GroupstandardTL233

Issue2018-07

Class.No.:50223

Descriptors:aluminumflake,basecoat,corrosionprotection,organiccoating,surfaceprotection,t330,t350,t630,

t650,topcoat,zinc,zincflake

Non-ElectrolyticallyAppliedZincFlakeCoatingswithanOrganicTopCoat

SurfaceProtectionRequirements

Preface

Incontrasttothesurfaceprotection(Ofl)typesspecifiedinTechnicalSupplySpecification

TL180

1)

andTL245

2)

,thisTLdescribesacoatingsystemwhichensuresthefunctionalcharacter‐isticsofcomponents,e.g.,thecolorand/orcorrosionprotection,additionallybymeansofacontinu‐ousorganictopcoatwithagreatercoatingthickness.

FornewdesignsoffastenerswithametricISOthread,thecoatingsinthisstandardmustnotbeusedanymore,asthefastenersmaycomelooseontheirownattemperaturesgreaterthan

T=80°C.TheuseofsurfaceprotectiontypesasperVolkswagenstandardVW01110-1

3)

,ta‐ble8,ispreferred.Forspringclampsonfuelhoses,coatingsasperTL134

4)

mustbeused.

Previousissues

TL233:1982-09,1983-02,1991-05,1992-06,1993-11,1998-02,2003-09,2003-11,2010-11,2016-09,2016-10

Changes

ThefollowingchangeshavebeenmadetoTL233:2016-10:

–Technicalresponsibilityupdated

–

Section"Layerstructureofthecoatingsystem"

:Exampleimage(

Figure1

)ofthecoat‐ingadded

–

Section4.1.1"Cross-cuttest"

describedmoreprecisely

1)TL180–Non-ElectrolyticallyAppliedZincFlakeCoatingswithaBlackTopCoat;SurfaceProtectionRequirements

2)TL245–Non-ElectrolyticallyAppliedZincFlakeCoatings;SurfaceProtectionRequirements

3)VW01110-1–ThreadedConnections–Part1:DesignandInstallationSpecifications

4)TL134–Non-ElectrolyticallyAppliedZincFlakeCoatingswithOrganicCoatingforIncreasedCorrosionProtectionRequirements;

RequirementsandTesting

Alwaysusethelatestversionofthisstandard.

Thiselectronicallygeneratedstandardisauthenticandvalidwithoutsignature.

TheEnglishtranslationisbelievedtobeaccurate.Incaseofdiscrepancies,theGermanversioncontrols.

Page1of11

Technicalresponsibility

GQL-M/1

Dr.Olaf

Claus

Tel.:

+4953619194081

GQL-M/1

Tobias

Schilling

Tel.:

+495361937641

GQL-M

Dr.FrankR?per

TheStandardsdepartment

K-ILI/5Ute

Hager-Suess

K-ILI

Tel.:

+495361949035

UweWiesner

Allrightsreserved.NopartofthisdocumentmaybeprovidedtothirdpartiesorreproducedwithoutthepriorconsentofoneoftheVolkswagenGroup’sStandardsdepartments.

?VolkswagenAktiengesellschaftVWNORM-2018-02

Page2

TL233:2018-07

–

Section"Generalinformation"

added

–

Section4.4"Resistancetochemicals"

updated

–

AppendixA"Releasedsurfaceprotectionsystems"

:Theappendix"Releasedsurfaceprotec‐tionsystems"hasbeensupersededbythe"MaterialreleaselistforTL233"(storedonthe

ONE.KonzernBusinessPlattform).Correspondingreferencestothestorageofthisdocumentadded.

–Applicabledocumentsupdated

–Othereditorialchanges

1Scope

Thisstandarddefinesrequirementsandtestsofsurfaceprotectiontypescomprisingnon-electrical‐lyappliedzincflakecoatings,withanadditionalorganictopcoat,onironmaterials.

Thecoatingsystemsasperthisstandardcanbeusedattemperaturesuptoamaximumof180°C.

