GMW11 2019 03 (Electrogalvanized Coating Sheet Steel)

Template For ENG STDS
WORLDWIDE
ENGINEERING Material Specification GMW11
STANDARDS
Electrogalvanized Coatings for Sheet Steel
1 Scope
This standard covers the requirements for both one and two side pure zinc and zinc nickel alloy electrogalvanized
coatings. These coatings are applied to a sheet steel substrate utilizing an electroplating process. The substrate
may be cold or hot rolled sheet steel specified per GMW2, GMW3032, GMW3399, or GMW17627. Additional
requirements or agreements shall be specified by regional GM business units. Coated substrates per
GMW14400 are not within the scope of this specification.
1.1 Material Description. The type of coating, and its mass and finish are specified by suffixes added to the
basic specification number. The first two letters EG will designate an electrogalvanized coating. The coating
mass for each side is designated by a minimum value in g/m 2. Only coating masses shown in Table 1 should be
used unless materials engineering is consulted. Other coating masses shall follow the same designation method.
For one side coated coils or sheets/blanks, a zinc residue of 40 mg/m2 maximum is permissible on the uncoated
side. The letter G designates a pure zinc coating. The letter N designates a zinc-nickel alloy coating. The first
set of digits along with the letter designation specifies the coating parameters of the unexposed side. The
remaining designation specifies exposed (E), unexposed (U), or temper rolled (T) to depict surface finish.
1.2 Symbols. Not applicable.
1.3 Applicability. Sheet metal parts consisting of steel grades described by GMW2, GMW3032, GMW3399, or
GMW17627.
1.4 Suffix Finishes.
1.4.1 Exposed (E). A finish produced by eliminating all visual spangle pattern and surface defects per 3.1.3.3,
to be used for critical appearance applications.
1.4.2 Semi Exposed (Z). A spangle free finish produced by minimizing surface defects per 3.1.3.3 is used for
secondary visible surfaces that do not require an exposed quality finish.
1.4.3 Unexposed (U). A minimum spangle finish used for non-critical appearance applications. See 3.1.3.3.
1.4.4 Temper Rolled (T). This surface shall have sufficient temper rolling such that Lüders lines or stretcher
strain will not show when formed and painted. All other requirements are the same as U surface described in
1.4.3.
2 References
Note: Only the latest approved standards are applicable unless otherwise specified.
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2.1 External Standards/Specifications.

ISO 1460 ISO 7438
2.2 GM Standards/Specifications.
GMW2 GMW3059 GMW14019 GMW16823
GMW3032 GMW3399 GMW14699 GMW17627
2.3 Additional References.
GWS-5A (ID)
(ID) = This reference is limited to internal use within General Motors and shall not be accessed outside this company. Contact the GM Lead
Engineer for further instructions.
© Copyright 2019 General Motors Company All Rights Reserved
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Copyright General Motors Order Number: W2169658

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GM WORLDWIDE ENGINEERING STANDARDS Template For ENG STDS GMW11
3 Requirements
3.1 Requirements on Test Delivery. The following defines specific requirements for material on delivery,
processing, performance, and other stages during life cycle.
3.1.1 Chemical Requirements.
3.1.1.1 Coating. The coating produced in continuous electrogalvanizing lines shall consist of pure zinc or zinc-
nickel alloy. Pure zinc coatings shall be 99.9% minimum pure zinc by mass. Zinc-nickel alloy coatings shall
contain 9% to 13% nickel by mass. Zinc-nickel alloy coatings shall be 99.9% minimum zinc-nickel by mass. For
zinc-nickel alloy coatings, nickel phase gamma shall consist of Ni 5Zn21 structure. Pure zinc and zinc-nickel alloy
coatings may contain 75 parts per million (ppm) maximum cadmium and 100 ppm maximum lead, and must
conform to GMW3059. The coatings shall not contain trace elements which are detrimental to adhesive
bondability, phosphateability or paintability.
3.1.1.2 Base Metal. The sheet steel base metal chemical composition shall conform to the requirements
specified in GMW2, GMW3032, GMW3399, or GMW17627.
3.1.1.3 Surface Treatment. Products coated with a designated lubricant (e.g., mill oil or prelube) shall comply
with GMW14019 and/or be approved by the local business unit. Material shall be supplied
unpassivated/unchromated and any supplemental coatings shall be approved by the local GM Materials
Engineering Department.
3.1.2 Mechanical Requirements.
3.1.2.1 Coating Bend Test. All bend tests shall be performed in accordance with ISO 7438. For all steels
supplied according to GMW2 and GMW3032 (with 0.2% offset yield strength < 500 MPa), a Zero T (0T) bend
test shall be performed. Test specimens of coated metal shall be capable of being bent through 180° in any
direction without evidence of flaking of the coating when viewed at 10x magnification on the outside of the bend
only. For steels supplied to GMW3032 with 0.2% offset yield strength > 500 MPa and all GMW3399 and
GMW17627 grades, the steel must be capable of a 90° bend test in any direction with a maximum former radius
(r) related to the steel thickness (t) without evidence of flaking when viewed at 10x magnification on the outside
of the bend. Refer to Appendix A for maximum bend test former radii for each grade and a diagram of the test
setup. For testing of all steels, flaking of the coating within 6 mm of the edge of the bend test shall not be cause
for rejection. The specimens shall not be cut < 25 mm from the coil edges of the test sheet.
3.1.2.2 Coated Base Metal. The mechanical properties of the coated material in the as-delivered condition shall
conform to the requirements specified in the applicable GMW or industry standard.
3.1.3 Physical Requirements. Coating mass and finish quality shall conform to the requirements prescribed in
Table 1.
Table 1: Preferred Coatings Note 1
Property Unit 36G36G 47G47G 50G60G 60G60G 70G70G 32N32N
Coating Mass (Triple

