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-

CMD

Code

B

Ch.

10

Edition

normazione

CORROSION-RESISTANTZINC,

ALUMINUMANDCHROMATEBASE

CHEMICALCOATINGFORFERROUS

METALPARTS

PROCUREMENTSPECIFICATION

9.57511Page:1/11

Date:06/28/2006

SUPERVISORDepartment:E.D.–M.E.–AnticorrosionSystem

MANAGERDeparment:E.D.–M.E.–AnticorrosionSystem

PURPOSE

ThisProcurementSpecificationcoversrequirements,testproceduresandtestequipmentforcorro-sion-resistantzinc,aIuminumandchromatebasechemicaIcoatingsforferrousmetaIparts.

Itdefinestheproceduresandequipmenttobeusedtochecksaidcharacteristics.

íííííííííííííííííííííííííííííí

íííííííííííííIPTNíTíííííííííííí

ííTcmlyitthEDretiv20/5/Eadollwigoifiatinf0/2/20,í

íícíoatíingíscíoveíredíiníthisíPríocuíremíenítSípecíificíatioín,UíSTíNOíTBíEíUSíEDíafteírííí

ííJíulyí1í,20í06íasítheíyinícoríporíateíheíxavíaleíntcíhroiíumísaltí.ííííííííí

íííííííííííííííííííííííííííííí

íííííííííííííííííííííííííííííí

ThisProcurementSpecificationconsistsof11pagesandNo.1Annex.

Change

Date

Description

A

A

--

--

--

A

B

Mar.,95

Jan.,96

Nov.,96

May,97

04/04/00

07/18/02

01/30/03

10/31/03

06/28/06

Edition6-§4.3.4.1“Adhesivetapemethod”and§4.3.5“FIexibiIityandresist-

ancetoimpacts”addedandeditingchangesmade.(DA)

””-“CIassificationofCharacteristics”in§8hasbeenchanged.(DA)

Edition7-UpdatedtypeRIV/DAC5PLandeditoriaImodificationsmade.(DA)

””-§2.2hasbeenchanged.(DA)

Edition8-CompIeteIyrevised.(DA)

Edition9-Reading“TEMPORARY”insertedonaIIpages,

waitingforthedocumentaudit.(DA)

Edition10-RevisedasperE.C.Directive2000/53/CEandeditoriaIchanges

made.(DA)

§1andnote“IMPORTANT”onpage1modified.(FD)

§2anddateinthenote“IMPORTANT”onpage1modified.(FD)

ANYPRINTEDCOPYISTOBEDEEMEDASUNCHECKED;THEREFORETHEUPDATEDCOPYMUSTBECHECKEDINTHEAPPROPRIATEWEBSITE

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9.57511

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Change

|§”A”:TESTEQUIPMENT

seetestequipmentondocumentsreferencedintext(see§“B”).

|§”B”:REFERENCES

|10395|wheeImountingscrews.TPM

|50022|Dataprocessingcodesforfeaturesofsemifinishedproducts.TMD|50180|Corrosiontests.TMD

|50757|MetaIIiccoatingthicknessmeasurementbymagneticmethod.TMD|50765|EIectroIyticpIatingandchemicaIcoatingheatshock.TMD

|7.G0114|MeasuringthecoefficientoffrictiononboItsandnuts.PGE|9.01102|QuaIityofsuppIies.CFO

|9.01102/01|suppIyinspectionrequirements.CFO

|9.01103|ProductquaIityandconformitycertificate.CFO

|9.52605/01|ThreadedfastenersandreIateditemsforstandardandspeciaIpurposes.CFO

|9.52605/03|ThreadedfastenersforsevereappIication.CFO

|9.55367|singIe一coated,pressure一sensitiveadhesivetapes.CMD

|9.57512|AIuminium一,zinc一andorganicbinder一baseanti一corrosionchemicaIcoatingforfer-

rousmateriaIparts.CMD

|9.57513|AIuminium一andzinc一IameIIarbaseanti一corrosioncoatingforferrousmateriaIparts.CMD

|§‘‘C’’:ANNEXES

|

1

|specificationsDatasheet.

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9.57511

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1

HEXAVALENTCHROMIUMNOTE

ComplyingwiththeECDirectiveonend–of–lifevehicles(2000/53/EC),alreadyadoptedinP.S.

9.01102AnnexCK,itisnecessary,forecological–environmentalreasons,toremovecompletelythehexavalentchromiumcompounds(CrVI)fromvehicleswithinJuly1,2007.

