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PEYRETTI CLAUDIO MARCHIARO GIANCARLO

CMD11

CodeCh.

G

Edition

CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

Manager

Supervisor

C.R.F. - Group Materials Labs Surface Treatment C.R.F. - Group Materials Labs Surface Treatment

Manager department Supervisor department

SPECIFICATIONS

9.57405

Fiat Group Automobiles

NORMAZIONE

ELECTROLYTIC ZINC COATING FOR FERROUS MATERIAL PARTS (Cast Iron, Carbon Steel and Alloys)

Page:

1/22

Date:

01/20/2010

PURPOSE OF THE STANDARD To define the features for electrolytic zinc coatings applied to cast iron, carbon steel or alloys with the main purpose of protecting them from corrosion. To define the tests to be carried out to verify such features. To classify coating types, to indicate choice criteria and to specify indications on drawings.

IMPORTANT

To comply with the provisions of European Community Directive 2000/53/EC and amendments dated June 27 2002, coatings with passivation containing hexavalent chromium salts mentioned in these Specifications MUST NOT BE USED after July 1 2006.

Change

Date

Description

= 07/03/00

= 10/13/00

= 07/17/02

= 01/30/03

A 10/31/03

B

C 09/07/04

12/17/03

D 12/15/05

E 01/15/07

F 08/08/08

G 01/20/10

Edition 8 - Updated to EC Directive 39/1999 and completely revised.

Edition 9 - Made changes to § 3.1 and to tables 1 and 6.

Edition 10 - Added the word "PROVISIONAL" on all pages awaiting document review.

Edition 11 - Updated to Directive 2000/53/EC and subsequent modification of June 27 2002.

Changed § 3.1, Table 1, note in Table 6 and "IMPORTANT" note on page 1. Annex 1: changed "Corrosion resistance" test limit.

§ 5.3.7.5.1: Changed table 6.

Changed §§ 3.1 and 1.2.2. Added notes ¥, ¦ and changed () in Table 1.

§ 5.3.4.5: Changed reference standards. § 5.3.8 Table 8: changed minimum

treatment time of DEIDR B.

"IMPORTANT" note on page 1: changed. Table 1: Changed "Orientations for use" Type VII S and note ¥. Table 3: changed. Added § 3.4 and changed title of § 5.3.7. Changed § 4.2.3. Annex 2: added commercial denomination under Type VII S and changed note ¥

Added Type Fe/Zn 7 VII ST. Table 1, 3 and 6: changed. Deleted "Coating nature identification". Annex 1: updated.

Added Type Fe/Zn 12 VII ST. Changed § 6.

Added Types VIII, VIII LUB and VIII F. Tables 1 and 6: changed. Annex 2:

changed; added § 3.

(RA/DA)

(DA)

(DA)

(DA)

(FD)

(FD)

(FD)

(FD)

(FD)

(FD)

(DC)

ANY PRINTED COPY IS TO BE DEEMED AS UNCHECKED; THEREFORE THE UPDATED COPY MUST BE CHECKED IN THE APPROPRIATE WEB SITE

DEEMED AS UNCHECKED; THEREFORE THE UPDATED COPY MUST BE CHECKED IN THE APPROPRIATE WEB SITE PUBLISHED

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CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

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§ "A": EQUIPMENT REQUIRED FOR THE TEST

 

The test equipment is specified in the Standards listed in § "B".

|

§ "B": DOCUMENTS REFERRED TO IN THE TEXT

 

|50022

|

|

|

|

|

|

|

|

|

|

|

|

|

|

Semi-finished product element code number. TMD Corrosion tests. TMD Inorganic and organic coating adhesion test through cross hatching. TMD Chemical or electrolytic cadmium, tin and zinc coating thickness determination - Gravimetric method. TMD Chemical or electrolytic coating thickness measurement - Coulombmetric method. TMD Metallic coating thickness measurements using magnetic method. TMD Metal coat and protective oxidation coating thickness measurement using micrographic method. TMD Electrolytic and chemical coating adhesion test through cross hatching. TMD Threaded fastener friction coefficient determination. PGE Metal parts - Test for verifying absence of hexavalent chromium (Cr VI) in coatings. PMD Fiat Group Automobiles S.p.A. Quality of Supplies. CFO Product quality and conformity certificate (CQC). CFO Quality of supplies - Forbidden/limited substances or substances to be monitored (Annex CK). CFO Threaded fasteners for normal and special uses. CFO Standard test Method for Measurement of coating Thickness by X-Ray Spectrometry.

|50180

|50461

|50755

|50756

|50757

|50758

|50765

|7.G0114

|7.M5000

|9.01102

|9.01103

|9.01108

| 9.52605/01 |

|ISO 3497

|UNI 5541

|

ISO metric triangular profile threading with pitch equal to or higher than 0.35 mm - Tolerance system for mobile couplings.

|

§ "C": LIST OF ANNEXES

 

|1

|

|2

|

Product Specifications Date Sheet Threaded fastener lubrication requirements

 

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CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IFWRITTEN THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

Fiat Group Automobiles

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1

INTRODUCTION

1.1

These Specifications describe types, properties and tests of electrolytic zinc coating applied to components made of cast iron, carbon steel and alloys with the main purpose of protecting them from corrosion. These Specifications also describe eutectic zinc alloy and aluminium coatings (Galfan and Bezinal types) for spring wire applied by hot immersion.

NOTE: the following types of coating may be used alternatively to those mentioned above following agreement by the competent Design and Material Engineering Departments providing the visual examination, thickness, corrosion resistance, coating adhesion and friction coefficient properties are respected:

a) Mechanical zinc coating;

b) Electrolytic zinc alloy coatings with 2% alloying element content, e.g. Zinc-Iron.

1.2

Range of application

1.2.1

These Specifications describe all parts with tensile strength < 1500 N/mm 2 , except for:

a) pre-coated steel sheets and strips;

b) helical springs (traction stress with close-wound springs);

c) connectors for pipes.

The requirements shown in the applicable Standards/Tables apply to aforesaid parts.

1.2.2

As guidelines for design, electrolytic zinc coating must not be used in the following cases:

I) Parts which reach continuous working temperature > 250°C; II) Parts which are in mutual contact in operation and for which seizing or scratching are important operating factors or for which corrosion products may interfere with normal operation; III) Parts exposed to weather which are assembled in contact with stainless steel, magnesium alloys, copper alloys or materials capable of forming a corrosion cell with zinc; IV) Steel components with R > 1200 N/mm 2 for which functional class 1 is required (see § 2).

2

FUNCTIONAL CLASSIFICATION Zinc coated parts may be divided into the following functional classes according to Std. 9.01102:

Functional class 1 - Parts the failure or early deterioration of which concerns safety. Functional class 2 - Parts expensive to replace, the failure or early deterioration of which concerns functionality.

Functional class 3 - All other parts.

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CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

 

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3

COATING CLASSIFICATION, INDICATION ON DRAWINGS, CHOICE CRITERIA AND CODE NUMBER

3.1

NOTE FOR HEXAVALENT CHROMIUM In compliance with the provisions of the European Community Directive on end-of-life vehicles (2000/53/EC), already implemented by Specifications 9.01108 Annex CK, hexavalent chromium compounds (CrVI) must be entirely eliminated from the vehicles by July 1 2007 for environment- protection reasons.

