4 - 01 - 05 - Eng - Paint Coating On Aluminium Parts

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_________________ _________________________________________________________________
:$51,1*6 The present document may be revised, when necessary, with the publication of new editions. It is therefore
essential that those who use the same ensure they have the latest edition

Reproduction forbidden. No part of the present document can be reproduced or revealed to third
Via Olmo, 37 parties without the authorisation of Carraro S.p.A
35011 Campodarsego (Pd)
Italy
Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

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1.1 Reference docum ent s 3

1.2 Raw m at erial 3
1.2.1 Mat erial qualit y 3
1.2.2 Cleanliness 3
1.2.3 Packaging 3
1.2.4 Not e 3

1.3 indicat
Drawing ions
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4
2.1 I nst rum ent s needed for t est ing 4
2.2 Test on t he coat ing 4
2.2.1 Checking t he appearance 4
2.2.1.1 Defining t he significant m easurem ent area 4
2.2.1.2 Defining zones according t o t heir "visibilit y” 4
2.2.2 Physical – m echanical characterist ics 5
2.2.2.1 Adhesion t est 5
2.2.2.2 Adhesion t est aft er t he heat cycle 5
2.2.2.3 Hardness 6
2.2.3 Chem ical – physical charact erist ics 6
2.2.3.1 Resist ance t o ult raviolet rays 6
2.2.3.2 Test ing t he colour shade 6
2.2.3.3 Test of resist ance t o rubbing wit h various subst ances 6
2.2.3.4 Test of resist ance t o being im m ersed in petrol 7
2.2.3.5 Test of resist ance t o wat er (blist ering) 7
2.2.3.6 Test of resist ance t o salt spray 7
2.2.3.6.1 Test of resist ance t o salt spray I 7
2.2.3.6.2 Test of resist ance t o salt spray I I 7
%
2.2.3.7 '&&())'&(+*'$,
Gloss 7
7
3.1 Paint coat ing 7
3.1.1 Est het ic appearance 8
3.1.1.1 Definit ions 8
3.1.1.2 Com bined evaluat ion of defect s 11
3.1.2 Physical – m echanical characterist ics 11
3.1.2.1 Adhesion 11
3.1.2.2 Adhesion aft er t he heat cycle 11
3.1.2.3 Hardness 11
3.1.3 Chem ical – physical charact erist ics 12
3.1.3.1 Resist ance t o ult raviolet rays 12
3.1.3.2 Shades 12
3.1.3.3 Resist ance t o rubbing 12
3.1.3.4 Resist ance t o cont act wit h petrol 12
3.1.3.5 Resist ance t o wat er ( blist ering) 12
3.1.3.6 Resist ance t o salt spray 12
3.1.3.6.1 Resist ance t o salt spray I 13
3.1.3.6.2 Resist ance t o salt spray I I 13
3.1.3.7 Gloss 13
3.2 Supply condit ions 13
3.2.1 Docum ent s enclosed wit h t he supply bat ch 14
3.2.2 Packaging 14
3.2.3 Accept ance 14
3.2.4 Procedure for rej ect ed bat ches 14

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To specify the characteristics to be satisfied by the raw materials and paint coating whether powder or
liquid for parts in aluminium (not including the components for the motors).
To define the procedures and equipment to be used in carrying out tests on the above characteristics.
To provide the procedures for indicating these coatings on the drawings.
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5HIHUHQFHGRFXPHQWV
Unless otherwise indicated, the following documents must be considered as pertaining to the version
in force on the issue date of this specification
VDA 621-411 "Paint adhesion: cross hatch testing"

ISO EN 2409 "Paints and varnishes - Cross-cut test"
S.T. APRILIA N. 9429 "Adhesive tape characteristics tesa band code 4651"
DIN 53209 "Definition of the level of blistering on painted parts"
UNI ISO 9227 "Corrosion in salt spray"
5DZPDWHULDO
0DWHULDOTXDOLW\
Free of any defects that may compromise the appearance and resistance to corrosion of the piece
itself. In particular for cast pieces, the maker shall make sure there are no defects such as
cracks from shrinkage, cracks due to heat treatment, porosity, inclusions of oxides, cold welds,
tool incisions, casting burs and soil residue in amounts greater than those defined by the sample.
The surface finish of the cast piece must be the same as the one defined by the sample.

