Public

Mercedes-BenzDBL1666

CompanystandardDatepublished:2023-08

Transitionperiod:0months

Dateoftranslation:2023-10Totalno.ofpages(includingannexes):10

Galvanicindividual-partanddrumcoating

ofcomponentpartsforbodyshellapplicationsthatsubsequentlyreceiveaCDCand/ortopcoatcoating

Observeapprovalofprocurementsource(BQF)

Foreword

ThisDBLspecifiestherequirementsforthecoatingqualityofelectroplatedpartsmadeofferrousmaterialswhichareinstalledatthebodyinthebodyshellanddescribestherelevanttestmethods.

E.g.,consoles,reinforcements,andhinges,aswellasallotherbodyshellpartsofthebodyThiseditionsupersedesthepreviouseditionoftheDBL8466standard.

Applicationnote:

Inaccordancewiththescope,theapplicationofthepresentversionofthiscompanystandardshallbecheckedfornewvehicleprojectsorcomponentsforwhichnoconceptspecifications/basicspecificationsorcomponentrequirementspecificationshaveyetbeenapprovedatthedateofpublicationofthisversion.

Therespectivecontractdocumentsregulatethemandatoryapplicationofthepresentversionofthiscompanystandardbythesupplier.

Changes

Thefollowingchangesweremadecomparedwithedition2018-10:

.Titlechanged:From'Galvanicindividual-part-coatingofcomponentsforbodyshellapplicationsthatsubsequentlyreceiveaCDCand/ortopcoatcoating'to'Galvanicindividual-partanddrumcoatingofcomponentpartsforbodyshellapplicationsthatsubsequentlyreceiveaCDCand/ortopcoatcoating'

.EditorialchangeinaccordancewithMBN50000

.Revisionofnormativereferences

NOTE:Thistranslationisforinformationpurposesonly.

TheGermanversionshallprevailaboveallothers.

CopyrightMercedes-BenzGroupAG

:WeikangDong,2023-12-04

Uncontrolledcopywhenprinted

Public

CopyrightMercedes-BenzGroupAG

:WeikangDong,2023-12-04

Uncontrolledcopywhenprinted

DBL1666:2023-08,page2

Contents

1Scope 3

2Normative references3

3Terms 4anddefinitions

4General 4requirements

5Materialentry 4forthefinalmaterialcondition

6Generalraw 5propertiesofmaterials,materials,anddeliverycondition

6.1Basic 5approval

6.2Corrosion-freedelivery 6

6.3Base materials6

6.4Material strength6

6.5Metalliccoat base6

7Dimensions andtolerances/formofsupply6

8Technical 7data

8.1Layerthicknesses/Metalliccoat 7base

8.2Climatictests 7

9Duties ofthesupplier8

AnnexA(Normative)References 10

DBL1666:2023-08,page3

1Scope

ThisDBLappliestopartsthathaveazinc,zinc-iron,orzinc-nickelcoating,andwhichpassthroughacompletepre-treatmentand/orpaintingprocessaftergalvanization.Amongthereasonsforthecoatingofindividualcomponents(coatingfollowingcomponentmanufacture)insteadofthepreferredcoilcoatingprocessisanintensiveformingprocesswhichwouldresultinabrasionofthecoilcoating,ortheintegrationofthreadedparts.