Spot Test), U side, g/m2 36 to 50 47 to 61 50 to 70 60 to 80 70 to 90 32 to 46
minimum to maximum:
Coating Mass (Triple
Spot Test), E/U side, g/m2 36 to 50 47 to 61 50 to 70 60 to 80 70 to 90 32 to 46
minimum to maximum:
Minimum Coating
Mass for any Individual g/m2 36 40 40 50 60 25
Spot
Coating Thickness
(Triple Spot Test), U
side, minimum to m 5.1 to 7.0 6.6 to 8.6 6.6 to 9.9 8.5 to 11.3 9.9 to 12.7 4.4 to 6.3
maximum Note 2
Note 1: Other coating masses may be used by exception.
Note 2: Coating thicknesses are shown for reference only, not for conformance to specification requirements.
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3.1.3.1 Coating Mass. ISO 1460 shall be used for determination of coating mass of electrogalvanized coatings.
Test sample size shall be 2000 mm2 minimum with a preferred sample size of 3330 mm2 (57.7 mm ± 0.1 mm
square or 65.1 mm ± 0.1 mm in diameter). Coating mass shall be measured by triple spot test and must conform
to the values in Table 1. The mass shall be the average of 3 measurements taken across the width of the strip
at least 25 mm from each edge. In no case shall the lowest value of any of the three test samples fall below the
minimum individual spot requirement in Table 1. Each side should be measured separately to ensure that the
requirements of Table 1 are met.
3.1.3.2 Coating Thickness. For conversion between coating thickness and coating mass, a density factor of
7.1 g/cm3 shall be used for pure zinc coatings and 7.3 g/cm3 for zinc-nickel alloy coatings. Coating thickness
measurements may be used for routine quality control evaluations. Coating thickness shall be measured using
a suitable layer thickness gauge, on-line x-ray gauge or from a specimen cut perpendicular to the panel surface.
Suitable instruments for evaluation of coating thickness (e.g., eddy current, ferromagnetic, or metallurgical
microscope) shall have a capability of ± 1.0 µm accuracy. When using a metallurgical microscope, standard
mounting practices shall be used and thickness shall be measured at 1000x magnification. The referee method
for determining coating thickness shall be coating mass, as specified in 3.1.3.1.
3.1.3.3 Coating Surface Quality. The steel shall be free from surface defects as negotiated between purchaser
and supplier. For unexposed (U) surfaces, defects such as slight indentations, small marks, minor scratches,
and slight coloring, which do not affect corrosion resistance, formability, or the application of surface coatings,
are allowed. Exposed (E) surface shall be free of defects which might affect the uniform appearance of a quality
paint or an electrolytic coating (Electrophoretic Priming Operation (ELPO), electrodeposited primer, cathodic e-
coat). Temper rolling may be required and shall be specified with a (T) designation. The other surfaces shall
conform at least to surface quality U. Certain applications require that both surfaces of the steel be of exposed
(E) surface quality. Regulations in detail will be issued by the local business unit.
3.1.3.4 Pure Zinc Blister Susceptibility. Zinc blisters on the surface of electrogalvanized steel are not allowed.
A zinc blister is a surface defect resulting from the separation of the zinc coating from the steel substrate, and is
not related to other surface defects (see Appendix B). Zinc blisters are typically caused by surface contamination
or the release of hydrogen from the substrate during the paint bake cycle. A surface image and cross section is
shown in Appendix B. Other surface requirements are covered in 3.1.3.3 Coating Surface Quality. The material
shall be capable of being baked at +190 °C (sample temperature) for 30 minutes without any blistering of the
pure zinc plating. The zinc surface shall be visually examined for the absence of blisters using a magnification
of 30x.
3.1.3.5 Surface Texture. Specific requirements for the texture for each region are detailed in GMW16823.
Regulations in detail will be issued by the local business unit.
3.1.4 Additional Requirements.
3.1.4.1 Marking. If ink for marking is allowed by the local business unit, the ink shall not interfere with welding,
phosphating/thin film pretreatments, transfer to the opposite side or print through during part fabrication. The ink
used for marking shall be released by the purchaser. If differential coating product is specified, although it is not
recommended, the heavy coated side of differentially coated product shall be identified with markings running
the length of the coil at sufficient intervals to assure positive identification of the blank.
3.1.4.2 Other Requirements. Requirements such as tolerances on product shape and dimensions, inspections
units, number of tests, sampling, test conditions, retests, inspection documents, packing, and handling of
disputes shall be agreed upon between supplier and the local business unit.
3.2 Processing Requirements.
3.2.1 Additional Requirements.
3.2.1.1 Pre-Treatment/Paint Compatibility (Qualification Testing). Refer to GMW14699 and the applicable
base metal specification for pre-treatment/paint compatibility requirements.
3.2.1.2 Welding. Refer to GMW14699 and the applicable base metal specification for welding/joining
requirements.
3.2.1.3 Adhesive Compatibility (Qualification Testing). Refer to GMW14699 and the applicable base metal
specification for adhesive compatibility requirements.