&OHDQOLQHVV
Material free of all traces of dirt, grease, casting residue.

3DFNDJLQJ
In packs suitable to ensure the above specifications.

1RWH
Those applying the paint are responsible for checking the requisites of the raw material at points 1.2.1,
1.2.2, 1.2.3.
If anything does not conform to the above, authorisation is not granted to carry out painting.

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All drawings must carry the following indications:

• Reference to this standard
7(676$1'$33529$/
,QVWUXPHQWVQHHGHGIRUWHVWLQJ
• Instrument for cross hatching

• Instrument for checking hardness TYPE 318 maker ERICHSEN
• 16 bulbs OSRAM 300 W, ULTRA VITALUX
• Differentiated light camera for checking colour shading
• Thermostatic tank for water resistance test (blistering)
Note: the above listed instruments may be substituted for others on condition that they have
equivalent characteristics, precision and repeatability.
7HVWRQWKHFRDWLQJ
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The components are inspected visually to make sure that the extent of the esthetic defects present
does not exceed the limits of acceptability specified in point 3.1.1.1.
'HILQLQJWKHVLJQLILFDQWPHDVXUHPHQWDUHD
2
The area of 300 cm is considered the unitary area of measurement.
The distance between the individual defects must be less than 70 mm. If it is not, the combined
evaluation of defects will be adopted in the acceptability criteria (see par. 3.1.1.2).
'HILQLQJ]RQHVDFFRUGLQJWRWKHLUYLVLELOLW\
Aprilia have adopted the following visible zone definitions:
A) Visible zone
B) Zone not directly visible
C) Temporarily covered area
D) Non visible zone

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The main visual concerns the surfaces that are directly visible and whose observation is not affected
by other parts or by their shadow.
The irregularities are noticed on direct reflection, instinctively and without disturbance.
Indication in the 6XUIDFHVWHFKQLFDOVKHHW: white colour.
%=RQHQRWGLUHFWO\YLVLEOH
The indirect visual concerns the surfaces that are directly visible, but their observation is
attenuated by other parts or by their shadow.
The irregularities are not directly reflected and are not immediately perceptible.
Indication in the 6XUIDFHVWHFKQLFDOVKHHW: yellow colour.
&7HPSRUDULO\FRYHUHGDUHD
The temporarily covered surfaces concern the portions that from one observation point are not visible
or are covered by mobile parts (e.g. saddles) and so can be seen rarely or occasionally.
Indication in the 6XUIDFHVWHFKQLFDOVKHHW: green colour
'1RQYLVLEOH]RQH
Concerns the portions of surfaces covered by fixed parts, such as for example mirrors, cowlings, etc.
Indication in the 6XUIDFHVWHFKQLFDOVKHHW: black colour.
NB: The value of the colours white, yellow, green and black, in which the samples are painted in the
6XUIDFHVWHFKQLFDOVKHHW photos is only limited to defining the various zones, while these colours have
no reference with the actual colour in which the piece will be produced.
3K\VLFDO±PHFKDQLFDOFKDUDFWHULVWLFV
Testing the following characteristics must be verified on samples left at room temperature
for at least 96 hours after the painting cycle.
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The test is carried out according to regulating standards VDA 621-411 and ISO EN 2409 with
TESABAND 4651 adhesive tape (technical sheet no. 9429). Once cross hatching has been applied,
the adhesive tape is stuck to the surface in question and then ripped away, to reveal the standard of
finish on the piece.
$GKHVLRQWHVWDIWHUWKHKHDWF\FOH
The test piece is subjected to the following cycle, which must be repeated 4 times.
• 4 hours at - (20 ± 2) °C
• 16 hours at + (90 ± 2) °C
• 4 hours at normal temperature
After which the adhesion test is carried out (par. 2.2.2.1).

The formation of blistering is also inspected.

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The hardness of the dry film must be kept within a value defined by the resistance to
scratching by a 318 ERICHSEN or similar piece of equipment.
&KHPLFDO±SK\VLFDOFKDUDFWHULVWLFV
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The treatment must resist to ultraviolet rays.

