GroupstandardTL245

Issue2018-08

Class.No.:50223

Descriptors:Cr(VI)-free,aluminum,aluminumflake,corrosionprotection,ferrousmaterial,flake,surfaceprotection,

zinc,zincflake,zincflakecoating

Non-ElectrolyticallyAppliedZincFlakeCoatings

SurfaceProtectionRequirements

Previousissues

TL245:1987-08,1989-10,1990-01,1991-03,1991-11,1992-10,1993-07,1997-12,2002-10,2004-12,2007-06,2011-07,2011-09,2013-12,2014-11

Changes

ThefollowingchangeshavebeenmadetoTL245:2014-11:

–Technicalresponsibilityupdated

–

Section1"Scope"

:Designationsofthreadsizesfor"conditionallysuitable"deleted,replaced

withreferencetoVW01110-1.Correspondingreferencestothestorageofthisdocumentadd‐ed

–

Section3.10"Adhesion"

:Footnoteaddedtonote

–

Section3.12"Resistancetochemicals"

updated

–

AppendixA"Releasedsurfaceprotectionsystems"

:Theappendix"Releasedsurfaceprotec‐tionsystems"hasbeensupersededbythe"MaterialreleaselistforTL245"(storedonthe

ONE.KonzernBusinessPlattform).Correspondingreferencestothestorageofthisdocumentadded

–Applicabledocumentsupdated

–Othereditorialchanges

Alwaysusethelatestversionofthisstandard.

Thiselectronicallygeneratedstandardisauthenticandvalidwithoutsignature.

TheEnglishtranslationisbelievedtobeaccurate.Incaseofdiscrepancies,theGermanversioncontrols.

Page1of9

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

TL245:2018-08

1Scope

ThisTechnicalSupplySpecification(TL)definestherequirementsplacedonCr(VI)-freesurfaceprotectiontypesmadeofzincflakesandaluminumflakesappliedtoferrousmaterialsinanon-electrolyticmanner.

Thesilver-grayflakecoatingsareusedasheavy-dutycorrosionprotectionforcomponentswithahighcorrosionload.Withanappropriatelayerstructure,thezincflakecoatingsareabletowith‐standtemperaturessuchasthoseoccurring,e.g.,intheenginecompartment(fordetails,see

table1

).

Sincethiscoatingprocessposesnoriskofhydrogen-inducedembrittlement,itispreferablyusedascorrosionprotectionforhardenedandhigh-strengthsteelpartswithtensilestrengthvalues

>1000MPaorhardnessvalues>320HV.Theprotectionsystemmustbechosensuchthatthestrengthandhardnessarenotnegativelyaffectedbythetreatmenttemperatures.

Zincflakecoatingsarealsosuitableforuseasacoatingforferrousmaterialsincontactwithalumi‐numcomponents(however,notforthoseincontactwithmagnesiumcomponents).

Thecoatingisnotsuitableforcomponents

–thatserveaselectricalconductors(e.g.,groundconnections)

–insideofengines(e.g.,oilflowarea)inordertoavoidcloggingbydetachedcoatingparticles.Thecoatingisonlyconditionallysuitableforcomponentswith

–triplesquaresocketsasperVolkswagenstandardVW01043<N8andhexalobularsocketsasperVW01048<T30

–hexagonsockets<5andcrossrecessesasperDINENISO4757<H3

–Externalthreads:seeVW01110-1

–Internalthreads:seeVW01110-1

–washerswiththicknesses<1.6mm

2Designation

See

VW13750

,section"Designation."

3Requirements

3.1Surfaceprotection(Ofl)types

Thesurfaceprotectiontypeslistedin

table1

apply.

ThereleasedsurfaceprotectionsystemsarelistedinthematerialreleaselistforTL245;seerefer‐encesin

appendixA

.

Page3

TL245:2018-08

Table1

Surfacepro‐

tectiontype

Characteristics/appearance

Ofl-t601

Basecoatingwithouttopcoatandwithoutlubricantadditive.

Zincflakecoating,Cr(VI)-free,silver-gray;suitableforcomponentsthataretobepainted

-Curingtemperatureuptomax.300°C

-Reducedcorrosionresistance(seesection

section3.11

)

-Reducedlong-termservicetemperaturewithoutadditionalcoatings(125°C).

