Klass.-Nr./Class. No.

50223 June 2007

Norm vor Anwendung auf Aktualität prüfen / Check standard for current issue prior to usage.
Non-Electrolytically Applied TL
Zinc Flake Coatings 245
Surface Protection Requirements
Konzernnorm
Descriptors: corrosion protection, surface protection, zinc, aluminum, flake, Delta-Protekt,
Delta-Tone, Geomet, Magni, Zintek
The English translation is believed to be accurate.In case of discrepancies the German version shall govern.

Changes
The following changes have been made as compared to Technical Supply Specification TL 245,
2004-12:
─ Section 1 "Scope" updated.
─ Surface protection type Ofl-t601 added
─ Table 2 updated
─ Section 3.1 "Dry film thickness" updated
─ Section 3.3 "Threaded parts with metric ISO standard threads" updated
─ Section 3.4 "Base coating" updated
─ Section 3.5 "Top coat/lubricant additives" updated
─ Section 3.7 "Pretreatment" updated
Section 3.9 "Dry film thickness" updated
Numerical notation according to ISO practice (see VW 01000).

─
─ Section 3.10 "Adhesion" updated
─ Section 3.11 "Corrosion behavior" updated
─ Section 3.12 "Resistance to chemicals" updated
─ Referenced standards updated
─ Appendix A updated

Previous issues
1987-08, 1989-10, 1990-01, 1991-03, 1991-11, 1992-10, 1993-07, 1997-12, 2002-10, 2004-12

1 Scope
This standard defines the requirements on Cr(VI)-free surface protection types made of zinc flakes
and aluminum flakes non-electrolytically applied to ferrous materials.
Silver-gray flake coatings shall be used as heavy-duty corrosion protection for components with a
high corrosion load. With an appropriate layer structure, the zinc-flake coatings are able to
withstand temperatures, such as those occurring in the engine compartment, for example (details
see Table 1).
Since this coating process poses no risk of hydrogen-induced brittling, it is preferably used as
corrosion protection for hardened and high-strength steel parts with tensile strength values
> 1 000 MPa or surface hardness values > 320 HV. The protection system shall be chosen such
that the strength and hardness are not impaired by the treatment temperatures.
Zinc-flake coatings are also suitable for use as a coating for ferrous materials in contact with
aluminum components (however, not for those in contact with magnesium components).
The coating is not suitable for parts
─ that serve as electrical conductors (e.g. ground connections),
─ with 12-point sockets acc. to Volkswagen Standard VW 01043 < N8 and hexalobular sockets
acc. to VW 01048 < T30,
Form FE 41 - 01.06

Page 1 of 9
Fachverantwortung/Technical responsibility Normung/Standards

K-GQL-2/2 Ackermann EKTC/4 Wiesner

Tel: +49-5361-9-38255 K-GQL-2/2 Laudien K-GQL-2 Dr. Eisenberg Tel.: +49-5361-9-29064 EKTC Terlinden

Confidential. All rights reserved. No part of this document may be transmitted or reproduced without prior permission of a Standards Department of the Volkswagen Group.
Parties to a contract can only obtain this standard via the B2B supplier platform “www.vwgroupsupply.com”.
 VOLKSWAGEN AG
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TL 245: 2007-06

─ with hexagon sockets < 5 and cross recesses according to DIN EN ISO 4757 < H3
─ with external threads < M6 and internal threads < M10
─ with washers with a thickness of < 1,6 mm
In order to avoid problems caused by coating particles that come loose, zinc flake coatings should
only be used inside units (e.g. oil chamber) in exceptional cases.