Tothatend,startingfromJuly1,2006,allcoatingscoveredinthisProcurementSpecificationwillbeeliminatedandFiatAutowillnolongersupplythem,astheycontainhexavalentchromium.

Duringthetransientphase,theinterventionstrategyadoptedbyFiatAuto,fortheEuropeanmarket,isthefollowing.

●Fornewmodels,beinghomologatedafter01/01/2004,completeeliminationofhexavalentchromiumfromallnewdrawings(Powertraincomponentsincluded).

Note:Theobligationtoeliminatehexavalentchromiumstartingfrom01/01/2004isnottobe

appliedto:

–derivativevehicles(e.g.vans,pick–ups,SWs,etc.),–face–liftings,

–restylings,

–homologationextensionsforversionsnotforeseenatthefirstlaunch,ofmodelshomologatedforthefirsttimebefore01/01/2004.

●Fornewdrawingsofmodelsalreadybeingproducedindecember2003,andfordrawingsofcomponentsalreadybeingproducedorcarry–overs(boltsandStandardsincluded),evenifmeantfornewmodelstobehomologatedforthefirsttimeafter01/01/2004,completeeliminationofhexavalentchromiumwithinJuly1,2006.

●Forcarry–overcomponentsinparticular(boltsandStandardsincluded),when,duringtherevisionoftheDrawingoroftheTable,acoatingwithouthexavalentchromiumisforeseen,itispossibletocontinuetosupplytheversionwithhexavalentchromiumuntilstockout,butnotafterJuly1,2006.Butinthiscaseitisnecessarytoformalizetherequestforvariation,asperP.S.9.01102.

AnydeviationfromthesegeneralinstructionsshallbeauthorizedbytheappropriateE.&D.departments.

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9.57511

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2

CoatingsSUPPRESSEDandREPLACEDfrom07/01/2006

UnlessotherwisespecifiedondrawingoragreeduponbetweenFiatAutoandSupplier,thediagramreportedonTable1istheonlyvalidreference.

TABLE1

SUPPRESSED

REPLACED

íííííííííí

íííRíIVí/DAí5可ííí

íIVE5a.9í.571í

íííIVDA②ííí

íííRíIV/íDAíC5íPLííí

RIV/EC8PLCap.9.57513

可IncasethedrawingrequirestheuseofDacromet500,therepIacementshaIIbecarriedoutwithRIV/EC5P.S.9.57513.

②RepIacementvaIidforthreadedeIementsandsmaIIitems.Fornon一threadedormediumandbigitems,the

repIacementofthistypeofcoatingmustbeagreedupon,eachtime,withFIATAutoE.D.一M.E.Laboratori.

2.1

Unlessotherwiseconcerted,startingfrom07/01/2006itwillnolongerbepossibletodelivertoFiatAutoanytreatedcomponentwithcoatingscontaininghexavalentchromium.

Therefore,startingfromthesamedate,allcodesregardingcoatingsinthisP.S.andintechnicaldocuments(drawings,tables,standards,etc.),shallbeintendedcompletelyequivalenttothecorrespondingreplacementcodesofcoatingswithouthexavalentchromium,asperTable1.

Therefore,complyingwiththisP.S.,theSuppliershallhavetomanufactureandsupplythecomponentswiththeircorrespondingcoatingswithouthexavalentchromiumasperTable1orasspecificallyconcertedwithFiatAuto,evenwhenthedocumentsrequirecoatingscontaininghexavalentchroumium.

3

GENERAL

3.1

ThisProcurementSpecificationcoverscorrosion一resistantchemicaIcoatingonferrousmetaIpartspro-ducedbyimmersioninawater一basesIurrycontainingzinc,aIuminumandchromatefIakesfoIIowedbystovingat~300。C.

3.2

Purposeofcoating

Majorpurposeofcoatingcoveredhereinistoprovidehighcorrosionresistance.

3.3

Fieldofapplication

Zinc,aIuminumandchromatebasechemicaIcoatingcanbeappIied,onscrews,Ioosecomponents,smaIIandmediumdimensioncomponentsofferrouspartsthancanbemasstreated,byimmersionorinsomecases,onrack一mounted:AgtypeII(see§3.5)isaIsosuitabIeforrack一mountedmediumtoIargeparts.

Formass一treatedparts,itisnecessarytocarryoutacentrifugationafterimmersion.

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Change

wheretherearenofinishtreatments(e.g.Iubricants,seaIantorcoIoringappIication),toheIpthehexa-vaIentchromiumexcesseIiminationpresentinsurfaceandofthepowderresiduesintothethreads,itisnecessarythatthecooIingafteranneaIingbefoIIowedbywaterwashing.ThistypeofcoatingdoesnotresuItinhydrogenbrittIingandcanthereforebeusedtoprotectspringsandotherveryhardparts.