Ofl-t602

Basecoatingwithtopcoat,withoutlubricantadditive.

Zincflakecoating,Cr(VI)-free,silver-gray;useinexposedinstallationpositions,e.g.,intheenginecompartmentandchassisareas.

-Curingtemperatureuptomax.300°C

-Long-termservicetemperaturemax.180°C(short-termtemperaturepeaksupto300°C).

Ofl-t610

LikeOfl-t601,butwithlowercuringtemperature.

Zincflakecoating,Cr(VI)-free,silver-gray;corrosionprotectionpreferablyforcom‐ponentsthataretobepainted(bodymanufacture).Standardsurfaceprotectionforthreadedpartswithadhesivecoating(

DIN267-27

)orwithlockingcoating

(

DIN267-28

).

-Curingtemperatureuptomax.200°C

-Reducedcorrosionresistance(see

section3.11

)

-Reducedlong-termservicetemperaturewithoutadditionalcoatings(125°C).

Ofl-t611

LikeOfl-t602,butwithlowercuringtemperature.Consequently,suitableforcompo‐nentsthatmustnotbeexposedtohightemperatures,e.g.,springelements,hot-

shapedsheets,orhigh-strengthsteelcomponents.

-Curingtemperaturemax.230°C

-Long-termservicetemperaturemax.180°C(short-termtemperaturepeaksupto300°C).

Ofl-t615

LikeOfl-t610,butadditionallywithlubricant(greenish)asper

TL52165

.

-Curingtemperatureuptomax.200°C,

-Reducedcorrosionresistance(see

section3.11

)

-Reducedlong-termservicetemperaturewithoutadditionalcoatings(125°C).

Ofl-t647

Basecoatingwithtopcoat,withlubricantadditive.Zincflakecoating,Cr(VI)-free,silver-gray;standardsurfaceprotectionforthreadedpartswithmetricISOthreads(see

VW01110-1

).

-Curingtemperatureuptomax.300°C

-Long-termservicetemperaturemax.180°C(short-termtemperaturepeaksupto300°C).

3.2Basicrequirements

Approvaloffirstsupplyandchangesasper

VW01155

.

Avoidanceofhazardoussubstancesasper

VW91101

.

10finishedpartsarerequiredforcompletetesting.Forinitial-samplereleaseofsmallparts,e.g.,threadedfasteners,atestproductionof>50kgmustbeperformed.

ThecoatingmaterialsmustnotcontainanyCr(VI)compoundsinordertoensurethattheresultantcoatingsarelikewiseCr(VI)-free.

Page4

TL245:2018-08

Unlesscertainsectionsofapartmarkedinthedrawingareexcludedfromthesurfacecoating,theentiresurfaceofthepartsmusthavetherequiredsurfaceprotectionwiththespecifiedproperties.Thecoatingsmustadherefirmlytothebasematerial(see

section3.10

)andthecoatingsmustnotchiporcrackduetoelasticdeformation.

Theprotectivecoatingsmustnothaveanypores,cracks,damage,orotherflawsthatnegativelyaffectthecorrosionprotectionand/orfunction.

Theproductionprocessanditscontrolmustnotimpairtheusepropertiesofthefinishedpart.Forexample,thecoatingmustnotchiporcrackwhenthespringsorspringwashersaremountedorusedasintended.

Ifthecoatedcomponentsareproperlyinstalled,thecoatingmustnotbedamagedinanywaythatwouldnegativelyaffectthefunctionandwouldreducethespecifiedcorrosionprotection.

TheselectionofmanufacturerandcoatingsystemsmustbeagreeduponwiththeMaterialsEngi‐neeringdepartmentoftheappropriatebrandineachcase,onapart-specificbasis,beforeuse.

3.3ThreadedpartswithmetricISOthreads

Thecoatingprocessmustnotnegativelyaffectthemechanicalandphysicalpropertiesspecifiedforfasteners.Therefore,themanufacturermustcheckwhetherthecuringconditionsspecifiedbythecoatingcompanyaresuitableforthecomponentstobecoated.