The test consists of subjecting the piece under examination to the action of ultraviolet rays for 30
hours, generated by 16 OSRAM 300 W, ULTRA VITALUX type bulbs set out on a square matrix at a
distance of 25 cm from each other. The test piece is placed at a distance of roughly 70 cm from the
lights. To assess the level of variation, half of the test piece must be protected from exposure to the
rays.
7HVWLQJWKHFRORXUVKDGH
The colour shade is tested by comparing the piece visually with the sample in a Buhler DUOLUX
camera under daylight and artificial light. The sample must be taken from a production piece with
definitive materials and cycle.

7HVWRIUHVLVWDQFHWRUXEELQJZLWKYDULRXVVXEVWDQFHV
Before carrying out the test the pieces are heated in an 80 °C ambient for 1 hour.
The pieces are checked immediately after being taken from the 80 °C ambient with a cotton cloth
dipped in the substances listed below and with normal hand pressure being exerted (of roughly 0.5
Kg) for 50 cycles.
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LEADED PETROL 2 cc per cycle

SHAMPOO 0.5 cc per cycle
ALCOHOL 2 cc per cycle
DIESEL 2 cc per cycle
MINERAL OIL 2 cc per cycle
LEAD-FREE PETROL 2 cc per cycle

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Half of the piece must be immersed in leaded petrol for 24 hours at room temperature.
7HVWRIUHVLVWDQFHWRZDWHUEOLVWHULQJ
The test consists of immersing the test pieces into a tank containing distilled water thermostatically
controlled at a temperature of 50 °C ± 1 °C.
The immersion time requested is 150 hours. A visual examination of the samples with a check for
blistering is made every 24 hours.
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Acceptance of pieces with regard to resistance to salt spray is subject to the following 2 tests being
passed.
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The test is carried out according to regulating standard UNI ISO 9227.
The pieces are exposed to salt spray after the surface being tested has been etched with a cross at 60
degrees made with a point in hard metal.
The requested exposure time is 240 hours.
7HVWRIUHVLVWDQFHWRVDOWVSUD\,,
The test is carried out according to regulating standard UNI ISO 9227.
The pieces are exposed to salt spray for an exposure time of 240 hours.
*ORVV
The test is carried out with a gloss meter with a reflective head at an angle of 60 degrees.
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The following are the definitions and acceptability limits of the defects according to their visibility. As
regards this point, if nothing is specified on the applicable drawings and documentation, then the
whole surface of the part is to be considered “visible surface”.
2
The area of 300 cm is considered as the unitary area of measurement.
The distance between the individual defects must be less than 70 mm. If it is not, the combined
evaluation of defects will be adopted in the acceptability criteria (see par. 3.1.1.2).
'HILQLWLRQV
The following are the definitions of the esthetic defects found on badly finished coatings.
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Scratches and colourless areas can be caused by incorrect handling of the painted surfaces,
for example due to the subsequent fitting of parts.
'HILQLWLRQRIDUHDV $FFHSWDEOHOLPLWIRUVLJQLILFDQWDUHD
visible zone No defects allowed

zone not directly visible/ temp. 5 retouched scratches less than 10 mm. are allowed
covered area Protection against corrosion must in any case be
guaranteed
non visible zone No requirements. Protection against corrosion must in any
case be guaranteed

5XQVDQGGULSV
Runs may be either base coat or paint.

They occur during or, independently, after painting with badly prepared paints or with
too many coats. Build ups of different sizes and thicknesses are formed.

visible zone Not allowed

zone not directly visible / 5 runs (drips) are allowed, with a max height of 1 mm.
temp. covered area Swellings on the edges are allowed.
The resistance of the paint and the fixings of the flat
pieces must not in any case be compromised
non visible zone Allowed if they do not compromise the resistance of the
paint and the fixings of the flat pieces

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The inclusions are seen with more or less sharp edged entities under the paint.
In removing the foreign bodies care must be taken not to worsen the quality with the residual stain.

visible zone 2 inclusions with a max 0.3 mm DUHDOORZHG
zone not directly visible/

LQFOXVLRQVZLWKDPD[PP DUHDOORZHG
temp. covered area
No requirement
non visible zone The tightness of the flat pieces fitted must however be
guaranteed

