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. 2017 by Navistar, Inc. MARCH 2017 Page 1 of 6 NAVISTAR, INC. Material, Parts, and Process Specifications
2、(MPAPS) NUMBER: MPAPS G-22 Former Designation: CEMS G-22 TITLE: Zinc-Nickel Plating CURRENT REV No.: 1703 DATE: Mar. 2017 WRITTEN/EDITED BY: W. Cook APPROVED BY: R. Goluch SUPERSEDES: 1410 - October 2014 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may inv
3、olve 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. 1.0 A
4、PPLICATION Zinc-nickel plating is used primarily for corrosion resistance of ferrous metal parts (fasteners, 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 p
5、lating) is preferred for parts supplied to this specification, since it provides better coating ductility, 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 spec
6、ified plating class and performance requirements. Plated parts should not come in contact with stressed polyamides 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
7、not intended for electrical grounding applications. 2.0 SCOPE This specification covers the Corporations 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 specificat
8、ion must comply with the requirements of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard I
9、SO 9001 or TS-16949 ASTM B 117 ASTM B 499 NAVISTAR Supplier Packing and Shipping Std. D-13 ASTM B 201 ASTM D 6492 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: 1703 This docume
10、nt 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. 2017 by Navistar, Inc. MARCH 2017 Page 2 of 6 4.0 REQUIREMENTS This specification covers zinc-nickel coatings on fer
11、rous metal substrates. The coating composition is essentially zinc, with 5-15% nickel by weight (Type A) or 10-17% 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
12、completed prior to performance of the coating operation. Uncoated parts will be thoroughly cleaned and free from 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
13、requirements of the coating class. Requirements for each class of coating are given in Table 1. 4.1 Passivation 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
14、 not permitted on zinc-nickel plated parts used on NAVISTAR products. 4.2 Appearance The clear/blue/silvery/gray 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 sp
15、ecified. If other colors are required, it must be specified on the drawing or purchase order. Black parts plated 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
16、black color. When Class ZNi-B2 is used, particularly for black cosmetic applications, parts will be subjected to 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 withstan
17、ding neutral salt spray testing for the required minimum number of hours for the plating class designated in Table 1. The performance expectation assumes that the part will be used as plated and that there is no “handling damage” to the coating or post-plating forming of the parts. The corrosion per
18、formance of parts subjected to additional fabrication or forming, or which are part of an assembly when tested after plating shall be by agreement with supplier and appropriately documented. After the specified minimum hours of test, there will be no zinc oxidation products or base metal corrosion (
19、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 fastener heads, socket recesses, SEMS washers, and external surfaces of nuts. Threads and points are excluded unless
20、 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 are excluded unless otherwise specified on drawing. See Section 6.2.2 for corrosion test method. (Note that the salt
21、 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 of the part.) 4.4 Plating Thickness Thickness of zinc-nickel plating on parts supplied to this specification shall m
22、eet 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 for the given Class. Use of a zinc strike layer is not permitted. Thickness of the passivation coating and other supp
23、lementary 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 be produced undersized prior to plating providing that the finished NUMBER: MPAPS G-22 TITLE: ZINC-NICKEL PLATING R
24、EVISION: 1703 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. 2017 by Navistar, Inc. MARCH 2017 Page 3 of 6 threaded part meets all mechanical property r
25、equirements specified for the part. See section 6.2.1 for plating thickness test methods. Table 1 CLASSIFICATION AND REQUIREMENTS FOR ZN-NI COATINGS NAVISTAR Designation Minimum plating thickness Min Neutral Salt Spray Test Hours (ASTM B 117) Additional Sealer/ Topcoat* Class Code m Zinc Oxidation R
26、ed 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 Reqd *For threaded fasteners when controlled lubricity is required, a torque-tension control fluid may be added to th
27、e 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 0.03m is assumed, unless otherwise specified. 4.5 Adhesion Coating on parts will not blister, chip, flake, or peel after adhesion tes
28、ting 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 Weathering Resistance Black zinc-nickel coated parts specified to Class ZNi-B1 or B2 shall provide UV resistance, and be tested
29、 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. Tested parts will have a gloss level of 3 or higher (20 degree gloss meter per ASTM D 523). 4.8 Torque Tension Requirement
30、 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 will be subject to torque-tension test monitoring through the use of surrogate M10 x 1.5 test bolts. Torque-tension will
31、 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 initial approval of the finish, applicators, and PPAP submissions, and will be part of the applicators statistical proces
32、s 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 appearance or corrosion protective value of the coating. The plating will have no gray or burned area and will not flak
33、e off. NUMBER: MPAPS G-22 TITLE: ZINC-NICKEL PLATING REVISION: 1703 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. 2017 by Navistar, Inc. MARCH 2017 Pag
34、e 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 of the supplier to ensure that supplied parts are free of hydrogen embrittlement and to see that such parts are baked w
35、ithin 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 surface hardness of 35 HRC, as well as all highly stressed cold worked parts, may be subject to embrittlement because of hyd
36、rogen absorption. Generally, the bake operation will involve heating in an oven until the part core temperature (not oven temperature) reaches 205-215C (400-420F), and holding at this temperature for 4 hrs minimum. Likewise, hardened parts which have been tempered at less than 175C (350F) should be
37、heated at 150C (300F) 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 one or more random samples from each shipment, or from authorized test specimens. The number of samples to be selected from e
38、ach 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 Engineering qualification of sources is required in advance of production shipments. Suppliers shall submit samples for approval of fi
39、nish, luster, color and appearance to the Navistar Industrial Design Group. Samples shall be accompanied by test data certifying that all requirements of the specification have been met. Upon approval, styling master samples denoting the minimum level of acceptable appearance quality shall be develo
40、ped 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 requirements of this specification will be established by mutual agreement between NAVISTAR and the supplier. Unless specific exce
41、ption is noted, the following characteristics, where applicable*, shall be included in the plan as features for management by statistical process control.* * Other characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See NAVISTAR Engi
42、neering 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 current (magnetic) method (ASTM B 499), the x-ray method (ASTM B 659), or the microscopic method (ASTM B 487). The microscopi
43、c 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 characteristics (fasteners only) NUMBER: MPAPS G-22 TITLE: ZINC-NICKEL PLATING REVISION: 1703 This document is restricted and may not
44、 be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2017 by Navistar, Inc. MARCH 2017 Page 5 of 6 6.2.3 Adhesion Sample plated parts will be exposed to 220 5C for 30 5 minutes, followed by quenchi
45、ng 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 referee purposes, presence of clear chromate coatings may be determined per ASTM B 201. The absence of hexavalent chrome may be dem
46、onstrated 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 SOURCE APPROVAL AND QUALITY CONTROL 7.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 900
47、1 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 must furnish
48、copies of registration certificates to their Corporate Buyer upon request. 7.2 Approval Parts supplied against contracts or purchase 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 pra
49、ctices 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 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