Because,withproperpretreatment,noriskofhydrogenembrittlementarisesasaresultofthe

coatingprocess,thiscoatingisalsosuitedascorrosionprotectionforhardenedandhigh-strengthsteelpartswithtensilestrengthvalues≥1000MPaorsurfacehardnessvalues>320HV(Vickershardness).Theindividualcoatsareappliedprimarilyusingdipspinning.

Coatingsasperthisstandardarenotsuitedforcomponentswithanelectricallyconductingfunction(e.g.,groundconnections).

2Designation

Dependingontheprotectionclassandonthelubricantcontent(see

table1

),adistinctionismadebetween4surfaceprotectiontypesforthecoatingsystemasperthisstandard,whicharedesigna‐tedwiththefollowingcodesasperthespecificationsin

VW13750

,"Designation"section:

Ofl-t330

Ofl-t350

Ofl-t630

Ofl-t650

3Requirements

3.1Appearanceofthetopcoat,lubricantadditive,andprotectionclass

Thesurfaceprotectiontypesofthecoatingsystemmustmeettherequirementsspecifiedin

table1

.

ThereleasedsurfaceprotectionsystemsarelistedinthematerialreleaselistforTL233;seerefer‐encesin

appendixA

.

Page3

TL233:2018-07

Table1–Appearance,lubricantadditive,andprotectionclass

Surfaceprotectiontype

Appearanceofthetopcoat

a)

Lubricantadditiveinthetopcoat

Protectionclass

Ofl-t330

Black

withlubricant

medium

Ofl-t350

withoutlubricant

Ofl-t630

withlubricant

heavy

Ofl-t650

withoutlubricant

a)Ifasilverappearanceofthetopcoatisrequired,thecodeforthesurfaceprotectiontypeisexpandedwiththeaddendum"silver."

Thisappliestoothercolorspecificationsaswell.

3.2Basicrequirements

Approvaloffirstsupplyandchangesasper

VW01155

.

Avoidanceofhazardoussubstancesasper

VW91101

.

Atleasttenparts(dependingonsize)arerequiredforcompletetesting.Fortheinitial-samplere‐leaseofsmallparts,≥50kgofspecimensmustbeproduced(e.g.,forfasteners).

Unlesscertainsectionsofapartmarkedinthedrawingareexcludedfromthesurfacecoating,theentiresurfaceofthepartsmusthavetherequiredsurfaceprotectionwiththespecifiedproperties.

Theprotectivecoatingsmustnothaveanypores,cracks,damage,orotherflawsimpairingcorro‐sionprotectionorthespecifiedappearance.Thecoatingsystemsmustfirmlyadheretothebasemetalandmustnotpeelofforcrackunderelasticdeformation.

Thecoatingsystemmustbefreeofanyflawsandexcessmaterialthathaveanegativeimpactonthepart'sfunction.Theproductionprocessmustbedesignedandcontrolledinsuchawaythattheusepropertiesofthefinishedpartarenotimpaired.

Ifthecoatedcomponentsareproperlyinstalled,thecoatingmustnotbedamagedinanywaythatwouldnegativelyaffectthefunctionand/orwouldreducethespecifiedcorrosionprotection.

FormetricISOthreadsasper

VW11611

,afterthecoatingprocess,thezerolineforouterthreadsmustnotbecrossed,andthezerolineforinnerthreadsmustnotbeundershot.Forfastenerswithametricthread,thecoefficientsoffrictionasper

VW01129

mustbecompliedwith(appliesonlytoOfl-t330andOfl-t630).

Becausethecoatingtemperaturesmayhaveeffectsonthepropertiesofmaterials,itmustbe

checkedwhethercoatingcanbecarriedoutusingsolvent-basedorwater-basedzincflakecoat‐

ings,dependingonthecomponent.Thebakingtemperatureforsolvent-basedzincflakecoatings

isusually200°Cto250°C.Atemperatureofapprox.300°Cisnecessaryforwater-basedzinc

flakecoatings.Therequirementsinthedrawingormasterdatalistalwaysapplytothecoatedcom‐ponent.

Theselectionofmanufacturerandsurfaceprotectiontypes,aswellasthecoatingmethod,mustbeagreeduponwiththeMaterialsEngineeringdepartmentoftheappropriatebrandineachcase,onapart-specificbasis,beforeuse.