For this purpose, all coatings containing hexavalent chromium will be eliminated from these Specifications and may no longer be supplied to Fiat Group Automobiles as from July 1 2006. During the transition period, the intervention strategy adopted by Fiat Group Automobiles for the European market is the following.

For new models with first type-approval date after January 1 2004, total elimination of hexavalent chromium from all new drawings (Powertrain components included). Note: the obligation to eliminate hexavalent chromium as from January 1 2004 therefore does not apply to:

- derived vehicles (e.g. van, pick-up, SW, etc.);

 

- face-lift operations;

 

- restyling operations;

- type-approval extensions for engine versions not included in first launch for models the first type-approval of which is prior to January 1 2004.

Complete elimination of hexavalent chromium within July 1 2006 is required for newly issued drawings related to models already in production in December 2003 and for drawings of components already in production or carry-overs (including threaded fasteners and standard parts), including those intended for new models type approved after January 1 2004.

With regards to carry-over components (including threaded fasteners and standard parts), the solution containing hexavalent chromium may be supplied until end of stocks and in all cases only until July 1 2006 if a hexavalent chromium free coating is contemplated in drawing or table review. In this case, however, the Supplier must inform the Customer of the time required to comply with new requirements.

Any

exceptions

to

these

general

provisions

must

be

authorised

by

the

competent

P.&P.E.

Departments.

 
 

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THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IFWRITTEN THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

CONFIDENTIAL

Fiat Group Automobiles Pag 5 Chan ge 9.57405 TABLE 1 Designation for indication on drawing

Fiat Group Automobiles

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Fiat Group Automobiles Pag 5 Chan ge 9.57405 TABLE 1 Designation for indication on drawing £

9.57405

Fiat Group Automobiles Pag 5 Chan ge 9.57405 TABLE 1 Designation for indication on drawing £
TABLE 1 Designation for indication on drawing £ (U) () Minimum Code Supplementary local number
TABLE 1
Designation for
indication on drawing
£ (U) ()
Minimum
Code
Supplementary
local
number
treatment and
Type
Base coating
thickness
Indications for use
(as per
trim colour
µm
Std.
Old
¥ ()
New
■©
50022)
¤
Fe/Zn 25 I
-
25
754
Required only if zinc coating
must be subjected during
Fe/Zn 12 I
-
12
755
subsequent processing to a
I
-
treatment not compatible
¡
Fe/Zn 7 I
-
7
with the presence of
passivation (e.g. brazing,
phosphating).
756
Fe/Zn 5 I
-
5
757
Fe/Zn 25 II
25
758
Electrolytic zinc
coating
For use when medium-
corrosion resistance is
Fe/Zn 12 II
12
759
Clear bright
II
passivation,
ZNT/BR
¢
hexavalent
needed (e.g. for applications
in passenger compartment
and boot, or in engine
compartment under covered
parts or in zones not directly
chromium free
Fe/Zn 7 II
7
exposed to weather and not
in sight). Appearance is, in
general, shiny metallic with
possible slight iridescence.
760
Fe/Zn 5 II
5
761
Replacing eliminated
Type III.
Fe/Zn 25 IV
-
25
For use when good
corrosion resistance is
required. Indicated for
general applications inside
passenger compartment,
811
Fe/Zn 12 IV
-
12
inside engine compartment
778
Electrolytic zinc
IV
and zinc alloy
¢
coating with 
2%
Very thick iridescent
passivation,
hexavalent
chromium free
and under floor.
Type Fe/Zn 7 IV must be
preferred for threaded
fasteners when friction
Fe/Zn 7 IV
-
7
coefficient C f 0.12 ÷ 0.30 is
required.
Appearance may be as Type
776
II
when obtained from acid
zinc coating baths or
Fe/Zn 5 IV
-
5
iridescent yellow-light green
when obtained from alkaline
baths.
810
Electrolytic zinc
Very thick iridescent
passivation,
hexavalent
IV
Fe/Zn 7 IV
LUB
and zinc alloy
chromium free
LUB
-
7
782
coating with 
As Type IV, to be used in
particular for threaded
fasteners when friction
coefficient must remain
within dispersion range
¢
2%
followed by
application of
lubricant (see
Annex 2)
C
f 0.10 ÷ 0.16.
Different values must be
indicated on the drawings.
(Continued.)

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2) C f 0.10 ÷ 0.16. Different values must be indicated on the drawings. (Continued.) PUBLISHED
2) C f 0.10 ÷ 0.16. Different values must be indicated on the drawings. (Continued.) PUBLISHED

CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

 

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TABLE 1

Type

Designation for indication on drawing £ (U) ()

Base coating

Supplementary

treatment and

trim colour

Minimum

local

thickness

Indications for use

Code

number

(as per

 

Old

¤

¥ ()

µm

Std.

New

©

50022)

           

Replacing eliminated Type II S. To be used when high

 

Fe/Zn 12 IV S

Fe/Zn 12 II S

Clear bright or iridescent passivation, hexavalent chromium free, with sealing finish. Appearance is opaque metal with no or minor iridescence.

12

corrosion resistance is needed also in presence of working temperatures up to ~100°C. Indicated, for example, for applications in

783

       

IV

S

¢

 

Fe/Zn 7 IV S

Fe/Zn 7 II S

Electrolytic zinc and zinc alloy coating with

7

engine compartment and under floor where high

esthetic stability is needed, for treating brackets and supports made of printed sheet assembled by welding with shielding of coupled surfaces.

784

2%

 

IV

SB

Fe/Zn 7 IV SB

-

Very thick iridescent passivation,

hexavalent

7

To be used exclusively for threaded fasteners when friction coefficient must be kept within dispersion range

785

¢

chromium free with addition of lubricant (see Annex 2)

C f 0.10 0.16 in combination with high corrosion resistance. Different values must be indicated on drawings.

           

To be used exclusively for threaded fasteners and small parts treated in bulk (barrel plating) when black colour and limited corrosion resistance is needed (e.g.

 

VII

S

use inside passenger compartment). In the case of threaded fasteners, the friction coefficient must be within the dispersion limits of Cf 0.12 0.30. Different Cf values must be indicated on drawings.

 

Fe/Zn 7 VII S

-

Hexavalent

7

786

Electrolytic zinc and zinc alloy coating with

chromium free

passivation followed

     

2%

by sealing

     

VII

ST

Fe/Zn 7 VII ST

-

7

For use when black colour and medium-high esthetic corrosion resistance are required. Treatment suitable for use inside passenger compartment, in engine compartment and on exteriors, limited to high

812

         

Fe/Zn 12 VII ST

parts, parts in sight with

-

12

minor exposure and operating temperatures of up to 100°C.

720

 

(Continued.)

 

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CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IFWRITTEN THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

Fiat Group Automobiles

 

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TABLE 1

Type

Designation for indication on drawing £ (U) ()

Base coating

Supplementary

treatment and

trim colour

Minimum

local

thickness

Indications for use

Code

number

(as per

 

Old

¤

¥ ()

 

µm

Std.