AsaruIe,saidcoatingshouIdnotbeusedinfoIIowingcases:

一ItemsintendedforassembIywithstainIesssteeI,copperbaseaIIoysorothermetaIswhichcouIdIeadtogaIvaniccorrosion.

一ComponentsconsistingofmateriaIswhosepropertiesdeteriorateattemperaturesof~300。C.

3.4

Flexibilityandresistancetoimpact

CoatingshaIIstandtonormaIextensionsandcompressionsforeseenforsprings,asweIIastonormaIfIexurestress,towhich,duringassembIy,aresubjectedtheeIasticwashersandfIatsprings,withoutshowfIakingsorIossofadhesionfrombasemetaI.

ItaIsomuststandtonormaIhandIingandstorageconditionswithoutshowfIaking,detachmentfrombasemetaIorotherimportantdamages.

3.5

Appearance

Coatingisauniformsemi一mattemetaIIicgrey.

AbIackpainttopcoatmaybespecifiedthatisobtainedbypaintingwhichaffectscoatingthickness(ingeneraI,thicknesswiIIexceedatotaIof15μm),andisthuscriticaIforthreadedparts.

3.6

Classification,designation,drawingcalloutandapplication

Type

Designation

Drawing

callout(■)

Application

Current(●)

Former

I

RIV/DAC5

RIV/DAC

RIV/DAC5P.S.9.57511

SmaIIandmediumsizepartsandfas-teners

II

RIV/DAC8

一一

RIV/DAC8P.S.9.57511

Rack一mountedtreatedmediumtoIargepartsoritemsforwhichhighcorrosionresistanceisrequired

III

(▲)

RIV/DAC5PL

一一

RIV/DAC5PLP.S.9.57511

ThreadedeIementsorotherpartswhichrequirereducedfrictioncoeffi-cientanddispersionvaIues,and/orahigherresistancetocorrosionandabrasion.

(●)NumberfoIIowingdesignation“RIV/DAC”representsminimumcoatingthicknessinmicrometers.

(■)wherebIacktopcoatisrequired,designationshaIIbefoIIowedbytheword“BIack”.

ExampIe:RIV/DAC5BIackP.S.9.57511.

(▲)TheRIV/DAC5PLcoatingiscomposedof2overIappingIayers:thefirstcorrespondstotheRIV/DAC

5treatment,thesecond,withathicknessbetween1.5and3μm,containsaIubricatingsubstance(e.g.

PFTE)abIetomodifythefrictioncoefficientofthedeposit.

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3.7

Dataprocessingcode(AsperStd.50022)

一RIV/DAC5:753

一RIV/DAC8:243

一RIV/DAC5PL:244

3.8

Dimensionsandtolerancesforcoatedpart

UnIessotherwisespecified,dimensionsandtoIerancesindicatedonpartdrawingincIudecoating,withexceptionofthreadsforwhichappIieswhatspecifiedinreIevantP.s.

4

COATINGQUALIFICATIONREQUIREMENTS

subjectcomponenttothechecksandtestsspecifiedintheparagraphsbeIowandcompareresuItswithrequirementsonthevaIues/Iimitsspecifiedondesignand/ortheattached“specificationDatasheet”reIativetothespecifictype.

4.1

Testenvironment(unIessotherwisespecified)Temperature:23±5。C

Atmosphericpressure:860to1060mbar

ReIativehumidity:45to70%

4.2

Materialandcoatingprocess

Basecoating(e.g.DACROMET320and500)andfinishing(e.g.PIusL,DacroIubandDacrokote)pro-ducedbyDACRALCompany.

NOTE:Materialandcoatingprocessusedduringsupplyshallbeidenticaltothoseemployedduringqualification.

ThecoatingprocessmustbecertifiedandperiodicallycheckedbythecompanyDACRALS.A.whowillinformFIATPurchasingItalia–D.A.–IspettoratoQualità.

Changesinmaterialpropertiesand/orcoatingprocesscharacteristicsmaybeintroducedonlywiththeauthorizationofFiatAuto–E.&D.–M.E.–Laboratori.

4.3

Requirements

RequirementsindicatedbeIowappIytothesignificantsurfaceofthecomponent.

significantsurfaceisdefinedasthatwhichisessentiaItotheappearanceand/orserviceabiIityofthefinishedcomponent.

significantsurfacemaybespecifiedondrawingoragreedupononorder;wherenosignificantsurfaceisspecified,theentiresurfaceofthepartshaIIbeconsideredsignificant.