Table1:Overviewofcurrentproductversions

Productversion

Method

Applicationexample

01

Electrodepositedzinccoatingandpassivation

Componentpartsthermallyormechanicallyjointedand/orbonded1

03

Electrodepositedzinccoatingandoiled

Componentpartsthermallyormechanicallyjointedand/orbonded

1

11

Galvaniczinc-nickelcoatedandpassivated

Componentpartsmechanicallyjointedand/orbonded*

1

2/

13

Galvanicallyzinc-nickel-coatedandoiled

Componentpartsmechanicallyjointedand/orbonded

1

2

15

Galvaniczinc/nickel

coatedandpassivated

withdefinedfrictioncoefficients

Fastenerswithmetricthreade.g.,screws

21

Galvaniczinc-iron

Coatedandpassivated

Componentpartsthermallyormechanicallyjointedand/orbonded

1

23

Galvanicallyzinc-iron-coatedandoiled

Componentpartsthermallyormechanicallyjointedand/orbonded

1

2Normativereferences

Inthetext,thefollowingdocumentsshallbereferencedinsuchawaythatsomepartsofthemortheirentirecontentdescribetherequirementsofthepresentdocument.Fordatedreferences,onlytheeditioncitedapplies.Forundatedreferences,thelatesteditionofthereferenceddocument(includinganyamendments)applies.

DBL6747

AnticorrosionOils

DBL7905

One-ComponentStructuralAdhesivesfortheBodyShell

DBL8451

ElectrodepositedZincandZincAlloyCoatings

forComponentsManufacturedfromFerrousMaterials

1High-strengthbodyshellstructureadhesivesinaccordancewithDBL7905exhibitnoadhesionwith

regardtocomponentpartsinaccordancewiththisDBLandarethereforeunabletoensurepower

transmission.Whenitcomestothedestructivetest,thefracturepatternisnotrelevantfortheevaluation.Theseadhesivesmerelyserveasashimmingandinsulatinglayer.Thesecomponentpartsshallbe

fastenedmechanicallyinordertoensurepowertransmissionandcomponentstrength.

2ThefollowingappliestoallMercedesplants:Nothermaljoiningmethodsandotherprocessingstepswhichgeneratefumesordustsarepermittedforthesecomponentparts,asnickeloxideswillformduringthemachiningandprocessingofnickel,nickelalloysandmaterialscontainingnickelinthepresenceofatmosphericoxygen,especiallyduringthermalprocesses.

DBL1666:2023-08,page4

DBL8585

GeneralRequirementsEnvironmentalProtection,HazardousSubstances,

DangerousGoodsNegativeSubstanceListfortheSelectionofMaterials

DBL9440

Fastenerswithmetricthreadsurfaceprotectionandsupplementarytechnicaldeliveryconditions

MBN10494-6

PaintTestMethods–Part6:ClimaticTests

MBN10300

StandardDesignationofMaterialsforTechnicalDocumentation

3Termsanddefinitions

BQF:Approvalofprocurementsource

CDCCathodicdippaint(cathodicelectrodeposition)

DBL:Daimler-Benzsupplyspecification

e.g.Forexample

ISIR:Initialsampleinspectionreport

MBN:MBstandard

MIG:Metalinertgas

N/ANorequirement

NSSNaturalsaltspraytest

PVProductversion

4Generalrequirements

Toguaranteeproductsafetyandproductquality,andtomeetcertificationrequirements,allrelevantstatutoryregulationsandlawsshallbecompliedwith.Inaddition,therelevantrequirementsoftheMercedes-BenzGroupapply.

Allmaterials,processengineering,componentparts,andsystemsshallcomplywithallapplicablelegalrequirementsregardingconstituentsandrecyclability.

DBL8585shallbeobserved.

Thesespecificationsalsoapplyinthecaseofcomponentpartsstillinusewithaprescribedproductversionthatisnolongerapprovedfornewdesigns(NfN).Whenperformingrenewedsamplingofcomponentpartsinaproductversionthatisnotuptodate,thetechnologicalrequirementsoftheDBLversioninwhichtheproductversionwaslastlistedas"current"apply.

5Materialentryforthefinalmaterialcondition

Theentryofthematerialsin2D/3DdatarecordsshallcontaintheinformationasperMBN10300from

Table

2

.