AnessentialfunctionalpropertyofthreadedpartswithmetricISOthreadsistheiradherencetospecifiedcoefficientsoffriction.Inordertoensurethatthecoefficientsoffrictionadhereto

VW01129

,atopcoatwithintegratedlubricantadditiveisprescribedforsurfaceprotectiontypeOfl-t647,inadditiontothebaseflakecoating.ForOfl-t615,thecoefficientsoffrictionasper

VW01129

areensuredbymeansofadditionallubricationasper

TL52165

.Forreleasesofnewcoatingsystemsandforthedetectionoffaultsinthecaseofcomplaintsduringinstallation,partswithmetricISOthreadsmustbetestedasper

VW01131

.

MetricISOthreadsmustbedesignedasper

VW11611

.Afterthecoatingprocess,externalthreaddimensionsmustnotexceedtheshafttolerancezonehintheshaftbasissystemasperISO286andinternalthreaddimensionsmustnotbebelowtheholetolerancezoneHintheholebasissys‐temasperISO286.

Especiallyinthecaseofthreadedpartswithtopcoats,itmustbeensuredthatthesurfacesarenotimpermissiblydamagedbyprocessescarriedoutafterthecoatingprocess,suchas100%part

check,packaging,transport,etc.Formoreinformation,seetheguideline""Berücksichtigungder

Schütt-undTransportprozessebeiderUmstellungaufCr(VI)-freieOberfl?chen"

[1]

(ConsiderationofDumpingandTransportProcessesDuringtheChangeovertoHexavalent-Chromium-FreeSur‐faces),publishedbyDeutscherSchraubenverbande.V.(GermanFastenersAssociation).Reworkmustalwaysbeannouncedandagreedupon.

Forfurtherinformation,see

VW01110-1

,section"Surfaceprotection."

3.4Basecoating

Thebasecoatingcontainsabindingagentandapprox.70%zincflakesandapprox.10%alumi‐numflakes.Theuseofzincdustisimpermissible.Inordertoreliablyachievecoatingsthathaveuniformcoverageandthatsatisfythetestrequirementsdefinedin

section3.11.2

,amultiple-coat‐ingprocessisrequired.

Page5TL245:2018-08

3.5Topcoat/lubricantadditive

Inordertoimprovecorrosionprotectionandtoachievethedefinedcoefficientsoffriction,addition‐alsystem-specifictopcoatsmustbeused,optionallywithanintegratedlubricantadditive.Thetopcoatsmustbematchedtothebasecoating.Theymustnotcauseanyfunctionalimpairment.

Zincflakecoatingswithtopcoatsmustnotbeusedifpaintabilityandthebondingofadhesives(al‐so:lockingoradhesivecoatingsforfasteners)arerequired.

3.6Basematerial

Seedrawingormasterdatalist(MDL).

3.7Pretreatment

Usuallybrightmetal.Alternatively(dependingonthecoatingsystem),amicro-crystalline,thin-layerphosphatecoating(1g/m2to3g/m2)ispermissible.

Beforecoating,hotalkalineand/ormechanicalcleaning(e.g.,abrasiveblasting)mustbeper‐formedonhigh-strengthandhardenedsteelpartswithtensilestrengthvalues>1000MPaorhardnessvalues>320HV.

ExceptionsarepermissibleonlyinindividualcasesuponagreementwiththeMaterialsEngineeringdepartmentoftheappropriatebrand.

3.8Dryfilm

CompositionasperInternationalMaterialDataSystem(IMDS)

3.9Dryfilmthickness

Testingasper

DINENISO1463

,

DINENISO2064

,and

DINENISO2178

;positionofmeasuringpointsforthreadedpartswithmetricISOthreadasper

DINENISO10683

Theaverageminimumcoatthicknessmustbe8μm;theresultsoftheindividualmeasurements

mayvarywithintherangefrom6μmto20μm.Forthreadedparts,thespecificationsonlyapplytotheheadand/ortothefacesurfaceandwrenchbearingsurface;forallothersurfaces,themini‐

mumcoatingthicknessisachievedifthecorrosionprotectionrequirementsarefulfilled.

