16 attribute definition / approach to defects

16 Decorative surfaces of accessories

and functional parts in the exterior and interior areas of automobiles

Attribute definition / approach to defects

Appendix to VDA Volume 16 3

rd revised edition 2016

Version October 17, 2016

Page Attribute definition / approach to defects


3

Pos. 1: Offset

11

Pos. 28d: Polishing stains

Pos. 2: Burn marks

Pos. 29: Polishing fishes

Pos. 3: Bumps/dents

Pos. 30: Polishing streaks

Pos. 4a: Bubbles

Pos. 31: Pores

4

Pos. 4b: Craters

12

Pos. 32: Visible mold seams

Pos. 5: Impressions

Pos. 33: Chafe marks

Pos. 6: Cracks in anodized surface

Pos. 34: Web imprints

Pos. 7: Paint mist

Pos. 35: Streakiness

5

Pos. 8: Color shade differences

13

Pos. 36: Over-leveling

Pos. 9: Bulging edge

Pos. 37: Waviness

Pos. 10: Stains

Pos. 38a: Clouds/haziness/schlieren

Pos. 11: Mold separation burr

Pos. 38b: Humidity schlieren / air schlieren

6

Pos. 12: Gloss level deviation

14

Pos. 39: Layer thickness fluctuations

Pos. 13: Burr Pos. 40: Dips

Pos. 14: Graininess

Pos. 41: Converging seams

Pos. 15: Hair scratches

Pos. 42: Sucker impression

7

Pos. 16: Contact or fastening point

15

Pos. 43: Joint line

Pos. 17: Scratches / striae

Pos. 44: Humidity inclusion

Pos. 18: Running paint

Pos. 45: Open spots

Pos. 19: Paint lens

Pos. 46: Joint gap/offset

8

Pos. 20: Weak spots

16

Pos. 47: Putty repairs in wood

Pos. 21: Macro-fissures

Pos. 48: Nicking

Pos. 22: Pinpricks

Pos. 49: Differences in structure and texture

Pos. 23: Nickel halo

Pos. 50: Pressing folds

9

Pos. 24: Orange peel

17

Pos. 51: Paint residues

Pos. 25: Oxide lines

Pos. 52: Burns

Pos. 26: Pimples / inclusions

Pos. 53: Orientation defects

Pos. 27: Pigment defect Pos. 54: Mold separation edges

10

Pos. 28: Polishing defects, various

18

Pos. 55: Fabric irregularities

Pos. 28a: Specks

Pos. 56: Fabric warping/distortion

Pos. 28b: Clouding

Pos. 57: Resin edges

16 Decorative surfaces of add-on and functional parts in the exterior and interior areas of automobiles




*) Process allocation: of 33

1) Anodizing 2) Powder coating (EPS) 3) Liquid painting 4) Extruding 5) Injection molding 6) Galvanizing 7) Plasma processes (vapor-depositing, sputtering,

CVD, PVD) 8) Forming 9) Polishing 10) Assembly/packaging/handling 11) Primary material

12) Plastics processing 13) Processed wooden surfaces 14) Application processes (bonding of foil inserts,

embossing of decorative films) 15) Metal die-casting 16) Mechanical processing (e. g.

grinding/polishing/deburring/drilling/milling/joining, etc.)

17) Laser marking 18) Fiber composite technology (CFK) 19) Leather material characteristics 20) Leather cladding process 21) Inmolded color / colored injection molding

22) Printed surfaces 23) Ceran coating of anodized aluminum 24) Caulking (cold) / welding (hot) 25) Weaving / textile 26) SMC, partly in connection with IMC (for trucks) 27) Hand laminate (for trucks) 28) Silk screening on glass surfaces 29) Galvanized multi-component parts 30) Carpet processing, e. g. deep-drawing, etc. 31) Flocking 32) Stainless steel surface processing

Pos. 28c: Holograms

Pos. 58: Black points



19

Pos. 59: Fabric discoloration

27

Pos. 91: Fiber weave warping

Pos. 60: White spots

Pos. 92: Weaving depression

Pos. 61: Lack of resin

Pos. 93: Uneven surface

Pos. 62: Resin surplus

Pos. 94: Weaving lines

20

Pos. 63: Fiber splitting

28

Pos. 95: Weaving offset

Pos. 64: Fabric overlapping

Pos. 96: Dark fibers

Pos. 65: Missing fabric

Pos. 97: Fiber openings

Pos. 66: Fraying in fabric

Pos. 98: Incision

21

Pos. 67: Tool impression

29

Pos. 99: Gap

Pos. 68: Resin flaking

Pos. 100: Shadows (ghost marks)