New

©

50022)

 

Fe/Zn 5 ZC

-

 

Transparent, silicate based coating dispersed in alcoholic solution,

 

5

In replacement/alternative to types IV and IV S when high corrosion resistance is required also in presence of

operating temperatures up to 200°C. Types Fe/Zn 5 and 7 ZC are to be used preferably for threaded fasteners for which C f from

0.12

to 0.30 is required.

A03

VIII

Fe/Zn 7 ZC

-

Electrolytic zinc

 

7

A04

¢,7

coating

chromium salt and cobalt free. Appearance is silvery metallic (see

Annex 2).

 

Fe/Zn 12 ZC

-

 

12

A05

VIII

Fe/Zn 5 ZC LUB

   

Transparent, silicate based coating dispersed in alcoholic solution,

 

5

As Type VIII, to be used in particular for threaded fasteners when friction coefficient must remain within the dispersion range C f 0.10 0.16. Different C f values must be indicated on the drawing.

A06

LUB

-

chromium salt and cobalt free, followed by application of lubricant (see Annex 2).

 

¢,7

Fe/Zn 7 ZC LUB

Electrolytic zinc

 

7

A07

coating

     
     

Zinc micro phosphating

     

Fe/Zn 7 F ZC

-

treatment, followed

by application of transparent, silicate based coating dispersed in alcoholic solution, chromium salt and

cobalt free. Silvery

 

7

In replacement/alternative to types IV and IV S when high corrosion resistance is required also in presence of operating temperatures up to 200°C. Type Fe/Zn 7 is preferably used for threaded

fasteners for which C f from

A08

VIII F

       

7

Fe/Zn 12 F ZC

-

 

12

A09

grey, semi-opaque treatment, similar to zinc flake treatment. (see annex 2).

 

0.12

to 0.30 is required.

¡

Type I must not be used for coating threaded fasteners.

 

©

12 and 25 m coating thickness must not be used for threaded fasteners (see § 4).

 

¢

If a particular colour is needed, special passivation processes free from organic colouring and hexavalent chromium may be used in agreement with Supplier. In this case, the required colour must appear on drawing (e.g. Fe/Zn 7 IV Green, or Fe/Zn 7 IV Yellow, or Fe/Zn 7 ZC Black). Corrosion resistance must not be lower than that of the specified type.

£

For materials with ultimate tensile strength in the 800 1000 N/mm 2 range, the following wording must appear on drawings if dehydrogenation is required: DEIDR A (e.g. Fe/Zn 7 II DEIDR A - see § 5.3.8). For materials with ultimate tensile strength 1000 N/mm 2 this indication may be omitted because dehydrogenation is compulsory.

¤

If the old designation appears on drawing, without the thickness indication, the latter is 7 m.

¥

In order to guarantee conformity to Directive 2000/53/EC, all passivation and sealing treatments must be hexavalent chromium, lead, cadmium and mercury free.

 

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7

The silicate based top coat specified here (see Annex 2) may be applied by immersion/centrifugation, immersion/dripping or spraying. A final drying step at temperatures from 80 to 120°C for 10 min is required.

() Sealing consists in depositing an organic, mineral or organic-mineral coating after passivation, 1 3 m thick, to improve corrosion resistance and/or confer a controlled friction coefficient to the coating. This treatment must not be used on parts which must later be painted by cataphoresis, on mount and bushing armatures intended for rubber-metal attachment and elements which must ensure an electric function.

The thicknessof the coating includes passivation and sealing layers.

 

U In case of mechanical zinc coating, the symbol on drawings is changed by adding letter M after the code identifying the type of passivation (e.g. Fe/Zn 7 II M).

The coating thickness may differ from that shown in the table for particular needs. In this case, the required thickness must be shown, e.g.: Fe/Zn 10 IV. Unless otherwise specified, when evaluating resistance to corrosion of treatments with non- unified thickness, the resistance value to be considered is that of the immediately lower class.

3.2

Eliminated coatings with hexavalent chromium passivation which MUST NOT BE USED after July 1 2006

 

TABLE 2

 

Designation for

   

Minimum

 

Code

indication on drawing

Supplementary

local

number

Type

£

Base coating

treatment and

trim colour

thickness

Indications for use

(as per

 

Old

()

m

Std.

50022)

New

¤

() ©

 

Fe/Zn 12 II S

   

White passivation,

12

To be used when high corrosion resistance is needed for temperatures up to ~100°C.

Appearance is opaque white with minor iridescence.

995

 

hexavalent

   

II S

Fe/Zn 7 II S

-

Electrolytic zinc

chromium free, with sealant

7

996

 

Fe/Zn 25 III

 

coating

 

25

 

762

Fe/Zn 12 III

Yellow chromic

12

Not for use on new designs.

763

III

ZNT

passivation (yellow

Appearance is yellow

   

iridescent, in general, with blue, red or green hues.

 
 

Fe/Zn 7 III

 

zinc coating)

7

764

Fe/Zn 5 III

5

 

765

 

(Continued.)

 

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CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IFWRITTEN THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

Fiat Group Automobiles

 

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9.57405

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Designation for

           

indication on drawing

£

Supplementary

treatment and

Minimum

local

Code

number

Type

   

Base coating

thickness

Indications for use

(as per

Std.

New

Old ¤

trim colour

()

 

m

   

() ©

50022)

 

Fe/Zn 12 III S

   

Yellow chromic

 

12

Not for use on new designs. Appearance is yellow, in

851

III

S

 

-

passivation and

   
 

Fe/Zn 7 III S

sealing

 

7

general, with slight iridescence.

852

 

Fe/Zn 25 V ¢

 

Electrolytic zinc

   

25

 

766

Fe/Zn 12 V ¢

coating

Olive green chromic passivation (olive green zinc coating)

 

12

Not for use on new designs. Appearance may sometimes have shades from brown to

767

V

 

ZNT/VOL

   

Fe/Zn 7 V ¢

 

7

bronze.

768

Fe/Zn 5 V ¢

   

5

769

 

Fe/Zn 25 VI

       

25

 

770

   

For use when black colour

 

VI

Fe/Zn 12 VI

ZNT/BLACK

Black colour

passivation (black

 

12

and medium corrosion resistance is needed (use in

771

     
 

Fe/Zn 7 VI

 

zinc coating)

 

7

inside passenger compartment).

772

Fe/Zn 5 VI

Electrolytic zinc

 

773

coating

 

5

 
 

Fe/Zn 12 VI S

 

Black colour

 

12

To be used when black

991

VI

S

 

passivation and

   
 

-

   
 

Fe/Zn 7 VI S

sealing

 

7

colour and high corrosion resistance is needed for

temperatures up to ~100°C

992

3.3

 

Coatings ELIMINATED and REPLACED after July 1 2006

 

The replacement chart shown in Table 3 applies unless otherwise specified on drawing or agreed by Fiat Group Automobiles and Supplier.

 

TABLE 3

 

ELIMINATED

 

REPLACED

 
   

TYPE IV S

(for general use)

 

TYPE II S

TYPE IV SB

(for threaded fasteners)

 

TYPE III

 

TYPE IV

   

 

TYPE IV S

(for general use)

 

TYPE III S

TYPE IV SB

(for threaded fasteners)

 
 

TYPE IV

(for corrosion resistance)

 

TYPE V

TYPE VII ST

(for identifying treated chassis components)

 

TYPE IV green or yellow

(for identification)

 
 

(Continued.)

