The English translation is believed to be accurate. In case of discrepancies the German version shall govern.

Non-Electrolytically Applied Zinc-Flake Coatings

Surface Protection Requirements

TL 245

Konzernnorm Descriptors: corrosion protection, surface protection, zinc, aluminum, flake, Delta-Protekt, Delta-Tone, Geomet Changes The following changes have been made as compared to Technical Supply Specification TL 245, 2002-10: Scope revised New descriptions of surface protection (Table 1) Section 3.11.1 Test according to DIN 50 017 KK: Permitted corrosion level changed from Ri 0 to Ri 1 to Ri 0 Section 3.11.2 Test according to DIN 50021 SS: Separation between barrel-coated and rack-coated goods introduced Requirements for corrosion resistance reduced for Ofl-t610 Section 3.12 Resistance to chemicals: This section was updated, and the separation between components of the engine compartment and components from outside the engine compartment was eliminated Surface protection type Ofl-t615 added Assignment of Cr(VI)-free alternatives changed Referenced standards updated Previous issues 1987-08; 1989-10; 1990-01; 1991-03; 1991-11; 1992-10; 1993-07; 1997-12; 2002-10 1 Scope

This standard defines the requirements on Cr(VI)-free surface protection types made of zinc and aluminum flakes non-electrolytically applied to ferrous materials. Silver-gray flake coatings shall be used as heavy-duty corrosion protection for components with a high corrosion load. With an appropriate layer structure, the zinc-flake coatings are able to withstand temperatures, such as those occurring in the area of the engine compartment and brake (details see Table 1). Since this coating process poses no risk of hydrogen-induced brittling, it is preferably used as corrosion protection for hardened and high-strength steel parts with tensile strength values > 1,000 MPa or surface hardness values > 320 HV. The protection system shall be chosen such that the strength and hardness are not impaired by the treatment temperatures.

The coating is not suitable for parts that serve as electrical conductors (e.g. ground connections), have multipoint sockets according to Volkswagen standard VW 010 43 < N8 and hexalobular sockets according to VW 010 48 < T30, have hexagon sockets < 5 and cross recesses according to DIN EN ISO 4757 < H3, have a thread of < M6.
Form FE 41 - 01.03

In order to avoid clogging caused by coating particles that come loose, zinc-flake coatings should only be used inside units (e.g. oil chamber) in exceptional cases. Page 1 of 8
Fachverantwortung/Responsibility K-QS-32/2 Ackermann Tel: -38255 Laudien Dr. Eisenberg Normung/Standards (EZTD, 1733) Wiesner Tel: +49-5361-9-29064 Sobanski

VOLKSWAGEN AG

Confidential. All rights reserved. No part of this document may be transmitted or reproduced without the prior written permission of a Standards Department of the Volkswagen Group. Parties to a contract can only obtain this standard via the responsible procurement department.

QUELLE: NOLIS

Zinc-flake coatings are also suitable for use as a coating for ferrous materials in contact with aluminum components (however, not for those in contact with magnesium components).

Norm vor Anwendung auf Aktualitt prfen / Check standard for current issue prior to usage.

Klass.-Nr. 50 22 3

December 2004

Page 2 TL 245: 2004-12

Designation

See VW 137 50, Section 2. 3 3.1 Requirements Surface protection types

The surface protection types listed in Table 1 apply; for replacement of surface protection types that are no longer permitted, see Table 2. Examples of systems that were previously released part-specifically are listed in Appendix A.1. Table 1 Surface protection type Ofl-t602 Characteristics and appearance Basic coating with topcoat (inorganic), without lubricant additive. Zinc-flake coating, Cr(VI)-free, silver-gray; use in exposed installation positions, e.g. in the engine compartment and chassis areas. Burn-in temperature up to max. +300 C, Endurance service temperature max. +180 C (short-term temperature peaks up to +300 C). Basic coating without topcoat, without lubricant additive. Zinc-flake coating, Cr(VI)-free, silver-gray; corrosion protection preferably for components that are to be painted (body construction). Standard surface protection for threaded parts with microencapsulation. Burn-in temperature up to max. +200 C, Reduced corrosion resistance (see Section 3.11), Reduced endurance service temperature without additional coatings (+125 C). As for Ofl-t602, but with lower burn-in temperature. Consequently, suitable for components that cannot be exposed to high temperatures, e.g. spring elements, low-temperature formed and hardened sheets or high-strength steel parts. Burn-in temperature max. +230 C, Endurance service temperature max. +200 C (short-term temperature peaks up to +300 C). As for Ofl-t610, but additionally lubricant (greenish) according to TL 521 65. Standard surface protection for self-locking nuts with plastic locking element. Ofl-t647 Burn-in temperature up to max. +200 C, Reduced corrosion resistance (see Section 3.11), Reduced endurance service temperature without additional coatings (+125 C).