Pos. 69: Structure

Pos. 101: Seam line

Pos. 70: Scars grown together

Pos. 102: Soiling in the surface

22

Pos. 71: Warts

30

Pos. 103: Grinding marks

Pos. 72: Hair pores

Pos. 104: Varnish runs

Pos. 73: Insect stings

Pos. 105: Fissures (cracks/chipping)

Pos. 74: Open pores

Pos. 106: Glossy spots

23

Pos. 75: Rough spots

31

Pos. 107: Pressure spots

Pos. 76: Neck striae

Pos. 108: Edge grinding defects

Pos. 77: Fat wrinkles

Pos. 109: Delamination (of edges)

Pos. 78: Veininess

Pos. 110: Resin defects

24

Pos. 79: Flank

Photos by kind permission of member companies in Working Group 16 Legal information

Despite all due diligence, errors cannot be entirely excluded.

Pos. 80: Loose leather

Pos. 81: Pressure spots

Pos. 82: Foreign objects

25 Pos. 83: Stains

Pos. 84: Glue residues













Pos. 85: Leather damaged In the event of inconsistencies, the printed edition of

VDA Volume 16 shall be conclusive. The contents of these pages are protected by copyright. Responsible for contents and technical realization: Verband der Automobilindustrie e.V. (VDA) Qualitäts Management Center (QMC) Behrenstr. 35 10117 Berlin, Germany www.vda-qmc.de

Pos. 86: Leather folds

26

Pos. 87: Leather too short

Pos. 88: Leather too long

Pos. 89: Transition panel-to-leather

Pos. 90: Fiber inclusions













Pos. 1 Offset


Definition: Offset due to joining of parts (e. g. by vulcanization or injection molding).

Process allocation: 5, 8, 12, 13, 15

Examples for tolerable attribute levels

Zone A: visible and palpable +/- 0.3 mm

Zone B: +/- 0.7 mm

Pos. 2

Burn marks


Definition: Dull-crumbly surface structure due to dendritic depositions in the limit current area (in pronounced form, called buds)

Process allocation: 1, 6


Zone A: according to MTP sample

Zone B: according to MTP sample

Pos. 3

Bumps/dents


Definition: Indentation of an area, caused by strong pressure.

Process allocation: 6, 8 -16

Examples for tolerable attribute levels:

Zone A: if visible within distance >= 800 mm, not permissible

Zone B: if visible within distance >= 1200 mm, not permissible.

Pos. 4a

Bubbles


Definition: mostly round, uniform elevations (hollow inside)


Examples for tolerable attribute levels:















Pos. 4b Craters


Definition: mostly circular, crater-like depressions in the topcoat or precoats. The raised edges are typical.





Pos. 5

Impressions


Definition: Slight depressions, randomly distributed over the surface, or in a closely confined area, due to impressed foreign particles.

Process allocation: 6, 8, 9, 10, 12, 13, 16


Zone A: d<= 0.7 mm max. 2 impressions within 400 mm distance

Zone B: d<= 1.0 mm max. 4 impressions within 300 mm distance

Pos. 6

Cracks in anodized surface


Definition: Micro-fissures; small linear structures in the anodized layer, caused by excessive local deformation of the part, or excessive layer thickness built up during anodizing.

Process allocation: 1




Pos. 7

Paint mist


Definition: Paint droplets finely sprayed on the surface, not homogeneously embedded in the paint film or distributed across the paint film.




Zone B: permissible













Pos. 8 Color shade differences


Definition: Color shade difference of a surface compared to adjoining surface or reference sample. This results from:

a) due to material b) due to process

c) sensory perception: saturation, brightness, purity, glossiness, depth and surface structure

Process allocation: 2, 3, 6, 13


Zone A: Deviation according to MTP sample


Pos. 9

Bulging edge


Definition: Accumulation of paint layers (bulge formation) on part edges, caused e. g. by surface tension. The effect is primarily correlated to the edge radius or with the position of the part in the process.




Zone B: permissible

Pos. 10

Stains


Definition: Locally sharply demarcated cloudiness of surface (e. g. soiling/corrosion (point-shaped or nest-shaped), drying stains)

Process allocation: 1, 2, 3, 6, 7, 13


Zone A: not permissible

Zone B: not permissible

Pos. 11

Mold separation burr


Definition: Burr that may be caused by inaccurate fit of mold halves or slides (e. g. sprue residues on injection-molded parts), sometimes also by wear, overflow.

