PRODUCTIVE MATERIAL NO: MS-4005

SPECIFICATION REV: D

TITLE: DATE: 01 DEC 08

CATHODIC ELECTRODEPOSITION PRIMER
PAGE: 1 of 5 Pages

ORIGINATED BY: FINAL APPROVAL:

John Dharte, Senior Chemist/Laboratory Quality Manager S. W. Cook, Director, Metallurgy & Materials Engineering

1.0 SCOPE:
1.1 This specification covers the pretreatment, paint materials and some processing
requirements for a waterborne, black, cathodic electrodeposition primer (Cathodic E-coat
or ELPO). Paint durability requirements are also included.
1.2 This specification covers four types of primers that contain different amounts of heavy
metals (chromium and lead). Type I primers contain both chromium and lead. Type II
primers do not contain chromium, and Types III and IV primers do not contain chromium
and lead. It is desirable to use Types III and IV primers on parts that will be welded. Due to
environmental concerns regarding heavy metals only Type III and IV primers are to be used
on e-coated parts. Pretreatment requirements will differ depending on primer used (6.1.2).
1.3 This specification applies to parts that are not top coated or painted at AAM facilities.

2.0 REFERENCE:
2.1 Engineering blue print specifications.
2.2 AAM-2-031 - Materials Specifications.
2.3 ASTM B117 - Salt Spray.
2.4 ASTM D1735 / D2247 - Humidity.
2.5 ASTM D3170 - Chip Resistance of Coatings.
2.6 ASTM D3359 - Tape Adhesion.
2.7 ASTM D5402 - Cure Test (Solvent Rub).
2.8 ASTM TBD - Cyclical Corrosion.

3.0 RESPONSIBILITIES:
3.1 Director, Metallurgy & Materials Engineering and/or designee.

4.0 GENERAL:
4.1 Revisions to this procedure require written approval of the manager or designee of
Materials Engineering.
4.2 Any changes in material or manufacturing process for the material requires approval of
American Axle & Manufacturing Product Engineering Department.

5.0 PROCEDURE:
5.1 General Requirements:
5.1.1 Processing parameters should conform to the recommended practice as stated by
the chemical suppliers. The typical process flow is shown in section 5.2.
 PRODUCTIVE MATERIAL NO: MS-4005
SPECIFICATION REV: D

TITLE: DATE: 01 DEC 08

CATHODIC ELECTRODEPOSITION PRIMER
PAGE: 2 of 5 Pages

ORIGINATED BY: FINAL APPROVAL:

John Dharte, Senior Chemist/Laboratory Quality Manager S. W. Cook, Director, Metallurgy & Materials Engineering

5.1.2 Chemicals that are present in any material or component must be reported to and
approved by AAM Corporate Environmental Engineering in compliance with U.S.
and international regulations that apply.
 NO: MS-4005 REV: D

PAGE: 3 of 5 Pages DATE: 01 DEC -08

5.1.3 Cathodic ELPO must meet the following requirements on all surfaces designated on
the Engineering drawing.
5.1.4 Parts must be thoroughly cleaned with cleaning agents that are compatible with the
coating, and applied in conformance with suppliers’ specifications. The cleaning
process must not hinder the functionality of the part, and must allow the part to
pass the requirements on the engineering blue print.
5.1.5 Deionized water rinses must be properly maintained in order to meet the
performance requirements of this specification. Alternate processes must receive
AAM Product Engineering approval.
5.1.6 A non-chrome sealer is required after phosphating when a Type III primer is to be
applied (1.2).
5.1.7 On-line treatments using more than one chemical supplier are unacceptable. Any
deviation to this must have prior approval of AAM Product Engineering.
5.2 Process Flow Diagram:
5.2.1 The following process steps are typical in a cathodic electrodeposition system:

Clean Zn-Phos – Rinse, Non-Chrome Seal, Rinse, Cathodic E-coat primer, Rinse,
Oven Cure

