NAVISTAR, INC.

NUMBER:
CEMS
CEMS A-6, PART II, APPX
(CORPORATE ENGINEERING MATERIAL SPECIFICATION)
TITLE: Low Carbon Steel, Flat Rolled And Structural Shapes - CURRENT ISSUE DATE:

Part II. Metallic CoatedSheet And Strip - APPENDIX October 2008

WRITTEN/REVIEWED BY: APPROVED BY: SUPERSEDES ISSUE OF:
Materials Engineering Materials Engineering August 2001

PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION

This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all
of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to
determine the applicability of regulatory limits prior to use.
Change Notice: Replaced “International Truck and Engine Corporation” with “Navistar, Inc.” per corporate
directive; deleted information on terne coated sheet; editorial changes.
APPENDIX
GENERAL INFORMATION (NOT A REQUIREMENT)
A.1 GRADES
A.1.1 GRADE 1A: ALUMINUM and ALUMINUM ALLOY COATED STEEL
A coating of aluminum or aluminum alloy is applied to the steel sheet by immersing the sheet in a bath
of molten metal. It is generally a continuous process using coiled sheet or strip. The product is generally
available in coils and cut lengths in thicknesses of 0.20-0.075 inch and in some products from 0.018-
0.140 inch. Two types of aluminum coating and one type of aluminum-zinc alloy coating are
commercially produced and available for design usage. The base metal applied to all aluminized steel
product used in exhaust applications should be designated as HTS (High Temperature Steel). Contact
Materials Engineering for specific information on product availability.
A.1.1.1 Type 1: T1-75 and T1-120 Class: These coatings are an aluminum-silicon (5-11%) alloy used
primarily for heat resisting applications where both heat and corrosion resistance are needed. This is the
aluminized steel sheet product commonly used in muffler and exhaust pipe applications. Corrosion
protection provided is primarily as a barrier coating preventing contact between the steel surface and the
corrosive atmosphere. If the coating is broken, galvanic protection is limited to a gap of 0.015 inch or
less. Commercial products offer good resistance to temperatures to approximately 1250 -1300 F.
Proprietary products offering improved temperature resistance to 1400 F are available for special
applications.
A.1.1.2 Type 2: T2-200 and T2-300 Class: These coatings are thicker than the Type 1 products. They
are essentially pure aluminum coatings used primarily for corrosion resistance. This type offers limited
heat resistance but its heavier (thicker) coatings offer improved corrosion resistance at temperatures
from ambient to approximately 600 F.
A.1.1.3 AZ Type: Classes AZ-150, AZ-165, and AZ-180: These are aluminum-zinc coating with 55%
aluminum and 43% zinc. Similar to the Type 1 aluminized coatings, they are used in high temperature
applications where corrosion resistance is also needed. It is also a barrier coating with service
temperature applications similar to Type 1 but provides significantly better galvanic protection if the
coating is broken.
This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. 2008 by Navistar, Inc.

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NUMBER: TITLE: Low Carbon Steel, Flat Rolled And Structural CURRENT ISSUE DATE:
CEMS A-6, PART II Shapes- Part II. Coated Sheet And Strip APPENDIX October 2008

A.1.2 GRADE 1 and GRADE 6 GALV: ZINC and ZINC ALLOY COATINGS
A coating of zinc or zinc-alloy is applied to the steel sheet by either an immersion (Hot Dip) process or
an electrolytic process. In the Hot Dip process, the sheet is immersed in a bath of molten zinc. The
hot zinc reacts with the steel to form a very thin layer of zinc-iron alloy with an essentially pure zinc
layer above. The thickness of the zinc coating is controlled by adjustable rollers or air knives that
remove part of the zinc on one or both sides as the sheet is withdrawn from the molten bath. The
molten zinc bath raises the temperature of the sheet or strip and may affect the mechanical properties of
the base metal. This is especially true for the very high formability Grade 1, and the higher strength
Grade 6, steel products. In the electrolytic process, the zinc is electroplated directly onto the steel
surface without the formation of the zinc-iron layer. The thickness of the electroplated layer is
controlled by the voltage and current density, time in the plating bath, and size and location of the
anodes. The coating thickness is more accurately controlled in, and base metal mechanical properties
are not affected by, the electrolytic process. Both Hot Dip and electrolytic are continuous processes
using coiled sheet or strip. The product is available in coils or cut lengths. The Hot Dip product is
available in thicknesses of 0.015-0.134 inch. The electrolytic product is available in thicknesses of
0.015-0.075 inch.
A.1.2.1 Type G Coating: The galvanized coating is essentially a pure zinc coating. It provides
corrosion protection by acting as a barrier between the steel surface and the environment and it also
provides sacrificial galvanic protection. The galvanic protection extends to bare, cut, or sheared edges
to a thickness of approximately 0.080 inch.
A.1.2.1.1 Hot Dip Type G: The coatings produced by the Hot Dip process include a thin zinc-iron
layer at the steel interface and a pure zinc outer layer that solidifies into very large zinc grains called
spangles. When painted, the spangled surface does not provide a Class A surface. The spangle effect
can be reduced by reducing the size of the zinc grains at the surface, i.e., minimized spangle, and by
giving the sheet a light rolling pass after galvanizing. The extra rolling pass produces an “extra smooth”
surface. For improved paintability, the hot dip galvanized steel sheet is generally ordered as a minimum
spangle, extra smooth product.
A.1.2.1.2 Electrolytic Type G: The coatings produced by the electrolytic process are smooth and
spangle-free, capable of providing a Class A painted surface without further treatment. The thickness
of the galvanized layers is readily controlled, and mechanical properties developed in the base metal
steel sheet are not affected by the electrolytic process.
A.1.2.2 Type A Zinc-Iron Coating: These are a spangle-free alloy coating commonly produced by
heating the Hot Dip galvanized product. This thermal treatment (galvanneal) causes iron to diffuse
from the steel surface throughout the entire zinc layer developing a zinc-iron (8-12%) alloy. The Type
A zinc-iron coating can also be produced by an electrolytic process in which zinc and iron are co-
deposited onto the sheet surface. As previously noted, coating thickness is more readily controlled, and
mechanical properties developed in the base metal sheet are not affected in the electrolytic process.
The zinc-iron coating offers improved weldability and better paintability than the pure zinc Type G
(spangled) coatings. Corrosion protection derives primarily from the barrier protection of the coating.
The sacrificial galvanic protection of the zinc-iron is less than that of the pure zinc, Type G
This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. 2008 by Navistar, Inc.