Page4

TL233:2018-07

3.3Requirementsformechanicalfasteners

Formechanicalfastenerswiththefollowingcharacteristics,thecoatingsystemmustbereleasedonanapplication-specificbasis:

–PartswithametricISOthread≤M8withspecificrequirementsregardingthelooseningtor‐quesoftheconnectioniftemperatures>80°Coccur

–Outerthreads≤M6andinnerthreads

–Forceappliedbytriplesquareasper

VW01043

,<N8

–Hexalobularsocketasper

VW01048

,<T30

–Hexagonsocket,nominalsize<5asper

DIN475-1

orproductstandards

–Crossrecessasper

DINENISO4757

,<H3

3.4Basemetal

Thesurfaceofthebasemetalbeingcoatedmustbebright.Thesurfacemustbecleanedtoensure

thatitcanbecoated.Forhardenedandhigh-strengthsteelpartswithtensilestrengthvalues

>1000MPa,alkalineormechanicalcleaning(e.g.,byabrasiveblasting)mustalwaysbecarriedoutbeforethecoatingprocess.

Theapplicationoffine-crystalzincphosphating(coatingweightof1g/m2to3g/m2)ispermissible.

3.5Coatingsystem

3.5.1Compositionofthedryfilm

Compositionofthedryfilm:SeetheInternationalMaterialDataSystem(IMDS).

3.5.2Coatinglayers

Layerstructureofthecoatingsystem

Thecoatingsystemconsistsofabasecoat(inorganiczincflakecoating)andatopcoat(organiccoating);see

figure1

.

Page5TL233:2018-07

Legend

1Embeddingcompound

2Topcoat

3Basecoat

4Basematerial

Figure1–Light-microscopeimageofazincflakecoatingasamicrosection(example).Thisimage

showsOfl-t630withasilver-coloredbasecoat(identifiedbythelight-coloredzincandaluminum

flakes)andablacktopcoat(darkgrayintheimage).

NOTE1:Thebasecoatandtopcoatmayhaveamulti-layerstructure,e.g.,2layersofbasecoat+2layersoftopcoat.

.1Basecoat

Thebasecoatconsistsofaninorganicmatrixwithatleast70%zincflakesandupto10%alumi‐numflakesbymass.Theuseofzincwithaglobularstructureispermissible.Theuseofzincdustisprohibited.

Page6

TL233:2018-07

.2Topcoat

Topcoatwithoutlubricant

Theorganicepoxyresincoatingwithoutlubricantmustcontainamaximumof5%lubricant(PTFE)bymass.

Topcoatwithlubricant

Theorganicepoxyresincoatingmusthave25%to30%lubricant(PTFE)bymass.

3.5.3Totalthicknessofthecoatingsystem

RequirementsforOfl-t330andOfl-t350

Theminimumcoatingthicknessis6μm(ofwhich3μmmustbethezincflakebasecoat).

Thecoatingthicknessmustnotexceedamaximumof25μm.

RequirementsforOfl-t630andOfl-t650

Theminimumcoatingthicknessis10μm(ofwhich6μmmustbethezincflakebasecoat).

Thecoatingthicknessmustnotexceedamaximumof25μm.

Exceptions

Forthreadedparts,thespecificationsapplyonlytothehead,ortofacesurfacesandwrenchbear‐ingsurfaces.

Ifmorestringentcorrosionprotectionrequirements(comparedtothebasicrequirements)are

agreedtointhedrawingormasterdatalist,thengreatercoatingthicknessesarealsopermissible(e.g.,forspringclamps).

4

4.1

4.1.1

Tests

Adhesionandductilityofthecoatingsystem

Cross-cuttest

Procedureasper

DINENISO2409

;requirement:characteristicvalue≤1

Thecuttingdistancemustbeselectedasspecifiedinthestandard.Forsmallparts,aminimumdis‐tanceof1mmmustbeadheredto.

NOTE2:Forsmallcomponentsorthosewithcomplexgeometry,asingle-blademanualcuttingtoolispreferred.Ifnocross-cuttestcanbeperformedduetothecomponent'ssizeorgeometry,asinglecutortwointersectingcutsarepermissible.Ifevenasinglecutcannotbemade,onlythe

tapetestasper

section4.1.2

mustbecarriedout.

