Product Specification Doc.

Type ATE
Silicate Sealing for Electroplated Doc. Num. N 553 81.09
 Zinc or Zinc Alloy Coatings Doc. Part 200 Doc.Ver. 09

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CONTENTS

Änderungen / Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Frühere Ausgaben / Previous Editions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 MANUFACTURER'S RESPONSIBILITY
[08] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4 GENERAL HINTS
[09] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5 DESCRIPTION OF PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.1 Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.2 Chemical resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.2.1 Resistance to organic solvents (accelerated test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.2.2 Resistance to brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.3 Thermal stability
[09] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6.4 pH after drying

[09] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6.5 Corrosion resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6.5.1 On passivated Zn and ZnNi coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.5.2 On bright steel or cast iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.6 Corrosiveness of brake fluid in the presence of sealing substance . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.7 Roughness, friction and wear behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6.8 Feasibility of adhesive bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.9 Testing the damage tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 PRODUCTS COMPLYING WITH THIS SPECIFICATION
[08] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7.1 Sealings for components which permanently come into contact with brake fluid /
[08] are operated in brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7.2 Sealings for components, which do not permanently come into contact with brake
fluid / are not operated in brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Änderungen / Changes

Items marked with [09] have been changed.

Weitergabe sowie Vervielfältigung dieses Dokuments, Verwertung und Mitteilung seines The reproduction, distribution and utilization of this document as well as the communication
Inhalts sind verboten, soweit nicht ausdrücklich gestattet. Zuwiderhandlungen verpflichten zu of its contents to others without express authorization is prohibited. Offenders will be held
Schadenersatz. Alle Rechte für den Fall der Patent-, Gebrauchsmuster- oder liable for the payment of damages. All rights reserved in the event of the grant of a patent,
Geschmacksmustereintragung vorbehalten. utility model or design.
No guarantee can be given in respect of the translation. MITTEILUNG NR. DATUM NORMUNG FACHABTEILUNG GESEHEN
In all cases the latest German-Language version of this
standard shall be taken as authoritative.
NOTE NO. DATE STANDARDS DEPT. OPERATING DEPT. SEEN

FRA-12115540 QPS QL FFM S

© Continental AG. 2012 2012-12-03
eSign 1991745 U. Czerwon Dr. M. Nader
82.9212-0000.4 / 800 / 01 “wpd”
 Product Specification Doc. Type ATE
Silicate Sealing for Electroplated Doc. Num. N 553 81.09
 Zinc or Zinc Alloy Coatings Doc. Part 200 Doc.Ver. 09

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Frühere Ausgaben / Previous Editions

[00] FRA-01125294 - 03.07.02, [01] FRA-03110071 - 06.03.06,

[02] FRA-04112018 - 25.06.04, [03] FRA-05111901 - 28.06.05,
[04] FRA-06111753 - 16.05.06, [05] FRA-06115618 - 15.12.06,
[06] FRA-07116177 - 13.11.07, [07] FRA-08112221 - 06.05.08,
[08] FRA-10111089 - 04.03.10

1 SCOPE

This specification applies to silicate-based Cr(VI)-free inorganic sealing products used

with electroplated and passivated zinc and zinc alloy coatings on brake components.

If identified as “vs”, they are part of the coating designation in accordance with
ATE N 106 61.00 (e.g. Zn8y vs); see also general definitions under Ob 258 and Ob 260
in ATE N 106 36.21.

The present standard specifies the product-specific quality characteristics as well as

their test methods and evaluation criteria.

