1、 APRIL 2009 Page 1 of 6 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. NAVISTAR, INC. CEMS (CORPORATE ENGINEERING MATERIAL SPECIF
2、ICATION) NUMBER: CEMS GT-24 TITLE: Phosphate System Compatibility CURRENT ISSUE DATE: April 2009 WRITTEN/REVIEWED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES ISSUE OF: February 2004 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification m
3、ay 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 use.
4、 Change Notice: Replaced “International Truck and Engine Corporation” with “Navistar, Inc.” per corporate directive; editorial changes. 1.0 SCOPE This is a method for determining the effect of contaminants (mill oils, drawing compounds, corrosion preventatives, adhesives, sealers, etc.) on the clean
5、ing stages of the phosphate coating system and on the phosphate coating developed by the system. 2.0 APPARATUS 2.1 A water bath with capabilities of both heating and agitation suitable to simulate the cleaning stage(s) of the phosphate coating system. 2.2 Draw bars capable of leaving 0.014 mm (0.54
6、mil) and 0.019 mm (0.75 mil) wet films - RDS Specialties Rods #6 only the bottom half of each panel is to be topcoated. Use Grade 56 primer and Grade 18 topcoat as per CEMS G-5, Parts II and Part III. 4.2.18 Determine the paint adhesion on both the primer and topcoat on one panel from each group in
7、accordance with the method described in CEMS Test Method GT-5A. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for Resale-,-,-NUMBER: CEMS GT-24 TITLE: Phosphate System Compatibility CURRENT ISSUE DATE: April 2009 APRIL 2009 Page 3 of 6 This document is res
8、tricted 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. 4.2.19 Perform a humidity test in accordance with CEMS Test Method GT-7E on one panel from each group.
9、 4.2.20 Perform a salt spray test in accordance with CEMS Test Method GT-7D on one panel from each group. 4.3 Report Report the following information: 4.3.1 The percent of processing lubricant and water separation at 5 minute, 60 minute, and 24 hour intervals. 4.3.2 The percent of water break-free (
10、% WBF) for each metal at each contaminant level and that of the controls. 4.3.3 The change in amount of foaming at each contaminant level. 4.3.4 The phosphate coating weight and coating appearance for each control and test panel of each metal at each contaminant level. 4.3.5 The minimum percent adhe
11、sion observed on each control and test panel of each metal for each of the contaminant levels. 4.3.6 Humidity test results for each control and test panel of each metal for each of the contaminant levels. 4.3.7 Salt spray test results for each control and test panel of each metal for each of the con
12、taminant levels. 5.0 PROCEDURE FOR LOW VOLUME CONTAMINANTS Low volume contaminants include but not limited to miscellaneous lubricants and solvents used to maintain the phosphate system. 5.1 Panel Preparation For each metal substrate (CR steel, galvanized steel, 5052-H32 aluminum) to be used in the
13、processing lubricant evaluation: 5.1.1 Prepare 4 control panels and 12 test panels for each metal as described in items 4.1.1 to 4.1.3. 5.1.2 Allow the specimens to equilibrate at atmospheric conditions for 2 hrs prior to testing. 5.2 Procedure 5.2.1 Test for cleanability as described in items 4.2.6
14、 thru 4.2.13 5.2.2 Test for phosphatability as described in items 4.2.14 thru 4.2.15 5.3 Report 5.3.1 The percent of water break-free (% WBF) for each metal at each contaminant level and that of the controls. 5.3.2 The phosphate coating weight and coating appearance for each control and test panel o
15、f each metal at each contaminant level. 6.0 PROCEDURE FOR SEALERS AND ADHESIVES This procedure is intended for all sealers and adhesives that will enter the phosphate system. 6.1 Panel Preparation Prepare 8 control panels, 8 test panels, and 8 sandwich test panels for each material to be evaluated.
16、Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHSNUMBER: CEMS GT-24 TITLE: Phosphate System Compatibility CURRENT ISSUE DATE: April 2009 APRIL 2009 Page 4 of 6 This document is restrict
17、ed 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. 6.1.1 Apply the sealer bead or adhesive patch to oiled panels representative of the production conditions.
18、6.1.2 Prepare a set of sandwich panels with a 6 mm gap using oiled panels representative of production conditions. 6.1.3 Allow the specimens to equilibrate at atmospheric conditions for 2hrs prior to testing. 6.2 Procedure Re-use the solution for each different set of samples. 6.2.1 Record the weigh
19、t of all the test panels and sandwich test panels. 6.2.2 Run 4 test panels and 4 sandwich test panels in all the stages of the phosphate system at the times and temperatures representative of production conditions. 6.2.3 Run 4 test panels and 4 sandwich test panels in all the stages of the phosphate
20、 system allowing the panels to remain at each bath for 24hrs. 6.2.4 Run 4 control panels in all the stages of the phosphate system at the times and temperatures representative of production conditions. 6.2.5 Record the weight of all the test panels and sandwich test panels. Calculate % weight loss.