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3.3 Requirements on Other Stages during Life Cycle.

3.3.1 Chemical Requirements. Provisions shall be made to prevent the addition of such elements (see 5.2)
from scrap or other materials used in the manufacturing process which would impair the recyclability of the
finished components.
3.4 All materials supplied to this standard must comply with GMW3059, Restricted and Reportable
Substances, including the requirement to obtain a GM-approved International Material Data System (IMDS)
submission.
4 Manufacturing Process
Not applicable.
5 Rules and Regulations

5.1 Legal Regulations. All materials must satisfy applicable laws, rules, regulations and recommendations valid
in the country of usage.
5.2 Language. In the event of conflict between the English and domestic language, the English language shall
take precedence.
5.3 Inspection and Rejection. Samples of components or materials released to a GM material specification
shall be tested for conformity with the requirements of this material specification and approved by the responsible
Engineering department prior to commencement of delivery of bulk supplies.
A new approval must be received for any changes, e.g., properties, manufacturing process, location of
manufacture, etc. If not otherwise agreed, all testing and documentation normally required for initial release must
be completed.
It is the responsibility of the supplier to inform the customer in a timely manner, without solicitation, and to include
documentation of all modifications of materials and/or processes and to apply for a new release.
5.4 Material Safety Data Sheets/Safety Data Sheets (MSDS/SDS). For new product submissions, or when a
change in chemical composition of an existing product has occurred, a complete copy of the Material Safety
Data Sheet/Safety Data Sheet must be submitted in compliance with the Globally Harmonized System of
Classification and Labeling of Chemicals (GHS) requirements or other country-specific MSDS/SDS
requirements.
6 Approved Sources
Materials supplied to this specification must be approved by General Motors (Materials Engineering).
The appropriate GM Materials Engineering department(s) must confirm material as meeting the requirements of
this specification. Any test data sheets of material submitted to General Motors for such confirmation (e.g., during
Production Part Approval Process (PPAP)) under this material specification must list all properties and must
apply corresponding test methods of this material specification.
The base material qualification approval (GMW2, GMW3032, GMW3399, GMW17627, etc.) for
electrogalvanized steel per GMW14699, shall also include requirements detailed in this specification.
7 Notes
7.1 Glossary. Not applicable.
7.2 Acronyms, Abbreviations, and Symbols.
0T Zero T (Bend Test)
CR Cold Rolled
CTS Component Technical Specification
E Exposed
EG Electrogalvanized
ELPO Electrophoretic Priming Operation
GHS Globally Harmonized System of Classification and Labeling of Chemicals
GMK General Motors Korea
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GMNA General Motors North America

