high level of production. The addition of the PRS to the
leaders in the coating and metal finishing industry standard TULZ dip-spin-tilt module reduces coating usage
throughout Europe, North America and Asia. The TULZ without sacrificing quality and productivity.
coating module has been sold over 200 times within the last A flexible programmable coating recipe system allows
20 years to 23 different countries. special programs to be created. These can be used to
The TULZ coating system is used for Zinc-Flake Coating as successfully coat small recessed head parts (e.g. Torx M3)
well as for Top Coats and waxes in the electroplating to achieve very high coating quality without head fill. This
business. The TULZ system is optimized and improved is accomplished by specifying a volume of parts and creating
contnously by our staff of engineers to assure customers a specific recipe that, in some cases, reorients and spins off
that they are imploying the finest technology available to paint multiple times.
process parts. The complete unit is encapsulated, the drive motor is
The exchangeable paint tank which is equiped with quick outside the machine and all sensors and contactors inside
change connectors makes it possible to change from one the unit are explosion proof. This is one of the many
paint to another in seconds without reducing the reasons the TULZ unit is the no. 1 choice for the application
performance of the system. of solvent based coatings.
Another advantage is the capability to tilt the centrifuge Another unique feature is the “loose” basket which makes
basket up to 90 degrees to reorientate the parts. Inside the it very easy to exchange the coating baskets for cleaning or
machine the centrifuge basket is completely closed, so for a paint change. In automated systems the exchange of
there will be no reduction of the available volume while baskets can be handled automatically without reducing the
tilting at extreme angles. capacity of the system.
Flat stampings and washers require a tilting angle of more
than 75 degrees to achieve optimal coating quality.
WMV provides vertical dip spin coating machines with a
standard Centrifuge Coating Recovery Shell. The PRS is a
proven coating recovery system which recovers coatings as
they are centrifuged off the coated parts. The PRS is now
being offered as an option on the versatile and flexible
WMV TULZ dip-spin-tilt coating module.
The TULZ unit is available in different sizes, e. g. with the

TULZ900 (basket diameter 900 mm) it is possible to run up
to 250 kg of parts per basket. Cycle times below 2 minutes
can be realized.
For lab applications and coating samples the TULZ300/500,
is an attractive and cost effective solution. The unit can
also be used in production facilities that do not require
extremely high levels of production. It is possible to use
the original paint pail of the paint supplier (Hobock) as
paint tank in the machine together with a small basket
(diameter 300 mm). This minimizes the amount of paint
that is required for testing or production coating.
To increase production a larger basket (diameter 500 mm)
with a different paint tank can be used in the machine.
It is possible to integrate the TULZ coating system into an
existing line or planning it as part of a new line.
WMV Apparatebau GmbH Präsidentenbrücke 3, Telefon:+49 (0) 22 92 952-0 eMail: office@wmv.com

51570 Windeck (Germany) Telefax:+49 (0) 22 92 952-150 Internet: www.wmv.com
Technologies from one source!
Dip-Spin-Equipment – Rack-Spin-Equipment –Pre-
treatment Lines – Sealing Equipment - Continuous
Dryers – KTL-Bulk Good Coating
Continuous Dryer for Zincflakes
 High temperature exactness
 Optimum heat transfer
 Efficient processes
 Upto 20% less energy

consumption
Forplan AG +41 32 366 77 78

Bernstrasse 18 +41 32 366 77 79
CH-2555 Brügg info@forplan.ch
Switzerland www.forplan.ch
SIDASA DIP SPIN SYSTEMS
The most flexible and highly productive lines with the smallest floor space.
Example: 14 tons/hr in a 33m x 13m footprint
SIDASA has more than 1.000 finishing systems operating around the world
SIDASA has an R&D department creating solutions to exceed customers’ expectations in Zink Flake, Electroplate,
Pre-treat and Post-treat processes
INTEGRATED PRE-TREATMENT LINES: COAT WITH EXCELLENT QUALITY:

• Barrel phosphate • Screws (from M4 to M24 and with a maximum length of 300mm)
• Basket or Archimedes screw degreasing • Stamped parts
• Shot blasting • Washers and flat parts
• Small assemblies
IMPROVE YOUR COATING QUALITY: NEW DR LINE:

• Clear recesses and internal threads with planetary • Soft handling
technology • Low drop heights
• Consistent coating thickness on parts with complicated • High production
geometry • High flexibility
• Reduced part-to-part contact during coating process • Smallest footprint
• Reduced risk of mixed product • Short cycles
• Avoid paint “drag-out” on parts
A • Reduced maintenance/operational costs
• Batch-to-batch consistency
Part of the UNITS Group