2 REFERENCES

DIN EN ISO 9227 SSN Salt Spray Testing

ATE N 106 36.11 Surfaces - Metallic Coatings

ATE N 106 36.21 Surfaces - Mechanically, Chemically and
Electrochemically Treated
ATE N 106 61.00 Surfaces - Metallic Coatings
ATE N 543 27.08 Noise Insulation Measures and Fastening of
Add-On Parts to Brake Pads
ATE N 543 81.02 Accelerated Condensation Test
ATE N 553 81.03 Test Specification - Zinc Coatings on Cast Iron and
Steel
ATE N 553 81.04 Test Specification - ZnNi, ZnFe and ZnCo Alloy
Coatings on Cast Iron and Steel
ATE N 553 81.07 Brake Caliper Housings, Holders and Frames of Cast
Iron electroplated with Zinc or Zinc Alloys
ATE N 553 11.05, Sheet 201 ATE Brake Fluids

Limit Sample Catalogues

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 Product Specification Doc. Type ATE
Silicate Sealing for Electroplated Doc. Num. N 553 81.09
 Zinc or Zinc Alloy Coatings Doc. Part 200 Doc.Ver. 09

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3 MANUFACTURER'S RESPONSIBILITY
[08]
Every manufacturer of parts, components or raw materials is responsible for the quality
of the products it supplies.

Motor vehicle components are safety items. As a result, special quality assurance
measures must be observed and the documentation requirements in the quality
assurance specifications apply.

All parts must correspond to the specified technical requirements in the performance
specification, drawings and specifications and other relevant internal specifications and
applicable DIN standards.

Production supplies of these parts shall only be permitted after completion of the internal
release process and unrestricted First Article release. Before First Article release,
supplied parts must be clearly designated and labeled as preproduction or prototype
parts.

Prior to making any change to a product, its chemical composition, the production
method or production location, identification or packaging, the supplier shall advise
Continental Automotive in writing and must obtain prior permission for the change. The
supplier shall advise Continental Automotive in writing early enough to allow a new
sampling procedure to take place through to production release if necessary due to the
change. The obligation to notify Continental Automotive shall also apply to changes
which have no effect on compliance with the agreed technical specifications.

Modified products may not be supplied as series production parts without written
approval from Continental Automotive.

Every change carried out after this must be fully documented, including at least the type
of change and the date when the change was introduced as well as the date of the first
production delivery to Continental Automotive.

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Silicate Sealing for Electroplated Doc. Num. N 553 81.09
 Zinc or Zinc Alloy Coatings Doc. Part 200 Doc.Ver. 09

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4 GENERAL HINTS
[09]
The sealings specified here serve to improve the protection against corrosion as well as
the temperature stability and staining resistance of electroplated and passivated zinc or
zinc alloy coatings. It also protects uncoated areas (bright cast iron or steel surfaces) in
transit and storage.

The sealing is applied as an aqueous solution immediately after the coating process, but
prior to drying, by the dipping method and, thus, represents a process step integrated
into the coating process.

As sealings based on organic polymers are not resistant to brake fluid, only sealings
based on inorganic silicate may be used for brake components which are permanently
operated in contact with / in brake fluid. A preselection with the aid of IR spectrometry,
which provides information on the chemical composition of the product, is advisable.

Water-glass-based silicate sealings leave a film on the component surfaces which may
exhibit a residual alkalinity, depending on the type of water glass and the method of
manufacture. In conjunction with a high air humidity, this residual alkalinity adversely
affects the corrosion resistance and feasibility of adhesive bonding of the passivated and
sealed zinc / zinc alloy coatings after prolonged storage. It may also lead to local
staining of the surface. In addition to this, damages at units, made of materials, which
react sensitive against alkalinity (e.g. Aluminium) can occur. These drawbacks must be
reliably precluded by selecting suitable sealants / maintaining closely toleranced process
parameters; see para. 5 of this specification.

The colourless sealings described here are so thin (typically:  1 μm) and transparent
that as a rule they will not show up during a visual inspection of the surface. Their
presence can be verified by a non-destructive X-ray fluorescence analysis for silicon
(e.g. EDX analysis in a scanning electron microscope).

Sealings may only be released by the central laboratory after consulting the respective
development department.

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Silicate Sealing for Electroplated Doc. Num. N 553 81.09
 Zinc or Zinc Alloy Coatings Doc. Part 200 Doc.Ver. 09

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5 DESCRIPTION OF PROCESS

The recommendations contained in the technical data sheets of the manufacturers shall
be used as starting point for optimizing the process.