21、6.2.6 Bake all test panels and sandwich test panels at the times and temperatures representative of the e-coat oven. 6.2.7 Record any visible loss of adhesion, dissolution and erosion on the adhesive/sealant surface. 6.2.8 Determine the phosphate coating weight in accordance with CEMS Test Method GT
22、-23 on one panel from each group. 6.2.9 Use a scanning electron microscope (SEM) to describe the general appearance of the phosphate coating on the remaining three panels of each group. 6.3 Report 6.3.1 % Weigh loss for each group. 6.3.2 Visible loss of adhesion, dissolution and erosion on the adhes
23、ive/sealant surface. 6.3.3 The phosphate coating weight and coating appearance for each control and test panel of each group. 7.0 SAMPLE REPORT A sample report is shown below as a guide in preparing the report for this test method. Copyright Navistar International Corporation Provided by IHS under l
24、icense with INTERNNot for Resale-,-,-NUMBER: CEMS GT-24 TITLE: Phosphate System Compatibility CURRENT ISSUE DATE: April 2009 APRIL 2009 Page 5 of 6 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers ar
25、e required to assume all patent liability. 2009 by Navistar, Inc. SAMPLE REPORT FOR HIGH VOLUME CONTAMINANTS Report Number_ Date_ Processing Lubricant Identification _ Control Oil Identification: Cold rolled Steel _ Galvanized Steel _ 5052-H32 Aluminum _ EMULSIFICATION TEST RESULTS Cleaner Concentra
26、tion Percent of Separation 5 Minutes 60 Minutes 24 Hours 0.25 oz/gal. 0.50 oz/gal. 1.00 oz/gal. 2.00 oz/gal 100% 100% 50% 0% - - 100% 50% - - - 100% PERCENT WATER BREAK-FREE (%WBF) TEST RESULTS Contamination Level % Weight % WBF - Area CR Steel Galvanized Steel 5052-H32 Aluminum 0.0% (Control) 0.0%
27、0.10% 0.25% 90% 100% 90% 50% 80% 90% 90% 40% 90% 100% 90% 40% FOAM TEST RESULTS Contamination Level % Weight Increase in Amount of Foam Times more Foam 0.0% 0.10% 0.25% - 1 4 PHOSPHATE COATING WEIGHT AND APPEARANCE Contamination Level % Weight Coating Weight, mg/ft.2 Appearance CR Steel Galvanized S
28、teel 5052-H32 Aluminum 0.0% (Control) 140 180 160 Uniform on All 0.0% 150 160 160 Uniform on All 0.10% 180 180 180 Light Streak on Steel & Galvanized 0.25% 90 130 80 Streaked on All Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for Resale-,-,-NUMBER: CEMS
29、GT-24 TITLE: Phosphate System Compatibility CURRENT ISSUE DATE: April 2009 APRIL 2009 Page 6 of 6 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
30、 Navistar, Inc. SAMPLE REPORT (Continued) ADHESION TEST RESULTS PER GT-5A Contamination Level, % Weight Adhesion, Minimum Percent Comment CR Steel Galvanized Steel 5052-H32 Aluminum 0.0% (Control) Primer Topcoat 100 100 100 100 100 100 - - 0.0% Primer Topcoat 100 95 100 95 100 100 - - 0.10% Primer T
31、opcoat 95 90 95 90 85 80 Aluminum Samples Failed Min % Adhesion HUMIDITY TEST RESULTS PER GT-7E Contamination Level, % Weight CR Steel Galvanized Steel 5052-H32 Aluminum Comment 0.0 (Control) Primer Topcoat Pass Pass Pass Pass Pass Pass - - 0.0% Primer Topcoat Pass Pass Pass Pass Pass Pass - - 0.10%
32、 Primer Topcoat Pass Pass Pass Pass Pass Pass - - 0.25% Primer Topcoat Pass Pass Fail Fail Fail Fail Blisters on Galvanized and Aluminum SALT SPRAY TEST RESULTS PER GT-7D Contamination Level, % Weight CR Steel Galvanized Steel 5052-H32 Aluminum Comment 0.0 (Control) Primer Topcoat Pass Pass Pass Pas
33、s Pass Pass - - 0.0% Primer Topcoat Pass Pass Pass Pass Pass Pass 0.10% Primer Topcoat Pass Pass Pass Fail Pass Fail Galvanized & Aluminum Blisters to Prime 0.25% Primer Topcoat Pass Fail Fail Fail Fail Fail Topcoat 1/8 Inch Creepage on All Samples Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for Resale-,-,-
