Finishing materials with zinc-rich coatings
URN: SEMMPF343
Business Sectors (Suites): Materials Processing and Finishing Suite 3
Developed by: Enginuity
Approved on:
30 Mar 2020
Overview
| This standard identifies the competencies you need to carry out finishing operations with zinc-rich coatings, using a range of methods, in accordance with approved procedures. You will be required to access the appropriate specifications, to check that these are the current issue and to extract all necessary information in order to carry out the zinc coating operations. You will be required to carry out all necessary pre and post-preparations to the components and this will include such items as liquid solvent degreasing, aqueous degreasing, shot blasting, biological cleaning, air blasting and curing using electric, gas or induction methods. You will be expected to prepare and adjust coating materials to give satisfactory results at optimal productivity levels. You will be expected to identify any zinc coating defects and to carry out the necessary actions and adjustments to equipment and coatings in order to correct them. You will need to carry out tests on the components to ensure that deposited layers meet their specification requirements. Your responsibilities will require you to comply with organisational policy and procedures for the zinc-rich coating activities undertaken and to report any problems with these activities or with the materials and equipment used, that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying zinc-rich coating methods, techniques and procedures. You will understand the zinc coating processes, and their application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the finished components are to the required specification. You will understand the different cleaning techniques that can be used for substrate preparation, which will include effluent treatment for the waste streams used prior to coating. You will understand the safety precautions required when carrying out the preparation, zinc-rich coating operations and post-treatments. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace and towards the environment. |
Performance criteria
You must be able to:
| 1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines 2. follow relevant job instructions and specifications 3. ensure the material surfaces to be treated are prepared for the finishing operations 4. check that the finishing equipment and treatment solutions are set up and maintained at required operating conditions and levels 5. carry out the treatment process in accordance with operating procedures and the component specification requirements 6. check that the treated workpiece achieves the required characteristics and meets the finishing specification 7. deal promptly and effectively with problems within your control and report those that cannot be solved 8. ensure that work records are completed, stored securely and available to others, as per organisational requirements 9. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements |
Knowledge and Understanding
You need to know and understand:
| 1. the specific safety precautions to be taken when working with zinc-rich the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials) 2. the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you 3. the hazards associated with the activities, and how to minimise them and reduce risks 4. the personal protective equipment and clothing (PPE) to be worn during the activities 5. the importance of extraction for acid pickling and cyanide and alkaline plating solutions 6. the types of specifications that are used during the zinc-rich coating activities and how to check that you have current issue 7. how to assess component suitability for zinc-rich coating (to include suitable methods of handling, methods of pre- and post-treatment, the coating material to use, the most efficient and appropriate method of application) 8. the basic principles of zinc-rich coating using techniques, such as dip spin, dip drain, flow coating and spraying techniques 9. the variety of jigging methods or baskets available to constrain work pieces during the coating operation 10. how to set up and check that the zinc-rich coating equipment and materials are fit for purpose 11. properties of zinc-rich coating deposits 12. methods of preparing and cleaning the components, prior to applying the zinc-rich coating 13. the mixing of coating materials from constituent parts 14. measurement of properties of coating materials and their control 15. the need to control temperature and the effects of temperature variation 16. the importance of spin speeds, fluid delivery rates, jigging precision and workpiece movement rates 17. types of agitation and filtration equipment 18. curing techniques and the importance of time and temperature 19. the importance of "pot life" and its effect on the type of delivery system or coating techniques to be used 20. how to handle workpieces, when wet, to minimise disturbance of applied material prior to curing 21. how to identify processing, faults and how to correct them 22. methods for checking coated surfaces for visual defects and other specified characteristics 23. procedures for cleaning down equipment and disposing of waste material 24. how to safely dispose of empty containers, or waste solutions, to specifications 25. the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve 26. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Finish materials with zinc-rich coatings, carrying out all of the following: 1. use the correct issue of process and other related specifications 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. ensure that the equipment is correctly prepared for the zinc-rich coating operations 4. ensure that any meters and gauges to be used are within their calibration periods 5. complete the production documentation (condition/pre-treatment of substrates, coating material preparation, equipment settings, confirmation of standard of finish) 6. clean all tools and equipment on completion of the zinc-rich coating activities 7. leave the work area in a safe and clean condition 2. Use one of the following zinc-rich coating techniques: 1. dip spin coating 2. dip drain coating 3. flow coating 4. spraying techniques 3. Measure and correct two of the following zinc-rich process conditions: 1. solid content of coating materials 2. pH of coating solution 3. viscosity of coating materials 4. different constituents of coating materials 5. temperature (both of the material and the substrate) 6. agitation of coating material 7. the change in properties within a material's "pot life" 4. Carry out two of the following zinc rich coating activities: 1. determine the type of spray gun to be used 2. determine the filter size to be used and type of pump required remove ferrous contaminants 3. use basket (size/type), to give optimal appearance/uniformity to dip spun components 5. Carry out one of the following process control techniques: 1. adjust spin speeds, times and number of reversals for dip spin coating 2. adjust spin speeds and times for dip-drain-spin coatings 3. determine the correct angle of location and time for dip drain coatings 4. adjust spray gun settings and times to give desired coating characteristics 6. Carry out one of the following processes for cleaning the substrates, prior to coating: 1. liquid solvent degreasing 2. aqueous degreasing 3. shot blasting 4. biological cleaning 5. air blasting 7. Use one of the following methods for locating the work during the zinc-rich coating activities: 1. jigs 2. baskets 3. hooks 8. Use one of the following methods for curing the coated components: 1. electric 2. gas 3. induction 9. Carry out three of the following tests/checks appropriate to the coating being applied: 1. wet film thickness testing 2. non-destructive thickness testing of cured coatings 3. checking fill profiles against a drawing on a shadowgraph 4. visual examination for blisters, drips, poor coverage 5. adhesion tests 6. weight gain or strip-and-weigh thickness checking 7. curing tests 8. corrosion testing 9. thread gauging and assembly checks 10. Check coatings applied to components by zinc-rich coating, comply with one of the following quality and accuracy standards: 1. military or aviation standards 2. current industry standards and codes of practice 3. international standards 4. company standards and requirements 5. customer standards and requirements |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
2
Indicative Review Date
31 Mar 2023
Validity
Current
Status
Original
Originating Organisation
SEMTA
Original URN
MPF3.43
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; finishing; casting; zinc rich; dip spin; flow; deep drain; spraying