1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. APRIL 2016 Page 1 of 4 NAVISTAR, INC. Material, Parts, and Process Specifications
2、(MPAPS) NUMBER: MPAPS- G-4520 Former Designation: TMS-4520 TITLE: Black Corrosion-Resistant Zinc-Aluminum Coating CURRENT REV No.: 1604 DATE: April 2016 WRITTEN/EDITED BY: W. Cook APPROVED BY: R. Goluch SUPERSEDES: Rev. 0902 FEB. 2009 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVI
3、SION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regula
4、tory limits prior to use. Change Notice: Released as MPAPS 1.0 APPLICATION This specification covers the requirements for a black, corrosion resistant, non-electrolytically applied, water-based coating for steel substrates. The coating is heat-converted from an aqueous dispersion of zinc and aluminu
5、m flakes, and contains a PTFE lubricant dispersed throughout the topcoat. This coating system is free of both hexavalent and trivalent chromium, and is suitable for high hardness parts since hydrogen embrittlement is not induced by the process. This type of coating is intended for fasteners size M6
6、and larger, for exterior applications, as well as small steel clips, brackets, etc., requiring good corrosion resistance. It is not intended for use on internal recessed drive fasteners. This coating should not be used on parts which will come in contact with uncoated copper, magnesium, or stainless
7、 steel, but will provide good bi-metallic corrosion resistance when in contact with aluminum. Coating should not be used on materials which might be adversely affected by a cure temperature range of 288-315C (550-600F). The maximum continuous service temperature is 180C (350F). 2.0 SCOPE This specif
8、ication covers the general coating requirements, coating performance and fastener torque-tension requirements, quality, KCC, source approval and quality control, packing, shipping, and identification requirements, and designation on drawings. 2.1 Restricted Chemical Substances Effective January 1, 2
9、007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 Specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations
10、 are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 ASTM B 117 NAVISTAR Engr. Design Standard A-16 ASTM D 610 NAVISTAR Manufacturing Standard MS-D-13 SAE J2334 NAVISTAR MPAPS B-50 SAE/USCAR-11 CFR Title 29, Part 1910 NUMBER: MPAPS G-4520 TITLE: Black Corrosion-Resista
11、nt Zinc-Aluminum Coating REVISION: 1604 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. APRIL 2016 Page 2 of 4 4.0 GENERAL REQUIREM
12、ENTS 4.1 Coating Requirements 4.1.1 Appearance Coated parts shall have a uniform black appearance, and be free from runs, sags, cracks, pores/blisters, and rough spots. The coating shall not be oily or tacky to the touch. 4.1.2 Thickness The coating will consist of a 2-layer basecoat (6-10 m min. th
13、ickness or 24 g/m2 min. coating weight), followed by a 2-layer topcoat (4-6 m min. thickness or 8 g/m2 min. coating weight). The total coating thickness will typically be 10-16 m (32 g/m2 coating weight), adequate to meet corrosion performance requirements. The coating shall not have an adverse effe
14、ct on production assembly and disassembly practices. After coating, the parts must pass the appropriate thread GO gages without sticking or binding. An evaluation of coating thickness on threads will be included in the Quality Control Plan for each part. 4.2 Part Performance 4.2.1 Adhesion After cur
15、ing, coated parts shall show no flaking, peeling, or loss of adhesion with normal handling. Parts shall show no evidence of blistering, flaking, peeling, or appearance changes, after heating coated parts to 120C for 60 minutes. 4.2.2 Flexibility Coating shall withstand normal handling and storage co
16、nditions without chipping and shall be capable of withstanding the normal extension and compression of springs and normal flexing of parts such as spring clips during assembly without loss of adhesion. 4.2.3 Corrosion Resistance Coated parts shall be subjected to corrosion testing in neutral salt sp
17、ray per ASTM B117 and/or cyclic corrosion testing per SAE J2334. Tested parts shall be evaluated per ASTM D 610, Grade 6 or better, and be free of corrosion product after testing per the following schedule: Salt spray testing Cyclic corrosion testing White corrosion Red rust White corrosion Red rust
18、 240 hr 1008 hr 20 cycles 60 cycles Threaded parts shall be evaluated on areas other than the threaded portion. 4.2.4 Torque Tension Requirement 4.2.4.1 Method SAE/USCAR 11 Control parts (7/16 x 20 UNF or M10 x 1.5 bolts) shall be processed along with each production lot of parts being coated. 4.2.4
19、.2 Required: The control parts will be tested to ensure that the torque values meet the required value of 48 10 Nm to develop a tension of 28.3 kN. Tightening speed shall be 30 3 RPM. NUMBER: MPAPS G-4520 TITLE: Black Corrosion-Resistant Zinc-Aluminum Coating REVISION: 1604 This document is restrict
20、ed and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. APRIL 2016 Page 3 of 4 5.0 QUALIFICATION Pre-production samples, accompanied by a certified laboratory repor
21、t indicating conformance to all requirements of this specification, shall be submitted to Materials Engineering and Technology Department for testing and/or approval prior to shipment of production parts. 5.1 KCC - Quality Control Plan A Quality Control Plan for this product will be established by m
22、utual agreement between Navistar and the supplier. Unless specific exception is noted, the following key control characteristics (KCC), where applicable*, shall be included in the plan as features for management by statistical process control*. 1. Torque-Tension Value of the control samples 2. Coati
23、ng Thickness 3. Corrosion Resistance * Other characteristics for inclusion in the control plan may be specified on the engineering drawing and/or purchase order. * See NAVISTAR Engineering Design Standard A-16. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to Navist
24、ar are required to be registered to ISO 9001 Quality System Requirements. Navistar will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification wit
25、h an accredited registrar and must furnish copies of registration certificates to their Navistar Corporate Buyer upon request. 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples which were approved by the pu
26、rchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify NAVISTAR Materials Engineering and Purchasing an
27、d Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6
28、.3 Process Control The supplier shall either, perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all re
29、quired properties. The part supplier and the plant metallurgist and/or the quality control manager of the using plant may determine testing and reporting requirements on specific products. NUMBER: MPAPS G-4520 TITLE: Black Corrosion-Resistant Zinc-Aluminum Coating REVISION: 1604 This document is res
30、tricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. APRIL 2016 Page 4 of 4 7.0 SHIPPING, PACKING, AND IDENTIFICATION Shipping and identification shall be i
31、n accordance with Manufacturing Standard MS-D-13. Parts must be sufficiently cured at the time of packing to withstand normal handling and shipping without marring. Parts supplied to this specification will still be able to meet the specified requirements for six months after received by the applica
32、ble plant(s) when stored at 5-28C (40-82F) with no direct heat or sunlight. 8.0 DESIGNATION ON DRAWINGS Drawings shall reference this specification as follows: “Finish per MPAPS G-4520” 9.0 APPROVED PRODUCTS GEOBLACK ML (Metal Coatings International) 10.0 TECHNICAL INFORMATION For further informatio
33、n related to the technical content of this specification, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/