4.3.1

Visualinspection

ComponentsurfaceshaIIbefreefromdefectssuchasporosity,incIusions,etc.

CoatingappearanceshaIIcompIywithrequirementsof§

3.5

.Moreover,coatingshaIIbefuIIycataIyzed,non一greasyandtack一free,andshaIIwithstandnormaIhandIing,storageandinstaIIationoperationswithoutfIaking,spaIIingorIossofadhesion.OnscrewstherearenoevidenceofproductaccumuIationonthreads,inheadrecesses,suchtointerferewithtighteningoperations.

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Change

4.3.2

Coatingidentification

checkthatcoatingconsistsofzincandaIuminumrespectiveIybycarryingoutthetestsspecifiedbeIow.

4.3.2.1

Zincidentification

4.3.2.1.1

Testsolutionsandreagents

a)SuIfuricacidsoIutionpreparedbydiIuting8cm3ofsuIfuricacid(specificgravity1.84)in100cm3distiIIedwater.

b)cupricsuIfatesoIution,preparedbydissoIving1gcupricsuIfatein1000cm3distiIIedwater.

c)MercuricthiocyanatesoIution,preparedbydissoIving2.7gmercuricchIorideand3gammoniumthiocyanatein100cm3distiIIedwater.

4.3.2.1.2

Procedure

AppIyafewdropsofsuIfuricacidsoIutiona)tosurfaceundertestandaIIowtoreactfor1minute.

TransfersoIutionsoobtainedtoasIideandaddonedropofcupricsuIfatesoIutionb)andonedropofmercuricthiocyanatesoIutionc)inthatorder,mixingthoroughIy.

4.3.2.1.3

AvioIetcoIororprecipitateindicatesthepresenceofzinc.

TherearenointerferingeIements.

4.3.2.2

Aluminumidentification

4.3.2.2.1

Testsolutionsandreagents

a)20%soIutionofsodiumhydroxideindistiIIedwater.

b)GIaciaIaceticacid.

c)SaturatedsoIutionofmorininmethyIaIcohoI.

4.3.2.2.2

Procedure

AppIy10cm3ofsodiumhydroxidesoIutiona)tosurfaceundertest.Heatto60to70。candaIIowtoreactuntiIcoatingiscompIeteIydissoIved.

Transfer2cm3oftheresuItingsoIutiontoatesttubeandaddgIaciaIaceticacidb)onedropatatimeuntiIneutraIoracidereactionoccurs(~2cm3),mixandcooI.Thenadd2to3dropsofmorinsoIutionc).

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4.3.2.2.3

ExaminesoIutionundernaturaIdayIightor,preferabIy,uItravioIetIightagainstabIackbackground.AfIuorescentgreencoIorindicatesthepresenceofaIuminum.

NOTE:ltisadvisabletocomparecolorwiththatofacontrolsolutionpreparedasfollows:

—2cm3ofsodiumhydroxidesolutiona)

—2cm3ofglacialaceticacidb)

—2dropsofmorinsolutionc)

4.3.2.3

RIV/DAC5PLcoatingqualityidentification

PartstreatedwithRIV/DAC5PLseenwithuItravioIetIightwithawave一Iengthof365nmappeartobegreenincoIor.

4.3.3

Thickness

4.3.3.1

CoatingthicknessshaIIbemeasuredatpointsonthesignificantsurfacebymeansofthemagneticmeth-odasperStd.50757usingaMagne一GagetesterorequivaIent,providinganaccuracyofatIeast±10%.

4.3.3.2

Thicknessmeasurementcoatingpointsforfasteners

4.3.3.2.1

Hexheadscrews

Atcenterofheadsurface(excIudingsIottedscrews),orononefIatofhexagonoratcenterofpoint(ex-cIudingconeorgimIetpoints).

4.3.3.2.2

Socket–headorcross–recessscrews

Onsurfaceofheadbetweenedgeandsocketorrecess,oratcenterofpoint(excIudingconeorgimIetpoints).

4.3.3.2.3

Nuts

OnonefIatofhexagonoronabearingsurface.

4.3.3.3

ThicknessrequirementsareasfoIIows:

一RIV/DAC5≥5μm

一RIV/DAC8≥8μm

一RIV/DAC5PL≥6.5μm

4.3.4

Adhesion

CoatingadhesiontobasemetaIshaIIbeassessedusingthefoIIowingmethods:

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4.3.4.1

Adhesivetapemethod

4.3.4.1.1

seIectNo.3specimensforeachtypeofparttobetested.

