STANDARD W+O **200/**219

Date: May 2013 Issue: 05 Authorized: Page: 1 of 5

ZINC COATINGS ON FERROUS ALLOYS, ELECTROLYTICAL PROCESS

CONTENTS
1 scope and field of application
2 general
3 properties and requirements
4 test methods
5 indication on drawing
6 additional delivery requirements
7 references

1 SCOPE AND FIELD OF APPLICATION

This standard establishes the properties and requirements for electrolytic applied zinc coatings on ferrous
alloys.

Note 1:
Note 1 is applicable for project 10170 and underlying projects as well as other current and new
projects.

All new and carry over parts must be released with / converted to CrVI-free surface treatments (see
flowchart W+O 00/999 for CrVI-free surface treatments non-threaded parts (non-fasteners)) with the
exception of:
− Standard fasteners (bolts and nuts according to product standards (class code >9000) and
external standards such as ISO, EN or DIN). This includes washers etc..
− Designed components derived from standard articles or product families, including supplier
parts. In this case, the whole family will be converted at ones. Designed dedicated components
may only be released with CrVI-free surface treatments after discussion with production and
purchasing.
− Non fastener components derived from standard components (class code >9000) or
component families (used in running business/service).

The exceptions will be released in dedicated projects via the ECR route.

2 GENERAL

The purpose of zinc electroplating is the protection of the base material against corrosion. Beside this,
improvement of the appearance is also an important benefit.

2.1 Threaded parts

Due to the risk of hydrogen embrittlement threaded parts of class 12.9 and higher may not be zinc
electroplated.

2.2 Hydrogen embrittlement

2
Parts manufactured from material with a tensile strength >1000 N/mm (or corresponding hardness) which
are strongly cold formed or subjected to tensile loading, are in danger of hydrogen embrittlement after zinc
plating.
To avoid this it is necessary to give relevant parts a heat treatment both before and after the zinc plating
process. Before zinc plating the products should be stress relieved. This treatment should be specified on
drawing (see also clause 5).
The heat treatment after zinc plating should be carried out as indicated in table 1. This heat treatment should
be started as quickly as possible, but within at most 1 hour after zinc plating.

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 STANDARD W+O **200/**219
Date: May 2013 Issue: 05 Authorized: Page: 2 of 5

Table 1
Tensile strength Period of heat treatment at 190 °C - 220 °C
object temperature
2
[N/mm ] [h]
< 1000 0
1000 - 1400 8
1400 - 1750 18
>1750 Do not zinc-electroplate

The period of heat treatment commences only when the whole workpiece reaches the specified minimum
temperature. For hardened parts the heat treatment temperature may not exceed the tempering
temperature. Parts with surface-hardened areas should be heat-treated for at least 5 hours at an object
temperature of 130 °C - 150 °C or 2 hours at 190 °C - 220 °C. Provided that it does not lead to an
unacceptable lowering of the substrate hardness, temperatures >150 °C are preferred.

2.3 Method
The zinc layer is deposited on the surface by immersion in an electrolytic solution through which an electric
current is passed. To increase the corrosion protection, all products should be passivated after zinc
electroplating.
With the exception of black passivation all passivations are applied by immersion in a chromate containing
solution. If the part, after the zinc plating, has to be heat treated at a temperature above 70°C (e.g. baking),
passivation should be done after completion of the heat treatment!

3 PROPERTIES AND REQUIREMENTS

3.1 Layer thickness and color

The layer thickness and color must comply with the requirements as given in table 2.

Table 2
W+O spec. No. Layer thickness Color + Application
[µm] suppl. treatment
**/200 1) 5-8 blue Threaded parts and spring washers
**/201 1) yellow non-visible interior parts, not subject to wear.
**/202 1) olive green
**/203 black
**/204 1) 12 - 16 blue Visible or parts subject to wear in the interior, washers
**/205 1) yellow and well protected parts in the exterior.
**/206 1) olive green
**/207 black
**/208 1) 25 - 30 blue Not protected exterior parts and pipes.
**/209 1) yellow
**/210 1) olive green
**/211 black
**/212 1) 8 - 12 blue Cavities in exterior parts.
**/213 1) yellow Hose clips and threaded parts.
**/214 1) 2-4 no requirement continuously zinc-plated sheet
**/216 1) 8 - 12 olive green + wax-dip Pipe unions with external epoxy coating.
**/217 1) 5-8 Standard, metric hexagon bolts and nuts
yellow + wax-dip M18 and M20 property class 8.8 en 8.
**/218 1) 8 - 12 Flange bolts and flange nuts of property class 10.9 resp.
10 and spring U-bolts of property class 8.8.