Process allocation: 5, 6, 13


Zone A: max. +0.3 mm

Zone B: max. +0.5 mm













Pos. 12 Gloss level deviation


Definition: Gloss level deviating from (original) sample or specified value on partial or complete areas.





Pos. 13

Burr


Definition: Sharp-edged structure of edge zones from earlier process (e. g. punch burr at cut edge, paint burr)





Pos. 14

Graininess


Definition: Visually perceived optical effect that may result from diffuse reflection on microstructure phases (e. g. etched grain boundaries).





Pos. 15

Hair scratches


Definition: Linear damages of finest structure.

















Pos. 16 Contact or fastening point


Definition: Small-sized, naked coating defect, mostly point-shaped (in non-visible area), caused by suspension clamps / contacting at rack / part carrier).





Pos. 17

Scratches / striae


Definition: Linear damages by incorrect handling (e. g. by demolding).


Examples for tolerable attribute levels (lengthwise)

Zone A: l <= 4mm, b <= 0.5mm, max. 2 scratches within 300 mm distance

Zone B: l <= 10mm, b<= 0.7mm, max. 4 scratches within 200 mm distance

Examples for tolerable attribute levels (crosswise)


Zone B: not permissible

Pos. 18

Running paint


Definition: Traces of paint running off in the topcoat or in a precoat on vertical surfaces (mostly around beadings, curvatures, folds or cut-outs).




Zone B: permissible

Pos. 19

Paint lens


Definition: Optical distortion / progression defect of paint surface that is not detectable by touch; running paint in its initial stadium.

















Pos. 20 Weak spots


Definition: Too little coating applied (substrate shining through).





Pos. 21

Macro-fissures


Definition: Fissures in electroplated layer due to deformation or tensions in the part.





Pos. 22

Pinpricks


Definition: Finest craters (see Pos. 4b), also micro-pores.



Zone A: An accumulation of <= 5 pinpricks on 4 cm² is permissible

Zone B: Pinpricks permissible

Pos. 23

Nickel halo


Definition: Yellowish spots in contact area and in the area of low current density.

















Pos. 24 Orange peel


Definition: Rough or wavy appearance of a painted surface, which may include a texture; grained paint surface with a structure resembling orange peel.



Zone A: Fine structure permissible according to MTP sample regarding degree and area percentage

Zone B: coarse structure permissible according to MTP sample regarding degree and area percentage

Pos. 25

Oxide lines


Definition: Designation: Stripes caused by oxide inclusions (oxide inclusions, oxide lines) Description and effects: Lines resembling pencil strokes (white to gray) in molding direction or rolling direction, more or less pronounced depending on type and quantity of trapped oxides.



Zone A: within distance of >= 800 mm, structures not permissible

Zone B: within distance of >= 1200mm, structures not permissible

Pos. 26

Pimples / inclusions


Definition: Impurities trapped in the surface such as dust or fluff, partly protruding from the coating, or growth impairment in the layer buildup.

Process allocation: 1, -7, 15


Zone A: see Section 10.2

Zone B: see Section 10.2

Pos. 27

Pigment defect














Definition: Disorientation of pigments, such as e. g. metal flakes.





Pos. 28 Polishing defects, various


Definition: Collective category for low percentages of defects, or rare types of defects. Specks: Polygonal stain areas by abrasion residues being polished in Clouding: Resulting after electrolytic polishing by excessive local heating (“no base polishing”, i. e. surface not fully polished) Holograms: Polishing defects with three-dimensional effect (esp. with dark colors) Polishing stains: Approximately circular areas with significantly

smoother surface than surroundings



Zone A: if visible within distance >= 800mm, not permissible

Zone B: if visible within distance >= 1200 mm, not permissible

Pos. 28a

Specks


Definition: Polygonal stain areas by abrasion residues being polished in.

Process allocation:




Pos. 28b

Clouding

No image available














Definition: Resulting after electrolytic polishing by excessive local heating (“no base polishing”, i. e. surface not fully polished)

Process allocation:




Pos. 28c

Holograms


Definition: Polishing defects with three-dimensional effect (esp. with dark colors)

Process allocation:




Pos. 28d Polishing stains (here: buffed too hot)


Definition: Approximately circular areas with significantly smoother surface than surroundings

Process allocation:




Pos. 29

Polishing fishes


Definition: “Fish-like” depression caused by polishing due to a foreign particle, a pore, or other preconditioning from previous processes (e. g. grinding).