Internaldrivesandthreadedareasmustnothaveanybasecoatand/ortopcoataccumulationsthatmightnegativelyaffectthefunctionalproperties.

3.10Adhesion

Ascribinglinebasedon

DINENISO9227

mustbeappliedifthecomponentdimensionsallowforthis.Afterthis,adhesivetapewithabondstrengthof(10±1)Nper25mmofwidthisused.Thistapeisfirmlypressedbyhandontothesurfaceandthenpulledoffwithasuddenmotionperpen‐diculartothesurface.Coatingmustnotberemovedfromalargearea.Smallparticlesofthecoat‐ingadheringtothetapearepermissible(≤5%ofthetestsurface).

Inthecaseofsmallparts,theadhesiontestcanbeperformedwithoutascribingline.

NOTE1:Suitableadhesivetapeforthistestis,e.g.,tesaband4657

1)

.

1)tesaband4657isthemanufacturer'sproductdesignation.ItisproducedbytesaSE.

Thisinformationisonlyintendedforinformationalpurposesfortheusersofthisin-housestandard.Thisdoesnotsignifyanen‐

dorsementofthementionedproductbytheVolkswagenGroup.Equivalentproductsmaybeusedifitcanbeverifiedthattheyleadtothesameresults.

Page6

TL245:2018-08

3.11Corrosionproperties

3.11.1StandardatmosphereCH(condensationatmospherewithconstanthumidity)asper

DINENISO6270-2

Thistestisonlyrequiredforthereleaseofnewcoatingsystems.Generally,thistestiscarriedoutoncoatedtestsheets(forthetestscope,seebelow).Withintheframeworkofaninitialsamplein‐spection,themoistureresistancecanalsobeprovenbyacertificateissuedbythecoatingmaterialmanufacturer.

Ascribinglinebasedon

DINENISO9227

mustbeapplied.Afteratestdurationof720handeval‐uationasper

DINENISO4628-3

,thefollowingrequirementsmustbesatisfiedineachcaseas

minimumspecifications:

–Basemetalcorrosiononsurface:Ri0

–Basemetalcorrosionpermissibleintheareaofthescribingline,butnocorrosioncreepage

3.11.2Neutralsaltspraytestasper

DINENISO9227

ThefollowingrequirementsapplytopartsintheReceiptofGoodsdepartmentoftheVolkswagenGroupplantusingtheparts(i.e.,afterpackagingandtransport).

NOTE2:Usually,thebasecoatmustbeapplied3timesinordertosafelyachieve≥600hofresistancetosaltspraywithoutbasemetalcorrosion.

Requirementsforcomponentsofageneralnature

–Nobasemetalcorrosion(Ri0)afteratestdurationof720h

–Nobasemetalcorrosion(Ri0)afteratestdurationof480hwiththermalaging(heataginginrecirculatedair)96hat180°C

Requirementsforthreadedbarrelplatedgoods

–Nobasemetalcorrosion(Ri0)afteratestdurationof600hwithoutthermalaging

–Nobasemetalcorrosion(Ri0)afteratestdurationof480hwiththermalaging(heataginginrecirculatedair)96hat180°C

RequirementsforcomponentswithsurfaceprotectiontypesOfl-t601,Ofl-t610,andOfl-t615

–Nobasemetalcorrosion(Ri0)afteratestdurationof480hwithoutthermalaging

3.12Resistancetochemicals

Theverificationoftheresistancetochemicalsisonlyrequiredforthereleaseofnewcoatingsys‐tems.Generally,thistestiscarriedoutoncoatedtestsheets(forthetestscope,seebelow).As

partoftheinitialsampleinspection,resistancetochemicalsmayalsobedemonstratedbyacertifi‐cateissuedbythecoatingmaterialmanufacturer.

Testingisperformedasper

DINENISO2812-3

.Theevaluationisperformedasper

DINENISO4628-1

.Fortestmediaandrequirements,see

table2

.

Page7TL245:2018-08

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

4Applicabledocuments

Thefollowingdocumentscitedarenecessarytotheapplicationofthisdocument:

SomeoftheciteddocumentsaretranslationsfromtheGermanoriginal.ThetranslationsofGer‐

mantermsinsuchdocumentsmaydifferfromthoseusedinthisstandard,resultinginterminologi‐calinconsistency.