**/219 5-8 yellow + wax-dip Pipe unions. 2)

1) Contain CrVI. See section 1, note 1.
See flowchart W+O 00/999 for the applications of standardized CrVI-free surface treatments non-threaded
parts (non-fasteners).
2) If specified on the drawing an alternative treatment can be applied (phosphating and oil-dip).

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Date: May 2013 Issue: 05 Authorized: Page: 3 of 5

Note 2:
The requirements for layer thickness and corrosion resistance does not apply to areas, which cannot be
touched by a 20 mm diameter ball, or to cavities. If a minimum layer thickness is required for such areas, this
should be indicated on the drawing. In the case of threaded parts, the requirements only apply to the heads
and larger surfaces as indicated in Figs. 1, 2 and 3 test surfaces.

Figure 1 Figure 2 Figure 3

3.2 Appearance
The zinc layer applied must be smooth and uniform in appearance. It should not show any signs of faults,
such as blisters, pits, nodules, stains and bare, rough, dull or burned areas.

3.3 Adhesion
– The zinc layer must not come loose when a saw cut is made, nor after heat treatment by heating to a
temperature of 250°C and quenching in cold water.
– The zinc layer may not come loose when brushed with a wire brush.
– After bending backwards and forwards to fracture, the zinc layer on sheet metal parts may not show
any signs of loss of adhesion at the fracture.
– For zinc plated pipes applies in addition that the zinc layer must not come loose by:
– Flaring and flattening;
– Bending on a mandrel having a diameter of 20 mm or twice the pipe diameter,
whichever is the greater.

3.4 Passivation
Considerable color variations can occur to the green (olive) passivation, exhibiting colors such as green
black and green brown, depending on the process conditions. As long as the other requirements are met,
this variation in color is no reason for rejection.

3.5.1 White corrosion: passivation quality

White zinc corrosion may not occur after the test period for the salt spray test given in table 3.

Table 3
Passivation color Test period
[h]
Blue 24
Black 24
Yellow 48
Green 48

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Date: May 2013 Issue: 05 Authorized: Page: 4 of 5

3.5.2 Rust formation: both zinc layer and passivation quality

Rust formation may not occur after the test period for the salt spray test given in table 4.

Table 4
W+O spec. No. Passivation color Test period
[h]
1) 1)
**/200 **/212 blue 96
**/203 black
1) 1)
**/201 **/217 yellow 120
**/219 yellow 120
1)
**/202 green
1)
**/204 blue 192
**/207 black
1)
**/205 yellow 240
1)
**/206 green
1)
**/208 blue 288
**/211 black
1)
**/209 yellow 360
1)
**/210 green
1) 1)
**/213 **/218 yellow 144
1)
**/214 no requirement 24
1)
**/216 green 168
1) Contain CrVI. See section 1, note 1.
See flowchart W+O 00/999 for the applications of
standardized CrVI-free surface treatments non-threaded
parts (non-fasteners).

4 TEST METHODS

4.1 Corrosion resistance

Corrosion resistance is determined by the salt spray test according to ASTM B 117.

Note:
Prior to the corrosion tests the parts are to be degreased with a suitable organic solvent at room
temperature, in case that they are provided with a wax-dip as specified in DAF standard W+O **926.

5 INDICATION ON DRAWING

The indication on drawing is according to DAF standard TKB 00801-023.

If it is necessary to carry out a supplementary heat treatment to avoid hydrogen embrittlement both W+O
treatments should be specified in one flagnote in the text field of the drawing.

Example:
A treatment according to W+O specification number **/201 and a supplementary baking treatment of 8 hours
at a temperature between 190 °C and 220 °C is indicated as follows: W+O 00/201, suppl. 8 hours baking at
190 °C - 220 °C.

6 ADDITIONAL DELIVERY REQUIREMENTS

Not applicable.

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 STANDARD W+O **200/**219
Date: May 2013 Issue: 05 Authorized: Page: 5 of 5

7 REFERENCES

7.1 DAF standards

TKB 00801-023 Indication of heat, surface and paint treatments on technical drawings
W+O **926 Wax-dip on threaded parts
7.2 External standards
ASTM B 117 Standard Practice for Operating Salt Spray (Fog) Apparatus

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