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Group standard TL 245

Issue 2014-11
Class. No.: 50223

Descriptors: corrosion protection, surface protection, zinc, aluminum, flake, Delta-Protekt, Delta-Tone, Geomet,
Magni, Zintek

Non-Electrolytically Applied Zinc Flake Coatings


Surface Protection Requirements

Previous issues
TL 245: 1987-08, 1989-10, 1990-01, 1991-03, 1991-11, 1992-10, 1993-07, 1997-12, 2002-10,
2004-12, 2007-06, 2011-07, 2011-09, 2013-12

Changes
The following changes have been made to TL 245: 2013-12:
Section A.1.6 "Ofl-t647": "GEOMET 500 PLUS VLh" added
Applicable documents updated

Always use the latest version of this standard.


This electronically generated standard is authentic and valid without signature. Page 1 of 10
The English translation is believed to be accurate. In case of discrepancies, the German version is alone authoritative and controlling.

Technical responsibility The Standards department


GQL-M/1 Matthias Ackermann Tel.: +49 5361 9 38255
GQL-M/1 Gnther Laudien Tel.: +49 5361 9 25846 EKDV/4 Gabriela Bochynek EKDV
GQL-M Dr. Frank Rper Tel.: +49 5361 9 21151 Tel.: +49 5361 9 21698 Maik Gummert

All rights reserved. No part of this document may be provided to third parties or reproduced without the prior consent of one of the Volkswagen Groups Standards departments.
Volkswagen Aktiengesellschaft VWNORM-2014-06a-patch5
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TL 245: 2014-11

1 Scope
This standard defines the requirements placed on Cr(VI)-free surface protection types made of zinc
flakes and aluminum flakes applied to ferrous materials in a non-electrolytic manner.
The silver-gray flake coatings are used as heavy-duty corrosion protection for components with a
high corrosion load. With an appropriate layer structure, the zinc flake coatings are able to with
stand temperatures such as those occurring, e.g., in the engine compartment (for details, see
table 1).
Since this coating process poses no risk of hydrogen-induced embrittlement, it is preferably used
as corrosion protection for hardened and high-strength steel parts with tensile strength values
>1 000 MPa or hardness values >320 HV. The protection system must be chosen such that the
strength and hardness are not negatively affected by the treatment temperatures.
Zinc flake coatings are also suitable for use as a coating for ferrous materials in contact with alumi
num components (however, not for those in contact with magnesium components).
The coating is not suitable for components
that serve as electrical conductors (e.g., ground connections)
inside of engines (e.g., oil chamber) in order to avoid clogging by detached coating particles
The coating is only conditionally suitable for components with
triple squares as per Volkswagen standard VW 01043 <N8 and hexalobular sockets as per
VW 01048 <T30
hexagon sockets <5 and cross recesses as per DIN EN ISO 4757 <H3
external thread <M6
internal thread <M10
washers with thickness values <1.6 mm

2 Description
See VW 13750, section 2.

3 Requirements

3.1 Surface protection types


The surface protection types listed in table 1 apply. Examples of systems previously released for
components are listed in appendix A.
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TL 245: 2014-11

Table 1
Surface pro Characteristics/appearance
tection (Ofl)
type
Ofl-t601 Base coating without top coat and without lubricant additive.
Zinc flake coating, Cr(VI)-free, silver-gray; suitable for components that are to be
painted
- Curing temperature up to max. +300 C
- Reduced corrosion resistance (see section 3.11)
- Reduced long-term service temperature without additional coatings (+125 C).
Ofl-t602 Base coating with top coat, without lubricant additive.
Zinc flake coating, Cr(VI)-free, silver-gray; use in exposed installation positions,
e.g., in the engine compartment and chassis areas.
- Curing temperature up to max. +300 C
- Long-term service temperature max. +180 C (short-term temperature peaks up
to +300 C).
Ofl-t610 Like Ofl-t601, but with lower curing temperature.
Zinc flake coating, Cr(VI)-free, silver-gray; corrosion protection preferably for com
ponents that are to be painted (car body assembly). Standard surface protection for
threaded parts with adhesive coating (DIN 267-27) or with locking coating
(DIN 267-28).
- Curing temperature up to max. +200 C
- Reduced corrosion resistance (see section 3.11)
- Reduced long-term service temperature without additional coatings (+125 C).
Ofl-t611 Like Ofl-t602, but with lower curing temperature. Consequently, suitable for compo
nents that must not be exposed to high temperatures, e.g., spring elements, hot-
shaped sheets, or high-strength steel components.
- Curing temperature max. +230 C
- Long-term service temperature max. +180 C (short-term temperature peaks up
to +300 C).
Ofl-t615 Like Ofl-t610, but additionally with lubricant (greenish) as per TL 52165.
- Curing temperature up to max. +200 C,
- Reduced corrosion resistance (see section 3.11)
- Reduced long-term service temperature without additional coatings (+125 C).
Ofl-t647 Base coating with top coat, with lubricant additive. Zinc flake coating, Cr(VI)-free,
silver-gray, standard surface protection for threaded parts with metric ISO threads
(see VW 01110-1).
- Curing temperature up to max. +300 C
- Long-term service temperature max. +180 C (short-term temperature peaks up
to +300 C).