2 Description
See VW 13750, Section 2.

3 Requirements

3.1 Surface protection types

The surface protection types listed in Table 1 apply; for replacement of surface protection types
that are no longer permitted, see Table 2. Examples of systems that were previously released part-
specifically are listed in Appendix A.1.
Table 1
Protection type Characteristics and appearance
Ofl-t601 Base coating without top coat and without lubricant additive.
Zinc flake coating, Cr(VI)-free, silver-gray; suitable for components that
are to be painted.
─ curing temperature up to max. +300 °C
─ reduced corrosion resistance (see Section 3.11)
─ reduced endurance service temperature without additional coatings
(+125 °C)
Ofl-t602 Base coating with top coat, without lubricant additive.
Zinc flake coating, Cr(VI)-free, silver-gray; use in exposed installation
positions, e.g. in the engine compartment and chassis areas.
─ curing temperature up to max. +300 °C
─ endurance service temperature max. +180 °C (short-term
temperature peaks up to +300 °C)
Ofl-t610 As for Ofl-t601, but with lower curing temperature.
Zinc flake coating, Cr(VI)-free, silver-gray; corrosion protection preferably
for components that are to be painted (body construction). Standard
surface protection for threaded parts with adhesive coating (DIN 267-27)
or with locking coating (DIN 267-28).
─ curing temperature up to max. +200 °C
─ reduced corrosion resistance (see Section 3.11)
─ reduced endurance service temperature without additional coatings
(+125 °C)
Ofl-t611 As for Ofl-t602, but with lower curing temperature. Consequently, suitable
for components that cannot be exposed to high temperatures, e.g. spring
elements, press-quenched sheets or high-strength steel parts.
─ curing temperature max. +230 °C
─ endurance service temperature max. +200 °C (short-term
temperature peaks up to +300 °C)
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TL 245: 2007-06

Table 1 (continued)
Surface protection Characteristics and appearance
type
Ofl-t615 As for Ofl-t610, but additionally with lubricant (greenish) acc. to TL 52165.
Standard surface protection for nuts with non-metallic locking element.
─ curing temperature up to max. +200 °C
─ reduced corrosion resistance (see Section 3.11)
─ reduced endurance service temperature without additional coatings
(+125 °C)
Ofl-t647 Base coating with top coat, with lubricant additive.
Zinc flake coating, Cr(VI)-free, silver-gray, standard surface protection for
threaded parts with metric ISO threads (see VW 01110-1).
─ curing temperature up to max. +300 °C
─ endurance service temperature max. +180 °C (short-term
temperature peaks up to +300 °C)

Table 2
Surface protection type not permitted for Protection type designated for new designs
new designs
Components of a general nature
Ofl-t300 Ofl-t601
Ofl-t310 Ofl-t610
Ofl-t320 Ofl-t611
Ofl-t600 Ofl-t602
Ofl-t620 Ofl-t611 1)
Threaded parts with metric ISO threads
Ofl-t300 Ofl-t647 2)
Ofl-t310 Ofl-t647 2)
Ofl-t320 Ofl-t647 2)
Ofl-t345 Ofl-t647 3)
Ofl-t600 Ofl-t647 2)
Ofl-t620 Ofl-t647 2)
Ofl-t645 Ofl-t647 3)
1) Ofl-t611 stipulates a lower endurance service temperature than Ofl-t620.
2) Ofl-t601 or Ofl-t610, if component is installed in body construction before painting. Ofl-t610 for threaded parts with locking coating
or adhesive coating
3) Ofl-t615 for nuts with non-metallic locking element.
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TL 245: 2007-06

3.2 General requirements

Approval of first supply and changes according to VW 01155.
Avoidance of hazardous substances according to VW 91101.
10 finished parts are required for complete testing. For first-sample release of small parts, e.g.,
threaded fastening elements, a test production of > 50 kg shall be performed.
The coating materials must not contain any Cr(VI) compounds in order to ensure that the resultant
coatings are likewise Cr(VI)-free.
Unless certain sections of a part that are marked in the drawing are excluded from the surface
coating, the entire surface of the parts must comply with the required surface protection type and
display the prescribed properties. There shall be firm adhesion between coatings and base material
(see Section 3.10) and there shall be no flaking of the coating or cracks under elastic deformation.
The protective coatings must not exhibit any pores, cracks, damage, or other flaws that impair the
corrosion protection and/or function.
The production process and its control shall not impair the functional characteristics of the finished
part. Thus for example, the coating must not flake or crack when the springs or spring washers are
mounted or used as intended.
With proper mounting, the coating shall not be damaged in a way that would result in impairment of
function and/or decrease in the specified corrosion protection.
For each individual part, the selection of suppliers and coating systems is subject to agreement,
prior to usage, with the Volkswagen AG Group Laboratory (K-GQL-2/2) and/or the Audi AG Test
Laboratories (I/GQ-322 and N/GQ-551).

