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. 2015 by Navistar, Inc. DECEMBER 2015 Page 1 of x NAVISTAR, INC. Material, Parts, and Process Specificati
2、ons (MPAPS) NUMBER: MPAPS G-4519 Former Designation: TMS 4519 TITLE: Black Corrosion-Resistant Cathodic E-coat Finish for Fasteners CURRENT REV No.: 1512 DATE: Dec. 2015 WRITTEN/EDITED BY: S. Brailey APPROVED BY: R. Goluch SUPERSEDES: Rev. A-June 2007 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED
3、 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 health practices and to determine the applic
4、ability of regulatory limits prior to use. Change Notice: Updated to new format and reactivated specification 1.0 APPLICATION This specification is for a black non-decorative corrosion-resistant finish consisting of zinc plating with a black cathodic electrocoat (e-coat) as applied to Fasteners. Thi
5、s type of finish is intended for exterior applications requiring good corrosion resistance, but not requiring UV resistance, such as for underhood or non-visible/non-exposed chassis parts. Fastener applications might include fasteners size M6 and larger, thread formers, tapping screws, some SEMS scr
6、ews, and hex flange bolts. This coating should not be used on small machine screws (less than M6) or on washers. 2.0 SCOPE This specification covers the requirements for the coating, part performance, quality, KCC, source approval and quality control, packing, shipping, and identification, and desig
7、nation on drawings. *Note* this specification is only for fasteners! See MPAPS G-9009 for cathotic electrocoat (e-coat) requirements associated with all non- fastener parts. 2.1 RESTRICTED CHEMICAL SUBSTANCES Effective January 1, 2007, all product supplied to the requirements of this specification m
8、ust 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 Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9
9、001 or TS-16949 CFR Title 29, Part 1910 ASTM B117 ASTM D1735 NAVISTAR Manufacturing Std. MS-D-13 ASTM D2247 NAVISTAR Engineering Design Std A-16 SAE/USCAR-11 NAVISTAR MPAPS B-50 MPAPS G-9009 NUMBER: MPAPS G-4519 TITLE: Black Corrosion-Resistant Cathodic E-coat Finish for Fasteners REVISION: 1512 Thi
10、s 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. 2015 by Navistar, Inc. DECEMBER 2015 Page 2 of 4 4.0 REQUIREMENTS 4.1 Coating Requirements 4.1.1 Pre-Treatme
11、nt Zinc shall be electroplated onto steel fasteners which have been pre-cleaned to remove rust, scale, oil, dirt, and other debris. The electroplated layer shall be uniformly dense over the entire surface and exhibit a thickness of 8-10 m. A thin layer of zinc phosphate shall be deposited on top of
12、the zinc to aid in adhesion of the topcoat. 4.1.2 Topcoat The topcoat will consist of black cathodic e-coat resulting in a maximum total film build of 12-16 m. The e-coat will not fill recesses or threads in threaded fasteners, or otherwise interfere with normal installation procedures for threaded
13、joints. The coating shall not have an adverse effect on production assembly and disassembly practices. After coating, the parts must pass the appropriate thread GO gages without sticking or binding. An evaluation of coating thickness on threads will be included in the Quality Control Plan for each p
14、art 4.2 Part Performance 4.2.1 Adhesion After curing, coated parts shall show no flaking, peeling, or loss of adhesion with normal handling. Parts shall show no evidence of blistering, flaking, peeling, or appearance changes, after heating coated parts to 120C for 60 minutes. 4.2.2 Corrosion Resista
15、nce Finished parts must exhibit no corrosion on significant surfaces after salt spray testing per ASTM B117 for 600 hrs. minimum. Significant surfaces are those which are visible and subject to wear or corrosion or both, or surfaces for which the coating is otherwise functionally necessary. Parts wi
16、ll not exhibit blistering or change in color. Threaded parts shall be evaluated on areas other than the threaded portion. 4.2.3 TorqueTension Requirement for Threaded Fasteners 4.2.3.1 Method: SAE/USCAR-11 Control parts 7/16 X 20NSF or M10 bolts) shall be processed along with each production lot of
17、parts being coated. The control parts will be tested to determine the torque required to develop a specified tension value in the fastener. 4.2.3.2 Required The measured torque value shall be within 3 of the median value established for this fastener. 5.0 QUALITY The black coating will be dense and
18、uniform in color, free from porosity, pinholes and blisters, and substantially free from other defects that may affect the appearance or protective value of the coating. The topcoat will withstand normal shipping and handling practices without chipping, flaking, or other damage. 5.1 Relief of Hydrog
19、en Embrittlement Steel parts heat treated or cold worked to a specified core hardness of 32 HRC or greater, or surface hardness of 35 HRC or greater, shall be baked after the zinc plating pre-treatment to prevent hydrogen embrittlement. Generally, the plated parts will be baked at a part core temper
20、ature (not oven NUMBER: MPAPS G-4519 TITLE: Black Corrosion-Resistant Cathodic E-coat Finish for Fasteners REVISION: 1512 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 p
21、atent liability. 2015 by Navistar, Inc. DECEMBER 2015 Page 3 of 4 temperature) of 200C (392F) minimum. The core temperature shall be reached within 2 hrs. after the electroplating process and held at this temperature for 4 hrs. minimum. The e-coat topcoat shall be applied to the electroplated parts
22、after the baking operation. It will be the responsibility of the supplier to ensure that supplied parts are free of hydrogen embrittlement. 6.0 QUALIFICATION Engineering qualification of sources is required in advance of production shipments. Suppliers shall submit samples for approval of finish, lu
23、ster, 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 developed and
24、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 exception is
25、 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 Engineering
26、Design Standard A-16 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 PPAP (Production P
27、art 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 purchase orders citing
28、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, or labeling of
29、 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 Safety Data Sheet(s)
30、 (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 1. Torque-Tension value of the control samples 2. Coating thickness NUMBER: MPAPS G-4519 TITLE: Black Corrosion-Resistant Cathodic E-coat Finish for Fasteners REVISION: 1512 This document is restricte
31、d and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. DECEMBER 2015 Page 4 of 4 7.3 PROCESS CONTROL The supplier shall either perform and report results of tests
32、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 the quality control manager of the using
33、NAVISTAR plant may determine testing and reporting requirements on specific products. 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
34、 of the part. 9.0 DESIGNATION ON DRAWINGS Example of note to use on drawings: Finish per MPAPS G-4519 The drawing should also include a note: “For KCC, see MPAPS G-4519” 10.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may
35、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 Website:
36、 http:/ A.0 GENERAL INFORMATION A.1 APPROVED PRODUCTS/SOURCES 1) Approved Product: Black Electropolyseal V (with zinc plating basecoat), PPG Industries 2) Approved applicators: a) Curtis Metal Finishing, Sterling Heights, MI or Machesney Park, IL b) Plating Technology Inc., Columbus, OH or Dayton, OH