 

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CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

9.57405 Pag 10 Change ELIMINATED REPLACED  TYPE VII S (for threaded fasteners and small

9.57405

9.57405 Pag 10 Change ELIMINATED REPLACED  TYPE VII S (for threaded fasteners and small parts)

Pag

10

Change

9.57405 Pag 10 Change ELIMINATED REPLACED  TYPE VII S (for threaded fasteners and small parts)
9.57405 Pag 10 Change ELIMINATED REPLACED  TYPE VII S (for threaded fasteners and small parts)
ELIMINATED REPLACED  TYPE VII S (for threaded fasteners and small parts) TYPE VI 
ELIMINATED
REPLACED
TYPE VII S
(for threaded fasteners and small parts)
TYPE VI
TYPE VII ST
(for treated chassis elements)
TYPE VI S
Fe/ZnNi VII S - Specifications 9.57409
3.4
Unless otherwise agreed, no components treated with hexavalent chromium coatings may be
delivered to Fiat Group Automobiles after July 1 2006. Consequently, from the same day, codes
related to coatings containing hexavalent chromium listed in Table 2 and shown on technical reference
documents (drawings, tables, specifications, etc.) must be considered to all intents and purposes
equivalent to the corresponding codes of hexavalent chromium free coatings shown in Table 1.
In presence of documentation showing requirements for coatings containing hexavalent chromium
eliminated by these Specifications, the Supplier must consequently make and supply the respective
components with corresponding hexavalent chromium free coatings, in accordance with the indications
in Table 3 or as specifically agreed with Fiat Group Automobiles.
4
THREADED FASTENERS
4.1
Thickness
For the purposes of corrosion resistance of threaded fasteners, thickness is one of the most significant
parameters of the electrolytic coatings. This parameter must be specified in drawings or agreed in the
order. Otherwise, the thickness must be 7 µm. The thickness of the coating is established according to
the ISO metric threading, as per UNI 5541, with the following classes of tolerance
-
g, f and e for outer threading (screws)
-
H and G for inner threading (nuts);
Unless otherwise specified, for outer threading, these tolerances refer to dimensions before coating;
for inner threading, they refer to dimensions after coating.
After coating, the upper difference must not be higher than zero (nominal dimension) for outer
threading and less than zero for inner threading.
a)
Screws - Coating thickness for screws depend on threading pitch and threading tolerance range.
Table 4 shows:
-
the theoretic maximum thickness inferred from fundamental differences in tolerance
positions g, f and e.
Thicker or thinner coatings than indicated may be specified. Thicker coatings must be agreed by
Customer and Supplier because part of the threading tolerance may be used in addition to
fundamental deviation. A few micrometers of undersizing on the average diameter in position "h" is
possible. In all cases, the screw-nut coupling must not be compromised.
"h" is possible. In all cases, the screw-nut coupling must not be compromised. PUBLISHED BY FGA
"h" is possible. In all cases, the screw-nut coupling must not be compromised. PUBLISHED BY FGA

PUBLISHED BY FGA - NORMAZIONE

CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IFWRITTEN THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

Fiat Group Automobiles Pag 11 Chan ge 9.57405 TABLE 4 - MAXIMUM THEORETICAL THICKNESS PERMITTED

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Fiat Group Automobiles Pag 11 Chan ge 9.57405 TABLE 4 - MAXIMUM THEORETICAL THICKNESS PERMITTED FOR

9.57405

Fiat Group Automobiles Pag 11 Chan ge 9.57405 TABLE 4 - MAXIMUM THEORETICAL THICKNESS PERMITTED FOR
TABLE 4 - MAXIMUM THEORETICAL THICKNESS PERMITTED FOR SCREWS ¥ Threading Threading Maximum permitted thickness
TABLE 4 - MAXIMUM THEORETICAL THICKNESS PERMITTED FOR SCREWS ¥
Threading
Threading
Maximum permitted thickness on threading
(m)
pitch
(mm)
Tolerance
Tolerance
Tolerance
Large pitch
Fine pitch
position "g"
position "f"
position "e"
0.50
M3
-
5
9
12
0.70
M4
-
5
9
14
0.80
M5
-
6
9
15
1.00
M6
M8x1
6
10
15
M10x1.15
1.25
M8
7
10
15
M12x1.25
M14x1.5
M16x1.5
1.50
M10
M18x1.5
8
11
16
M20x1.5
M22x1.5
1.75
M12
-
8
12
17
M24x2
M27x2
2.00
M14; M16
9
13
17
M30x2
M33x2
2.50
M18; M20; M22
-
10
14
20
M36x3
3.00
M24; M27
12
16
21
M39x3
3.50
M30; M33
- 13
17
22
4.00
M36; M39
- 15
19
23
¥
Unless otherwise specified on drawings or in order, screws must in all cases have a coating thickness of  7 m. The resistance value of the
immediately lower class must be considered when evaluating corrosion resistance of non-unified thickness coatings.
b) Nuts - In practice, the coating thickness of nuts do not depend on the threading tolerance position
or the threading pitch because in the current zinc coating technological processes there is
no significant addition of protective coating on the threading compared to other surfaces
(faces of the hexagon and resting surfaces).
An addition on the first threads for pitches up to 0.8 mm is tolerated providing it does not affect the
screw-nut coupling.
Table 5 shows the maximum thickness for nuts.

PUBLISHED BY FGA - NORMAZIONE

it does not affect the screw-nut coupling. Table 5 shows the maximum thickness for nuts. PUBLISHED
it does not affect the screw-nut coupling. Table 5 shows the maximum thickness for nuts. PUBLISHED

CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

9.57405 Pag 12 Change TABLE 5 - MAXIMUM THEORETICAL THICKNESS PERMITTED FOR NUTS ¦ Threading

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9.57405 Pag 12 Change TABLE 5 - MAXIMUM THEORETICAL THICKNESS PERMITTED FOR NUTS ¦ Threading Maximum

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9.57405 Pag 12 Change TABLE 5 - MAXIMUM THEORETICAL THICKNESS PERMITTED FOR NUTS ¦ Threading Maximum
9.57405 Pag 12 Change TABLE 5 - MAXIMUM THEORETICAL THICKNESS PERMITTED FOR NUTS ¦ Threading Maximum
TABLE 5 - MAXIMUM THEORETICAL THICKNESS PERMITTED FOR NUTS ¦ Threading Maximum permitted thickness on
TABLE 5 - MAXIMUM THEORETICAL THICKNESS PERMITTED FOR NUTS ¦
Threading
Maximum permitted thickness on
threading (m)
Threading
pitch
(mm)
Tolerance
Large pitch
Fine pitch
Tolerance position
"H"
position "G"
0.5
M3
-
0.7
M4
-
0.8
M5
-
7
12
1.00
M6; M7
M6x1
M10x1.25
1.25
M8
M12x1.25
M14x1.5
M16x1.5
1.50
M10
M18x1.5
7
12
M20 x1.5
M22x1.5
1.75
M12
-
M24x2
M27x2
2.00
M14; M16
M30x2
M33x2
7
12
2.50
M18; M20; M22
-
M36x3
3.00
M24; M27
M39x3
3.50
M30; M33
-
4.00
M36; M39
-
¦
Unless otherwise specified on drawings or in order, nuts must in all cases have a coating thickness of ≥ 7 µm. The resistance value of the
immediately lower class must be considered when evaluating corrosion resistance of non-unified thickness coatings.
4.2
Friction coefficient
4.2.1
Unless otherwise specified on drawings, the friction coefficients of threaded fasteners must be within
the dispersion limits Cf = 0.12  0.30 specified in Specifications 9.52605/01.
If friction coefficients comprised in the dispersion range 0.10 - 0.16 are required, special friction
conditioners consisting of suitable lubricants (LUB type) or sealants (S type) must be applied after zinc
coating (see Annex 2).
Different values must be shown on drawings
E.g.: Fe/Zn 7 IV S (Cf = 0.12 ÷- 0.18)
2). Different values must be shown on drawings E.g.: Fe/Zn 7 IV S (Cf = 0.12
2). Different values must be shown on drawings E.g.: Fe/Zn 7 IV S (Cf = 0.12

