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. OCTOBER 2014 Page 1 of 6 NAVISTAR, INC. Material, Parts, and Process Specification
2、s (MPAPS) NUMBER: MPAPS G-22 Former Designation: CEMS G-22 TITLE: Zinc-Nickel Plating CURRENT REV No.: 1410 DATE: Oct. 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: CEMS G-22 - August 2011 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REV
3、ISION 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 applicability of regul
4、atory limits prior to use. Change Notice: Changed to new MPAPS format; added note in Section 1.0 related to contact with stressed polyamides; updated reference documents; editorial changes. 1.0 APPLICATION Zinc-nickel plating is used primarily for corrosion resistance of ferrous metal parts (fastene
5、rs, fittings, clips, brackets, etc.) where levels of corrosion resistance greater than standard zinc plating are required. The alkaline zinc-nickel plating process (rather than acid zinc-nickel plating) is preferred for parts supplied to this specification, since it provides better coating ductility
6、, minimal flaking, and higher corrosion resistance. A trivalent chromium passivate will be applied to the zinc-nickel plating. Supplementary sealers/topcoats may be applied, depending on the specified plating class and performance requirements. Plated parts should not come in contact with stressed p
7、olyamides 6 or 66, due to the potential for stress cracking in the presence of road salts. The service temperature range of zinc-nickel plated parts is -50 to 120C (-58 to 248F). This coating is not intended for electrical grounding applications. 2.0 SCOPE This specification covers the Corporations
8、requirements for hex-chrome-free zinc-nickel plating on steel substrates. 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 specification. 3.0 REFERENCE DOCUMENTS Unless oth
9、erwise specified, the latest 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 ASTM B 117 ASTM B 499 NAVISTAR Manufacturing Standard MS-D-13 ASTM B 201 ASTM D 6492
10、CFR Title 29, Part 1910 ASTM B 487 SAE/USCAR-11 NAVISTAR MPAPS GT-31 MPAPS B-50 ASTM D 523 SAE/USCAR-7 ASTM B 659 NUMBER: MPAPS G-22 TITLE: ZINC-NICKEL PLATING REVISION: 1410 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Techni
11、cal Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 2 of 6 4.0 REQUIREMENTS This specification covers zinc-nickel coatings on ferrous metal substrates. The coating composition is essentially zinc, with 5-15% nickel by weight (Type A) or 10-1
12、7% nickel (Type B) (for alkaline plating). Type B coating provides higher corrosion performance than Type A. All required base metal heat treatments and forming/bending operations will be completed prior to performance of the coating operation. Uncoated parts will be thoroughly cleaned and free from
13、 rust, scale, oil and other foreign matter detrimental to the quality and performance of the zinc-nickel coating. Supplementary sealers/topcoats should be applied based on the performance requirements of the coating class. Requirements for each class of coating are given in Table 1. 4.1 Passivation
14、Treatment A trivalent chromium passivation treatment will be applied to the zinc-nickel plated surface in order to enhance corrosion resistance. Hexavalent chromate conversion coatings are not permitted on zinc-nickel plated parts used on NAVISTAR products. 4.2 Appearance The clear/blue/silvery/gray
15、 color characteristic of trivalent chromium passivation coatings will be provided for C Class codes (e.g., Class ZNi-C1). If black is desired, a B class code (e.g., Class ZNi-B1) can be specified. If other colors are required, it must be specified on the drawing or purchase order. Black parts plated
16、 to Class ZNi-B1 or ZNi-B2 should exhibit a harmonious deep black appearance when subjected to natural light, and not show lighter areas or areas of iridescence not consistent with a deep black color. When Class ZNi-B2 is used, particularly for black cosmetic applications, parts will be subjected to
17、 48 hr salt spray testing after which no white blush will be observed. 4.3 Corrosion Resistance Parts plated according to the requirements of this specification will be capable of withstanding neutral salt spray testing for the required minimum number of hours for the plating class designated in Tab
18、le 1. After the specified minimum hours of test, there will be no zinc oxidation products or base metal corrosion (red rust) on significant surfaces. Significant surfaces for evaluation of fasteners will be defined as all exposed surfaces of fastener(s) when installed, including but not limited to f
19、astener heads, socket recesses, SEMS washers, and external surfaces of nuts. Threads and points are excluded unless otherwise specified on drawing. On parts other than threaded fasteners, significant surfaces will include all plated surfaces; deep recesses, blind holes, edges, and tubing interiors a
20、re excluded unless otherwise specified on drawing. See Section 6.2.2 for corrosion test method. (Note that the salt spray test is used to verify that the plating meets the requirements of the specification. The test shall not be assumed to have any correlation to actual service life or performance o
21、f the part.) 4.4 Plating Thickness Thickness of zinc-nickel plating on parts supplied to this specification shall meet the minimum plating requirements for the applicable class as specified in Table 1. Coating thickness will be sufficient to provide corrosion performance requirements as specified fo
22、r the given Class. Use of a zinc strike layer is not permitted. Thickness of the passivation coating and other supplementary coatings (sealers, topcoats, waxes, etc.) is not included in thickness measurements. Coated fasteners must pass all appropriate Thread Go gages for thread sizing. Threads may
23、be produced undersized prior to plating providing that the finished threaded part meets all mechanical property requirements specified for the part. See section 6.2.1 for plating thickness test methods. NUMBER: MPAPS G-22 TITLE: ZINC-NICKEL PLATING REVISION: 1410 This document is restricted and may
24、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. OCTOBER 2014 Page 3 of 6 Table 1 CLASSIFICATION AND REQUIREMENTS FOR ZN-NI COATINGS NAVISTAR Designation Minimum plati