To avoid heavy surface alkalinity, either of the following two sealing processes may be
used:

1. If sealing chemicals based on sodium or potassium water glass are used (such
as Rogard Supreme Seal 500, Finigard 200 A), then the ware must be rinsed in
water (pH 9) after completion of the sealing process and before drying.

2. Only silicate sealings which leave no heavily alkaline films with long-time stability
after drying and, thus, react almost neutrally after drying may be used if rinsing
after completion of the sealing process is impossible for process equipment or
other reasons (such as lack of space, cycle time relevance).

If the ware cannot be rinsed, then the process must be optimized with respect to
solids content of the sealant solution and drying conditions such that the sealant
coating is fully reacted in order to keep the share of resoluble alkalies as low as
possible. For a complete reaction of water glass sealings, CO2 (abundantly
present in the atmosphere) is required. Drying in pure vacuum is not a viable
approach for this variant.

The “pH of the surface” measured with universal pH-paper in a water drop
(approx. 0.05 ml) 10 s after impingement on the surface may be used as an aid
for optimizing the sealing process. The measured value must lie between pH7
and pH9. This pH-measurement is not a substitute for application technology
studies, but represents an accelerated test which is useful and sufficient for
process optimization purposes.

In view of the differences of the geometries of the components to be sealed, the sealing
products used and the equipment available, only the basic process sequence can be
defined in this specification. The sealing process to be used for a specific application
must therefore be defined in a special job instruction based on tests / past experience,
taking into account the requirements of this specification.

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Silicate Sealing for Electroplated Doc. Num. N 553 81.09
 Zinc or Zinc Alloy Coatings Doc. Part 200 Doc.Ver. 09

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6 REQUIREMENTS

6.1 Appearance

The sealing shall not significantly change the typical appearance of the passivated zinc or
zinc alloy coating.

Acceptable are:
- light brightening in the case of coloured passivation,
- suppression of the partially iridescent character of the passivation.

Not acceptable are:

- blisters, pimples, voluminous sealant residues in functional and decorative areas
- discolouration and stains.

Component-specific limit samples (limit sample catalogues) shall be used for inspection
or defined if required.

6.2 Chemical resistance

For the resistance tests described below, approx. 5 sealed steel sheets are required
which shall be prepared as follows:

Preparation (for one steel sheet)

A bright steel sheet of stainless steel with a total surface area of approx. 200 cm² shall
be cleaned (e.g. by degreasing in a hot alkaline cleaning solution), carefully rinsed with
fully demineralized water and dried approx. 1 hour at 120°C until its weight remains
constant.

The clean sheet, accurately weighed to within 0.1 mg, shall be dipped into the sealing
solution at room temperature for 5 minutes and predried in air at RT for 1 h in a
1
suspended position . To ensure largely equal weights, the solids content of the sealing
solution must lie betwen 15 and 25%.

Then the suspended sheet shall be finish-dried in a convection hot cabinet for 1/2 h at
120°C. After cooling to room temperature, the sheet shall be accurately weighed to
within 0.1 mg and the drying process repeated until the weight of the sealing remains
constant. The difference in weight between the cleaned sheet and the sealed sheet
gives the amount of sealing applied.

1
Care must be taken to ensure that no large drops adhere to the sheet edge as these may form blisters during
drying at elevated temperature. The excess drops of the sealing may be removed with blotting paper or rags.

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Silicate Sealing for Electroplated Doc. Num. N 553 81.09
 Zinc or Zinc Alloy Coatings Doc. Part 200 Doc.Ver. 09

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6.2.1 Resistance to organic solvents (accelerated test)

This test can provide first information on the presence of organic substances in the
product which may lead to malfunctions in contact with brake fluid.

Test method

One half of one steel sheet each prepared with the sealing to be tested shall be dipped
in acetone / ethanol and stored at room temperature for approx. 1/2 h.

Requirements

After 2 minutes drying in air, no difference shall be visible between the dipped and not
dipped halves under 10-fold magnification.