DBL1666:2023-08,page5

Table2:Shortdescriptionofthefinalmaterialcondition

Coating/surface

standard

Typeof

coating/surface

Standardtitle

Coating

system/lubricati

on/

usecase

Commentsand

notes

DBL16

66.11

Metallic

coatings:ZnNiand

passivated

Galvanicindividual-partanddrumcoatingofcomponentpartsforbodyshell

applications

Galvanic

zinc-nickel

coatedand

passivated

Componentparts

mechanicallyjointedand/orbonded

6Generalpropertiesofmaterials,rawmaterials,anddeliverycondition

6.1Basicapproval

6.1.1CDCcoatability

PassivationexertsastronginfluenceupontheCDCcoatability.Consequently,onlyfail-safepassivationsystemsforwhichthepassivationhasreceivedaprincipleapprovalwithregardtothecoatermaybeused.Theprincipleapprovalisissuedbytheanti-corrosionmaterialsteam.

TheapplicationforissuanceofbasicapprovalcanbefoundintheAnnexofDBL1666,supplementarypage1.

Passivation

Ingeneral,thepassivationoperationmustinvolveathin-layerpassivationprocedure.

Thepassivationlayershallnotincludeanythickeningcausedbyparticulatematterinthenanometerrange.

Aftertreatmentofthepassivation,e.g.,bymeansofoiling,sealing,bleaching,ortheuseoflubricants(screwedparts),isnotpermissible(exceptionPV15).

ThetradenameandthemanufacturerassociatedwiththepassivationshallbespecifiedinmaterialpartslistWEBV600.

Column:"Tradenameofsurfacematerial,manufacturerofsurfacecoating/material+productionlocation"

6.1.2PV15

TheprincipleapprovalfortheCDCcoatabilityforthisPVshouldbeverifiedusingtestpanels.

(Sheetsteel,100x200mm,perforatedattopandbottom(8mm))

Coefficientsoffriction/threadingbehaviorandaftertreatment

RefertoDBL9440-Supplyspecification;fastenerswithmetricthreads;surfaceprotectionandadditionaltechnicaldeliveryconditions;heading:Frictionfactorsfriction/threadedconnectionbehaviorand

aftertreatment

6.1.3Adhesivebonding

High-strengthbodyshellstructureadhesivesinaccordancewithDBL7905exhibitnoadhesionwithregardtocomponentpartsinaccordancewiththisDBLandarethereforeunabletoensurepowertransmission.Whenitcomestothedestructivetest,thefracturepatternisnotrelevantfortheevaluation.Theseadhesivesmerelyserveasashimmingandinsulatinglayer.

Thebondingshallbedocumentedinthedrawing/3Ddatarecord.

DBL1666:2023-08,page6

6.1.4Componentpartswiththermaljoining

Passivationexertsastronginfluenceupontheweldability.Consequently,onlyfail-safepassivationsystemsforwhichthepassivationchemistryandthepassivationhavereceivedaprincipleapprovalwithregardtothecoatermaybeused.

ProofofweldabilityshallbeprovidedbythesupplieranddocumentedintheISIR

Thematerials,includingthecorrosionprotectionappliedinaccordancewiththisDBL,shallbecapableofbeingprocessedusingthemethodsnormallyusedforthebody-in-whitesuchasspotwelding,spot-weldbonding,MIGsoldering,andlaserwelding.

6.1.5Oiledcomponentparts(anticorrosionoilapplication)

OnlyoilsapprovedinaccordancewithDBL6747maybeused.

WorkinstructionsfortheexecutionoftheoilingcanbeobtainedfromtheMercedes-BenzAGdepartmentresponsibleforcorrosionprotectionifnecessary.

Thelayerthicknessoftheanticorrosionoilingshallbe>1,5g/m2,butshallnotexceed3g/m2.

ThetradenameoftheoilshallbespecifiedinthematerialpartslistWEBV600.Column:‘Componentpartoiled(no,oroil’stradename)’

6.2Corrosion-freedelivery

Withrespecttotransportationandstorage,thesuppliershalltakeappropriatemeasures,e.g.,packaging,toensurecorrosion-freedeliveryofthepartswithoutzinccorrosionorotherchangesfollowingcoating.Additionalmeasuresshallbedefinedinthecaseofincreasedcorrosionprotectionrequirementse.g.,inthecaseofoverseasshipping.