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4.2.2

The correct application of friction conditioners must be tested by determining the friction coefficient as

illustrated in Test Standard 7.G0114.

 

Other testing methods must be agreed beforehand and approved by the competent Fiat Group

Automobiles Departments (E&D/ACV).

 

4.2.3

Correspondence between designations adopted by Fiat Group Automobiles and commercial

denominations of qualified friction conditioners are shown in Annex 2.

 

The use of products other than those shown is allowed, providing they respect the requirements of

these Specificationsand any indications on drawings as well as restrictions concerning the use of

forbidden and/or to be monitored products as defined in Annex CK of Specifications 9.01102.

The technical data sheet of the product used must be made available to Fiat Group Automobiles upon

demand along with the respective application cycle parameters.

 

4.3

Corrosion resistance

 

a)

Screws

The corrosion resistance of electrolytically coated screws according to the thickness of the applied coating must be as specified in § 5.3.6. Resistance must be nearly uniform on the entire surface (head and shank).

b)

Nuts Corrosion resistance of electrolytically coated nuts must be determined exclusively on screw-nut couplings in order to protect the inner threading by simulating operating conditions because, as mentioned in § 4.1 b, there is not significant addition of coating.

This resistance, according to thickness, must be as specified in § 5.3.6.

5

SPECIFICATIONS FOR PRODUCT QUALIFICATION

 

5.1

Subject component to the checks and tests specified in the points below. Check that test results comply with values/limits on the design and/or annexed "Product Specifications Data Sheet" for the type concerned.

5.2

Test environment (unless otherwise specified)

 

temperature:

23 ± 5°C

atmospheric pressure:

860 1060 mbar

relative humidity:

45 70%

 

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CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

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5.3

Properties

The requirements shown below are essential for the significant surface. Significant surface is the part which is essential for appearance or use of treated component. This surface may be shown in drawings or agreed beforehand in orders. Otherwise, the significant surface is all the part of the surface of the component which may be touched by a 13 mm diameter ball. See § 4.3 and § 5.3.4.8 for corrosion resistance and coating thickness of threaded fasteners. Unless otherwise specified by the Customer, holes, cavities,inner threading, sharp edges and corners are not significant surfaces. Non-significant surfaces may be masked or appropriately protected (e.g. with tape or appropriate paint) before salt spray corrosion test.

5.3.1

Visual inspection

Parts must not show visible faults, such as bubbles, pitting, excessive roughness,cracks or uncoated areas, on the significant surface. The passive layer must not be dusty. It must entirely cover the zinc coated surfaces of the parts and must be uniform and free from other faults which could alter appearance or reduce the protective power. The appearance of the passive layer according to the solution used must comply with the requirements in § 3. Unless otherwise specified by the Customer, the final coating must be shiny. Direct agreements must be made between Customer and Supplier if good reproduction of the passive layer colour is needed. The colour must be agreed by means of a deposited reference specimen. Lubricated parts must be clean and dry to the touch.

5.3.2

Dimensional limits of the parts

Resulting dimensions on part after zinc coating must be within the tolerances specified in drawings.

5.3.3

Absence of hexavalent chromium in coating

Tested in accordance with Std. 7.M5000.

5.3.4

Thickness

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5.3.4.1

Minimum local thickness The minimum local thickness, measured with the methods below, allowing an accuracy of at least ± 10%, must beas specified in § 3 for the various types of coatings, on all parts of the significant surface (see § 5.3).

5.3.4.2

Magnetic method In accordance with Std. 50757. Method to be adopted in current inspections.

5.3.4.3

Coulombmetric method In accordance with Std. 50756. Method to be preferably used for thin coatings.

5.3.4.4

Microscopic method In accordance with Std. 50758. Method to be used mainly in case of complaints and when the methods listed above cannot be employed.

5.3.4.5

X-ray fluorescent method According to ISO 3497. General method to be preferably used for small sized parts.

5.3.4.6

Small item coating thickness The X-ray fluorescent method must preferably be used for surface significant area 1 cm 2 (see § 5.3.4.5). Alternatively, the minimum local thickness must be the minimum value of the average thickness determined using gravimetric method according to Std. 50755.

5.3.4.7

Threaded fastener coating thickness The thickness of coating for threaded fasteners measured according to § 5.3.4.1 must be as specified in § 4. Requirements related to the significant surface for measuring the thickness of coatings for threaded fasteners are shown in § 5.3.4.8.

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9.57405 Pag 16 Change Measurement point Maximum thickness (µm) Zones for determining coating thickness Given

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9.57405 Pag 16 Change Measurement point Maximum thickness (µm) Zones for determining coating thickness Given its
9.57405 Pag 16 Change Measurement point Maximum thickness (µm) Zones for determining coating thickness Given its

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9.57405 Pag 16 Change Measurement point Maximum thickness (µm) Zones for determining coating thickness Given its
9.57405 Pag 16 Change Measurement point Maximum thickness (µm) Zones for determining coating thickness Given its
9.57405 Pag 16 Change Measurement point Maximum thickness (µm) Zones for determining coating thickness Given its

Measurement point

Maximum thickness (µm)

Zones for determining coating thickness Given its variability, the thickness of electrolytic coating on screws and nuts is measured in a significant point for the purpose of evaluating corrosion protection. In the case of screws, this point is approximately in the middle of the surface of the head or in the middle of the end (see Figures 1 and 2). For socket head and cross head screws, the measuring point is on the flat surface of the head between the edge and the socket, between the edge and the cross or on a face of the hexagon (see Figures 3, 4 and 5). Surfaces of sockets and crosses are excluded. In the case of nuts, the thickness is measured on a side face of the hexagon or on a resting surface (see Figure 6).

Measurement point
Measurement point

Maximum thickness limits

The maximum thickness values to be respected cannot be defined because of many factors, such as shape and size of components, type of coating process used for the treatment and the thickness determination method used. By way of example, the following values may be considered for dimensioning component design and defining equipment machining tolerances before surface treatment:

Minimum thickness (µm)

One of the methods shown below must be used unless otherwise agreed between Customer and Supplier and according to the features of the part to be tested. (The heat shock only must be used for threaded fasteners).

of the part to be tested . (The heat shock only must be used for threaded

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5.3.4.8

5.3.4.9

5.3.4.8 5.3.4.9 5.3.5 Adhesion 5.3.5.1

5.3.5

Adhesion

5.3.5.1

5

7

12

5+ 3

7+ 5

12+ 10

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Fiat Group Automobiles

 

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5.3.5.2

There must be no signs of separation of the coating from the metal base at the end of the test.