4.1.2Tapetest

Ascribinglinebasedon

DINENISO9227

mustbeappliedifthecomponentdimensionsallowforthis.Afterthis,adhesivetapewithabondstrengthof(10±1)Nper25mmofwidthisused.Thistapeisfirmlypressedbyhandontothesurfaceandthenpulledoffwithasuddenmotionperpen‐diculartothesurface.Thecoatingmustnotpeeloffoveralargeareawhenthetapeisremoved

Page7TL233:2018-07

(particlediameter≤1mm).Smallparticlesofthecoatingadheringtothetapearepermissible(≤5%ofthetestsurface).

NOTE3:Suitableadhesivetapeforthistestis,e.g.,tesaband4657

5)

.

4.1.3Ductilitytest

Thecoatingmustnotflakeoffwhenspringsareexpandedorcompressedasintended,orwhenspringwashersarebentduringassembly,orwhenspringclampsareopenedtotheirmaximumdiameter.

4.2Coatingthickness

Thecoatingthicknessismeasuredusingamicroscopicmethodasper

DINENISO1463

and

DINENISO2064

;thelocationofthemeasuringpointsandtolerancezonepositionsforthreadedpartswithametricISOthreadarespecifiedin

DINENISO10683

.

NOTE4:Forbulkproducts,theedgeareasconstituteaweakpoint;acheckontheexistingedgecoverageinthemicrosectionisrecommended.

4.3Testingcorrosionproperties

4.3.1Neutralsaltspraytest

Generalinformation

Theneutralsaltspraytestmustbeperformedasper

DINENISO9227

.

Halfofthespecimensmustbefurnishedwithascribinglinebasedon

DINENISO9227

,ifthecomponentdimensionsallowforthis(forscrewsandbolts,thefacesurfaceissuitable).

Forboltsandnuts,thetestrequirementsapplyonlytothehead,facesurface,and/orwrenchbear‐ingsurfaces.Forthreadedpartsandthread-likeparts,e.g.,tap-endstuds,theyapplytotheface

surfaces.Lessstringentrequirementsapplyinthethreadedarea.Thesearespecifiedinlistitems

1.to4.below.

1.Evaluationofcoatingcorrosion(applicabletoallsurfaceprotectiontypes)

After120h,withandwithoutthermalconditioning(heataginginrecirculatedair)for96hat

180°C,coatingcorrosionuptoamaximumdegreeofchangeS5asper

DIN34804

ispermis‐sible.Coatingcorrosionisnotevaluatedintheareaofthreads.

2.EvaluationofbasemetalcorrosionforOfl-t330andOfl-t350(interior)

After240h,nobasemetalcorrosionandnocorrosioncreepagealongthescribelinemustoc‐cur,withandwithoutthermalconditioning(heataginginrecirculatedair)for96hat180°C.

Alessstringentrequirementof120happliesinthethreadedarea.

3.EvaluationofbasemetalcorrosionforOfl-t630andOfl-t650(exterior)

After480h,nobasemetalcorrosionandnocorrosioncreepagealongthescribelinemustoc‐cur,withandwithoutthermalconditioning(heataginginrecirculatedair)for96hat180°C.

Alessstringentrequirementof240happliesinthethreadedarea.

4.Evaluationofbasemetalcorrosionforspringclamps(Ofl-650)

5)tesaband4657isthemanufacturer'sproductdesignation,producedbytesaSE.

Thisinformationisonlyintendedforinformationalpurposesfortheusersofthisin-housestandard.Thisdoesnotsignifyanen‐

dorsementofthementionedproductbytheVolkswagenGroup.Equivalentproductsmaybeusedifitcanbeverifiedthattheyleadtothesameresults.

Page8

TL233:2018-07

UnlesssurfaceprotectionasperTL134

6)

isrequired,thefollowingapplies:

Thepartsmustbeopenedtotheirmaximumdiameterfivetimesusingspring-clamppliersbe‐forethestartofthesaltspraytest.