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Craters, pores and shrinkages are seen by a reduction in the painted layer. On a coloured crater the
thickness of the paint is thin. On an open one the base coat can be seen.
visible zone No defect allowed

zone not directly visible/ 5 coloured craters with a max 1 mm are allowed
temp. covered area No thickenings are allowed. Touching up is necessary
10 FRORXUHGFUDWHUVZLWKDPD[ PPDUHDOORZHG
non visible zone
Touching up is necessary
6FRULQJIURPVDQGLQJRUVLPLODU
Scoring from sanding occurs when too coarse a grade is used. The base coat given to
rough surfaces enters the hollows interrupting the surface gloss and the even spread of the paint.
Single scores only just visible are allowed.

visible zone
Build ups and hollows are not allowed.
zone not directly visible/
Single scores only just visible are allowed
temp. covered area
non visible zone No requirements

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These are small hard blisters that may be single or in groups. The causes can be excessive paint
thicknesses or the use of unsuitable solvents.
Visible zone No defects allowed

Zone not directly visible/ 5 single blisters are allowed.
Temp. covered area Build ups are allowed
Non visible zone No requirements
/DFNRISDLQW
Description: a rough and opaque surface is generally the result of an insufficient thickness of paint. In
addition, an insufficient thickness can also be noticed by a visible base (minimum current thickness)
and a variation in local colour.
visible zone No defects allowed

Colour variations only just visible due to insufficient cover
zone not directly visible/ are only allowed if they satisfy the qualitative
temp. covered area specifications.
Visible colour variations are not allowed
non visible zone No requirements

3DLQWSHHOLQJ
These can be caused by a lack of adhesion or inappropriate working conditions and manifest
themselves as paint peeling in the areas around the processing.

visible zone Not allowed

zone not directly visible Not allowed
temp. covered area Not allowed
Slight paint peeling is allowed at the edges of the processed
non visible zone area, as long as adhesion of the paint to the piece is
guaranteed

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For direct visibility in the case of combinations of defects, the maximum tolerance limit for each type of
defect is reduced by 50%.
([DPSOH
A piece contains at the same time the defects of "craters" and "inclusions" in a visible area:

- -
6LQJOHGHIHFWDOORZHGRYHUFP 7RWDOGHIHFWVDOORZHGRYHUFP
Craters 5 coloured craters with a max RI 1 mm 2 coloured crateUVZLWKDPD[ RIPP
Inclusions 3 inclusions ZLWKDPD[ RIPP 1 LQFOXVLRQVZLWKDPD[ RIPP

3K\VLFDO±PHFKDQLFDOFKDUDFWHULVWLFV
$GKHVLRQ
The limit of acceptability (see point 2.2.2.1) is that specified by regulating standard ISO EN 2409 in
"Table 1 - Classification of test results" for classification no. 1.
$GKHVLRQDIWHUWKHKHDWF\FOH
The limit of acceptability (for the adhesion test) is that specified by regulating standard ISO EN
2409 in "Table 1 - Classification of test results" for classification no.1.
As regards the formation of blisters the required result is: m 2, g 2 - m 2, g 3 (DIN 53209).
+DUGQHVV
Carrying out the test according to the methods described in point 2.2.2.3, no traces of
penetrator must be noted with the following parameters:
7\SHRISDLQW /HYHOVSULQJ
Powder 8/red
Liquid 5/red

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11

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5HVLVWDQFHWRXOWUDYLROHWUD\V
After the test the piece exposed to UV rays must not show evident differences in colour compared to
the protected part.
6KDGHV
No difference is allowed in the shades compared to the definitive sample deposited in Carraro.
5HVLVWDQFHWRUXEELQJ
At the end of the test (ref par. 2.2.3.3) there must be no obvious dulling, discolouring
or paint removal.
5HVLVWDQFHWRFRQWDFWZLWKSHWURO
After the test cycle the piece, described in point 2.2.3.4, must show no signs of alteration in the
treatment layer.
5HVLVWDQFHWRZDWHUEOLVWHULQJ
Test to be carried out according to the procedures stated in point 2.2.3.5.