3.2 General requirements


Approval of first supply and changes as per VW 01155.
Avoidance of hazardous substances as per VW 91101.
10 finished parts are required for complete testing. For initial sample release of small parts, e.g.,
threaded fasteners, a test production of >50 kg must be performed.
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The coating materials must not contain any Cr(VI) compounds in order to ensure that the resultant
coatings are likewise Cr(VI)-free.
Unless certain sections of a part that are marked in the drawing are excluded from the surface
coating, the entire surface of the parts must have the required surface protection type with the pre
scribed properties. The coatings must adhere firmly to the base material (see section 3.10) and the
coatings must not chip or crack due to elastic deformation.
The protective coatings must not have any pores, cracks, damage, or other flaws that negatively
affect the corrosion protection and/or function.
The production process and its control must not impair the functional characteristics of the finished
part. For example, the coating must not flake or crack when the springs or spring washers are
mounted or used as intended.
If the coated components are properly mounted, the coating must not be damaged in a way that
would negatively affect the function and/or would reduce the specified corrosion protection.
The selection of manufacturers and coating systems must be agreed upon with the Volks
wagen AG Laboratory (GQL-M/1) and/or with the Audi AG test laboratories (I/GQ-31 and/or
N/GQ-551) for each individual component before use.

3.3 Threaded parts with metric ISO threads


The coating process must not negatively affect the mechanical and physical properties specified
for fasteners. Therefore, the manufacturer must check whether the curing conditions specified by
the coating company are suitable for the components to be coated.
An essential functional property of threaded parts with metric ISO threads is their adherence to
specified coefficients of friction. In order to ensure that the coefficients of friction adhere to
VW 01129, a top coat with integrated lubricant additive is prescribed for surface protection type
Ofl-t647, in addition to the base flake coating. For Ofl-t615, the coefficients of friction as per
VW 01129 are ensured by means of additional lubrication as per TL 52165. For the release of new
coating systems and the detection of faults in the case of complaints during installation, parts with
metric ISO threads must be tested as per VW 01131-1 and VW 01131-2.
Metric ISO threads must be designed as per VW 11611. After the coating process, external thread
dimensions must not exceed the shaft tolerance zone h in the shaft basis system as per ISO 286
and internal thread dimensions must not be below the hole tolerance zone H in the hole basis sys
tem as per ISO 286.
Especially in the case of threaded parts with top coats, it must be ensured that the surfaces are not
impermissibly damaged by processes carried out after the coating process, such as 100% part
check, packaging, transport, etc. For more information, see the guideline "Bercksichtigung der
Schtt- und Transportprozesse bei der Umstellung auf Cr(VI)-freie Oberflchen" ("Consideration of
Dumping and Transport Processes During the Changeover to Hexavalent-Chromium-Free Surfa
ces"), published by Deutscher Schraubenverband e.V. (German Fasteners Association). Rework
must always be announced and agreed upon.
For further information, see VW 01110-1, section 3.

3.4 Base coating


The base coating contains a binding agent and approx. 70% zinc flakes and approx. 10% alumi
num flakes. The use of zinc dust is not permissible. In order to reliably achieve coatings that have
uniform coverage and that satisfy the test requirements defined in section 3.11.2, a multiple-coat
ing process is required.
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TL 245: 2014-11

3.5 Top coat/lubricant additive


In order to improve corrosion protection and to achieve the defined coefficients of friction, addition
al system-specific top coats must be used, optionally with an integrated lubricant additive. The top
coats must be matched to the base coating. They must not cause any functional impairment.
Zinc flake coatings with top coats must not be used if paintability and the bonding of adhesives (al
so: locking or adhesive coatings for fasteners) are required.

3.6 Base material


See drawing or master data list (MDL).

3.7 Pretreatment
Usually bright metal. Alternatively (depending on the coating system), a micro-crystalline, thin-layer
phosphate coating (1 g/m2 to 3 g/m2) is permissible.
Before coating, hot alkaline and/or mechanical cleaning (e.g., abrasive blasting) must be per
formed on high-strength and hardened steel parts with tensile strength values >1 000 MPa or hard
ness values >320 HV.
Exceptions are only permissible following agreement with the Volkswagen AG Laboratory (GQL-
M/1) and/or the Audi AG test laboratories (I/GQ-31 and/or N/GQ-551).