4.3.4.1.2

ThefIattest,non一threadedsurfaceofatIeast1cm2shaIIbeassumedastestsurfaceforthepart.4.3.4.1.3

Degreasethesurfaceusingheptane.

4.3.4.1.4

AppIyastripofeIasticvinyIpIasticadhesivetape(P.s.9.55367)onthesurfaceatambienttemperaturebyIightIyanduniformIypressingwiththehandandavoidingairbubbIeformation.

4.3.4.1.5

ManuaIIyremovethetapebypuIIingitquickIyupwardsandperpendicuIarIytothetestsurface.

4.3.4.1.6

TheworstresuItamongthe3testsperformedforeachpartshaIIbeconsidered.

AdhesionofcoatingtobasemetaIshaIIbegreaterthancoatingcohesion.

4.3.4.1.7

smaIIcoatingtraces(<3mm2)coveringIessthan20%ofthetestsurfaceinaIIareaIIowedonthetape.Nocoatingfragments>3to4mm2insizeandnocoatingseparationfrombasemetaIareaIIowed.

4.3.5

Corrosionresistance

4.3.5.1

AtIeast24hoursafterstovingcoating,seIectanumberofpartssuchthattotaIsignificantsurfaceareaisatIeast2dm2.

4.3.5.2

subjectpartstosaItspraycorrosiontestasperstd.50180,methodA1.ExposureperiodshaIIbeasspecifiedbeIowforeachcoatingtype.

一RIV/DAC5=300h

一RIV/DAC8=800h

一RIV/DAC5PL=500h

4.3.5.3

ExaminecomponentsurfacesbytheunaidedeyeatnormaIreadingdistance.Checkthatthenumberofferrouscorrosionspots(ifany)doesnotexceed1dm2.

4.3.6

Stovingcheck(OnlyforRIV/DAC5andRIV/DAC8types)

4.3.6.1

Rubcoatedsurfaceofitemundertestfor~10secondswithacottonswabsoakedin28to30%soIutionofammonia(specificgravity≤0.859),exertingaforceof15to20N.

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4.3.6.2

coatingremovaIindicatesinsufficientstoving.

5

Attritioncoefficientforscrew

5.1

AttritioncoefficientofscrewshaIIbewithintherequirementsspecifiedinP.S.9.52605/01and9.52605/03forreIevantcIasses.

ForthreadedeIements,forwhichIowerattritioncoefficientorreduceddispersionforkscomparedtothestandard(0.12to0.30)arerequired,unIessotherwisespecifiedondrawing,itispossibIetousetheDa-cromet500orDacromet320foIIowedwiththeappIicationoftypePIusorDacroIubIubricant.

5.2

ForwheeIfixingboIts(asforStd.10395orspecificdrawing),whenconditioningofattritioncoefficientisrequired,itisnecessarytouseDacromet320+PIusLexcIusiveIy.

5.3

LubricatedpartsshaIIbecIeananddrytotouch.

LubricantappIicationshaIInotmodifythecorrosionresistancerequirementspecifiedin§

4.3.5

.checkofrightappIicationofIubricantshaIIbecarriedoutbythemeasurementofattritioncoefficientaccordingtoExperimentationStandard7.G0114.

OthercheckmethodshaIIbeagreeduponandapprovedbyFiatAutoDepts(E.&D.–Prototypes,Testing&Services).

5.4

UseofIubricantotherthanthoseindicatedshaIIbeauthorizedbyquaIifiedFiatDepartments(E.&D.–Prototypes,Testing&ServiceseM.E.Laboratori)andspecifiedondrawing.

6

REQUIREMENTSFORSUPPLYINSPECTION

(tobecarriedoutbyPlantQualityAcceptanceDepts)

6.1

SuppIyinspectionshaIIbecarriedoutaccordingtoP.S.9.01102/01(RestrictedDistribution)

7

SUPPLIERREQUIREMENTS

7.1

TheSuppIier(s)shaIIcompIywiththegeneraIrequirementscontainedinP.S.9.01102“QUALITYOFSUPPLIES”.

7.2

ProductQualificationSupplies

TheSuppIier(s)shaIIsubmittheamountofproductspecifiedinthepurchaseorderandattachtheQuaIi-tyandconformitycertificate(seeP.S.9.01103);aIIcharacteristicsspecifiedontheattachedSpecifica-tionsDataSheetappIicabIetothespecifictypeshaIIbechecked.

“Non一conforming”suppIiesarenotpermissibIe.

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