5.3 Painted Product Requirements:

5.3.1 Appearance: Visual inspection shall be performed in a well lit area prior to
additional surface finishing.
5.3.1.1 Color: The color must be black, unless otherwise designated on the
Engineering Part Drawing.
5.3.1.2 Gloss: Required gloss should be specified on the engineering drawing.
5.3.1.3 Surface Quality: The baked ELPO shall have no blisters, run outs, rinsing
residues or other surface defects which could require the removal of the
coating system to the bare metal for repair. The coating shall have a
smooth and uniform surface.
5.3.2 Film Thickness: The film thickness must be in the range of 10 to 20 µm. A target
film thickness is 15µm. When Type III primers (2.2) are applied, thickness must be
in the range of 20 to 30 µm. A target film thickness for type III is 25µm.
 NO: MS-4005 REV: D

PAGE: 4 of 5 Pages DATE: 01 DEC -08

5.3.3 Performance Requirements: The durability of the coated components and defined on
the Engineering drawing. The drawing should contain at a minimum: 1) the ASTM
testing required; 2) the duration of the test; and 3) test specific requirements, e.g.
salt spray per ASTM B117, 168hrs with 10% max. red rust.
5.3.3.1 The electrodeposited coating shall have the ability to cover a surface to
which the current has limited access, such as the interior of a section, and
meet any requirements stated in the engineering drawing.
5.3.3.2 Testing standards for specified performance requirements are listed below:

Standard Test Type

ASTM B117 Salt Spray
ASTM D2247 Humidity
ASTM D3170 Chip Resistance
ASTM D3359 Tape Adhesion
ASTM D5402 Cure Test
TBD Cyclical Corrosion
5.4 Source Shipment Responsibility:
5.4.1 It will be the responsibility of the supplier to insure that the material is not exposed
to temperatures during shipment which would cause the material to fail to meet any
of the requirements of this specification.
5.5 Initial Source Approval:
5.5.1 No shipment shall be made by any supplier until representative initial production
samples have been approved by AAM Product Engineering and the receiving plant as
meeting the requirements of this specification.
5.5.2 Completed copies of the Material Safety Data Sheet meeting AAM information
requirements must be submitted with any new submission or where a composition
change has occurred.
5.6 Inspection and Rejection:
5.6.1 All shipments of material or part under contract or purchase order manufactured to
this specification shall be equivalent in every respect to the initial samples approved
by engineering. No changes in either formulation or manufacturing processes are
permitted without prior notification and approval by engineering. Lack of
notification by the supplier constitutes grounds for rejection of any shipment. While
samples may be taken from incoming shipments and checked for conformance to
this specification, the supplier shall be responsible for incoming shipments meeting
this specification without dependence upon purchaser’s inspection. In addition, the
supplier shall be responsible for submitting a CERTIFICATE OF ANALYSIS with
each batch of material if required by the receiving plant.
 NO: MS-4005 REV: D

PAGE: 5 of 5 Pages DATE: 01 DEC -08

5.7 Approved Sources:

5.7.1 Engineering qualification of an approved source is required for this specification.
The sources listed below have been qualified by AAM Product Engineering as
meeting the requirements of this specification.

SOURCE
Crown Group
Meto Kote Corp.
Meto Kote Corp.
Meto Kote Corp.
Wright Coatings
Industrial Metal
Coating (IMC)
Meridian Automotive
Systems
Powder Cote II
LOCATION
Warren, MI
Grand Blanc, MI
Lima, OH
Sheffield Village, OH
Kalamazoo, MI
Sterling Heights, MI
Grand Rapids, MI
Mount Clemens, MI

6.0 ACCOUNTABILITY:
6.1 The functional manager of Materials Engineering is responsible for the implementation,
approval, and maintenance of this procedure.

7.0 REVISION RECORD

DATE REV REVISION

17 JUN 98 0 Original issue
10 NOV 98 1 Added additional approved source (Section 5.7.1)
27 JAN 06 C Revised Sections 5.16 and 5.2.1 to remove chrome sealer and add non-
chrome sealer.
01 DEC 08 D Added Industrial Metal Coating (IMC), Powder Cote II and Meridian
Automotive Systems to Section 5.7.1.