65 YEARS OF EXPERIENCE
www.sidasa.com
DIP SPIN OPTIONS

PLANETARY DIP-SPIN TILTING DIP-SPIN RACK SPIN
REFERENCE
ZT-16+ ZT-100+ ZT-MAX ZT-60 ZT-MAX RACK SPIN
BASKET
DIAMETER INT K-TYPE 3 x 390 mm 3 x 15 inch 3 x 570 mm 3 x 22 inch 3 x 670 mm 3 x 26 inch 1 x 900 mm 1 x 35 inch 3 x 670 mm 3 x 26 inch
DIP-SPIN EQUIPMENT
MAXIMUM DEGREES OF TILTING N/A N/A N/A 90° N/A
PERFORMANCE
MAXIMUM CYCLE TIME 3 BASKETS 135 sec 135 sec 135 sec 103 sec 90 sec
MAXIMUM OUTPUT (*) 80 baskets/h 80 baskets/h 80 baskets/h 35 baskets/h NA
MAXIMUM OUTPUT WITH ROBOT (**) 112 baskets/h 112 baskets/h 112 baskets/h N/A 112 baskets/h
MAXIMUM LOAD 45kg/basket 100lb/basket 90kg/basket 200lb/basket 135kg/basket 300lb/basket 280kg/ basket 620lb/basket N/A N/A
3200 L/h 840 Gallon/h 6800 L/h 1790 Gallon/h 9870 L/h 2600 Gallon/h 6640 L/h 1750 Gallon/h N/A N/A
MAXIMUM PRODUCTION (*)
3600 Kg/h 8000 lb/h 7200 Kg/h 16000 lb/h 10800 Kg/h 24000 lb/h 9780 Kg/h 21660 lb/h N/A N/A
4480 L/h 1180 Gallon/h 9520 L/h 2510 Gallon/h 13820 L/h 3650 Gallon/h N/A N/A 13820 L/h 3650 L/h
MAX PRODUCTION WITH ROBOT (**)
5040 Kg/h 11200 lb/h 10080 Kg/h 22400 lb/h 15120 Kg/h 33600 lb/h N/A N/A N/A N/A
* Dip-Spin cycle time: 120 s
** Dip-Spin cycle time: 90 s


OMSA Company has been working in the

sector of surface treatment for more than 40
years specializing in the design and
production of automatic plants and now
according to requirements from Industry 4.0.
We build up machineries and plants on demand, for which we need to be flexible and open
to the customer’s suggestions.
A few points about our production:

- Drum washers for surface preparation before shoot blasting operation
- Drum washers for Dephosphating process before Hardening operation
- Rack oven by rollers or chains conveyor
- Belts cascading oven with different belt shapes
- Trays oven
- Continuous oven with overhead conveyor
- Box oven for hydrogen relief process with electrical/gas heating
- Box oven for paint cure with electrical/gas heating
- Booths for electrostatic application of zinc-lamellar;
Example of box oven Example of belt conveyor oven
Example of drum washer Example of s spray coating line on 3 coats
1
Notes
70 - Notes
Notes
Notes - 71
Dörken MKS-Systeme GmbH & Co. KG
Wetterstraße 58
58313 Herdecke
Germany
Telephone +49 2330 63-243
Fax +49 2330 63-354
E-Mail mks@doerken.de
www.doerken-mks.com
A member of the DÖRKENGROUP REV. 06/2019

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APPLICATION MANUAL

• INFORMATION AND NOTES ON OUR ZINC FLAKE PRODUCT PORTFOLIO

3. PREPARING THE PAINT 17

4. GENERAL SAFETY NOTICES 20

8. IN-PROCESS MAINTENANCE INTERVALS 42

• information and notes on our zinc flake product portfolio;

Telephone: +49 2330, 63243

non-noble corrosion resistance noble

Fig 1: Dependence of corrosion resistance on standard potential.

Advantages of Dörken MKS basecoats:

Various properties of the coating system can be achieved with a topcoat:

• Setting of a defined coefficient of friction;

The first two letters have the following meaning:

EXAMPLES OF SOME PRODUCTS

DELTA-PROTEKT® VH 300: Inorganic water-based sealant.

DELTA-PROTEKT® VH 301.1 GZ: Inorganic water-based sealant with lubricant additive.

DELTA®-SEAL GZ SILBER: Organic silver topcoat with lubricant additive.

DELTACOLL® 80 SCHWARZ: Black sealant for galvanised surfaces.

DELTA®- DELTA- DELTA- DELTA- DELTA- DELTA-

High temperature Very good ductility

DELTA®- DELTA- DELTA- DELTACOLL®- SPECIAL

Solvent-based topcoats Solvent-based topcoats Water-based sealings Solvent-based Bonding agents

DELTA- DELTA®-SEAL DELTACOLL® DELTACOLL®

Each order confirmation is accompanied by a factory test certificate.

Zinc flake basecoats are supplied in

The water-based, colourless topcoats

Thinners and some paints such as

Table 1: Delivery form of the products

Fig 2: Sample labelling Abbildung 2: Sicherheitsetikett mit Gefahrensymbolen

Increased temperatures – as with all paints – shorten the service life.

"Pre-treatment is the be-all and end-all!"

2.1. Uncoated metals

• Blasting grains become smaller;

air extraction air extraction parts container

Fig 5: Blast system

Phosphating is not generally recommended as a standard pre-treatment process, as it involves

2.2. Galvanically coated metals

The stirrer is adapted to the respective

In the case of solvent-containing base-coats,

In addition to this standard method, there

PREPARATION OF THE PAINT - 17

The paints in the coating process must continue to be kept homogeneous.

These supporting measures should be carried out regularly.

18 - PREPARATION OF THE PAINT

1. Evaporation of the solvent

The rule of thumb for base-coat is:

Fig 7: Increased temperatures lead to a decrease in viscosity

PREPARATION OF THE PAINT - 19

20 - GENERAL SAFETY NOTICES

5.1. Dip spinning

Fig 9: Dip spinning process

The centrifugal force is calculated as follows: F = mω²d/2

m = mass of a drop of paint (almost constant)

Corrosion protection reduction (%)

5.2. Rack dip spinning

5.3. Dip drawing

Fig 14: Schematic structure of a dip drawing system

Speed [mm/min] Layer density [μm]

The spraying process is influenced

The process of spraying is however also influenced by the equipment.

6.1. Curing process

Conveyor belt oven (continuous oven)

Tray oven (continuous oven)