Material Specification Finish (Coating)

GMW4707

Corrosion Protective Coating Zinc Plating/Organic 1 Scope

This specification covers requirements for a non-oily corrosion protective coating consisting of zinc plate and subsequent aluminum rich topcoat. 1.1 Material Description. This coating system must be free of hexavalent chromium, with no hexavalent chromium in final product per GMW3059 requirements. The plating shall be called out on the part drawing per example shown in section 7. 1.2 Cross-Reference of Replaced Specifications. GMW Delta Motors GM do Brasil GM Holdens GMNA ISUZU ITDC SAAB 1.3 Symbol. Not applicable. 1.4 Typical Application. The coating is suitable for internally and externally threaded and nonthreaded ferrous parts where a high level of corrosion protection is required. When applied over steel that is to be coupled with aluminum, the coating provides exceptional galvanic protection. 1.5 Remarks. Use of this coating system on threaded surface and/or bearing surface of joints could effect the torque-tension relationship. It is recommended that a torque-tension study of the fastener joint be performed before releasing this finish on any new application. GM7113M GMW4707
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ISO 9227 SAE/USCAR-5 SAE/USCAR-11 2.2 GM. GM4260P GM9071P GM9508P GMW3059

SAE/USCAR-1 SAE/USCAR-7

GM4265P GM9501P GMW3001

3 Requirements
3.1 Requirements on Delivery. 3.1.1 Chemical Requirements. Not applicable. 3.1.2 Mechanical Requirements. Not applicable. 3.1.3 Physical Requirements. 3.1.3.1 Appearance. This coating shall have a uniform gray/green appearance and shall be free of tears, sags, and excess coating which affects appearance and performance. The coating shall not be oily or tacky to the touch. 3.1.3.2 This finish shall not fill driver recess or threads nor interfere with normal fastener installation procedures. The finish shall withstand normal handling and storage conditions without damage (chipping, flaking or other) and must not stain or transfer to adjacent parts or operators hands. 3.1.3.3 The total coating system as received shall not adversely affect the drive system: internal recess dimensions, hex size, etc. or function of the fastener. 3.1.3.4 Thickness. The zinc plate and passivation treatment thickness shall be minimum 6 m unless otherwise specified. The total coating thickness shall be (12...20) m. 3.1.3.4.1 Thickness shall be determined by microscopic examination of cross sections taken perpendicular to significant surfaces. See GM4260P, Recommended Practices for Measuring Thickness of Plated Deposits and Anodic Coatings. 3.1.3.4.2 In case of bolts and screws, plating thickness shall be determined at top of head at midpoint of largest continuous surface. In case of nuts, determine at midpoint of flats (wrenching facets).

2 References
Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 Normative. ASTM F1470 DIN 946

Copyright 2002 General Motors Corporation All Rights Reserved Originating Department: North American Engineering Standards, Records and Documentation
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GMW4707