The acceptable result as regards the phenomenon of blistering (bubble formation),
evaluated according to regulating standard DIN 53209 is: m 2, g 2 ÷ m 2, g 3 (after 150 hours).
Additionally no reductions are allowed in the hardness and adhesion of the paint and other defects
that compromise the appearance of the part.
A slight variation of shade is allowed, to be agreed with Carraro in each individual case.
If after 72 hours no bubbles have formed, or stains, or loss of adhesion, or colour toning and other
defects that compromise the appearance of the part, the test can be considered passed successfully.
5HVLVWDQFHWRVDOWVSUD\

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12

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The test is carried out according to the procedures stated in 2.2.3.6.1. After the test the piece must
show no significant variations in shade or tone, stains and any other alteration that may
prejudice the appearance of the piece.
There must be no areas of corrosion over the entire piece.
Penetration of the corrosion in the areas adjacent to the incisions must be no greater than 2 mm (see
fig. 1).
On the same piece, in the area of the incisions, carry out the adhesion test (see par. 2.2.2.1); the
amount of paint removed from the support must be no greater than 3 mm (fig. 2).
5HVLVWDQFHWRVDOWVSUD\,,
The test carried out according to what is stated in par. 2.2.3.6.2, must give the following results:
• after 240 hours areas of corrosion on the flat surfaces are not acceptable.
• after 240 hours areas of corrosion on the perimeter of the piece or test pieces are allowed up to a
maximum of 10% of the total perimeter.
*ORVV
The gloss must be the same as that indicated in the “paint technical sheet”.
6XSSO\FRQGLWLRQV

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13

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st
The technical data for the paint cycle approved (by the supplier and by Carraro, through the 1 supply
batch) must be communicated to the Carraro Q.C. with the “Paint technical Sheet” filled in.
Any changes to this cycle must be previously agreed with Carraro Q.C.
3DFNDJLQJ
The pieces must be packaged in such a way as to prevent damage during transportation,
storage and handling.
The containers must carry the following information on the front:
• supplier
• supply date
• code number of pieces
• number of piece contained in the package

$FFHSWDQFH
CARRARO may subject each incoming batch of material to ensure the pieces conform to this
specification.
The decision to subject the incoming batch to inspection or not and the number of pieces to be
examined is at the indisputable discretion of CARRARO.
If one or more pieces of the incoming batch, subjected to examination does not pass the
requirements of this Carraro Specification with the relative enclosed, the batch will be considered rejected.
3URFHGXUHIRUUHMHFWHGEDWFKHV
When a batch is considered rejected, The Carraro Quality Control will notify the supplier
who will agree with the Programming Department the counter measures to be adopted (e.g.
returning the batch, selection, repair, etc.).
All pieces recognised as rejects at the time of assembly (even if they are part of a batch found to be
suitable on arrival) will be returned as rejects.
If a batch is found to be defective Carraro will also return as rejected all the pieces on which tests have
been carried out (even if destroyed).
Carraro reserves the right to identify (without prior notice) by indelible marking, in areas where the
possibility of recycling the pieces is not compromised, all the pieces contained in rejected batches.

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14

4 - 01 - 05 - Eng - Paint Coating On Aluminium Parts

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4 - 01 - 05 - Eng - Paint Coating On Aluminium Parts

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Copyright:

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Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

1.1 Reference docum ent s 3

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

VDA 621-411 "Paint adhesion: cross hatch testing"

Material free of all traces of dirt, grease, casting residue.

In packs suitable to ensure the above specifications.

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

All drawings must carry the following indications:

• Instrument for cross hatching

Aprilia have adopted the following visible zone definitions:

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

After which the adhesion test is carried out (par. 2.2.2.1).

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

The treatment must resist to ultraviolet rays.

LEADED PETROL 2 cc per cycle

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

visible zone No defects allowed

Runs may be either base coat or paint.

visible zone Not allowed

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

visible zone 2 inclusions with a max 0.3 mm DUHDOORZHG

zone not directly visible/

visible zone No defect allowed

Single scores only just visible are allowed.

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

Visible zone No defects allowed

visible zone No defects allowed

visible zone Not allowed

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

Craters 5 coloured craters with a max RI 1 mm 2 coloured crateUVZLWKDPD[ RIPP

Inclusions 3 inclusions ZLWKDPD[ RIPP 1 LQFOXVLRQVZLWKDPD[ RIPP

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

Test to be carried out according to the procedures stated in point 2.2.3.5.

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

Carraro Group- DOC:4-01-05_EN-1 ECO:APPROV Orig: Des: S.Des: - 6/3/2017

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Craters 5 coloured craters with a max RI 1 mm 2 coloured crateUVZLWKDPD[ RIPP

Inclusions 3 inclusions ZLWKDPD[ RIPP 1 LQFOXVLRQVZLWKDPD[ RIPP