Zone A: t <= 0.3 mm, b <= 2.5 mm, l < 5 mm max. 2 within 400 mm distance

Zone B: t <= 0.5 mm, b max. 3 mm, l <= 8 mm max. 4 within 300 mm distance

Polishing streaks













Pos. 30


Definition: Finest local accumulation of visible striae, caused by polishing (unfavorable selection of polishing paste and/or polishing disk)



Zone A: l <= 60 mm, b <= 0.5 mm, max. 6 within 300 mm distance

Zone B: l <= 80 mm, b <= 3 mm, max. 10 within 200 mm distance

Pos. 31

Pores


Definition: Holes in the coating surface, visible by naked eye, some of which may go down to the base material.



Zone A: see Section 10.2

Zone B: see Section 10.2

Pos. 32 Visible mold seams


Definition: Designation: Visible longitudinal mold seam (visible extrusion seam, visible welding zone) Description and effect: (Narrow) stripes in direction of extrusion, brighter or darker than the rest of the material, depending on lighting conditions. May occur in connection with chamber/web imprints. Visible longitudinal mold seams are process-related and unavoidable, but their degree can be influenced.

















Pos. 33 Chafe marks


Definition: Local roughening of the surface, mostly obvious by differences in gloss.





Pos. 34

Web imprints (linear markings - rolling groove)


Definition: Stripes running parallel to the direction of extrusion across the length of the profile, usually located above webs, that become particularly apparent after coating processes.



Zone A: if visible within distance >= 800 mm, not permissible

Zone B: if visible within distance >= 1200 mm, not permissible

Pos. 35

Streakiness


Definition: Liquation streaks; electro-potentiostatic effect, caused during pretreatment for anodization due to liquation in primary material.





Pos. 36 Over-leveling


Definition: Slightly scarred appearance of an electroplated surface; comparable to the orange-peel attribute on painted surfaces.





No image available













Pos. 37 Waviness


Definition: Wave-shaped, parallel markings on the sheet metal or profile surface, transversely to the direction of rolling or extrusion, that are visible in special observation positions (e. g. rear mirror view, deflectometry control in longitudinal direction under a very narrow viewing angle).



Zone A: Not permitted if the following conditions apply:

Part in installation position

Artificial light source 1.2 m above test object

Distance observer to test object 2.5 m +/- 0.5 m

Viewing direction 20°-45° to longitudinal vehicle axis under static observation

Zone B: visible within distance of >= 4 m not permitted if evaluated according to Zone A

Pos. 38a

Clouds/haziness/schlieren


Definition: In polishing: Local matte or dull cloud-shaped or stripe-shaped areas with diffuse transitions (process allocation 9)

In painting: Obvious partial light/dark areas within a (metallic-effect) paint, with diffuse transitions (process allocation 3)

Dull areas within the overall surface, with diffuse transitions (process allocation 6, 7)





Pos. 38b

Humidity schlieren / air schlieren


Definition: In plastic injection: Caused by humidity in the plastic material, or by trapped air during injection molding.

















Pos. 39 Layer thickness fluctuations


Definition: In electroplating, resulting from unfavorable current density distribution (process allocation 6), or in other processes from varying particle flows / angles of incidence or depositing conditions.





Pos. 40

Dips


Definition: Visible surface depressions, caused by elements located behind, such as webs, ribs and domes (process allocation 6)

Recessed areas on the part, caused by incorrect part geometry or insufficient shrinkage compensation (process allocation 12)





Pos. 41

Converging seams


Definition: Scratch-like, visible flow marks on plastic parts, where the flowing fronts meet.





Pos. 42

Sucker impression


Definition: Resulting from contact of the surface with rubber suckers; visible mark on the surface, caused by deposits from the sucker during demolding/removal of the part.

















Pos. 43 Joint line


Definition: Resulting from two mass flows flowing together behind cut-outs and mandrels (convergence line).





Pos. 44

Humidity inclusion


Definition: Humid material, caused by incorrect material preparation; expanding humidity condenses in the form of schlieren or small bubbles on the part surface.




Zone B: permissible according to MTP sample

Pos. 45

Open spots


Definition: Holes in the coating surface that go down to the base material, visible by naked eye.





Pos. 46

Joint gap/offset


Definition: Joint gap: Caused by incorrect joining of the face veneer / visible streak or line. Joint offset: Caused by incorrect joining of the face veneer / offset structural symmetry.




