WORLDWIDE ENGINEERING SDD) Material Specification Flakh GMw3044 Zinc Plating 1 Scope This specication covers the basic requirements for electroplated zinc applied to iron and steel substrates with provision for plating thickness, use for non-use of supplementary treatments | and corrosion resistance. Provision is also made to specify mechanical plating. GMNA MATSPC. approvals for this finish are specific to the post- supplementary treatment (Suffix) evaluated for inital chemicavapplicator approval (reference section 6 Approved Sources) 14 Material Description. This coating system must be free of hexavalent chromium, per GMW3059 requirements. The plating shall be shown on the part drawing as per the example shown in Section 7. Table 1 lists the common plating thickness codes covered by this. specification Itis recommended to use these common codes 10 avoid product complexity This plating is at present approved in clear (bright) color only. Black color (passivation product) as shown in Table 1 is not approved yet. Any other colors (where color is developed by adding pigment), if required don't need specially approved source for the color. Establish availabilty at one of the sources approved to the required post- supplementary code (suffix) before putting any color other than clear (Bright) on the drawing 4.2 Cross-Reference of Replaced Specifications. ouw omws044 [Delta Motors [GM do Brasil (GM Holdens: HNI264 (GMINA GMa345M 1suzU _| Troe (GME 00252 SAAB 1.3 Typical Applications. Zinc plating is typically applied on small to medium-sized ferrous parts such as castings, fasteners, stampings, and clip. 1.31 Zine plated parts of their corrosion products ‘must not come in contact with stressed Polyamides 6 or 66. 4.3.2 Zinc plating types without supplementary treatment are also used as a basecoat for an ‘additional paint, This coating must be so applied that-no negative influence in appearance and adhesion appears (e.g. blistering by effusion of hydrogen), 2 References Note: Only the latest approved standards are applicable unless otherwise specified 24 Extemal Standards/Specifications. ASTM F1470 SAEJUSCAR-S DIN 946 SAEJUSCAR-7 180 9227 SAE/USCAR-11 2.2 GM Standards/Specifications. 984004 GMB175M 9985490 Gme189P eaz60P mw3001 cme12iM mw3059 cmet2im 3 Requirements 3.4 Appearance. The as-received appearance and ‘color hue shall be as agreed upon between the purchaser and supplier using approved color and hhue engineering standards when available. In the ‘case of zine plus passivation coating listed herein. ‘a clean, commercial finish Is required: range of ‘color, iridescence, opaqueness, and sheen are normally not critical unless otherwise specified by the purchaser. In the case of bright zinc plus clear finishes listed herein, a clear bright appearance (also referred to as colorless, blue-bright and clear silver-white) is required. Specified colors shall be Uniform, tightly adherent, hard and dry. 3.2 Plate Thickness. Thickness of plate shall be fo less than the values shown in Table 1 or as designated for the suffix specified by Product (© Copyright 2005 Genera Motors Corsraion Al Rights Reseved ‘Orighating Deparment Norh Anrican Engineering Slandarde ‘April 2005 Page 1 of 5GMW3044 GM WORLDWIDE ENGINEERING STANDARDS. Engineering. Such values are intended to apply to significant surfaces as specified on engineering drawings. Inthe case of finishes with supplementary treatment, color, ete, the values shown apply to the thickness of plate after treatment. Supplementary treatments such as ols, waxes. or other specified coatings are_not applicable to thickness measurements. The plating thickness on bolts and screws shall be measured ‘on the head and the thread tip, on nus it shall be measured on the spanner fats 3.2.1 The thickness of the plated finish shall be determined by microscopic examination of cross sections taken perpendicular to significant surfaces, or by other methods agreed upon by the supplier and purchaser. For recommended practice for measuring thickness of electrodeposits see Gwmazsor. 