The Q.A./Q.C Procedure is implemented to maintain quality production of Alubond U.S.A. Aluminum Composite Panel. The three phases are Pre-production Inspection, Production Proper and After Production Inspection.

A. Pre-production Inspection

The following raw materials are being subjected to series of test and getting approval before it is brought to the next phase.

  • Aluminum Coil
  • Plastic Granules
  • Adhesive Film
  • Protective Film

Aliminium

Quality
   
     
   
Test

Physical Properties

Tools:

Visual, Micrometer- with O.05mm Tolerance accepted International , Meter Tape, weighing scale, new Coil & color coil guide (200x 200mm).

Procedure:

Visually inspect the coil from damages arise from unloading and specification such as color code, coil thickness using Micrometer, width and weight as per shipping documents.

  • Color check by placing together new coil sample and the color guide 3 meter away from eyesight in 70degree angle from horizontal surface.
  • Measure Coating thickness with gauge and accept standard minimum average 25 microns
Test

Dry Adhesive Test

Tools: 50 mm width Scotch Tape, Sharp pointed metal, New coil Sample
Procedure:
  • Make 5 parallel lines using pointed metal I mm apart on the new coil sample, make another lines crossing the first lines.
  • Apply the Scotch tape evenly with pressure o Pull the tape off quickly at right angle.

Passing Result:

No cracks visible on the surface of the sample, no coating Peel-off should be seen on the tape
Test

Pencil Hardness Test

Tools:

2H Pencil- Flat lead, New coil sample( 200x200mm)

Procedure:
  • Make 6mm line on the surface of the sample coil using the
  • Pencil on 45 degrees angle with putting download pressure
Passing Result: No coating cracks and coating peel off visible on the surface of the sample.
Test

Impact Test

Tools:

Impact tester, New coil sample( 200x200mm)

Procedure:
  • Drop the lkg weight from 500mm height directly to the coil sample.
Passing Result:

No coating cracks and coating peel off visible on the surface of the sample.

Test

T-Bend Test

Tools:

New coil sample( 200x200mm)

Procedure:
  • Partially cut lOmm strip from the edge of the sample.
  • o Fold lOmm strip 3 times to zero degree
Passing Result:

No coating cracks and coating peel off visible on the surface of the sample

Test

MEKTest

Tools:

MEK, Cotton cloth, New coil sample( 200x200mm)

Procedure:
  • Pour ample amount of the MEK on the cotton cloth.
  • Wipe the cotton cloth with MEK directly to the sample surface 50 times backward & 50 times forward.
Passing Result:

No color fading off visible on the surface of the sample.

General Notes  
 

All specimen samples are labeled at the back with testing date, kind of test performed & results obtained.

PLASTIC GRANULES

Test

Physical Properties

Tools:

Visual, sense of touch, LDPE sample

Passing Result:

Visually inspect that granule are smooth and soft when touched, shining under light, needle hole in the middle are not present

Test

Float Test

Tools:

Tub with water, LDPE sample

Procedure:
  • Put ample amount of granule sample on the tub with water. Greater quantity floats on the water surface.

Passing Result:

Greater quantity floats on the water surface

   
ADHESIVE FILM
Test

Physical Properties

Tools:

Visual, Meter Tape, weighing scale

Procedure:
  • Visually inspect the adhesive film from damages arise from unloading and specification width and weight as per shipping documents.

Passing Result:

Moisture not present in any areal part of adhesive. No cloudy marks on the surface of the adhesive.

Test

Boil Test

Tools:

Specimen sample, Iron box,

Procedure:
  • Prepare the sample by heating the adhesive over the panel using Iron
  • Boil the sample with adhesive continuously for 2 hours.
Passing Result:

Delaminating should not be observed.

   
PROTECTIVE FILM
Test

Physical Properties

Tools:

Visual, Meter Tape, thinner, cotton clothe

Procedure:
  • Visually inspect the adhesive film from damages arise from unloading and specification width and weight as per shipping documents.
  • Wipe cotton clothe with thinner on the print design of the sticker.
Passing Result:

Moisture not present in any areal part of protective film. Printed design should retain after wiping with thinner.

Test

Oven Test

Tools:

Specimen samples, Oven

Procedure:
  • Prepare the sample by stick the protective film.
  • Put in oven for 2 hours at 80 degrees Celsius.
  • Take out from the oven & let it naturally cool completely
  • Peel off the film.
Passing Result:

The film should not leave any gum or adhesive on the panel surface.

   
     
   

Production Proper

The production line is in three 8-hour shift with Q.A./Q.C. present on each shift.

  • Boiling water test is performed on each coil change.
  • Defective part of sandwiched panel coming from the production line are cut off immediately and recorded.
  • Sandwich panel should meet the characteristics as listed prior to application of Protective Film.

Testing items

Standard index

Vestige

Indistinct

Ripples, edge wave

Indistinct

Bubble (<10mm)

< / m2

Flaw (<3mm)

< pieces/m2

Scratch

Total length <100mm/m

Abrasion

Total area < 300mm/m

Color difference

Indistinct by eyes; De< 2 by color

 

matching machine

Boiling water resistance

No change within two hours

Coating omit

Not allowed

  • The Finished product should meet the physical characteristics with in the tolerance allowed.

Length

±3mm

Width

±2mm

Thickness

±O.2mm

Squareness

<5mm

Warpage

< 5mm1m

1800 peeling force

4mm panel: 0.5aluminum 2:7N/mm

 

3mm panel: O.3aluminum 2:5N/mm

  • Pulling strength of panel are checked every 30 minutes interval.
  • Each panel are marked with sequence no., color code, panel specification, production date, time, shift no .. The same are recorded in sheet report including the quantity produced per batch of production.
  • One sample of 200 x 1250mm is kept per batch of production with marking at the back side of panel such as Production date, color, coil no, batch no & customer's name.

 

   

After Production Inspection

Final Quality check is done after the sandwich panel comes out from the production line.

  • Dimensions are checked as per production chart order
  • Bubble, ripple, edge wave, abrasion are checked.
  • Accomplish Final Inspection Report.
  • Q.C. Passed stickers are fixed at the back of each sheet.

 

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