StandardswhosetitlesaregiveninGermanmaybeavailableonlyinGerman.Editionsinotherlanguagesmaybeavailablefromtheinstitutionissuingthestandard.

TL52146

HydraulicOil;LubricantRequirements

TL52165

Lubricant(greenish)forThreadedFasteners;MaterialRequirements

TL52167

Factory-FillEngineOilSAE5W-40;LubricantRequirements

TL766

BrakeFluid;MaterialRequirements

TL774

EthyleneGlycol-BasedCoolantAdditive;RequirementsonMaterials

TL788

DieselFuel;FuelRequirements

VW01110-1

ThreadedConnections;Part1:DesignandAssemblySpecifications

VW01129

LimitValuesforCoefficientsofFriction;SteelMechanicalFastenerswith

MetricISOThreads

VW01131

DeterminationofCoefficientsofFriction;SteelMechanicalFasteners

withMetricISOThreads

Page8

TL245:2018-08

VW01155

VehicleParts;ApprovalofFirstSupplyandChanges

VW11611

MetricISOThread;LimitDimensionswithProtectiveCoatingforMediumToleranceClass;ExternalThreads6gh/InternalThreads6H

VW13750

SurfaceProtectionforMetalParts;SurfaceProtectionTypes,Codes

VW50554

StandardAtmospheresandRoomTemperatures;Requirementson

StandardAtmospheres

VW91101

EnvironmentalStandardforVehicles;VehicleParts,Materials,Operat‐ingFluids;AvoidanceofHazardousSubstances

DIN267-27

Fasteners-Part27:Steelscrews,boltsandstudswithadhesivecoating,Technicalspecifications

DIN267-28

Fasteners-Part28:Steelscrews,boltsandstudswithlockingcoating,Technicalspecifications

DINEN228

DINENISO10683

Automotivefuels-Unleadedpetrol-RequirementsandtestmethodsFasteners-Non-electrolyticallyappliedzincflakecoatings

DINENISO1463

Metallicandoxidecoatings-Measurementofcoatingthickness-Micro‐scopicalmethod

DINENISO2064

Metallicandothernon-organiccoatings-Definitionsandconventionsconcerningthemeasurementofthickness

DINENISO2178

Non-magneticcoatingsonmagneticsubstrates-Measurementofcoat‐ingthickness-Magneticmethod

DINENISO2812-3

Paintsandvarnishes-Determinationofresistancetoliquids-Part3:

Methodusinganabsorbentmedium

DINENISO4628-1

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

DINENISO4628-3

Paintsandvarnishes-Evaluationofdegradationofcoatings-Designa‐tionofquantityandsizeofdefects,andofintensityofuniformchangesinappearance-Part3:Assessmentofdegreeofrusting

DINENISO6270-2

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

DINENISO9227

Corrosiontestsinartificialatmospheres-Saltspraytests

5Bibliography

[1]

DSVGuideline"BerücksichtigungderSchütt-undTransportprozessebeiderUmstellung

aufCr(VI)-freieOberfl?chen"

;DeutscherSchraubenverbande.V.

Page9TL245:2018-08

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

Freigabedatum2018-08

Material-Freigabeliste

zurTL245:2018-08

FrühereAusgaben

keine

Hinweis

DiehierfreigegebenenMaterialiengeltennurinVerbindungmitderTL245:2018-08,welchediezuerfüllendenSpezifikationenenth?lt!

ZurAufnahmeeinesMaterialsindieMaterial-FreigabelisteistdieEinhaltungderjeweiligenTechnischenLieferbedingung(TL)bzw.VW-NormanhandvonseriennahgefertigtenReferenzbauteilenvom

Materialherstellerbzw.Bauteillieferantennachzuweisen.DieReferenzbauteilewerdeninAbstimmungzwischendemHerstellerundderfachverantwortlichenMarkenWerkstofftechnikderVolkswagenAGfestgelegt.

NachVorlagedervollst?ndigenUnterlagenundTeileerfolgteinezeitnaheBewertung,obdieKriterienzurAufnahmeindieMaterial-Freigabelisteerfülltsind.

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

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