Specification

Class:

Previous Edition

2014-03

2015-11
Class No.:50

Surface protection

ZINC-NICKEL COATINGS WITH PASSIVATION

ON FERROUS MATERIAL

JED
739

Part name (for databases)

Passivation, Zn-Ni-steel

852 007 390 4

1 Scope
The specification refers to
parts which are extremely stressed with regard to corrosion,
i. e. parts which are exposed to the outdoor atmosphere (direct outdoor weathering). It is especially
applicable for parts subjected to high operating temperatures above +80 C and refers to corrosion
protection of parts made of ferrous materials. All coatings must be free from Hexavalent Chromium.
There are the following types:
JED-739-0

Invalid! If JED-739-0 is indicated on the drawing, JED-739-5 has to be applied.

JED-739-1

Invalid! If JED-739-1 is indicated on the drawing, JED-739-3 has to be applied.

JED-739-2

Invalid! If JED-739-1 is indicated on the drawing, JED-739-6 has to be applied.

JED-739-3

zinc-nickel coating with subsequent passivation of the zinc-nickel surface,

followed by a sealing process, with silver coulour of the coating;

JED-739-4

zinc-nickel coating with subsequent passivation of the zinc-nickel surface,

followed by a sealing process, with black coulour of the coating;

JED-739-5

zinc-nickel coating with subsequent passivation of the zinc-nickel surface,

without sealing process, with electrical conductivity, with silver coulour of the coating;

JED-739-6

zinc-nickel coating with subsequent passivation of the zinc-nickel surface,

without sealing process, with electrical conductivity, with black coulour of the coating.

If JED-739 is quoted in the drawing JED-739-0 shall be used.

Warning instruction for use
Certain customers (VOLVO and SCANIA at the time of preparation of this standard) require that the
release of Nickel does not exceed 0,5 g/cm/week (test according to EN 1811). If zinc-nickel
processes are used for these customers it must consequently be guaranteed that the threshold value is
kept.
Thermal range of application of the parts with surface protection:
-60 C to +150 C.

Continuation page 2 to 5
Compiler

Approved

Katarzyna piewak

Hans Vo

JED.dot Template version 03

Product Group:

4961

Doc. Code

Language

Rev.

008

- en -

JED-739 : 2015-11

Page 2

2 Requirements
2.1

Requirements on the substrate

The parts to be electroplated shall be free form surface, treatment, or other defects adversely affecting
the corrosion protection or the adhesion of the coating to the substrate. These are for instance slag inclusions, laps, score marks with a depth of more than 0.2 mm, pore clusters, sink marks, weld marks,
whirls and bubbles.
Parts with cracks or with material separations transversal to the force must not be used.

2.2

Requirements on the coating

The parts shall have a dense and homogeneous coating.

The nickel content of the coating must be 10 to 15 %.
The coatings must not have any defects affecting corrosion protection, as for instance pores, cracks,
roughnesses, stains or damages. The coatings must firmly adhere to the substrate and must not spall in
case of slight deformation.
The process conditions must be chosen in such a way that the usability of the finished part is not
affected. Prior to passivation or chromating, an appropriate heat treatment to avoid hydrogen
embrittlement shall be applied to parts with a strength of more than 1000 N/mm (Corresponding
hardness: 30 HRC, 295 HV, 280 HB). This also includes those parts where the strength locally exceeds
1000 N/mm due to case hardening or cold working.
The parts surface protection included shall be within the tolerances provided on the standard sheets or
drawings, with special consideration given to the thread dimensions.
The requirements on the corrosion protection of formed areas apply to areas formed after plating.
Measuring points for the coating thickness on screws and nuts
In case of screws the approximate center of the head surface or the approximate center of the end is
the measuring point. This statement is based on the assumption that the coating thickness in these
areas approximates that in the first turn of the thread (fig. 1 and fig. 2) for screws with a length of about
5 d.
If necessary, particular agreements concerning the measuring points are to be made for screws whose
length exceeds 5 d and for special parts.
In case of screws with internal drive the coating thickness is measured in the center of the remaining
head surface or in the center of the end (fig. 2 to fig. 5).
The coating thickness on nuts is measured in the center of a wrench surface (fig. 6).

Specification

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Page 3

Examples of measuring points (X):

X

Figure 1

2.2.1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Subsequent sealing process (JED-739-3 and -4)

For the purpose of sealing which increases corrosion and temperature resistance, substances with a
low tendency to coat formation are placed in the wet or dry passivation or chromate coating. Only
sealings which are resistant against cold degreasing agents are allowed. Sealing may considerably
reduce the conductivity of the coating. If conductivity is significant for the particular case of application,
sealing shall not be applied.