3.8 Dry film


Composition as per International Material Data System (IMDS).

3.9 Dry film thickness


Testing as per DIN EN ISO 1463, DIN EN ISO 2064, and DIN EN ISO 2178; position of measuring
points for threaded parts with metric ISO thread as per DIN EN ISO 4042.
The average minimum coat thickness must be 8 m; the results of the individual measurements
may vary within the range from 6 m to 20 m. For threaded parts, the specifications only apply to
the head and/or to the face surface and wrench bearing surface; for all other surfaces, the mini
mum coating thickness is achieved if the anti-corrosion requirements are fulfilled.
Driving recesses and threaded areas must not have any base coat and/or top coat accumulations
that might negatively affect the functional properties.

3.10 Adhesion
A scribing line based on DIN EN ISO 9227 is applied if the component dimensions allow. Adhesive
tape with an adhesive strength of (10 1) N per 25 mm in width is then used for the adhesion test.
The tape is firmly pressed by hand onto the specimen surface and then removed with a sudden
motion perpendicular to the surface. Coating must not be removed from a large area. Small parti
cles of the coating that adhere to the tape are permissible.
NOTE 1:Suitable adhesive tape for the test is, e.g., "Tesaband 4657".
NOTE 2:In the case of small parts, the adhesion test can be performed without a scribing line.
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3.11 Corrosion behavior

3.11.1 Test atmosphere: Condensation atmosphere with constant humidity (CH) as per
DIN EN ISO 6270-2
This test is only required for the release of new coating systems. Usually, this test is carried out on
coated test panels (for the test scope, see below). Within the framework of an initial sample inspec
tion, the moisture resistance can also be proven by a certificate issued by the coating material
manufacturer.
A scribing line based on DIN EN ISO 9227 must be applied. After a test duration of 720 h and eval
uation as per DIN EN ISO 4628-3, the following requirements must be satisfied in each case as
minimum specifications:
Base metal corrosion on surface: Ri 0
Base metal corrosion permissible in the area of the scribing line, but no corrosion creepage

3.11.2 Natural salt spray (NSS) test as per DIN EN ISO 9227
The following requirements apply to parts in the Receipt of Goods department of the Volkswagen
Group plant using the parts (i.e., after packaging and transport).
NOTE 3:Usually, the base coat must be applied 3 times in order to safely achieve 600 h of re
sistance to salt spray fog without base metal corrosion.

3.11.2.1 Requirements for components of a general nature


No base metal corrosion (Ri 0) after a test duration of 720 h
No base metal corrosion (Ri 0) after a test duration of 480 h with thermal aging (heat aging/re
circulated air) 96 h at +180 C

3.11.2.2 Requirements for threaded barrel plated goods


No base metal corrosion (Ri 0) after a test duration of 600 h without thermal aging
No base metal corrosion (Ri 0) after a test duration of 480 h with thermal aging (heat aging/re
circulated air) 96 h at +180 C

3.11.2.3 Requirements for components with surface protection types Ofl-t601, Ofl-t610, and
Oflt615
No base metal corrosion (Ri 0) after a test duration of 480 h without thermal aging

3.12 Chemical resistance


The verification of the resistance to chemicals is only required for the release of new coating sys
tems. Usually, this test is carried out on coated test panels (for the test scope, see below). As part
of the initial sample inspection, resistance to chemicals may also be demonstrated by a certificate
issued by the coating material manufacturer.
Testing is performed as per DIN EN ISO 2812. The evaluation is performed as per
DIN EN ISO 4628-1. For test media and requirements, see table 2.
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Table 2
No. Test medium and test conditions Requirement
1 E10 gasoline as per DIN EN 228, ethanol content 9 to 10% (V/V):
Testing as per DIN EN ISO 2812-3, room temperature, 10 min, filter
2 B7 diesel fuel as per TL 788-B: Testing as per DIN EN ISO 2812-3,
room temperature, 60 min, filter
3 Reference engine oil as per TL 52185 (Lubrizol OS 206 304): Test Characteristic value
ing as per DIN EN ISO 2812-4, room temperature, 16 h, dripping 1
4 Hydraulic fluid as per TL 52146: Testing as per DIN EN ISO 2812-3,
room temperature, 16 h, filter
5 Coolant as per TL 774: Testing as per DIN EN ISO 2812-3, room
temperature, 60 min, filter
6 Brake fluid as per TL 766: Testing as per DIN EN ISO 2812-3, room Characteristic value
temperature, 60 min, filter 1; swellings that
have disappeared af
ter 24 h are permissi
ble.