GMSA General Motors South America
GSSLT Global Subsystem Leadership Team
HR Hot Rolled
IMDS International Material Data System
ISO International Organization for Standardization
MPa Mega Pascal
MPS Manufacturing Engineering Metal Parts Specification
MSDS Material Safety Data Sheet
PATAC Pan Asian Automotive Technical Center
PPAP Production Part Approval Process
ppm Parts Per Million
SDS Safety Data Sheet
SEM Scanning Electron Microscope
T Temper Rolled
t Thickness
U Unexposed
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Z Semi Exposed
8 Coding System
The coding system for GMW sheet steel specifications on engineering part drawings and GMNA Manufacturing
Engineering Metal Parts Specification (MPS) Sheets shall use a nomenclature consisting of material, grade, and
coating designation. An example of the complete steel specification for electrogalvanized steel is shown in 8.1
and follows the applicable GMW base metal material specification.
8.1 Example of Engineering Part Drawing or Manufacturing Engineering Document Coding.
8.1.1 Example of engineering part drawing/manufacturing engineering document coding for sheet steel, grade,
and coating (material, grade, and coating system):
GMWXM-ST-S-XXX-EG60G60G-E
Where:
GMW = Validation Area (GM Worldwide)
X = Sequential Number
GMWX = Base Metal Specification
M = Material Type: Metals
ST = Category: Steel
S = Subcategory: Sheet
XXX = Steel Product Type, Grade
EG60G60G = Coating Designation
E = Surface Quality (Exposed)

9 Release and Revisions

This standard was originated in June 1996. It was first approved by GMNA, Opel ITDC, GMB, Delta Motors, and
Holden Ltd. in May 1998. It was first published in October 1998.
Issue Publication Date Description (Organization)
1 OCT 1998 Initial publication.
2 OCT 2000 With this released Revision A, the document is also valid for Isuzu and Saab. // Paragraph
1: “This material specification...electroplating process.” replaced by “This standard...
electroplating process.”; “sheet steel base metal” replaced by “substrate”; “low carbon,...
or dual phase” deleted // Paragraph 1.4: “rephosphorized” deleted “dual phase,
martensitic” added // Paragraph 2.1: References EN 10152 and EN 10271 added //
Paragraph 2.2: References GM1000M and QU 000000 replaced by GMW3059 (also
paragraph 5.3); GM9073P deleted // Paragraph 3.1.2.1: “oT (zero T)” added // Paragraph
3.1.3.1: Initial testing: “more”/”maximum” replaced by “less”/”minimum”; average:
“maximum value” replaced by “minimum value” // Paragraph 3.1.3.6: Test to GM9073P
deleted // Table 1: Maximum coating thickness of Grades 47G00G and 47G47G was 8.4
μm; Grades 32N32N and 32N00N was 6.5 μm; Note 2: “Refer to...” added // Appendix B:
Table of phosphate and paint systems reworked // Deviations paragraph added. (GME
Specification Center)
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3 APR 2004 Revisions to sections 1.4, 2.1, 2.2, 3.1.1.1, 3.1.1.2, Table 1, 3.1.3.1, 3.1.3.5 (deleted),
3.1.3.6 (renumbered), 3.1.3.7 (renumbered), 3.2.4.3, 3.2.4.4 (renumbered), Editorial
changes to 7.1 and 7.2, Deviations added (Tables 2-4, 3.2.4.1, 3.2.4.3).(GMNA, GME,
(Opel and Saab), Holden, GMB, and Isuzu)
4 JAN 2008 Revisions to sections 1, 1.1, 1.1.1 (added), 1.2, 1.3, 2.1, 2.2, 2.3, 3.1.1.1, 3.1.1.2, 3.1.1.3,
3.1.2.1, 3.1.3 - Table 1, 3.1.3.4, 3.1.3.5, 3.1.3.6 (removed), 3.2.1.1, 3.2.1.3, 3.2.1.4
(removed), 5.3 (added), 6, 7 (added), Appendix A (added-Cross Reference Table),
Appendix B (added – Coating Bend Test), deleted – Zinc Crystal Morphology), Appendix
C (added – Zinc Blisters, deleted – Phosphateability/Paint Appearance), Appendix D –
Adhesive Compatibility on New Substrates (GME) (added), Deviations – 3.1.2.1 (added),
3.1.3.1 Coating Mass, 3.2.1.3 (deleted). (Global Sheet Metal Specialists Team)
5 JUL 2008 Section 3.2.1.4 (Paint Appearance Screening Test) added. (Global Sheet Metal
Specialists Team)
6 MAY 2009 Section 3.2.1.4, (Paint Appearance Screening Test) deleted. Deviations 3.1.2.1 deleted.
Appendix D update. (Global Sheet Metal Specialists Team)
7 OCT 2014 Updated Scope, 1.1 (Material Description), 1.4 (added), 2.1/2.2/2.3 (Updated
References), 3.1.1.3 (Surface Treatment), 3.1.2.1, Table 1 (Coating thicknesses), 3.1.3.3
(Added T-designation), 3.1.3.5 (Updated surface texture spec), 3.2.1.1 (Updated all paint
requirements), 3.2.1.2 (New paragraph with weld requirements), 3.2.1.2.1/3.2.1.2.2
(Deleted), 3.2.1.3 (Updated adhesive requirements), 6 (Approved source requirement
updated), 7.2 (updated acronyms), 8/8.1/8.1.1 (Coding designations updated), 8.2
(Deleted), Appendix A (deleted) –replaced by former Appendix B, Table A1 (Updated title
and grade designations for adhesion bend test), Former Appendix C now Appendix B,
Former Appendix D (deleted), Table Dev1 (Eliminated 28G coating), Table Dev2 (Isuzu
coatings deleted), Dev. 3.2.1.1 (Holden requirement deleted), Dev 3.1.2.1 (Updated for
GME – coating by bonding), Dev 3.1.3.3 (deleted). (Materials-Ferrous and Sheet Metal
GSSLT)
8 MAR 2019 Updated template and references for 5-year refresh; Revised Section 1 (removed GM
regional callouts), Table 1 (removed surface type references, removed single-side
coating designations), changed qualification requirements in 3.2.1.1 through 3.2.1.3 to
refer to GMW14699 and base metal specification, Table A1 (modified coating adhesion
test former radii to align with base metal specifications), Deviations (removed). (Materials
– Ferrous Materials and Sheet Metals Global Subsystem Leadership Team (GSSLT))