Ofl-t610

Ofl-t611

Ofl-t615

Basic coating with topcoat (inorganic), with lubricant additive. Zinc-flake coating, Cr(VI)-free, silver-gray, standard surface protection for threaded parts with metric ISO standard threads (see VW 011 10) Burn-in temperature up to max. +300 C, Endurance service temperature max. +180 C (short-term temperature peaks up to +300 C).

Page 3 TL 245: 2004-12

Table 2 Impermissible surface protection type for new designs Components of a general nature Ofl-t300 Ofl-t310 Ofl-t320 Ofl-t600 Ofl-t620 Ofl-t300 Ofl-t310 Ofl-t320 Ofl-t345 Ofl-t600 Ofl-t620 Ofl-t645
1) 2) 3)

Protection type designated for new designs

Ofl-t610 Ofl-t610 Ofl-t611 Ofl-t602 1) Ofl-t602 1) Ofl-t647 2) Ofl-t647 2) Ofl-t647 3) Ofl-t647 3) Ofl-t647 2) Ofl-t647 3) Ofl-t647 3)

Threaded parts with metric ISO standard threads

Ofl-t611, if operating temperatures of up to 200 C and/or if lower burn-in temperatures up to max. 230 C are required Ofl-t610, if component is installed in the body construction before painting or for threaded parts with microencapsulation Ofl-t615, if self-locking nut with plastic locking element

3.2

General requirements

Approval of first supply and changes according to VW 011 55. Avoidance of hazardous substances according to VW 911 01. 10 finished parts are required for complete testing. For first-sample release of small parts, e.g., threaded fastening elements, a test production of > 50 kg shall be performed. The coating materials must not contain any Cr(VI) compounds in order to ensure that the resultant coatings are likewise Cr(VI)-free. Unless certain sections of a part that are marked in the drawing are excluded from the surface coating, the entire surface of the parts must comply with the required surface protection type and display the prescribed properties. There shall be firm adhesion between coatings and base material (see Section 3.10); there shall be no flaking of the coating or cracks under elastic deformation. The protective coatings must not exhibit any pores, cracks, damage, or other flaws that impair the corrosion protection and/or function. The production process and its control shall not impair the functional characteristics of the finished part. Thus for example, the coating must not flake or crack when the springs or spring washers are mounted or used as intended. With proper mounting, the coating shall not be damaged in a way that would result in impairment of function and/or decrease in the specified corrosion protection.

Page 4 TL 245: 2004-12 The selection of supplier and coating system is subject to agreement with the VW Group Central Laboratory (K-QS-32) and/or the AUDI Group Test Laboratories (I/GQ-32 and N/GQ-55) prior to usage of the given part. 3.3 Threaded parts with metric ISO standard threads

The coating process shall not impair the mechanical and physical properties specified for joining elements. Therefore, the manufacturer has to check whether the baking conditions specified by the coating company are suitable for the parts to be coated. An essential functional property of threaded parts with metric ISO standard threads is their compliance with specified coefficients of friction. In order to ensure that the coefficients of friction comply with VW 011 29, a topcoat with integrated lubricant additive is prescribed for surface protection type Ofl-t647, in addition to the base flake coating. In the case of screws and bolts, the test requirements listed below only apply to the head and/or the wrench bearing surfaces, in the case of nuts, they apply only to the nut body with the exception of the thread. For threaded and similar shaped parts, such as studs, the test requirements only apply to the face surfaces. Reduced requirements (see Sections 3.9 and 3.11.2) apply to process- or geometry-related weak spots of coating areas on joining elements and quick fastening elements. Prior to coating, threaded parts shall exhibit tolerances corresponding to the coating thickness. Metric threaded parts shall preferably be designed according to VW 116 24 (internal threads) or VW 116 27 (external threads). After the coating process, the zero line must not be exceeded in the case of external threads, and it must not be fallen below in the case of internal threads. For further information see VW 011 10, Section 2. 3.4 Base coating