4 Applicable documents
The following documents cited in this standard are necessary to its application.
Some of the cited documents are translations from the German original. The translations of Ger
man terms in such documents may differ from those used in this standard, resulting in terminologi
cal inconsistency.
Standards whose titles are given in German may be available only in German. Editions in other
languages may be available from the institution issuing the standard.

TL 52146 Central Hydraulic System Fluid; Lubricant Requirements


TL 52165 Lubricant (greenish) for Threaded Fasteners; Material Requirements
TL 52185 Reference Engine Oil SAE 5W-30 for Testing of Compatibility with Re
spect to Elastomer Materials; Lubricant Requirements
TL 766 Brake Fluid; Material Requirements
TL 774 Ethylene Glycol-Based Coolant Additive; Material Requirements
TL 788 Diesel Fuel; Fuel Requirements
VW 01110-1 Threaded Joints; Design and Assembly Specifications
VW 01129 Limit Values for Coefficients of Friction; Mechanical Fasteners with Met
ric ISO Threads
VW 01131-1 Determination of Coefficients of Friction; Practice- and Mounting-Orien
ted Testing
VW 01131-2 Determination of Coefficients of Friction; Release of New Surface Coat
ing Systems
VW 01155 Vehicle Parts; Approval of First Supply and Changes
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VW 11611 Metric ISO Thread; Limit Dimensions with Protective Coating for Medium
Tolerance Class; External Threads 6gh / Internal Threads 6H
VW 13750 Surface Protection for Metal Parts; Surface Protection Types, Codes
VW 91101 Environmental Standard for Vehicles; Vehicle Parts, Materials, Operat
ing Fluids; Avoidance of Hazardous Substances
DIN 267-27 Fasteners - Part 27: Steel screws, bolts and studs with adhesive coating,
Technical specifications
DIN 267-28 Fasteners - Part 28: Steel screws, bolts and studs with locking coating,
Technical specifications
DIN EN 228 Automotive fuels - Unleaded petrol - Requirements and test methods
DIN EN ISO 1463 Metallic and oxide coatings - Measurement of coating thickness - Micro
scopical method
DIN EN ISO 2064 Metallic and other non-organic coatings - Definitions and conventions
concerning the measurement of thickness
DIN EN ISO 2178 Non-magnetic coatings on magnetic substrates - Measurement of coat
ing thickness - Magnetic method
DIN EN ISO 2812-3 Paints and varnishes - Determination of resistance to liquids - Part 3:
Method using an absorbent medium
DIN EN ISO 2812-4 Paints and varnishes - Determination of resistance to liquids - Part 4:
Spotting methods
DIN EN ISO 4042 Fasteners - Electroplated coatings
DIN EN ISO 4628-1 Paints and varnishes - Evaluation of degradation of coatings - Designa
tion of quantity and size of defects, and of intensity of uniform changes
in appearance - Part 1: General introduction and designation system
DIN EN ISO 4628-3 Paints and varnishes - Evaluation of degradation of coatings - Designa
tion of quantity and size of defects, and of intensity of uniform changes
in appearance - Part 3: Assessment of degree of rusting
DIN EN ISO 6270-2 Paints and varnishes - Determination of resistance to humidity - Part 2:
Procedure for exposing test specimens in condensation-water atmos
pheres
DIN EN ISO 9227 Corrosion tests in artificial atmospheres - Salt spray tests
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Appendix A (informative)

A.1 Released surface protection systems

A.1.1 Ofl-t601
Any system, e.g.:
DELTA-TONE 9000
DELTA-PROTEKT KL100
GEOMET 321
Magni Flake B46
Magni Flake D90
ZINTEK 200

A.1.2 Ofl-t602
Any system, e.g.:
DELTA-PROTEKT KL100 + DELTA-PROTEKT VH300
GEOMET 321 PLUS 10
ZINTEK 200 + ZINTEK TOP
Magni Flake B46 + Magni Top T06E

A.1.3 Ofl-t610
DELTA-TONE 9000
Magni Flake D90

A.1.4 Ofl-t611
DELTA-PROTEKT KL100 + DELTA-PROTEKT VH300
ZINTEK 200 + ZINTEK TOP

A.1.5 Ofl-t615
DELTA-TONE 9000 + lubricant (greenish) as per TL 52165
Magni Flake D90 + lubricant (greenish) as per TL 52165
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A.1.6 Ofl-t647
Any system. For fasteners, however, only:
DELTA-PROTEKT KL100 + DELTA-PROTEKT VH301.1GZ
DELTA-PROTEKT KL105 + DELTA-PROTEKT VH301.1GZ
GEOMET 321 PLUS VLh
GEOMET 500 PLUS VLh
Magni Flake B46 + Magni Top T06E-GZ
ZINTEK 200 + ZINTEK TOP LV