GM WORLDWIDE ENGINEERING STANDARDS

3.1.3.6.5 Significant surfaces on parts other than threaded fasteners shall be all surfaces excluding sharp edges. 3.1.3.7 Gasoline Resistance. For initial approval of new materials, coated parts shall be soaked for (200 2) s in gasoline as described in GM9501P. After removal of the parts, they shall be allowed to air dry before visual examination. There shall be no color change, wrinkling, or any other change in the coating appearance. 3.1.3.8 Relief of Hydrogen Embrittlement. All parts heat treated or highly cold worked to the specified core hardness greater than HRC 32 or surface hardness HRC 35, shall be processed by the finish applicator per SAE/USCAR-5 and tested for de-embrittlement per SAE/USCAR-7. The sample size for the SAE/USCAR-7 test shall be per ASTM F1470. 3.1.3.8.1 When supplementary treatment is specified for a part that requires baking after plating, the supplementary treatment shall be applied after the baking operation. 3.1.3.8.2 Hardened parts which have been tempered at less than +175 C shall be heated to +150 C and held 8 h or longer if necessary. 3.1.3.9 Flexibility and Chip Resistance Test. The coating must withstand normal extensions, flexing and compressions encountered by springs and spring clips during end product assembly, without evidence of flaking or loss of adhesion from the base metal. It shall withstand normal handling and storage conditions without chipping or flaking. 3.1.3.9.1 Chip Resistance. Panels or parts coated with the coating, excluding threaded fasteners shall be exposed per GM9508P(Gravelometer Test). After exposure the minimum rating shall be 6. 3.1.3.9.2 Torque-Tension Test. Metric threaded fasteners M6 and larger shall be subject to torque-tension monitoring through the use of surrogate M10X1.5 test bolts. Ten surrogate bolts shall be processed with the production parts. A minimum of 10 bolts per finish line per shift shall be monitored per SAE/USCAR-11, except tightening speed shall be (30 3) min-1 (RPM). The six (6) sigma torque range values must be within the listed range (see Table 1). The test results shall be maintained in file to be submitted when required.
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3.1.3.4.3 The maximum thickness of coating which may be applied to threads on threaded products is limited by the basic thread size (tolerance h or H). After coating, parts must gage with appropriate basic size GO thread gage. Threads may be produced undersize/oversize (before coating) to accommodate the coating thickness, providing the finished product (after coating) meets all specified mechanical properties. Where mechanical properties are not specified, undersizing/oversizing is subject to approval by pertinent engineer, and all undersize/oversize shall be within permissible limits as agreed upon. 3.1.3.5 Adhesion. Parts coated to this specification shall show no evidence of blistering or other appearance changes after exposure to humidity testing per GM4465P for 96 h minimum. When tape tested per GM9071P, 10 minutes after removal from humidity there will be no more than 3.0 mm total peel back (peel back adding both sides of scribed line) from the lines scribed in an X and no other peeling in the area under the tape. This is not applicable to threaded fasteners. Note: This test is applicable for initial approval, applicator approval and PPAP submission parts. 3.1.3.6 Corrosion Resistance. Significant surfaces of parts exposed to neutral salt spray per ISO 9227 shall show no base metal corrosion after 480 h exposure. For this test externally threaded fasteners shall be power driven into a tapped hole or nut or steel panel, simulating production usage, removed, then installed finger tight or with a hand driver with proper drive bit into acrylic plastic or other inert panel, and exposed to salt spray at (15...30) from the vertical to allow wetting. Fasteners shall not drip onto other fasteners during the test (SAE/USCAR-1). 3.1.3.6.1 For normal production, processes that are in statistical process control shall yield parts that are capable of meeting the salt spray requirments. 3.1.3.6.2 A periodic NSS test of the parts being processed on each line running this coating shall be conducted with sample size of 3 pieces minimum per line per shift. 3.1.3.6.3 Actual processing control checks to be made and recorded shall be based on chemical manufacturers instruction. 3.1.3.6.4 Significant surfaces for test evaluation include but are not limited to fastener head, socket recess, sems washer and external nut surface. Sharp edges are excluded.

Copyright 2002 General Motors Corporation All Rights Reserved

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Table 1:

GMW4707

Tension (kN) Thread Size Surrogate Bolt Part Number 11516105 Test Nut Part Number 11516090 Test Washer Part Number 11502644 Torque (Nm) SAE/ USCAR 11 48 8 28.3

M10 x 1.5

3.1.3.10 Coefficient of Friction. The coefficient of friction of threaded fasteners shall be 0.13 0.03 (six sigma values) when tested per DIN 946 with the following exceptions: Tightening speed shall be (30 3) min-1 (RPM) Test samples (excluding driven fasteners) shall be thoroughly cleaned with an appropriate fluid/chemical to remove any grease/oil/wax/other contaminants. Test clamping force shall be calculated as 75 % of proof load. Note: Both, Torque-Tension and Coefficient of Friction tests are required only for the initial aproval of the finish material. Suppliers/Applicators can run either Torque-Tension Test or Coefficient of Friction Test for quality control. 3.1.4 Additional Requirements. Not applicable. 3.2 Processing Requirements. were not applicable. 3.3 Performance Requirements. were not applicable. Subparagraphs Subparagraphs

4 Manufacturing Process
Not applicable.

5 Rules and Regulations

5.1 All materials supplied to this specification must comply with the requirements of GMW3001, Rules and Regulations for Material Specifications. 5.2 All materials supplied to this specification must comply with the requirements of GMW3059, Restricted and Reportable Substances for Parts.

6 Approved Sources
Suppliers to this specification must be approved by the Specialist Team/ TDGs. GMNA approved suppliers names are available on the on-line MATSPC System For other GM locations the responsible engineering group should be contacted to obtain the approved sources in the individual countries.

7 Coding System
This material specification shall be referenced in other documents, drawings, VTS, CTS, etc. as follows: GMW4707 Where GMW 4707 = = GM Worldwide Specification Number

3.4 Requirements on other Stages during Life Cycle. 3.4.1 Chemical Requirements. 3.4.1.1 Recyclability. Parts with this coating shall not have any negative effect on recyclability of the parts. 3.4.1.2 Physiological Safety. The coating material must not cause any health hazard either to line operators or customers. 3.4.2 Mechanical Requirements. Not applicable. 3.4.3 Physical Requirements. Not applicable. 3.4.4 Additional Requirements. Not applicable.

8 Release and Revisions

8.1 Release. This material specification was first approved in August 2001 and was first published in April 2002.

Copyright 2002 General Motors Corporation All Rights Reserved

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Copyright GM Worldwide Reproduced by IHS under license with GMW No reproduction or networking permitted without license from IHS

April 2002

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