Forpre-openedspringclampswithoutaclip,thecontactpointsforthepliersandthelatchingareasareexemptfromtheevaluation.

After720h,nobasemetalcorrosionandnocorrosioncreepagealongthescribelinemustoc‐cur,withandwithoutthermalconditioning(heataginginrecirculatedair)for96hat180°C.

NOTE5:Forreliablefulfillmentofcorrosionprotectionspecifications,acoatingsystemwithatleast2basecoatlayersand2topcoatlayersisusuallynecessaryforspringclamps.

4.3.2Testinginthecondensationatmospherewithconstanthumidity(CH)

TestingintheCHstandardatmosphereasper

DINENISO6270-2

Requirement:After240h,theremustnotbeanyblistersorothercoatingdetachments,orany

basemetalcorrosion.Aftersubsequentacclimatizationfor24hatroomtemperature

VW50554

–2,therequirementsspecifiedin

section4.1

muststillbemet.

4.4Resistancetochemicals

Thetestingofresistancetochemicalsisonlyrequiredforthereleaseofnewcoatingsystems.Thistestisusuallycarriedoutoncoatedtestsheets(see

table2

forthetestscope).Aspartoftheinitialsampleinspection,resistancetochemicalsmayalsobedemonstratedbyacertificateissuedby

thecoatingmaterialmanufacturer.

Testingisperformedasper

DINENISO2812-3

.Theevaluationisperformedasper

DINENISO4628-1

.Fortestmediaandrequirements,see

table2

.

6)TL134–Non-ElectrolyticallyAppliedZincFlakeCoatingswithOrganicCoatingforIncreasedCorrosionProtectionRequirements;

RequirementsandTesting

Page9TL233:2018-07

Table2

No.

Testmediumandtestconditions

Requirement

1

E10gasolineasper

DINEN228

,

blendedfrompremiumunleadedgasolineand10%ethanol:

Testingasper

DINENISO2812-3

;

10minatroomtemperature

VW50554

–2

Characteristicvalue≤1

2

B7dieselfuelasper

TL788

-B:

Testingasper

DINENISO2812-3

;

60minatroomtemperature

VW50554

–2

3

Factory-fillengineoilasper

TL52167

:

Testingasper

DINENISO2812-3

;

60minatroomtemperature

VW50554

–2

4

Centralhydraulicfluidasper

TL52146

:Testingasper

DINENISO2812-3

;

16hatroomtemperature

VW50554

–2

5

Coolantasper

TL774

,J5blend:

Testingasper

DINENISO2812-3

;

60minatroomtemperature

VW50554

–2

6

Brakefluidasper

TL766

-X:

Testingasper

DINENISO2812-3

;

60minatroomtemperature

VW50554

–2

Characteristicvalue≤1;

instancesofswellingthathaverece‐

dedafter24harepermissible

5Applicabledocuments

Thefollowingdocumentscitedarenecessarytotheapplicationofthisdocument:

SomeoftheciteddocumentsaretranslationsfromtheGermanoriginal.ThetranslationsofGer‐

mantermsinsuchdocumentsmaydifferfromthoseusedinthisstandard,resultinginterminologi‐calinconsistency.

StandardswhosetitlesaregiveninGermanmaybeavailableonlyinGerman.Editionsinotherlanguagesmaybeavailablefromtheinstitutionissuingthestandard.

TL52146

HydraulicOil;LubricantRequirements

TL52167

Factory-FillEngineOilSAE5W-40;LubricantRequirements

TL766

BrakeFluid;MaterialRequirements

TL774

EthyleneGlycol-BasedCoolantAdditive;RequirementsonMaterials

TL788

DieselFuel;FuelRequirements

VW01043

DriveTypesforThreadedParts;TripleSquareProfile

VW01048

DriveTypesforThreadedParts;HexalobularSocketProfile

VW01129

LimitValuesforCoefficientsofFriction;SteelMechanicalFastenerswith

MetricISOThreads

VW01155

VehicleParts;ApprovalofFirstSupplyandChanges

Page10

TL233:2018-07

VW11611

MetricISOThread;LimitDimensionswithProtectiveCoatingforMediumToleranceClass;ExternalThreads6gh/InternalThreads6H

