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. 2014 by Navistar, Inc. APRIL 2014 Page 1 of 4 NAVISTAR, INC. Material, Parts, and Process Specifications
2、(MPAPS) NUMBER: MPAPS G-1 Former Designation: CEMS G-1 TITLE: Phosphate Coatings on Iron and Steel CURRENT REV No.: 1404 DATE: April 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: CEMS G-1 - August 2009 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FO
3、R CURRENT REVISION This specification 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 applicabi
4、lity of regulatory limits prior to use. Change Notice: Changed to new MPAPS format; changed coating classifications; added hydrogen embrittlement requirements in Section 4.4; editorial changes. 1.0 APPLICATION This specification covers Navistars requirements for phosphate coatings applied to metal p
5、arts for corrosion resistance, lubricity, or as a foundation for subsequent coatings or paint. Phosphate coatings prevent galling and scoring and facilitate the break-in of gears, rocker arms, and bearings, etc. Phosphate coatings, with oil films applied, is used on fasteners to provide both torque
6、control and limited corrosion resistance. 2.0 SCOPE This specification covers Navistars requirements for two types of conversion phosphate coatings applied by chemical treatment primarily for adhesive wear resistance and corrosion resistance. Proprietary phosphate systems used as paint-bond systems
7、under painted parts are not included in this specification. 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 MPAPS B-50. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest
8、 issue 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 MS-D-13 FED-STD-791 NAVISTAR MPAPS B-50 ASTM B 117 ASTM F 519 4.0 REQUIREMENTS T
9、his specification provides for two types of phosphate coatings: 4.1 Type M (formerly designated as Type A) - Manganese phosphate base coating used for corrosion protection, anti-galling and lubricity. Manganese phosphate coatings are the hardest, while providing unbeatable corrosion and abrasion pro
10、tection. In comparison to zinc phosphate coatings, manganese phosphate coatings offer continued wear protection after the breaking in of components that are subject to wear. These coatings are applied only by immersion. Use of manganese phosphate is especially useful in projects that require sliding
11、 of parts, such as automotive engines and transmission. NUMBER: MPAPS G-1 TITLE: Phosphate Coatings On Iron And Steel REVISION: 1404 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to a
12、ssume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 2 of 4 4.2 Type Z (formerly designated as Type B) Zinc phosphate base for corrosion resistance. They can be applied by immersion or spraying. Zinc phosphate is a lighter alternative to manganese phosphate. Zinc phosphate coatings are
13、 typically used to retain rust preventive oils and waxes. The coatings provide good corrosion protection by bonding the final finish (stain, oil, wax or paint) to the treated material. The treatment produces a uniform coating and is particularly good for corrosion protection of threaded areas and pa
14、rts that have small holes or recesses. 4.3 Additional treatments are specified by the use of class numbers as shown in the table below. Phosphate treatments will cause a moderate increase in surface roughness; a surface buildup of 0.00015 to 0.0005 inch (4 to 13 m) for all types and as great as 0.00
15、1 inch (25 m) for type Z class 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 the supplier. CLASSIFICATION AND REQUIREMENTS Type Additional Treatment class Type of Service
16、 Quality of Coating Neutral Salt Spray(1) Adhesive Wear Test Hours Tolerable Corrosion M Oiled 1 To prevent scuffing, seizing or galling on sliding or bearing surfaces during assembly and initial service, Class M-2 will also provide mild corrosion protection. Coating must be finely crystalline and a
17、dherent. 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, galling or scuffing. passivating * rinsed and oiled (rust inhibiting oil) 2 16 After the specified hours
18、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 significant surface one rust spot per piece will be permitted. No rust spots larger than 0.06 inch (1.5 m
19、m) will be tolerated. Z passivating * rinsed and oiled (rust inhibiting oil). 1 Normally used where corrosion resistance is required. Class Z-2 is recommended for threaded fasteners. Coatings will be dense, continuous, uniform and gray or dull black. 24 N/A passivating * rinsed and oiled (special ru
20、st inhibiting oil).* 2 72 proprietary systems. 3 Used for higher corrosion resistance. Some systems will also meet Class M wear resistance requirements. 96 * The required passivating rinse must be free of hexavalent chrome. * The oiled parts will be clean and dry to the touch. Oils used on standard
21、parts will have prior approval from the controlling Engineering Dept; those used for fasteners must be approved by Fastener Engineering, See “Appendix” - General Information” for a list of suitable oils. (1) Neutral salt spray requirements will be met by parts which have been subjected to normal han
22、dling. (2) Significant surfaces will be defined by the controlling engineering department and/or specified on the applicable engineering drawing(s). NUMBER: MPAPS G-1 TITLE: Phosphate Coatings On Iron And Steel REVISION: 1404 This document is restricted and may not be sent outside Navistar, Inc. or
