1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. AUGUST 2009 Page 1 of 4 NAVISTAR, INC. CEMS (CORPORATE ENGINEERING MATERIAL SPECIF
2、ICATION) NUMBER: CEMS G-1 TITLE: Phosphate Coatings on Iron and Steel CURRENT ISSUE DATE: August 2009 WRITTEN/REVIEWED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES ISSUE OF: August 2003 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specificatio
3、n may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regulatory limits prior to u
4、se. Change Notice: Replaced “International Truck and Engine Corporation” with “Navistar, Inc.” per corporate directive; added CEMS B-50 requirement; better defined Class A as Mn phosphate and Class B as Zn/Fe phosphate; editorial changes. 1.0 SCOPE This specification covers Navistars requirements fo
5、r phosphate coatings applied by chemical treatment primarily for adhesive wear resistance and corrosion resistance. Those proprietary phosphate systems used primarily as paint-bond systems under painted parts are not included in this specification. 2.0 INTRODUCTION Phosphate coatings are used primar
6、ily for wear resistance to prevent galling and scoring and to facilitate the break-in of gears, splines, and bearings, etc. Phosphate coatings, with oil films applied, continue to be used on fasteners to provide both torque control and limited corrosion resistance. However, the use of phosphate coat
7、ing as a means to provide the primary corrosion resistance is declining. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the CEMS B-50 specification. 3.0 CONTENTS PAGE REFERENCE DOCUMENT
8、S 1 CLASSIFICATION AND REQUIREMENTS 2 QUALITY 3 METHODS OF TEST 3 SOURCE APPROVAL AND QUALITY CONTROL 3 DESIGNATION ON DRAWINGS AND PURCHASE ORDERS 3 PACKING AND SHIPPING 3 APPENDIX GENERAL INFORMATION (Not a Requirement) Green Sheets 4.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest is
9、sue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 CFR Title 29, Part 1910 NAVISTAR Mfg Std MS-D-13 Federal Standard 791 NAVISTAR CEMS B-50 ASTM B 117 Copyright Navist
10、ar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: CEMS G-1 TITLE: Phosphate Coatings On Iron And Steel CURRENT ISSUE DATE: August 2009 This document is restricted and may not be sent outsid
11、e Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. AUGUST 2009 Page 2 of 4 5.0 CLASSIFICATION AND REQUIREMENTS This specification provides for two classes of phosphate coatings: Class A (
12、manganese phosphate) for the prevention of adhesive wear, and Class B (zinc or iron phosphate) for corrosion resistance. Additional treatments are specified by the use of suffix numbers as shown in the Classification table below. Phosphate treatments will cause a moderate increase in surface roughne
13、ss; a surface buildup of 0.00015 to 0.0005 inch (4 to 13 m) for all classes and as great as 0.001 inch (25 m) for Class B-3 is common. Coating thickness tolerances, where critical, will be specified on the engineering drawing. Specific tolerances are subject to agreement between the purchaser and th
14、e supplier. CLASSIFICATION AND REQUIREMENTS Basic Class Additional Treatment SU F F I X Type of Service Quality of Coating Neutral Salt Spray(1) Adhesive Wear Test Hours Tolerable Corrosion A Oiled 1 To prevent scuffing, seizing or galling on sliding or bearing surfaces during assembly and initial s
15、ervice, Class A-2 will also provide mild corrosion protection. Coating must be finely crystalline and adherent. Significant surfaces must be free from streaks, stains or other evidence of non-uniformity. 4 Will carry a 10 lbf (44.5 N) load with a maximum scar of 2.5 mm and no evidence of seizing, ga
16、lling or scuffing. passivating * rinsed and oiled (rust inhibiting oil) 2 16 After the specified hours of test there will not be visible to the unaided eye more than one rust spot per square inch (6.5 cm2) of significant surface. (2) On pieces having an area less than one square inch (6.5 cm2) of si
17、gnificant surface one rust spot per piece will be permitted. No rust spots larger than 0.06 inch (1.5 mm) will be tolerated. B passivating * rinsed and oiled (rust inhibiting oil). 1 Normally used where corrosion resistance is required. Class B-2 is recommended for threaded fasteners. Coatings will
18、be dense, continuous, uniform and gray or dull black. 24 N/A passivating * rinsed and oiled (special rust inhibiting oil).* 2 72 proprietary systems. 3 Used for higher corrosion resistance. Some systems will also meet Class A wear resistance requirements. 96 * The required passivating rinse must be
19、free of hexavalent chrome. * The oiled parts will be clean and dry to the touch. Oils used on standard parts will have prior approval from the controlling Engineering Dept; those used for Truck Group design parts must be approved by Fastener Engineering, TDTC, Fort Wayne. See “Appendix” - General In
20、formation” for a list of suitable oils. (1) Neutral salt spray requirements will be met by parts which have been subjected to normal handling. (2) Significant surfaces will be defined by the controlling engineering department and/or specified on the applicable engineering drawing(s). 6.0 GENERAL REQ
21、UIREMENTS Refer to Section 5.0 for requirements. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: CEMS G-1 TITLE: Phosphate Coatings On Iron And Steel CURRENT ISSUE DATE: A
22、ugust 2009 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. AUGUST 2009 Page 3 of 4 7.0 QUALITY All product supplied shall be clean
23、 and free from dirt, oils, or defects harmful to product performance. Parts to be coated will be thoroughly cleaned and free from rust, scale, oil and other foreign matter detrimental to the final finish. See “Appendix - General Information” section. 8.0 METHODS OF TEST 8.1 Neutral Salt Spray Conduc