Appendix A
Maximum former radii for bend testing of High Strength, Advanced High Strength, and Retained Austenite
Bearing Advanced High Strength Steels are given in Table A1. Zinc adhesion testing shall be performed in
accordance to ISO 7438. Figure A1 shows a generic schematic of the bend test setup.
Table A1: Maximum Former Radii for Coating Adhesion Tests

Grade Maximum Former Radius, r
GMW3399M-ST-S-CR690T/550Y-DP-EGxxGxxG-U 2t
GMW3399M-ST-S-CR780T/420Y-DP-EGxxGxxG-U 2.5t
GMW3399M-ST-S-CR780T/440Y-MP-EGxxGxxG-U 2t
GMW3399M-ST-S-CR980T/550Y-DP-EGxxGxxG-U 3t
GMW3399M-ST-S-CR980T/700Y-MP-LCE-EGxxGxxG-U 2.5t
GMW3399M-ST-S-CR980T/800Y-CP-EGxxGxxG-U 2t
GMW3399M-ST-S-CR1180T/875Y-MP-EGxxGxxG-U 3.5t
GMW3399M-ST-S-CRxxxT/xxxY-MS-EGxxGxxG-U 4t
All other GMW3399 steels 1t
All GMW17627 steels 3t
Figure A1: Bend Test Schematic

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Appendix B
B1 Pure Zinc Blister Susceptibility

An example of an electrogalvanized steel containing a zinc blister defect is shown in Figures B1 and B2.
Separation of the zinc from the substrate causes a surface defect that may be visible on a painted steel surface.
Scanning Electron Microscope (SEM) image, Figure B1 shows a zinc blister on the surface of electrogalvanized
steel, and Figure B2 shows a cross section of the separation of zinc from the steel substrate.
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Figure B1: Zinc Blister Top View
Figure B2: Zinc Blister Cross Section


GMW11 2019 03 (Electrogalvanized Coating Sheet Steel)

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Template For ENG STDS

Electrogalvanized Coatings for Sheet Steel

2.1 External Standards/Specifications.

© Copyright 2019 General Motors Company All Rights Reserved

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Property Unit 36G36G 47G47G 50G60G 60G60G 70G70G 32N32N

Coating Mass (Triple

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3.3 Requirements on Other Stages during Life Cycle.

5 Rules and Regulations

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GMNA General Motors North America

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9 Release and Revisions

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Table A1: Maximum Former Radii for Coating Adhesion Tests

Figure A1: Bend Test Schematic

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B1 Pure Zinc Blister Susceptibility

Figure B1: Zinc Blister Top View

Figure B2: Zinc Blister Cross Section

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