32.2 The maximum allowable thickness of the Piating on threaded fasteners shall be twice the minimum specified plating thickness. The maximum thickness of plating, which may be applied to threads on threaded products, is limited by the basic thread size (tolerance h o H). After coating, parts must gage with appropriate basic size GO thread gage. Threads may be produced Undersizeloversize (before coating) to accommodate the coating thickness, providing the finished product (after coating) meets all specified mechanical properties. Where _ mechanical properties are not specified, undersizingoversizing is subject to approval by pertinent engineer, and al Lndersizefoversize shall be within permissible limits 28 egreed upon 3.2.3 The allowable vatition of maximum plating thickness in case of non fasteners could be more than twice the minimum specifies plating thickness, as long as it shall not effect the function of the part Note: In special cases, such as welding applications, limiting the maximum plating thickness to a specific requirement shall be noted ‘on the engineering drawing 33 Adhesion. The coating shall have good adhesion to the base material. There shall be no blistering or faking of the finish, including after any heat treatment as follows The adhesion in the as-received conditions shall be checked as follows: Expose coated parts to 22045°C for 30#5 minutes and quench in water at room temperature. ‘After quenching in water bistering andior chipping is not allowed. Electroltically coated components produced from ‘aqueous solutions must satisfy the mechanical property requirements of the uncoated parts. 34 Corrosion Resistance. Parts plated to these specifications shall be capable of withstanding NSS testing for the minimum number of hours shown in Table 1 or as designated for the suffix specified by the purchaser. 3.4. Parts must be tasted to ISO 9227 to meet the Corrosion resistance requirements on significant surfaces per 3.4.4 and 3.4.5 for initial approval of the finish, applicator and PPAP submissions. 3.4.2 For the normal production process, the NSS test shall be part of the applicators ‘statistical process control to ensure that parts meet the ‘corrosion resistance requirements, 3.4.3 The applicator shall run a periodic NSS test. of the parts in process on each line running this coating, with sample size of three pieces minimum per shift per line. Based upon the chemical ‘manufacturer's instructions the actual processing control checks shall be made and recordes. The supplier shall maintain the test results in a file to be submitted when required by GM, unless otherwise. agreed between the purchaser and supplier. 3.4.4 Significant surfaces for test evaluation of fasteners shall be all exposed surfaces of the fastener when installed, including but not limited to fastener heads, socket recess, sems washers and external surface of nuts, Fastener threads and point are excluded unless otherwise specified on the drawing 3.4.5 Significant surfaces on parts other than threaded fasteners. shall be all surfaces. Deep recesses, such as blind holes and the interior of tubes are excluded unless otherwise specified on the drawing 34.6 In the case of finishes involving supplementary treatment, parts shall be aged at the ambient laboratory temperatures for at least 24 hn before the test. In some cases, a heat treatment 1h £5 minutes at +150 # 5°C may be required prior to NSS testing. When such treatment is necessary, it shall be specified on the part drawing by using an H in the plating suffix as shown in the section 7 of tis specification. In this case the finish shall meet the corrosion resistance requirements before and after heat treatment 3.4.7 When evaluation of zinc corrosion products is specified, acceptable resistance is defined as no white corrosion products on significant surfaces after exposure to NSS for the number of hours shown {© Copynght 2005 Genera Motors Corporation Al Rights Resened Page 2 ofS ‘April 2005GM WORLDWIDE ENGINEERING STANDARDS GMw3044 3.4.8 Except for black, color dyed. bright, light iridescent blue and clear coatings, the degree of ‘color change after salt spray testis not a significant parameter unless otherwise agreed purchaser and supplier. upon by the Table 1: Zine Plating and Related Finishes Neutal Sa Spray h Miimum Pang (note 5) a Thickness | Supplementary | TYPES! to Specicaton Teaneet | Appearance Number um rea a Zine (ote 2) ote 3) Base Metal | Corrosion Comrsion | Product (ote) au240 3 2 