5.3.5.3

Cross hatching method

In accordance with Std. 50461.

5.3.5.4

Bending method (suitable for use for parts made from metal sheet or strips)

 

5.3.5.4.1

Bend a flat specimen obtained from the test component either manually or using pincers to form an

acute angle first on one side and then on the other to breakage.

 

5.3.5.4.2

Check that the coating does not flake in the breakage area and that it is not easily removed with a blade.

5.3.5.5

Heat shock method In accordance with Std. 50765.

5.3.6

Corrosion resistance

5.3.6.1

The salt mist test must be carried out according to Std. 50180 method A1 at least 24 h after the end of the passivation or sealing operation.

5.3.6.2

Before exposure, parts must be cleaned and degreased at ambient temperature using non-chlorinated organic solvents (e.g. acetone, xylene, petroleum ether). Use of alkaline detergents or electrolytic degreasing is not allowed.

5.3.6.3

During process qualification, the number of exposed parts must be such that the total of significant surfaces is 1 dm 2 . Different types of coatings must fulfil the requirements specified in Table 6.

5.3.7

Corrosion resistance after heat shock for Types II S, III S and VI S (eliminated) and Types IV S,

IV SB and VII ST

5.3.7.1

Expose test parts in ventilated thermostatic cell for 1 h ± 5 min at a temperature of 120 ± 5°C and then subject them to salt mist corrosion test according to Std. 50180 method A1 for the time specified in Table 6. The salt mist test must start after 1 h ± 5 min and within 24 h from the end of exposure in thermostatic cell.

5.3.7.2

The corrosion resistance limits shown in Table 6 must be respected for the various coating types.

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9.57405 Pag 18 Change TABLE 6 - CORROSION RESISTANCE Minimum exposure time (h) to salt

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9.57405 Pag 18 Change TABLE 6 - CORROSION RESISTANCE Minimum exposure time (h) to salt mist

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9.57405 Pag 18 Change TABLE 6 - CORROSION RESISTANCE Minimum exposure time (h) to salt mist
9.57405 Pag 18 Change TABLE 6 - CORROSION RESISTANCE Minimum exposure time (h) to salt mist
TABLE 6 - CORROSION RESISTANCE Minimum exposure time (h) to salt mist during which no
TABLE 6 - CORROSION RESISTANCE
Minimum exposure time (h) to salt mist during which no
occurrences must appear§
Type
Coating designation
White zinc corrosion products ¨
Base metal corrosion products
Fe/Zn 25 I
Fe/Zn 12 I
Fe/Zn 7 I
Fe/Zn 5 I
96
72
I
-
48
36
(Continued.)
TABLE 6 - CORROSION RESISTANCE
Minimum exposure time (h) to salt mist during which no
occurrences must appear§
Type
Coating designation
White zinc corrosion products ¨
Base metal corrosion products
Fe/Zn 25 II
Fe/Zn 12 II
384
192
II
Fe/Zn 7 II
Fe/Zn 5 II
24
96
72
II
S
()
Fe/Zn 12 II S
Fe/Zn 7 II S
600
200
400
500
III
()
Fe/Zn 25 III
Fe/Zn 12 III
Fe/Zn 7 III
Fe/Zn 5 III
216
48
96
72
III
S
Fe/Zn 12 III S
600
200
()
Fe/Zn 7 III S
400
Fe/Zn 25 IV
600
Fe/Zn 12 IV
240
IV
96
Fe/Zn 7 IV
168
Fe/Zn 5 IV
120
IV LUB
Fe/Zn 7 IV LUB
96
168
Fe/Zn 12 IV S
480
IV
S
120
Fe/Zn 7 IV S
360
IV SB
Fe/Zn 7 IV SB
120
240
Fe/Zn 25 V
750
V
Fe/Zn 12 V
288
96
()
Fe/Zn 7 V
192
Fe/Zn 5 V
144
120 240 Fe/Zn 25 V 750 V Fe/Zn 12 V 288 96 () Fe/Zn 7 V
120 240 Fe/Zn 25 V 750 V Fe/Zn 12 V 288 96 () Fe/Zn 7 V

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Fiat Group Automobiles Pag 19 Chan ge 9.57405 Fe/Zn 25 VI 192 VI Fe/Zn 12

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Fiat Group Automobiles Pag 19 Chan ge 9.57405 Fe/Zn 25 VI 192 VI Fe/Zn 12 VI

9.57405

Fiat Group Automobiles Pag 19 Chan ge 9.57405 Fe/Zn 25 VI 192 VI Fe/Zn 12 VI
Fe/Zn 25 VI 192 VI Fe/Zn 12 VI 120 24 () Fe/Zn 7 VI 72
Fe/Zn 25 VI
192
VI
Fe/Zn 12 VI
120
24
()
Fe/Zn 7 VI
72
Fe/Zn 5 VI
48
VI
S
Fe/Zn 12 VI S
600
150
()
Fe/Zn 7 VI S
400
VII
S
Fe/Zn 7 VII S
24
72
Fe/Zn 7 VII ST
240
VII ST
120
Fe/Zn 12 VII ST
480
(Continued.)
TABLE 6 - CORROSION RESISTANCE
Minimum exposure time (h) to salt mist during which no
occurrences must appear§
Type
Coating designation
White zinc corrosion products ¨
Base metal corrosion products
Fe/Zn 12 ZC
480
VIII
Fe/Zn 7 ZC
Fe/Zn 5 ZC
360
96
240
VIII LUB
Fe/Zn 7 ZC LUB
Fe/Zn 5 ZC LUB
360
96
240
600
VIII F
Fe/Zn 12 F ZC
Fe/Zn 7 F ZC
96
480
§
Unless otherwise specified, corrosion resistance must be determined by the unaided eye from
normal reading distance.
The presence of corrosion products in holes, angles or zones not constituting significant surfaces
is not grounds for rejection.
¨
At the end of exposure, the presence of white zinc corrosion products and/or esthetic alterations
to the passivation layer (black stains) for extension < 10% of the total exposure significant
surface is not grounds for rejection. For black finish (Fe/Zn 7 VII S) a slight whitening of the
coating is also allowed mainly due to the absorption of sodium chloride by the passivation layer.
In this case, the passivation layer must be maintained intact with the original colouring after
delicate rubbing of whitened surfaces and/or washing with hot water. On the contrary, the
presence of oxidation for extension higher than 10% of the significant exposed surface is
grounds for rejection.
() Eliminated code.
() Do not use as described in § 3.1.

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is grounds for rejection. () Eliminated code. () Do not use as described in § 3.1.
is grounds for rejection. () Eliminated code. () Do not use as described in § 3.1.

CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

9.57405 Pag 20 Change 5.3.7.3 Corrosion resistance for pre-zinc coated wire coatings The following requirements

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9.57405 Pag 20 Change 5.3.7.3 Corrosion resistance for pre-zinc coated wire coatings The following requirements refer

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9.57405 Pag 20 Change 5.3.7.3 Corrosion resistance for pre-zinc coated wire coatings The following requirements refer
9.57405 Pag 20 Change 5.3.7.3 Corrosion resistance for pre-zinc coated wire coatings The following requirements refer
5.3.7.3 Corrosion resistance for pre-zinc coated wire coatings The following requirements refer to steel wires
5.3.7.3
Corrosion resistance for pre-zinc coated wire coatings
The following requirements refer to steel wires protected with zinc coating (Type A) or eutectic zinc-
aluminium alloy (Zn 95 / Al 05) (Type B) obtained by hot immersion before forming. Unless otherwise
indicated in drawings, such coatings must be determined on finished product and must fulfil the
requirements shown in Table 7.
TABLE 7 - CORROSION RESISTANCE FOR PRE-ZINC COATED WIRE COATING
TYPE
Designation for
indication in drawing
Minimum exposure time (h) to salt
mist during which no occurrences
must appear in base metal
Code number
(in accordance with Std.
50022)
Fe/Zn 25 II from pre-zinc coated wire
192
803
Fe/Zn 12 II from pre-zinc coated wire
120
804
A
Fe/Zn 7 II from pre-zinc coated wire
72
805
Fe/Zn 5 II from pre-zinc coated wire
48
806
Fe/ZnAl 60 (:) from pre-zinc coated wire
B
240
807
()
Fe/ZnAl 40(▲) from pre-zinc coated wire
120
808
() Example: Bezinal ® and Galfan type coatings.
(:)
Weight of coating  60 g/m 2 , for wire diameters  1.25 mm.
(▲) Weight of coating  40 g/m 2 , for wire diameters < 1.25 mm.
5.3.8
Dehydrogenation
5.3.8.1
The parts must undergo a dehydrogenation treatment within 4 h from application of the electrolytic zinc
based coating unless otherwise specified in drawings.
Dehydrogenation must be carried out by means of heating in air recirculation oven or oil bath, followed
by cooling at ambient temperature. The time and temperature of the dehydrogenisation treatment must
respect the minimum requirements shown inTable 8.
5.3.8.2
In general, the times shown in Table 8 may be reduced by appropriately increasing temperatures on
the basis of experimental determinations.
If the heating temperatures specified in Table 8 may cause a decrease of minimum required hardness
or other fault affecting functionality of the part, dehydrogenation must be carried out at the maximum
temperature compatible with maintaining the required physical properties and in all cases  135°C and
appropriately prolonging the treatment time.
properties and in all cases  135°C and appropriately prolonging the treatment time. PUBLISHED BY FGA
properties and in all cases  135°C and appropriately prolonging the treatment time. PUBLISHED BY FGA

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Fiat Group Automobiles Pag 21 Chan ge 9.57405 TABLE 8 - DEHYDROGENATION TREATMENTS Dehydrogenation treatment

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Fiat Group Automobiles Pag 21 Chan ge 9.57405 TABLE 8 - DEHYDROGENATION TREATMENTS Dehydrogenation treatment

9.57405

Fiat Group Automobiles Pag 21 Chan ge 9.57405 TABLE 8 - DEHYDROGENATION TREATMENTS Dehydrogenation treatment
TABLE 8 - DEHYDROGENATION TREATMENTS Dehydrogenation treatment Dehydrogenation V Material tensile strength (N/mm 2 )
TABLE 8 - DEHYDROGENATION TREATMENTS
Dehydrogenation treatment
Dehydrogenation V
Material tensile strength
(N/mm 2 )
Treatment min. time
Temperature
(h)
(°C)
DEIDR A
800  < 1000
2
DEIDR B
1000
 < 1350
4
180  200
DEIDR C
1350
 < 1500
12
V
Except for the cases in note £ of Table 1, indication in drawing of the dehydrogenation type is optional.
6
SUPPLY INSPECTION REQUIREMENTS
6.1
Supply inspection shall be carried out according to Spec. 9.01102.
7
SUPPLIER REQUIREMENTS
7.1
The supplier must adhere to the general requirements contained in Specification 9.01102 "QUALITY
OF SUPPLIES".
7.2
Product Qualification Supplies
The Supplier must produce the quantity of product required on the purchase order enclosing the
specified Quality and Conformity Certificate (see Spec. 9.01103); all features described in the
enclosed "Product Specifications Data Sheet", related to the specific type, must be checked. "Non
conformities" are not allowed.
7.3
Product supplies
The supplied product shall conform to drawing requirements and to this Specification requirements.
When defining the type of manufacturing process to be used and the final test severity, the Supplier
must consider the classes of importance that FIAT has assigned to each of the features to which the
requirements refer (see § 8).
NOTA: Both during the product qualification and supply check, checks can be carried out on
components not undergoing destructive tests (indicated as NM in § 8); if the components have
undergone destructive tests (M) they cannot be used for further tests or checks, unless
otherwise specified on each individual occasion.

PUBLISHED BY FGA - NORMAZIONE

used for further tests or checks, unless otherwise specified on each individual occasion. PUBLISHED BY FGA
used for further tests or checks, unless otherwise specified on each individual occasion. PUBLISHED BY FGA

CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

9.57405 Pag 22 Change 8 - FEATURE CLASSIFICATION TABLE SPECIFICATION CLASSIFICATION Type of test Bolt

9.57405

9.57405 Pag 22 Change 8 - FEATURE CLASSIFICATION TABLE SPECIFICATION CLASSIFICATION Type of test Bolt and

Pag

22

Change

9.57405 Pag 22 Change 8 - FEATURE CLASSIFICATION TABLE SPECIFICATION CLASSIFICATION Type of test Bolt and
9.57405 Pag 22 Change 8 - FEATURE CLASSIFICATION TABLE SPECIFICATION CLASSIFICATION Type of test Bolt and
8 - FEATURE CLASSIFICATION TABLE SPECIFICATION CLASSIFICATION Type of test Bolt and nut friction coefficient
8 - FEATURE CLASSIFICATION TABLE
SPECIFICATION CLASSIFICATION
Type of test
Bolt and nut friction coefficient
Important
M
Visual inspection
Secondary
NM
Absence of hexavalent chromium in coating
Secondary
M
Thickness
Important
M (*)
Adhesion
Secondary
M
Corrosion resistance
Important
M
Corrosion resistance after heat shock
Important
M
(*)
NM if the magnetic method or the X-ray fluorescence method for small parts is used for measuring
thickness.
method or the X-ray fluorescence method for small parts is used for measuring thickness. PUBLISHED BY
method or the X-ray fluorescence method for small parts is used for measuring thickness. PUBLISHED BY