Clouding, separation or delimination of the sealing by one of the above-mentioned

solvents indicates an incompatibility with brake fluid. Such sealing must not be used for
components which permanently come into contact with brake fluid / are operated in
brake fluid. In that case, the resistance to brake fluid (para. 6.2.2 below) need not be
tested.

6.2.2 Resistance to brake fluid

Test method

A steel sheet which has been prepared with the sealing to be tested and weighed as
described under para. 6.2 above shall be placed on a wire net in a jar which can be
sealed hermetically and covered with new ATE Super DOT4 brake fluid. The
hermetically sealed jar with contents shall then be stored at 120°C for 2 h.

After storage at elevated temperature, the cooled sheet shall be carefully rinsed with
anhydrous acetone to remove the brake fluid clinging to the surface, blown dry with
clean compressed air and weighed accurately to within 0.1 mg. The procedure shall be
repeated at least once until the weight remains constant.

The difference in weight before and after soaking in brake fluid gives the mass change
of the sealing, which shall be stated in percent.

Requirements

- After soaking in brake fluid as described above, the sealing shall exhibit no
visible separation or swelling.

- The mass change of the sealing shall not exceed ±8%.

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Silicate Sealing for Electroplated Doc. Num. N 553 81.09
 Zinc or Zinc Alloy Coatings Doc. Part 200 Doc.Ver. 09

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6.3 Thermal stability

[09]
For thermal loaded parts with high optical requirements the applied sealant shouldn’t
show any discoloration after a thermal tratment of 72h/150°C + 2h/200°C

6.4 pH after drying

[09]
After drying, the sealed surface should posses a pH value of pH  9.
This can also be realised by a subsequent thermal treatment.

The measurement of the pH value can occur with a humidified universal pH indicator
paper which is slightly rubbed on the sealed surface.
The pH value can be also measured, by applying a water drop (0,05 ml) on the surface
to be evaluated. After exposure of 10 s, the pH value is measured by using universal pH
indicator paper or an applicative digital measuring device.

The measured pH value should be inbetween pH 7 and pH 9

6.5 Corrosion resistance

Using a sealing solution with max. 6 weight % solids content ready for use.

6.5.1 On passivated Zn and ZnNi coatings

Test method

Salt spray fog testing in accordance with DIN EN ISO 9227 SSN after thermal
pretreatment:

2h/150°C for cast calipers (ATE N 553 81.07)

5h/120°C for parts coated with ZnNi
24h/100°C for parts coated with ZnFe / ZnCo

In conjunction with the electroplated and passivated coatings, the sealed surface shall
afford the protection against corrosion demanded in the drawing or product
specification.

In the absence of any specific requirements, the values specified in

ATE N 553 81.03, ATE N 553 81.04 and ATE N 553 81.07 shall apply:

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 Product Specification Doc. Type ATE
Silicate Sealing for Electroplated Doc. Num. N 553 81.09
 Zinc or Zinc Alloy Coatings Doc. Part 200 Doc.Ver. 09

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6.5.2 On bright steel or cast iron

Test method

Accelerated condensation test in accordance with ATE N 543 81.02

This test serves to test the corrosion-protective effect of the sealing on bright steel or
cast iron surfaces.

Requirement

Max. 1% red rust acceptable after 2 cycles.

6.6 Corrosiveness of brake fluid in the presence of sealing substance

This test is required for components which permanently come into contact with brake
fluid / are operated in brake fluid.

Test method

The corrosion tests shall be based on para. 5.12 of the product specification for ATE-
brake fluids, ATE N 553 11.05, Sheet 201.

In a Petri dish, approx. 20 ml of sealing substance shall be condensed to a dry

concentrate within one hour at 120°C. The condensed sealing concentrate shall be
pulverized in a mortar. Then 200 mg each of dried sealing substance shall be placed in
4 corrosion test jars. This shall be followed by adding - as described in more detail in
ATE N 553 11.05 - one metal chain each (consisting of tinplate, steel, gray cast iron,
AlCu4Mg, copper, brass, ZnAl4Cu) and one rubber cup seal each. Two each of the 4
corrosion test jars shall be filled with approx. 300 ml of new / hydrous (5%)
ATE Super DOT4 brake fluid and sealed hermetically. One each of the jars with new
brake fluid shall be stored at 120°C for 5 days and 80°C for 6 weeks respectively. The
two jars containing hydrous brake fluid shall be subjected to the same procedure.