6.3Basematerials

Thecomponentpartsdesignatedforcoatingshallnotexhibitanymaterial,machining,orsurfacedefects,whichcouldimpairthecorrosionprotectionand/ortheappearanceofthecoatings.Thisincludes,forexample,cracks,clusteredporosity,foreignsubstanceinclusions,andlaminationsinthecaseofworkpiecesmanufacturedfromrolledproducts.Ifnecessary,anagreementconcerningsurfacefinishmayhavetobemade.

Anycontaminationonthesurfaceofthepartstobetreated(corrosionproductsorscale,oil,grease,dirtetc.)shallbecompletelyremovableinthenormallyusedautomaticcleaningandpre-treatmentfacilitieswithoutleavinganyresidue.

6.4Materialstrength

TherequirementspertainingtotherespectivematerialstrengthcanbefoundinDBL8451

6.5Metallicbasecoat

Thetypeofgalvaniclayercompositionshouldbespecifiedinthematerialpartslist.Column-"Typeofsurfacecoating/material(7)"

Forfurtherrequirementswithregardtothemetallicbasecoat,refertoDBL8451.

7Dimensionsandtolerances/formofsupply

Followingcoating,partsshallbewithinthespecifiedtolerancesstatedonthestandardsheetsordrawings,takingthreadsizesintospecialconsideration.

DBL1666:2023-08,page7

8Technicaldata

8.1Layerthicknesses/Metallicbasecoat

Thethicknessofthezinclayerandthedistributionofthezinclayeronthecomponentpartshaveamajorinfluenceontheweldingsuitability,e.g.,spotwelding.Inthecaseofgalvanicbatchgalvanizing,thisvarianceof

thezinclayerthicknessissignificantlylargerthaninthecaseofcontinuoussheetgalvanizingduetothecharacteristicsoftheprocess.Toensureareliablespot-weldingprocess,thecoatingofthecomponentpartsshallbespecificallyoptimizedwithregardtoalayerthicknessdistributionwhichisasuniformaspossiblewithinthejoiningareas.

Forthejoiningareasinwhichthermaljoiningmethodsareused,areasinwhichalayerthicknesstoleranceof8–12μmshallbemaintainedaredefinedonthedrawingbymeansofreferencehooks.

8.2Climatictests

Table3

indicatestherequirementsforsaltspraytestingNSS

Table3:Saltspraytest(4partspertest)

AffectedPVsandtheirrequirements

Preload/test

01/03

21/23

11/13

15

Testmethod

Saltspraytest

MBN10494-6

Zinccorrosion

Testdurationin[h]

N/A3

Visualassessment

N/A

3

Ironcorrosion(basemetalcorrosion)

Testdurationin[h]

72

240

720

720

Visualassessment

Nobasemetalcorrosion

3*Corrosion-freedeliveryshallbeguaranteed;seeChapter

6.2

DBL1666:2023-08,page8

Table4

indicatestherequirementsforCDC-coatedpartsintheconstantcondensedwaterclimate

Table4:Constantcondensedwaterclimate(4partspertest)

AffectedPVsandtheirrequirements

Preload/test

01/03/11/13/21/23

(15onsampleplates)

Testmethod

Constantcondensedwaterclimate

MBN10494-6

Testdurationin[h]

240

Blistering,degreeofblistering

0(S0)

PressurizedwaterspraytestonSt.Andrew’scross

D0

Table5

indicatestherequirementsforCDC-coatedpartsinthecorrosioncycletest

Table5:Corrosioncycletest

AffectedPVsandtheirrequirements

Preload/test

01/03/11/13/21/23

(15onsampleplates)

Testmethod

Corrosioncycletest1

MBN10494-6

Corrosioncycletest1

Testdurationincycles

6

Blistering,degreeofblistering

0(S0)

Cross-cut

Gt1

Pressurizedwaterspray