PUBLISHED BY FGA - NORMAZIONE

CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

9.57405 Fiat Group Automobiles ANNEX 1 NORMAZIONE ELECTROLYTIC ZINC COATING FOR FERROUS MATERIAL PARTS (Cast
9.57405
Fiat Group
Automobiles
ANNEX 1
NORMAZIONE
ELECTROLYTIC ZINC COATING FOR
FERROUS MATERIAL PARTS
(Cast Iron, Carbon Steel and Alloys)
Page:
1/1
Date: 01/20/2010
CLASSIFICATION
TEST CONDITIONS
LIMITS
Spec. 9.52605/01 or according
Bolt and nut friction coefficient
§ 4.2
to drawing
Visual inspection
-
§
5.3.1
§
5.3.3
Absence of hexavalent chromium in coating
§
5.3.3
Std. 7.M5000
Thickness
§ 5.3.4
§ 5.3.4
Adhesion
§ 5.3.5
§ 5.3.5
Zinc corrosion products and
esthetic alterations  10% of the
Corrosion resistance
§ 5.3.6
exposed significant surface.
Absence of ferrous corrosion
spots.
Zinc corrosion products and
esthetic alterations  10% of the
Corrosion resistance after heat shock
§ 5.3.7
exposed significant surface.
Absence of ferrous corrosion
spots.
Edition
CMD11
Ch.
G
Code

CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

CMD11

Fiat Group Automobiles

NORMAZIONE

C M D 1 1 Fiat Group Automobiles NORMAZIONE § 1 LUBRICANTS 7.G0114. ELECTROLYTIC ZINC COATING

§ 1

LUBRICANTS

7.G0114.

ELECTROLYTIC ZINC COATING FOR FERROUS MATERIAL PARTS (Cast Iron, Carbon Steel and Alloys)

FERROUS MATERIAL PARTS (Cast Iron, Carbon Steel and Alloys) 9.57405 ANNEX 2 Pa g e: 1/2
FERROUS MATERIAL PARTS (Cast Iron, Carbon Steel and Alloys) 9.57405 ANNEX 2 Pa g e: 1/2
FERROUS MATERIAL PARTS (Cast Iron, Carbon Steel and Alloys) 9.57405 ANNEX 2 Pa g e: 1/2

9.57405

ANNEX 2

Page:

1/2

Date: 01/20/2010

Alloys) 9.57405 ANNEX 2 Pa g e: 1/2 Date: 01/20/2010 Lubricants to be used for global
Alloys) 9.57405 ANNEX 2 Pa g e: 1/2 Date: 01/20/2010 Lubricants to be used for global
Alloys) 9.57405 ANNEX 2 Pa g e: 1/2 Date: 01/20/2010 Lubricants to be used for global

Lubricants to be used for global friction coefficient conditioning of metric threaded fasteners within the

condition ing of metric threaded fasteners within the range of dispersion C f = 0.10 ÷

range of dispersion Cf = 0.10 ÷ 0.16, qualified according to Specifications 9.57405 and Test Standard

TYPE COMMERCIAL DESCRIPTION SUPPLIER 1186 Torque 'N Tension Control Fluid ¡ Mac Dermid Gleitmo 605
TYPE
COMMERCIAL DESCRIPTION
SUPPLIER
1186 Torque 'N Tension Control Fluid ¡
Mac Dermid
Gleitmo 605 ©
Gleytmolybdän Schmiermittel
LUB
Gardolube L 6255 ¢
Chemetall
Granolube 6352 IT ¢
Henkel
Merwin 65 Oil £
Rods Oil
Reference dilution:
¡
3:7 mixture in water
©
mixtures from 1:5 to 1:6 in water
¢
1:3 mixture in water
£
1:2 mixture in water.
§
2
LUBRICANT SEALING SYSTEMS
Lubricant sealing systems to be used for global friction coefficient conditioning of metric threaded
fasteners within the range of dispersion Cf = 0.10 - 0.16, qualified according to Specifications 9.57405
and Test Standard 7.G0114.
TYPE
COMMERCIAL DESCRIPTION
SUPPLIER
Finigard system
Coventya
II S ¤
Zink Protector system
Glomax
Finigard system
Coventya
III S ¥
Zink Protector system
Glomax
FOM Finigard system
Coventya
IV SB
Zink Protector system
Glomax
VI S ¥
Zinthium 302
Coventya
FOM Finigard system
Coventya
VII S
Zink Protector system
Glomax
¤
Eliminated code.
¥
Eliminated type not to be used after July 1 2006.
Protector system Glomax ¤ Eliminated code. ¥ Eliminated type not to be used after July 1
Protector system Glomax ¤ Eliminated code. ¥ Eliminated type not to be used after July 1
Protector system Glomax ¤ Eliminated code. ¥ Eliminated type not to be used after July 1

Code

G

Ch.

Protector system Glomax ¤ Eliminated code. ¥ Eliminated type not to be used after July 1

Edition

CONFIDENTIAL THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THE THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY FGA S.P.A. IN CASE OF DISPUTE THE ONLY VALID REFERENCE IS THE ITALIAN EDITION. IF THE ITALIAN EDITION IS NOT AVAILABLE OR NOT UPDATED, THE ENGLISH EDITION IS THE VALID REFERENCE.

CMD11

Fiat Group Automobiles

NORMAZIONE

C M D 1 1 Fiat Group Automobiles NORMAZIONE § 3 ELECTROLYTIC ZINC COATING FOR FERROUS
C M D 1 1 Fiat Group Automobiles NORMAZIONE § 3 ELECTROLYTIC ZINC COATING FOR FERROUS

§ 3

ELECTROLYTIC ZINC COATING FOR FERROUS MATERIAL PARTS (Cast Iron, Carbon Steel and Alloys)

FERROUS MATERIAL PARTS (Cast Iron, Carbon Steel and Alloys) 9.57405 ANNEX 2 Pa g e: 2/2
FERROUS MATERIAL PARTS (Cast Iron, Carbon Steel and Alloys) 9.57405 ANNEX 2 Pa g e: 2/2
FERROUS MATERIAL PARTS (Cast Iron, Carbon Steel and Alloys) 9.57405 ANNEX 2 Pa g e: 2/2

9.57405

ANNEX 2

Page:

2/2

Date: 01/20/2010

Alloys) 9.57405 ANNEX 2 Pa g e: 2/2 Date: 01/20/2010 SILICATE TOP COAT SYSTEMS BASE COMMERCIAL
Alloys) 9.57405 ANNEX 2 Pa g e: 2/2 Date: 01/20/2010 SILICATE TOP COAT SYSTEMS BASE COMMERCIAL
Alloys) 9.57405 ANNEX 2 Pa g e: 2/2 Date: 01/20/2010 SILICATE TOP COAT SYSTEMS BASE COMMERCIAL

SILICATE TOP COAT SYSTEMS BASE

g e: 2/2 Date: 01/20/2010 SILICATE TOP COAT SYSTEMS BASE COMMERCIAL DESCRIPTION ZEC-Coat 888 T M

COMMERCIAL DESCRIPTION

ZEC-Coat 888 TM

Systems to be used when VIII, VIII LUB and VIII F types are required, qualified according to Spec. 9.57405 and Test Standard 7.G0114.

according to Spec. 9.57405 and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB

TYPE

(*) See § 1

VIII, VIII LUB (*) , VIII F

and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,
and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,
and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,
and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,

SUPPLIER

HSK/GLOMAX

and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,
and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,
and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,
and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,
and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,
and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,
and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,
and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,
and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,
and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,

Code

G

Ch.

and Test Standard 7.G0114. TYPE (*) See § 1 VIII, VIII LUB ( * ) ,

Edition