Repeated treatment would be useful to produce an even and opaque coating. It is compulsory for barrel coating. The coating systems corrosion protection performance is enhanced by repeated coating. Type and number of the coating processes for flake coating should be specified in the drawing if this is important for the quality of the basic layer in addition to the specified layer thickness. 3.5 Topcoats/lubricant additives

In order to observe the anti-corrosion requirements and to guarantee the defined coefficients of friction, additional system-specific topcoats, optionally with integrated lubricant additive, may be used. The topcoats must be coordinated to suit the base coating. They must not cause any functional impairment. If, in addition to corrosion protection, further functional surface characteristics such as paintability, compatibility with other agents, friction properties, threading behavior, vulcanizability or temperature behavior are required, part-specific tests or functional tests must be performed. 3.6 Base material

See drawing.

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3.7

Pretreatment

Principally metallically bright. Alternatively (depending on the coating system) micro-crystalline thin layer phosphating (1 to 3 g/m) is permissible. Prior to coating, hot alkaline and/or mechanical cleaning (e.g. abrasive blasting) shall be carried out on hardened or high-strength steel parts with a tensile strength > 1,000 MPa. Special treatments that could lead to hydrogen absorption are only possible in individual cases upon provision of verification of the process management in coordination with the responsible QA laboratory of the Volkswagen Group. 3.8 Dry film

Composition, see International Material Data System (IMDS). 3.9 Dry coating thickness

Testing according to DIN EN ISO 1463, DIN EN ISO 2064 and DIN EN ISO 2178; measuring point position for threaded parts with metric ISO standard thread according to DIN EN ISO 4042. Requirement: minimum coating thickness 8 m; maximum coating thickness 18 m. If due to the process or geometry, the minimum coating thickness is not achieved, this is permitted as long as the corrosion protection and functionality, e.g. threading behavior, are not impaired. 3.10 Adhesion

Adhesive tape with an adhesive strength of (7 1) N per 25 mm width is used for the adhesion test acc. to DIN EN ISO 10683. It is firmly pressed onto the specimen surface and then removed with a jerk-like motion perpendicular to the surface. There must be no large-area removal of the coating. Small particles of the coating that adhere to the tape are permissible. 3.11 3.11.1 Corrosion behavior Test according to DIN 50017-KK (only for first-sample test)

The scribing line is applied on the basis of DIN EN ISO 7253, component dimensions permitting. After a test duration of 720 h and evaluation according to DIN EN ISO 4628-3, the following minimum requirements must be adhered to at all times: base metal corrosion on surface: Ri 0, base metal corrosion permissible in the scribing line, but no rust creep.

Page 6 TL 245: 2004-12

3.11.2

Test according to DIN 50021 SS

General requirements (not for Ofl-t610 and barrel-coated goods with thread): no base metal corrosion (Ri 0) after a test duration of 720 h without thermal conditioning, no base metal corrosion (Ri 0) after a test duration of 480 h with thermal conditioning for 96 h at +180 C (for Ofl-t611: +200 C). Deviating requirement for Ofl-t610: no base metal corrosion (Ri 0) after a test duration of 480 h without thermal conditioning. Deviating requirements for barrel-coated goods with thread (see also Section 3.3): no base metal corrosion (Ri 0) after a test duration of 600 h without thermal conditioning, no base metal corrosion (Ri 0) after a test duration of 480 h with thermal conditioning for 96 h at +180 C (for Ofl-t611: +200 C). 3.12 Resistance to chemicals (only for first-sample test)

Testing according to VDA1) 621-412 in the following media: FAM test fuel according to VDA 621-412, test A 4.1.1 Y, Diesel fuel according to TL 788 and VDA 621-412, test A 4.1.2 X, Biodiesel (FAME) according to DIN EN 14214 and VDA 621-412, test A 4.1.2 X, Premium unleaded gasoline according to DIN EN 228 and test according to VDA 621-412, test A 4.1.3 Y, Factory-fill engine oil according to TL 521 73 (Burmah Castrol Oil code A97075PBC) and VDA 621-412, test A 4.1.4 X, Hydraulic fluid according to TL 521 46 and VDA 621-412, test A 4.1.6 X, Automatic transmission fluid according to TL 521 62 and VDA 621-412, test A 4.1.7 X, Coolant according to TL 774 and VDA 621-412, test A 4.2.2 X. A surface change is not permitted (max. characteristic value 1 according to DIN EN ISO 4628-1). Additionally, tests are performed in the following medium: Brake fluid according to TL 766 and VDA 621-412, test A 4.2.1 X. The following requirement applies to this medium: swellings that have returned to normal after 24 h are permitted. For small parts, test B must be used instead of test A. Small parts can be submersed completely and compared with a new part from the same manufacturing batch. 4 TL 766 TL 774 TL 788 TL 521 46 TL 521 62 TL 521 65 TL 521 73 Referenced standards2) Brake Fluid; Material Requirements Ethylene Glycol-Based Coolant Additive; Material Requirements Dieselkraftstoff, Kraftstoffanforderungen (currently only available in German) Central Hydraulic System Fluid; Lubricant Requirements Factory-Fill-for-Life Automatic Transmission Fluid; Lubricant Requirements Lubricant (Greenish) for Threaded Fasteners; Material Requirements Factory Fill Engine Oil SAE 0W-30 with Fuel-Saving Properties for Extended Oil Change Intervals; Requirement, Testing