24、t this test according to ASTM B 117. 8.2 Adhesive Wear Conduct this test according to FED-STD-791, Method 6505 (or equivalent). Use a non-additive mineral oil of SAE 10W viscosity. 9.0 SOURCE APPROVAL AND QUALITY CONTROL 9.1 Supplier Requirements All suppliers to NAVISTAR are required to be register
25、ed to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and
26、must furnish copies of registration certificates to their Corporate Buyer upon request. 9.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples that were approved by the purchaser. No changes in formulation or pr
27、ocessing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify Materials Engineering (TDTC) and Purchasing and Supplier Development of the proposed cha
28、nge(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 9.3 Process Control The supplier shall eith
29、er perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and th
30、e plant metallurgist and/or the quality control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products. 10.0 DESIGNATION ON DRAWINGS AND PURCHASE ORDERS Phosphate coatings will be specified on drawings and purchase orders as indicated in the followi
31、ng examples (Note - type of phosphate coating, manganese or zinc phosphate, must be specified): Manganese Phosphate Coating, Class A-2, CEMS G-1 Zinc Phosphate Coating, Class B-3, CEMS G-1 11.0 PACKING AND SHIPPING Packing and shipping shall be in accordance with Manufacturing Standard MS-D-13. Copy
32、right Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: CEMS G-1 TITLE: Phosphate Coatings On Iron And Steel CURRENT ISSUE DATE: August 2009 This document is restricted and may not be
33、 sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. AUGUST 2009 Page 4 of 4 12.0 TECHNICAL INFORMATION For further information related to the technical content of this specific
34、ation, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. Truck Development and Technology Center (TDTC) 2911 Meyer Road Fort Wayne, IN 46803 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood C
35、O 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/ Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-This document is restricted and may not be sent outsid
36、e Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. AUGUST 2009 Page 1 of 2 NAVISTAR, INC. CEMS (CORPORATE ENGINEERING MATERIAL SPECIFICATION) NUMBER: CEMS G-1, APPX TITLE: Phosphate Coati
37、ngs on Iron And Steel - APPENDIX CURRENT ISSUE DATE: August 2009 WRITTEN/REVIEWED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES ISSUE OF: August 2003 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve hazardous materials, eq
38、uipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regulatory limits prior to use. Change Notice: Replaced “Internat
39、ional Truck and Engine Corporation” with “Navistar, Inc.” per corporate directive; editorial changes. APPENDIX GENERAL INFORMATION (NOT A REQUIREMENT) CONTENTS PAGE A.1 PROPERTIES OF PHOSPHATE COATINGS 1 A.2 SPECIAL RUST INHIBITING OILS 2 A.3 SURFACE PREPARATION 2 A.4 INCREASE OF DIMENSIONS 2 A.5 PH
40、OSPHATE COATING GUIDE 2 A.6 PHOSPHATE COATING, DETERMINATION OF WEIGHT 2 A. 1 Properties Of Phosphate Coatings Phosphate coatings having a wide range of thickness and density may be produced. These depend upon the method of cleaning, type, concentration and temperature of solution and the time of tr
41、eatment. Since no electric current is used, the type of coating produced is solely dependent upon the solution contacting the work. Thus, uniform coatings may be produced on irregularly shaped objects and recessed areas. A.1.1 Phosphate coatings are applied by chemical treatment primarily for adhesi
42、ve wear resistance or corrosion resistance. These properties are obtained because the nonmetallic coating is slightly porous and will retain oil or other lubricating or sealing materials. Since these coatings are nonmetallic, they are poor electrical conductors and should not be applied to parts use
43、d in an electrical circuit. A.1.2 Adhesive wear reduction is important during assembly and initial service. Phosphate coatings furnish a non-metallic oil-absorbing surface on the moving parts and tend to prevent seizure. Rapid break-in of coated new parts, such as cylinder liners, pistons, rings, ca
44、mshafts, tappets and gears may be accomplished without harmful effects. Manganese phosphate coatings are generally used for this purpose. A.1.3 The solutions used to produce the nonmetallic coating generally contain one or more of the following chemicals: manganese phosphate, iron phosphate, zinc ph
45、osphate, dihydrogen phosphate or phosphoric acid. In addition, an accelerator such as a nitrate or chlorate may be added. The coatings produced are manganese, zinc and/or iron phosphates and usually gray or dull black in color. They have a fine silky texture or fine crystalline appearance, depending
46、 on the type of coating and the thickness. The manganese phosphate coatings are usually used for reducing adhesive wear, while the zinc phosphate coatings are used for corrosion resistance. The use of phosphate coating as the primary corrosion inhibitor is declining. Copyright Navistar International
47、 Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: CEMS G-1, APPX TITLE: Phosphate Coatings On Iron And Steel CURRENT ISSUE DATE: August 2009 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. AUGUST 2009 Page 2 of 2 A.2 Special Rust Inhibiting Oils The following oils, applied at 140F (60C) min