VW13750

SurfaceProtectionforMetalParts;SurfaceProtectionTypes,Codes

VW50554

StandardAtmospheresandRoomTemperatures;Requirementson

StandardAtmospheres

VW91101

EnvironmentalStandardforVehicles;VehicleParts,Materials,Operat‐ingFluids;AvoidanceofHazardousSubstances

DIN34804

Fasteners-Changeofappearanceofblacksurfaces

DIN475-1

Widthsacrossflatsforbolts,screws,valvesandfittings

DINEN228

DINENISO10683

Automotivefuels-Unleadedpetrol-RequirementsandtestmethodsFasteners-Non-electrolyticallyappliedzincflakecoatings

DINENISO1463

Metallicandoxidecoatings-Measurementofcoatingthickness-Micro‐scopicalmethod

DINENISO2064

Metallicandothernon-organiccoatings-Definitionsandconventionsconcerningthemeasurementofthickness

DINENISO2409

Paintsandvarnishes-Cross-cuttest

DINENISO2812-3

Paintsandvarnishes-Determinationofresistancetoliquids-Part3:

Methodusinganabsorbentmedium

DINENISO4628-1

Paintsandvarnishes-Evaluationofdegradationofcoatings-Designa‐tionofquantityandsizeofdefects,andofintensityofuniformchangesinappearance-Part1:Generalintroductionanddesignationsystem

DINENISO4757

Crossrecessesforscrews

DINENISO6270-2

Paintsandvarnishes-Determinationofresistancetohumidity-Part2:Condensation(in-cabinetexposurewithheatedwaterreservoir)

DINENISO9227

Corrosiontestsinartificialatmospheres-Saltspraytests

Page11TL233:2018-07

AppendixA(informative)Releasedsurfaceprotectionsystems

ThereisamaterialreleaselistforthisTL.

ThematerialreleaselistisstoredontheONE.KonzernBusinessPlattform(ONE.KBP)–(Volks‐wagenGroupSupply–

)atthefollowingpath:

Start>Information>Divisions>QualityAssurance>MaterialsEngineering>MaterialReleaseLists

Toaddamaterialtothematerialreleaselist,compliancewiththeTLmustbeverifiedonthebasisofreferencecomponentsmanufacturedinclose-to-productionconditionsbythematerialmanufac‐turerorcomponentsupplier.Thereferencecomponentsaredefinedinagreementbetweenthe

manufacturerandthepersonwithtechnicalresponsibilityfortheTL.

Aftersubmittingthefullscopeofdocumentsandparts,apromptevaluationiscarriedouttodeter‐minewhetherthecriteriaaremetforthematerialtobeaddedtothematerialreleaselist.

ThecontactforthereleaseprocedureandforaddingthematerialtothematerialreleaselististhepersonwithtechnicalresponsibilityasspecifiedintherespectiveTL.

PUBLIC

··FFENTlCH

Nr.1

Freigabedatum2018-07

Material-Freigabeliste

zurTL233:2018-07

FrühereAusgaben

keine

Hinweis

DiehierfreigegebenenMaterialiengeltennurinVerbindungmitderTL233:2018-07,welchediezuerfüllendenSpezifikationenenth?lt!

ZurAufnahmeeinesMaterialsindieMaterial-FreigabelisteistdieEinhaltungderjeweiligenTechnischenLieferbedingung(TL)bzw.VW-NormanhandvonseriennahgefertigtenReferenzbauteilenvom

Materialherstellerbzw.Bauteillieferantennachzuweisen.DieReferenzbauteilewerdeninAbstimmungzwischendemHerstellerundderfachverantwortlichenMarkenWerkstofftechnikderVolkswagenAGfestgelegt.

NachVorlagedervollst?ndigenUnterlagenundTeileerfolgteinezeitnaheBewertung,obdieKriterienzurAufnahmeindieMaterial-Freigabelisteerfülltsind.

DerKontaktfürdasFreigabeprozedereunddieAufnahmedesMaterialsindieMaterial-FreigabelistesinddieFachverantwortlichenderjeweiligenTechnischenLieferbedingung(TL)bzw.VW-Norm.

Seite1von2

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