eussio 6 4 No eureo lone 2 . Requirement | 72 12960 2 %6 ssur200 15 720 oo 8 Panavaton % 2 ax40ri20 3 ‘comerson | oar gigny (2 120 18K360/120 6 seaang 360 120 Paseivaon es2401120 ° ‘Conversion | Black 240 120 Coating ‘Note: Ofer codes we possible n spacial canes 0g TK3G0/120 ond ‘valent before creating spo oes ‘Note: Where 2 mechanical (pee) plating i equred new of eecopl {olor the bickness number, eg GMWGO48 SMUG ay be devieed as per be gidaines in paragraph 11. Establish ng, ne eter Mis added to the code in the positon immediatly Note 2: See paragraphs 2.2.2 and 2.23 for maxmum thickness requirements. Ary deviation forthe plang thickness requirements can be ‘own onthe srawing ofthe pat Note 3: Further supplementary testments such 28 ol, wax other coatings, required, are specied onthe drawing a8 uF Y Any ‘Changes hat afer coroson properties sal be aegaiied between te purchaser and supper. Note 4: Clas (right) and Back colors ae avaiable. Esabisn avatabity before puting any colr eter than Ciear (Brot) and Black on Growing Unies oer oor a speciod supe wil proces the parts n Clear (gh) color Note 5: When tne fish s to be heat este prior o seit spray tosting, te fete H shal be shown as the last charac ofthe pang code, (0 GMINaOs4 ak240/120KH. Samples eal be heat vealed for th 5 minutes at (1504 °C [Note 6: Codes that spect more than 48 hto zine corosion products may requte speci hanaing. The suflxes T,X. ¥, Gor N when ‘Bided fo the plang code, inate the apple of pestsreatent rates as Gescibedn 3 Example 8K240/120X 3.8 Hydrogen Embrittlement. All parts heat treated or highly cold worked to the specified core hardness greater than HRC 32 or surface hardness HRC 35, which are processed through ‘the hydrogen generating processes. shall be processed per SAE/USCAR-S and tested for de- ‘embrittiement per SAE/JUSCAR-T. The sample size for the SAE/USCAR-7 test shall be per ASTM F1470. 3.5.4 When supplementary treatment is specified for a part that requires baking after plating, the supplementary treatment shall be applied after the baking operation. 3.6 Processing Requirements. For certain applications a posttreatment of the electrolytically ‘coated components — with or without passivation — may be necessary, using lubricants, waxes, dipping solutions or other materials. In this case the following suffixes apply T: with or without dipping solution, coefficient of friction 0.13 + 0.03 (6-sigma). This suffix is to be used on fasteners of special applications to meet 3.7, 3.8 and 3.9 requirements, (© Conyight 2008 General Motes Corporation Al Rights Reserved ‘April 2005 Page 3 of 5GMw3044 GM WORLDWIDE ENGINEERING STANDARDS X with dipping solution only. : with or without dipping solution, coefficient of friction 0.13 + 0.03 (6-sigma). This sufi is to be used on general fasteners to meet the basic torque- tension/coefficient of friction requirements per 3.7 and 3.8, Y: other material, as specified on drawing. Y suffic ‘could be used along with other suffix in 2 code if required (example: GMW3044 8K 240/120NY, then describe 'Y" on the drawing) NN: without any dipping solution, lubricant, or any ‘chemicals applied. Note: If no suffix to the code is used the provision of suffix N shall apply 3.6.1 All these treatments shall not reduce the ‘corrosion protection of the finish. 3.7 Torque-Tension Test. For bolts and nuts Which are posttreated to suffixes G and T, M10 x 1.5 surrogate bolts shall be processed with the production parts. A minimum of ten bolts per finish line per shift shall be tested per SAE/USCAR-11, ‘except tightening speed shall be 30 + 3 RPM and. test paris as shown in Table 2. The six sigma torque value must be within the listed range (Table 2). The test results shall be maintained inthe file to be submitted when required by GM. Table 2: Test Parts Toad size Test Nut Part] Test Washer | rorquo Nm) | Tension (kN}| Suites wwioxts | 11stoi0s | tisieo00 | tremaess | asa | 283 | Tews Note: Engineenng arawings for surrogate festeners for Torque-Tension test are avadstie tom Giobal Engineenng DooumentiIAS 3.8 Coefficient of Friction. For fasteners, which are post-reated to suffixes G and T, the coefficient of friction of the threaded fasteners tested per DIN {946 shall be 0.13 + 0.03 (6-sigma). Note: Both tests shall be run