1) 2)

VDA = German Association of the Automotive Industry In this section, terminological inconsistencies may occur as the original titles are used.

Page 7 TL 245: 2004-12 VW 010 43 VW 010 48 VW 011 10 VW 011 29 VW 011 55 VW 116 24 VW 116 27 VW 137 50 VW 911 01 VDA 621-412 Multipoint Socket Profile; Drive Shape for Threaded Parts Round Hexagon Socket; Drive Shape for Threaded Parts Threaded Joints; Design, Assembly and Process Assurance Limit Values for Coefficients of Friction; Mechanical Joining Elements with Metric ISO Thread Vehicle Supply Parts; Approval of First Supply and Changes Metric ISO Thread; Limit Dimensions for Tolerance Class 6f/6G Thread Limit Dimensions for External Threads of Tolerance Class 6e; Metric ISO Threads Surface Protection of Metal Parts; Degrees of Protection, Codes, Requirements Environmental Standard for Vehicles; Vehicle Parts, Materials, Operating Fluids; Avoidance of Hazardous Substances Anstrichtechnische Prfungen; Chemikalienbestndigkeit von Kraftfahrzeug-Lackierungen (Tests for Coating Methods; Resistance to Chemicals of Motor Vehicle Paints; only available in German) Atmospheres and their Technical Application; Condensation Water Test Atmospheres Spray Tests with Different Sodium Chloride Solutions Automotive Fuels Unleaded Petrol Requirements and Test Methods Automotive Fuels Fatty Acid Methyl Esters (FAME) for Diesel Engines Requirements and Test Methods Metallic and Oxide Coatings Measurement of Coating Thickness Microscopical Method Metallic and Other Non-Organic Coatings Definitions and Conventions Concerning the Measurement of Thickness Non-Magnetic Coatings on Magnetic Substrates Measurement of Coating Thickness Magnetic Method Fasteners Electroplated Coatings Paints and Varnishes Evaluation of Degradation of Coatings Designation of Quantity and Size of Defects, and of Intensity of Uniform Changes in Appearance Part 1: General Introduction and Designation System Paints and Varnishes Evaluation of Degradation of Coatings Designation of Quantity and Size of Defects, and of Intensity of Uniform Changes in Appearance Part 3: Assessment of Degree of Rusting Cross Recesses for Screws Paints and Varnishes Determination of Resistance to Neutral Salt Spray (Fog) Fasteners Non-Electrolytically Applied Zinc Flake Coatings

DIN 50017 DIN 50021 DIN EN 228 DIN EN 14214 DIN EN ISO 1463 DIN EN ISO 2064 DIN EN ISO 2178 DIN EN ISO 4042 DIN EN ISO 4628-1

DIN EN ISO 4628-3

DIN EN ISO 4757 DIN EN ISO 7253 DIN EN ISO 10683

Page 8 TL 245: 2004-12

Appendix A (informative) A.1 A.1.1 Released surface protection systems Ofl-t602

Any system, e.g.: DELTA-PROTEKT KL100 + DELTA-PROTEKT VH300 GEOMET 321 PLUS 10 A.1.2 Ofl-t610

DELTA-TONE 9000 A.1.3 Ofl-t611

DELTA-PROTEKT KL100 + DELTA-PROTEKT VH300 A.1.4 Ofl-t615

DELTA-TONE 9000 + lubricant (greenish) according to TL 521 65 A.1.5 Ofl-t647

Any system. However, for joining elements only: DELTA-PROTEKT KL100 + DELTA-PROTEKT VH301GZ GEOMET 321 PLUS VL