0487100126

2011-10-07

CB-Norm

0487100126-AB

COATINGS
ZINC ALLOY ELECTROPLATING

Folder: none
Technical responsibility: bae2dy CB/QMM-Mat3 (203)

Standardization organization:

CB

Replaces edition: 5J0124-C

Created by:

hud2dy CB/QMM-Mat1 (203)

Document language:

EN

Original language:

EN

Change:

- Renumbering of NDT 5.J.01.24

- Removal of appendix (hexavalent chromium)

Change information:

0499A08491

Translation
Release date

Source language

Responsibility
Target language

Translated by

Unit code

BWN

In case of doubt the original language edition of this CB-norm applies.

Printed versions and copies of CB-norms are not subject to

the CB-norms update service. Up-to-dateness is not guaranteed.
Page 1 of 5
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applications for industrial property rights.
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Area of validity, binding force, freedom to disclose

Valid for

CB products

Binding for

CB products

Binding due to

Technical documentation of components

Recommended for

NA

Disclosure

No restrictions

TABLE OF CONTENTS

1 SCOPE

2 APPLICATION

3 COATING PROCESS

3.1 Initial surface condition

3.2 Coating deposit

3.3 Degassing operation

4 REQUIREMENTS

4.1 Appearance

4.2 Designation

4.3 Thickness and corrosion test

4.3.1 Salt spray test

4.3.2 Thickness

4.4 Adhesion properties

4.5 Sealer homogeneous thickness test

5 MANDATORY INFORMATION IN CB TECHNICAL DOCUMENTATION

6 NORMATIVE REFERENCES

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1 Scope
This standard defines tests, types and requirements of zinc alloy electroplating (electrolytic
coating) with a Cr III (trivalent chromium) passivating and a sealer.

2 Application
The zinc alloy coating is applied to increase corrosion resistance of steel and cast iron
components.
Zinc alloys covered by this standard are ZnFe, ZnCo and ZnNi.
The different coating methods (rack or barrel) are covered by this standard.
Zinc alloy electrolytic coatings are not recommended for steel parts with tensile strength 1000
MPa (Hardness 31 HRC).
When this electrolytic coating cannot be avoided, requirements mentioned in 0 204 Y81 063
standard to reduce hydrogen embrittlement risk have to be applied.
Alternative solution for corrosion protection is the non electrolytic applied zinc flake according to 0
204 Y81 074 standard.
Zinc coating with Cr VI (hexavalent chromium) are not authorized.

3 Coating process
3.1 Initial surface condition
Integrity of the coating depends upon the quality of the initial surface. The initial component
surface must be free from defects which could impair the coating deposit as pits or rust.
Appropriate shot blasting is mandatory on cast iron component to fulfill the requirements of this
standard.
3.2 Coating deposit
The process steps include:
Cleaning and preparation
Zinc alloy deposition with alkaline or acidic electrolytes. In case of cast iron component, acidic
electrolyte process must be used.
Transparent passivating: trivalent chromium (CrIII).
Sealer: Thin dry protective film (less than 2 m) made of silicates from mineral sealer water
based solution. Sealer application process and sealing parameters must ensure a regular
thickness with no defects as dry drops, retention or peal off. Organo-mineral (silicate based)
sealer can be used for friction properties requirements. Organic sealers are not authorized.
3.3 Degassing operation
Parts with tensile strength 1000 MPa (Hardness 31 HRC) must be degasified before
passivating according 0 204 Y81 063 standard.

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4 Requirements
4.1 Appearance
Coating shall be uniformly silver or black in color and free from defects as blisters, stains, pits,
peeling or cracks.
4.2 Designation
The Zinc alloy coatings mentioned in this standard are defined as follows:
ZnX (D) FYR
ZnX= Zinc alloy coating with X which corresponds to the alloying element: Fe, Co or Ni.
The letter D (D= Degassing) is added when degassing operation is mandatory (see chapter 3.3).
FYR = CrIII passivating and sealer with Y which corresponds to the color: B= Silver; N= Black.
(FBR = Finition Blanche Renforce, FNR = Finition Noire Renforce).
Examples:
ZnNi FBR = Zinc Nickel coating with CrIII passivating + sealer and silver color
ZnNi DFBR = Zinc Nickel coating with mandatory degassing operation and with CrIII
passivating + sealer and silver color.
4.3 Thickness and corrosion test

Thickness
indicative range

Salt spray duration

without white rust

Salt spray duration

without red rust

10 to 20 m

120 h

480 h

4.3.1 Salt spray test

Neutral salt spray test according to 0 204 Y81 063.
Salt spray test requirements must be fulfilled:
As received condition
After a 1 hour period of ageing at temperature 120 (+5/0) C prior to the salt spray test (place
the component for 1h at 120 (+5/0)C then let it cool down to ambient temperature)
4.3.2 Thickness
Thickness range is only indicative according to 0 204 Y81 063.
When mandatory values are necessary, thickness must be defined within CB product technical
documentation.
Thickness measurement according one of the three following methods according to 0 204
Y81 063:
Micrographic cut according to ISO 1463
Magnetic measurement according to ISO 2178
X ray fluorescence measurement according to ISO 3497
In case of dispute, the thickness measurement method must be micrographic cut.

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applications for industrial property rights.

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4.4 Adhesion properties

Components are heated during 30 minutes at:
220 C for ZnFe and ZnCo
300 C for ZnNi
Then components are quenched into water at room temperature.
Acceptance criteria: no degradation such as flaking or blistering.
4.5 Sealer homogeneous thickness test
Components are heated during 30 minutes at 300 C and then let it cool down to ambient
temperature.
Acceptance criteria: no local coloration (sealer extra thickness).

5 Mandatory information in CB technical documentation

Material definition: designation according 4.2
Material standard: 0487100126
Bosch material code(s)

6 Normative references
No.

1)

Document number
(edition date)

0 204 Y81 063

ISO 1463 (2003-03)

ISO 2378 (1982-08)

ISO 3497 (2000-12)

0 204 Y81 074

Title

Coatings against corrosion General requirements

Metallic and oxide coatings Measurement of coating
thickness Microscopical method
Non-magnetic coatings on magnetic substrates
Measurement of coating thickness Magnetic method
Metallic coatings Measurement of coating thickness
X-ray spectrometric methods
Coatings Non electrolytically applied zinc flake coating

Type1)

Z
Z
Z
Z
Z

Type: M = Document to be supplied; Z = Cited document; H = Historical document

Robert Bosch GmbH. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of
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