23、reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 3 of 4 4.4 Hydrogen Embrittlement Relief Heat Treatment After coating, steel parts (including carburized parts) having a the minimum Rockwel
24、l hardness of 39 HRC shall be given a hydrogen embrittlement relief heat treatment. The treatment shall consist of 8 hours at 210F to 225 F or for 120 hours at room temperature. The treatment should be done after coating but before any stressing operation. After treatment, parts shall be tested for
25、hydrogen embrittlement. 5.0 QUALITY All product supplied to this specification shall be clean and free from dirt 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 “Appe
26、ndix - General Information” section. 6.0 METHODS OF TEST 6.1 Neutral Salt Spray Conduct this test according to ASTM B 117. 6.2 Adhesive Wear Conduct this test according to FED-STD-791, Method 6505 (or equivalent). Use a non-additive mineral oil of SAE 10W viscosity. 6.3 Hydrogen embrittlement Conduc
27、t this test according to ASTM F 519. 7.0 SOURCE APPROVAL AND QUALITY CONTROL 7.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PP
28、AP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. 7.2 Approval Parts supplied against contracts or purchas
29、e orders citing this specification shall be equivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color
30、, or labeling of the product are required, the supplier shall notify NAVISTAR Materials Engineering and Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safe
31、ty Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 7.3 Process Control The supplier shall either; perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evid
32、ence 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 the quality control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products. NUMBER: MPAPS G
33、-1 TITLE: Phosphate Coatings On Iron And Steel REVISION: 1404 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. 2014 by Navistar, Inc. APRIL 2014 Page 4 of
34、 4 8.0 SHIPPING AND HANDLING Shipping and identification shall be in accordance with NAVISTAR Manufacturing Standard MS-D-13. Parts shall be packaged so as to avoid any damage in shipment detrimental to the appearance of the part. 9.0 DESIGNATION ON DRAWINGS Example of note to use on drawings: Finis
35、h: Manganese Phosphate Coating, Type M-2, MPAPS G-1 Zinc Phosphate Coating, Type Z-3, MPAPS G-1 Note - type of phosphate coating, manganese or zinc phosphate, must be specified. 10.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppli
36、ers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com
37、Website: http:/ 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. 2014 by Navistar, Inc. APRIL 2014 Page 1 of 3 NAVISTAR, INC. Material, Parts, and Process
38、 Specifications (MPAPS) NUMBER: MPAPS G-1 APPX Former Designation: CEMS G-1 APPX TITLE: Phosphate Coatings on Iron and Steel - APPENDIX CURRENT REV No.: 1404 DATE: April 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: CEMS G-1 APPX - August 2009 PRINTED C
39、OPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification 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 healt
40、h practices and to determine the applicability of regulatory limits prior to use. Change Notice: Changed to new MPAPS format; changed coating classifications; editorial changes. APPENDIX GENERAL INFORMATION (NOT A REQUIREMENT) CONTENTS PAGE A.1 PROPERTIES OF PHOSPHATE COATINGS 1 A.2 SPECIAL RUST INH
41、IBITING OILS 2 A.3 SURFACE PREPARATION 2 A.4 INCREASE OF DIMENSIONS 2 A.5 PHOSPHATE 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
42、cleaning, type, concentration and temperature of solution and the time of treatment. Since no electric current is used, the type of coating produced is solely dependent upon the solution contacting the surface. Thus, uniform coatings may be produced on irregularly shaped objects and recessed areas.
43、A.1.1 Phosphate coatings are applied by chemical treatment primarily for adhesive 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 nonmetal
44、lic, they are poor electrical conductors and should not be applied to parts used 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.
45、Rapid break-in of coated new parts, such as cylinder liners, pistons, rings, camshafts, 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 o
46、r more of the following chemicals: manganese phosphate, iron phosphate, zinc phosphate, 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
47、color. They have a fine silky texture or fine crystalline appearance, depending on the type of coating and the thickness. The manganese phosphate coatings are usually used for reducing adhesive wear, while the zinc NUMBER: MPAPS G-1 APPX TITLE: Phosphate Coatings on Iron and Steel - APPENDIX REVISIO
48、N: 1404 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. 2014 by Navistar, Inc. APRIL 2014 Page 2 of 3 phosphate coatings are used for corrosion resistanc
49、e. The use of phosphate coating as the primary corrosion inhibitor is declining. A.2 Special Rust Inhibiting Oils The following oils applied at 140F (60C) min and allowed to drip dry, have been found suitable for fastener applications: Heatbath Solidry #1 or Laboil 72D Rust Lick WS 200 Tectyl 140D McDermott M-685 Parcolac 96 A.2.1 The use of any one of these oils does not