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NUMBER: TITLE: Low Carbon Steel, Flat Rolled And Structural CURRENT ISSUE DATE:
CEMS A-6, PART II Shapes- Part II. Coated Sheet And Strip APPENDIX October 2008

coating. If required, Type A coating produced by the electrolytic process may be specified by adding
the EG-prefix to the Class designation for the Type A coating (for example, EG60A60AE).
A.1.2.3 Type N Zinc-Nickel Coating: These coatings are a zinc-nickel (9-16%) alloy produced (only)
in an electrolytic process by co-depositing zinc and nickel onto the sheet surface. The zinc-nickel
coating is primarily a barrier coating with a lesser degree of galvanic protection. The zinc-nickel
coatings provide improved weldability and better paintability than the Type G coatings. It is more
expensive than either the Type G or the Type A coatings. Materials Engineering should be consulted
regarding availability of specific Type N coating classes.

A.2 BASE METAL

The base metal for all grades included in this specification is carbon steel sheet. All product supplied
will meet the applicable requirements of CEMS A-6, Part I. Sheet steel may be either cold rolled or hot
rolled, provided that the strength and formability properties of the steel supplied will meet Engineering
requirements and successfully produce the part required. The designation of the sheet steel as hot rolled
or cold rolled steel will generally be made on the purchase order or in the contract and will not be
specified on the Engineering drawing. The base metal applied to all aluminized steel products used in
exhaust applications should be designated as HTS (High Temperature Steel). Minimum required
mechanical properties are shown in CEMS A-6, Part I.
A.3 COATING CLASSES
A.3.1 GRADE 1A – Aluminum and Aluminum Alloy Coated
The coating class designates the type and amount (weight) of the coating on the steel sheet. Coating
weight is expressed in grams per square meter and applies to both sides of the sheet. It may be
expected that half the coating weight (but not less than 40% of the min specified value) will be found
on one side, and half on the other side. The test for coating thickness/weight is by chemical
dissolution per ASTM A 428; the triple spot test is a nominal value whereas the single spot test is a
minimum value. The coating classes shown in Table III of the specification are the most commonly
used and readily available. Three types of coating, T1 aluminum-silicon (5-11%), T2 pure aluminum,
and AZ aluminum-zinc (43%), are available. All three types are applied by the Hot-Dip Process.

A.3.2 GRADE 1 GALV and GRADE 6 GALV – Zinc and Zinc Alloy Coated
A system for designating the coating class for the galvanized Grade 1 GALV and Grade 6 GALV
coatings is included in this specification. Coating weight, expressed in grams per square meter, is
described as a range with min and max values. The coating weight is applicable to one side of the sheet
only. For referee purposes, the single spot chemical dissolution test per ASTM A 90 will be used to
determine coating weight.
A.3.2.1 The coating weight is specified for each side of the sheet by using a seven character alpha-
numeric code as described in the specification. The first two digits describe the minimum coating
weight on the unexposed/non-visible side of the sheet and the third character/letter describes the type
of zinc coating on the unexposed side. The fourth and fifth digits describe the minimum coating weight
on the exposed/visible side of the sheet and the sixth character/letter describes the type of zinc coating
on the exposed side. The seventh character describes the part application as E (for exposed part, class
A, good surface required) or U (unexposed part, class A surface not required).
This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. 2008 by Navistar, Inc.

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NUMBER: TITLE: Low Carbon Steel, Flat Rolled And Structural CURRENT ISSUE DATE:
CEMS A-6, PART II Shapes- Part II. Coated Sheet And Strip APPENDIX October 2008

A.3.2.2 The minimum coating weight specified is the same for both Hot Dip and electrolytic coating
classes. The coating weight/thickness variation for coatings applied by the Hot Dip process is greater
than for coatings applied by the electrolytic process, as shown in Table IV and V of the specification.
In general, the surface of the electrolytic coated steel is better/smoother than the Hot Dip coated
products. Coating weight tolerance ranges closer than those shown in Table V can be obtained by
negotiation with specific steel suppliers. Engineering can specify the electrolytic process by adding the
prefix EG to the seven character alpha-numeric code. The two-side galvanized class 60G/60G is the
most commonly used class in Navistar design.

A.4 PREFERRED SIZES and TOLERANCES FOR COATED SHEET

Whenever practical, Engineering should select one of the preferred thickness values for coated sheet
steels as shown in CEMS A-6, Part I, Tables 11 and 12 (thickness values include both the metal and
the coating). Utilization of preferred sizes contributes to reduced inventories and minimized cost.
Engineering Design should indicate thickness on drawings by nominal values (not minimum values),
and commercial gage numbers should no longer be shown. Tolerances for thickness are plus and minus
about the nominal value.

This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. 2008 by Navistar, Inc.

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