2.3

Coefficients of friction of threaded parts

On threaded parts to be used with preformed threads in the counterpart, plating shall be carried out in
such a way that
In steel counterparts a total coefficient of friction ST from 0,12 to 0,18, is met, if measured
according to ISO 16047.
In aluminium counterparts the total coefficient of friction AL does not exceed 0,25. The actual
tolerance range must be provided and agreed with WABCO Engineering, preferably the same limits
as for steel should be kept.
The measurement should be conducted according to ISO 16047, but:
o material of nut: wrought aluminium alloy
o nut free from oil or grease, no ultrasonic cleaning
o hardness of aluminium nut: 90 to 110 HB (2,5/62,5)
o tightening torque: 60% of VDI 2230 (for strength 8.8 and =0,12)
To achieve these requirements lubricants can be applied as parts of the top-coat or separately.
This does not apply to thread-forming screws (see JED-836 and 837). In cases where a different
coefficient range is defined in the drawing, that has to be used. Uneven, rough or too thick coatings
shall be avoided in the threaded area.
For measuring the coefficient of friction of screws and nuts screw testing equipment shall be applied
which permits a uniform slow tightening and releasing of the screwed connection.

Specification

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2.4
2.4.1

Page 4

Requirements on the corrosion protection

Requirement until appearance of white (zinc) corrosion

Test in accordance with ISO 9227, NSS test

Test duration
Rack parts
Drum parts

Requirement
Formed surface
areas
no requirement without zinc corrosion,
(2)
grey haze is accepted

JED-739-3 a. -4 240 h (1)

120 h (1)
JED-739-5 a. -6 168 h (1)
120 h (1)
(1) As well after heat treatment 24 h at +120 C.
(2) For steel parts which have been tempered for stress relief (e.g. Crimp Ring) the requirement
is 120 h.

2.4.2

Requirement until appearance of red (base metal) corrosion

Test in accordance with ISO 9227, NSS test

Test duration
Rack parts
Drum parts
JED-739-3, -4, -6 720 h (1)
JED-739-5

720 h (1)
480 h (1, 2)
720 h (1)
480 h (1, 2)

720 h (1)

Requirement
Formed surface
areas
720 h (1)
480 h (1, 2)
without
base metal corrosion
720 h (1)
600 (3)
480 h (1, 2)

(1) As well after heat treatment 24 h at +120 C.

(2) Exceptional requirement for the shaft and thread area of parts with thread.
(3) Exceptional requirement for steel parts which have been tempered for stress relief, (e.g. Crimp
Ring).

2.5

Coating thickness

In general, the required resistance is achieved with the nominal thicknesses indicated below:
Parts without thread
10 m

2.6

Threaded parts
6 m

Test for hexavalent chromium

Hexavalent Chromium must not be present in the coating.

The test to prove that no hexavalent chromium is present has to be done according to ISO 3613. If the
concentration of hexavalent chromium is below 0,1 g/cm according to this test, the parts are regarded
as being free from hexavalent chromium.

2.7

Resistance to media

Zinc and zinc alloy coatings according to this specification are not resistant to acids and strong alkaline
materials, as for instance cleansing agents.

2.8

Test of brittle fracture tendency for materials with strength > 1000
N/mm

The parts are subjected to a pre-loading test according to or similar to ISO 15330. No fracture must
occur.

2.9

Test of adhesion

The parts are stored 30 minutes at +220 C 10 C in air and immediately afterwards immersed in
water with a temperature of +15 C to +25 C. No spalling or blistering of the coating may occur.

Specification

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2.10

Page 5

Colour of coating

For types JED-739-3 and JED-739-5 the colour silver may be defined in the drawing. A slight yellow,
blue or green coloration is accepted in this case. There are no requirements for the gloss.
All colours can have yellow, blue or green iridescence. Identical parts from one process must have a
homogeneous appearance.

3 Guarantee
3.1

General

The manufacturer is obliged to prove by regular random test that the requirements specified in chapter
2 are observed, and to keep the inspection documents accessible to the customer.

3.2

Initial sample

Together with each initial delivery several initial samples and the initial sample inspection report must
be submitted for the inspection of dimensions and material.

3.3

Guarantee

The material supplied subsequently must correspond to the released sample, to the drawings and to
the requirements of this specification.

4 Document Versions
Revision

Date

Changes

1995-01

Initial Version

2001-06

Types JED-739-2 and JED-739-3 added

2006-11

Types JED-739-4, JED-739-5 and JED-739-6 added, application of

CrVI free passivations included

2009-04

Inalidation of the variant -0; -1 ;-2 due to hexavalent chromium ions

(Chromium VI) limits

2013-10

10

2014-02

11

2014-03

12

2015-10

Changes in point 2.3 coefficient of friction limits updated

Requirement until appearance of corrosion in points 2.4.1 and 2.4.2
changed.
Requirement until appearance of corrosion in points 2.4.1 and 2.4.2
changed.
Point 3 Guarantee added.
Colours of the coatings added to the JED variants in point 1 Scope.
Error correction
Definition of significant surface by ball with 20 mm diameter removed
in chapter 2.2.
Technical update of 2.8

Specification