Requirement

The sealing shall be considered to be uncritical if all requirements defined in

para. 5.12 of ATE N 553 11.05, Sheet 201, are met.

6.7 Roughness, friction and wear behavior

A sealed surface may differ from other surfaces in terms of roughness as well as friction
and wear behavior. Sealed components for which these properties are relevant for the
function of the component require a corresponding test and release by the development
department. A potential dependence on temperature of the coefficient of friction must
always be taken into account. In that case, the released sealings must be shown on the
component drawing or in associated product specifications with their product names.

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Silicate Sealing for Electroplated Doc. Num. N 553 81.09
 Zinc or Zinc Alloy Coatings Doc. Part 200 Doc.Ver. 09

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6.8 Feasibility of adhesive bonding

Sealing may modify the surface such that it will no longer form an adhesive-bonded joint
with brake linings provided with double bonding sheets, for example. Compliance with
the requirements of ATE N 543 27.8 for feasibility of adhesive bonding and adhesion
must be ensured by a suitable process control and selection of chemicals.

6.9 Testing the damage tolerance

Particularly high resistance to corrosion, e.g. 480 h to base metal corrosion with
Zn8yvs2, can be achieved by using sealings with pronounced damage tolerance or
“self-healing powers”. These properties shall be verified by the following test sequence:

- Stone impact test in accordance with DIN 55996-1 Method B on the finished-coated
component. The damage must not be caused earlier than 24 h after completion of
the component.

- Tempering at 150°C/2h

- Corrosion testing

The sealing used exhibits a pronounced damage tolerance if the resistance to corrosion
in the areas damaged by stone impact is only slightly inferior to that in the undamaged
areas.

7 PRODUCTS COMPLYING WITH THIS SPECIFICATION

[08]
The requirements of this specification are met by the products listed below. The release
of specific components requires additional functional tests (see para. 6.5).

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Silicate Sealing for Electroplated Doc. Num. N 553 81.09
 Zinc or Zinc Alloy Coatings Doc. Part 200 Doc.Ver. 09

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7.1 Sealings for components which permanently come into contact with brake fluid /
[08] are operated in brake fluid

Manufacturer /
Product name Remarks
Supplier
Sealer 300 W Fa. Atotech
Sealer 300 W CT Fa. Atotech
Sealer 300 WL Fa. Atotech with slip additive
Sealer 303 W Fa. Atotech
Finigard 200 A Coventya
Enseal 29 Polyclad
Slotofin 20 Schlötter
Rogard Supreme Seal 500 Atotech

A solids concentration of 2.5 - 6% (determined as evaporation residue) is recommended

as a suitable concentration for application.

Additional requirement for wheel brake components: Unless expressly specified

otherwise (e.g. by a drawing entry), sealings shall be aplied as defined below:

Surface Holder Housing Frame

Zn8yvs/ Zn8yvs2 Sealer 300W / 300W CT Sealer 300W / 300W CT Sealer 300W / 300W CT

ZnNi8fvs / ZnZnNi8fvs Sealer 300W / 300W CT Sealer 300W / 300W CT Sealer 300W / 300W CT
(alkaline electrolyte)

ZnNi8fvs Sealer 300WL7 Sealer 300W / 300W CT Sealer 300WL7

(acid electrolyte)

7.2 Sealings for components, which do not permanently come into contact with brake
fluid / are not operated in brake fluid

Manufacturer /
Product name Remarks
Supplier

DELTACOLL 80 Dörken only for Temic

Finigard 105 Coventya
AQUARES 3 OC Enthone

A solids concentration of 3 - 6% (determined as evaporation residue) is recommended

as a suitable concentration for application.

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