25、ng thickness Min Neutral Salt Spray Test Hours (ASTM B 117) Additional Sealer/ Topcoat* Class Code m Zinc Oxidation Red Rust CLEAR - ZNi-C1 5 120 480 Optional ZNi-C2 5 168 620 Reqd ZNi-C3 8 120 600 Optional ZNi-C4 8 168 840 Reqd ZNi-C5 8 240 1000 Reqd BLACK - ZNi-B1 5 168 620 Reqd ZNi-B2 8 240 1000
26、Reqd *For threaded fasteners when controlled lubricity is required, a torque-tension control fluid may be added to the sealer/topcoat. The suffix L will be added to the class code on part drawings (e.g., ZNi-C2-L). (see Section 6.8) For controlled lubricity, a friction range of 0.14 0.03 m is assume
27、d, unless otherwise specified. 4.5 Adhesion Coating on parts will not blister, chip, flake, or peel after adhesion testing as described in Section 6.2.3. 4.6 Paintability Parts plated to this specification shall provide good adhesion to paint and be compatible with plant paint systems. 4.7 Weatherin
28、g Resistance Black zinc-nickel coated parts specified to Class ZNi-B1 or B2 shall provide UV resistance, and be tested for weatherability as described in Section 6.2.5. After 500 hr testing, parts shall show no blistering, peeling, cracking, loss of adhesion, fading, discoloration, or red rust. Test
29、ed parts will have a gloss level of 3 or higher (20 degree gloss meter per ASTM D 523). 4.8 Torque Tension Requirement Threaded fasteners M6 and larger requiring torque-tension control will be specified on the part drawing by the addition of the suffix L to the plating class code. These fasteners wi
30、ll be subject to torque-tension test monitoring through the use of surrogate M10 x 1.5 test bolts. Torque-tension will be monitored per SAE/USCAR-11, except tightening speed shall be 30 3 rpm. The six sigma torque range value must be 40-56 Nm with a clamp load of 28.3 kN. Testing is required for ini
31、tial approval of the finish, applicators, and PPAP submissions, and will be part of the applicators statistical process control. . 5.0 QUALITY The zinc-nickel coating will be dense and uniform, free from porosity, pinholes and blisters, and substantially free from other defects that may affect the a
32、ppearance or corrosion protective value of the coating. The plating will have no gray or burned area and will not flake off. NUMBER: MPAPS G-22 TITLE: ZINC-NICKEL PLATING REVISION: 1410 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corpo
33、rate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 4 of 6 5.1 Hydrogen Embrittlement Some processes used to produce zinc-nickel coatings may induce hydrogen embrittlement in parts with high hardness. It will be the responsibility
34、 of the supplier to ensure that supplied parts are free of hydrogen embrittlement and to see that such parts are baked within one hour of electroplating (but before any supplementary coatings are applied) to relieve hydrogen embrittlement. Steel parts having core hardness greater than 32 HRC or surf
35、ace hardness of 35 HRC, as well as all highly stressed cold worked parts, may be subject to embrittlement because of hydrogen absorption. Generally, the bake operation will involve heating in an oven until the part core temperature (not oven temperature) reaches 205-215 C (400-420 F), and holding at
36、 this temperature for 4 hrs minimum. Likewise, hardened parts which have been tempered at less than 175 C (350 F) should be heated at 150 C (300 F) for at least 8 hours. Refer to SAE/USCAR-7 for test methods used to detect hydrogen embrittlement of steel parts. 5.2 Sampling Procedure Select for test
37、 one or more random samples from each shipment, or from authorized test specimens. The number of samples to be selected from each size lot will be agreed upon between the supplier and the purchaser. If results fall below the test requirements, the shipment may be rejected. 6.0 QUALIFICATION Engineer
38、ing qualification of sources is required in advance of production shipments. Suppliers shall submit samples for approval of finish, luster, color and appearance to the Navistar Industrial Design Group. Samples shall be accompanied by test data certifying that all requirements of the specification ha
39、ve been met. Upon approval, styling master samples denoting the minimum level of acceptable appearance quality shall be developed and retained by the supplier and the quality department of each using NAVISTAR facility. 6.1 Quality Control Plan A Quality Control Plan for products supplied to the requ
40、irements of this specification will be established by mutual agreement between NAVISTAR and the supplier. Unless specific exception is noted, the following characteristics, where applicable*, shall be included in the plan as features for management by statistical process control.* * Other characteri
41、stics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See NAVISTAR Engineering Design Standard A-16 6.2 Methods Of Test 6.2.1 Plating Thickness Determine thickness of coating on significant surfaces (see definition in Section 6.3) using the eddy
42、 current (magnetic) method (ASTM B 499), the x-ray method (ASTM B 659), or the microscopic method (ASTM B 487). The microscopic method will be used as a referee test when necessary. 6.2.2 Corrosion Testing Perform salt spray testing per ASTM B 117. Plating Thickness, Adhesion, Torque-Tension charact
43、eristics (fasteners only) NUMBER: MPAPS G-22 TITLE: ZINC-NICKEL PLATING REVISION: 1410 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,
44、Inc. OCTOBER 2014 Page 5 of 6 6.2.3 Adhesion Sample plated parts will be exposed to 220 5 C for 30 5 minutes, followed by quenching in water at room temperature. 6.2.4 Passivation Treatment Presence of a hex-free chromate coating may be verified per certification by the plater. When necessary for re
45、feree purposes, presence of clear chromate coatings may be determined per ASTM B 201. The absence of hexavalent chrome may be demonstrated using ASTM D 6492, as required. 6.3.5 Weatherability Testing Parts requiring UV resistance shall be tested for weatherability using Method A per MPAPS GT-31. 7.0
46、 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 PPAP (Production Part Approval Process) do
47、cumentation 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 purchase orders citing this specification shall
48、 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, or labeling of the product are require
49、d, 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 Safety 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 p