forthe initial approval of the finish materials. Suppliers are required to run either the Torque-Tension Test or the Coefficient of Friction Test for routine test 3.8.1 Coofficient of Friction Test. The coefficient of friction of threaded fasteners shall be tested per DIN 946 withthe following exceptions: + Tightening speed shall be 30:3 RPM + Test samples (excluding driven fasteners shall bbe thoroughly cleaned with an appropriate fluidichemical —to—remove. any ‘greaseloilwax/other contaminants + Test clamping force shall be calculated at 75%. of proof load. 3.9 Bearing Surface Characteristics. For bolts and nuts which are post treated to suffix T, M10 heavy flange bolts (part number 11900183. or equivalent) shall be monitored per SAE/USCAR-11 with the following requirements: Tightening speed shall be 30 = 3 RPM. Test nut shall be 11516090, Tension load shall be 24 KN. Tests shall be conducted with ELPO coated test washers (11515490 except unhardened and coated with 19984094, medium build ELPO) and aluminium test washers (3.0 mm min thick, (10.25..10.50) hole size, AAGGE3TS2 aluminium). The 6-sigma torque range must le within (35..52) Nim for ten samples tested for both the ELPO and aluminum bearing surfaces, Noto: This testis required forthe intial approval of the finish chemicals only. This testing does not supersede PPAP requirements of the individual part. 3.10 Thread Locking/Sealing Compatibility. The finish shall be compatible with thread adhesives, ‘non- metalic elements/sealers in thread locking/sealing abilities when tested per GM6124M (paragraphs 3.4 & 4.1), GM6175M (paragraph 6.1), GMe189P (paragraph 4.1), and 9985490 (paragraph 4.3) specifications. Note: This testis required forthe initial approval of the finish chemicals only. This testing does not supersede PPAP requirements of the individual part. 3.11 Label Adhesion Compatibility. This finish shall_be compatible with labels (Part Number 112585535 oF label of equivalent construction) in adhesion when tested per GM6121M (paragraph 4.2). Test plaques (Steel, 75 x 125 mm) containing the plating post treatment and affixed label shall be tested per GMB121M Note: This testis required forthe initial approval of the finish chemicals only. This testing does not supersede PPAP requirements of the individual part ‘© Gopyight 2008 General Motors Corporation I Rights Reserved “Page 4 of 5 ‘April 2005GM WORLDWIDE ENGINEERING STANDARDS _ GMW3044 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 respective GM Specialist Teams/TOGs. GMNA approved supplier names are available in the on- line MATSPC system. GMNA approvals are ‘specific to the post supplementary treatment suffix (F, G, X, of N) tasted for initial approval of the ‘supplier. Approval to suffix G & X will be automatic with a suffix T approval, and a suffix X approval wil bbe automatic with a suffix G approval due to subset test requirements. Any approved applicator can provide zinc plated parts without passivation ‘conversion (code U). The GM MATSPC system ‘supplier approval listings include the specific sutfix ‘approvals. For other GM locations, the appropriate ‘engineering group should be contacted to obtain the approved sources in the individual countries. 7 Coding System This material specication shall be referenced in ‘ther documents, drawings, VTS, CTS, ete. as follows Material per GMW3044 Example: Zinc Plating per GMW3044 15K360/120XH (clear) indicates the following: 3044 — Specification Number 415~ 15 micrometer min thickness K — Clear conversion coating 360 — 360 h NSS without evidence of base metal corrasion 4120 — 120 h NSS requirement for white corrosion X-- with dipping solution only H —Heat Treatment required prior to NSS testing Clear ~ Clear appearance 8 Release and Revisions 8.4 Release. This specification was first approved in February 2000 and published in June 2000 8.2 Revisions. Rev | Approval Date Description (Organization) E | SEP 2004| Revised Table 1 and Note 2 and 6, old paragraphs 34322, 34414, 32, 3.2.2.2.1'and Appendix A and rewrote in new GMW {empiate. (GMNA) F | APR 2008] Revised sections 1, 6 and Table 1, added tightening speed to 3.1.4.10.deleted Appendix A with some editorial changes. (© Copyreht 2005 General Motors Corpration Al igh Reserved April 2005 Page 5 of 5