Zone B: permissible

No image available

No image available













Pos. 47 Putty repairs in wood


Definition: Due to missing pieces, holes, and cracks.




Zone B: permissible

Pos. 48

Nicking


Definition: Caused by damages by the knife during peeling.





Pos. 49

Differences in structure and texture


Definition: Irregular structure, branches, pattern too weak; caused by nature.




Zone B: permissible

Pos. 50

Pressing folds


Definition: visible lines; overlapping of material.




Zone B: permissible













Pos. 51 Paint residues


Definition: Not the entire surface was removed by laser treatment.





Pos. 52

Burns


Definition: Thermal change of the plastic substrate (color change).





Pos. 53

Orientation defects


Definition: Incorrect orientation of fiber direction; different running direction





Pos. 54

Mold separation edges


Definition: Form offset due to tool separation, line formation due to tool separation





No image available

No image available

No image available













Pos. 55 Fabric irregularities


Definition: Fiber imprints in the fabric, fiber cracks in the fabric





Pos. 56

Fabric warping/distortion


Definition: Warping due to geometry





Pos. 57

Resin edges


Definition:





Pos. 58

Black points


Definition:





No image available

No image available













Pos. 59 Fabric discoloration


Definition: Fabric color variance





Pos. 60

White spots


Definition:





Pos. 61

Lack of resin


Definition:





Pos. 62

Resin surplus


Definition:





No image available

No image available

No image available













Pos. 63 Fiber splitting


Definition:





Pos. 64

Fabric overlapping


Definition:





Pos. 65

Missing fabric


Definition:





Pos. 66

Fraying in fabric


Definition:





No image available

No image available

No image available

No image available













Pos. 67 Tool impression


Definition:





Pos. 68

Resin flaking


Definition:





Pos. 69

Structure


Definition:





Pos. 70

Scars grown together


Definition:





No image available

No image available

No image available













Pos. 71 Warts


Definition:





Pos. 72

Hair pores


Definition:





Pos. 73

Insect stings


Definition:





Pos. 74

Open pores


Definition: Irregularity in the animal hide, visible by naked eye

















Pos. 75 Rough spots


Definition: Irregularity in the animal hide, visible by naked eye





Pos. 76

Neck striae


Definition: Skin folds, visible by naked eye





Pos. 77

Fat wrinkles


Definition: Skin folds, visible by naked eye





Pos. 78

Veininess


Definition: Vein markings, visible by naked eye





No image available













Pos. 79 Flank


Definition: Irregularity in the animal hide, visible by naked eye, giving evidence of the particularly soft and loose “flank” section of the hide.





Pos. 80

Loose leather


Definition: Missing glue under the leather





Pos. 81

Pressure spots


Definition:





Pos. 82

Foreign objects


Definition:

















Pos. 83 Stains


Definition:





Pos. 84

Glue residues


Definition:





Pos. 85

Leather damaged


Definition:





Pos. 86

Leather folds


Definition:

















Pos. 87 Leather too short


Definition: Leather not covering the carrier substrate





Pos. 88

Leather too long


Definition: Leather protruding over the carrier substrate





Pos. 89

Transition panel-to-leather


Definition: Gap or bulge formation





Pos. 90

Fiber inclusions


Definition: Lint, fluff

Process allocation: 18.2




No image available

No image available













Pos. 91 Fiber weave warping


Definition:





Pos. 92

Weaving depression


Definition:





Pos. 93

Uneven surface


Definition:





Pos. 94

Weaving lines


Definition: Fiber displacement





No image available

No image available

No image available

No image available













Pos. 95 Weaving offset


Definition:





Pos. 96

Dark fibers


Definition:





Pos. 97

Fiber openings


Definition:





Pos. 98

Incision


Definition:





No image available

No image available

No image available

No image available













Pos. 99 Gap


Definition:





Pos. 100

Shadows (ghost marks)


Definition:





Pos. 101

Seam line


Definition:





Pos. 102

Soiling in the surface


Definition: Of same color / contrasting color





No image available

No image available

No image available

No image available













Pos. 103 Grinding marks


Definition:





Pos. 104

Varnish runs


Definition: Running paint





Pos. 105

Fissures (cracks/chipping)


Definition:





Pos. 106

Glossy spots


Definition:





No image available

No image available













Pos. 107 Pressure spots


Definition:





Pos. 108

Edge grinding defects


Definition:





Pos. 109

Delamination (of edges)


Definition:





Pos. 110

Resin defects


Definition:





No image available

No image available

No image available

No image available

16 attribute definition / approach to defects

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