3.3 Threaded parts with metric ISO threads

The coating process must not impair the mechanical and physical properties specified for joining
elements. Therefore, the manufacturer shall check whether the curing conditions specified by the
coating company are suitable for the parts to be coated.
An essential functional property of threaded parts with metric ISO threads is their compliance with
specified coefficients of friction. In order to ensure that the coefficients of friction comply with
VW 01129, a top coat with integrated lubricant additive is prescribed for surface protection type
Ofl-t647, in addition to the base flake coating. For releases of new coating systems and for the
detection of faults in the case of objections during installation, parts with metric ISO threads shall
be tested acc. to VDA 235-203.
Prior to coating, threaded parts shall respect a tolerance zone position corresponding to the coating
thickness. Metric threaded parts shall preferably be designed according to VW 11624 (internal
threads) or VW 11627 (external threads). After the coating process, the zero line must not be
exceeded in the case of external threads, and it must not be fallen below in the case of internal
threads.
Especially in the case of threaded parts with top coat, it shall be ensured that the surfaces are not
impermissibly damaged by processes carried out after the coating process, such as 100%
verification, packaging, transport, etc. For more information, see guideline "Berücksichtigung der
Schütt- und Transportprozesse bei der Umstellung auf Cr(VI)-freie Oberflächen" (Consideration of
Handling and Transport Processes during the Changeover to Hexavalent-chromium-free Surfaces,
currently only available in German), published by Deutscher Schraubenverband e.V. (German
Fasteners Association). On principle, rework shall be announced and agreed upon.
For further information see VW 01110 -1, Section 2.
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3.4 Base coating

The base coating contains a binding agent and approx. 70% zinc flakes and approx. 10%
aluminum flakes. The use of zinc dust is not permissible.
In order to achieve homogeneously covering coatings in a reliable process and in compliance with
the test requirements defined in 3.11.2, multiple coating is necessary.

3.5 Top coat/lubricant additive

In order to improve the anti-corrosion requirements and to achieve the defined coefficients of
friction, additional system-specific top coats, optionally with integrated lubricant additive, may be
used. The top coats must be coordinated to suit the base coating. They must not cause any
functional impairment.
Zinc flake coatings with top coats shall not be used if paintability and adhesion of adhesives (also:
locking or adhesive coatings for fasteners) are demanded.

3.6 Base material

See drawing.

3.7 Pretreatment
Principally plain metal. Optionally (depending on the coating system) micro-crystalline thin layer
phosphating (1 g/m² to 3 g/m²) is permissible.
Prior to coating, hot alkaline and/or mechanical cleaning (e.g. abrasive blasting) shall be carried out
on high-strength or hardened steel parts with a tensile strength > 1 000 MPa or surface hardnesses
> 320 HV.
Exceptions are only permissible after agreement with the Volkswagen AG Group Laboratory
(K-GQL-2/2) and/or the Audi AG Test Laboratories (I/GQ-322 and N/GQ-551).

3.8 Dry film

Composition acc. to International Material Data System (IMDS).

3.9 Dry film thickness

Testing according to DIN EN ISO 1463, DIN EN ISO 2064 and DIN EN ISO 2178; measuring point
position for threaded parts with metric ISO standard thread according to DIN EN ISO 4042.
The average minimum coat thickness shall be 8 µm; the results of the individual measurements
may vary within the range from 6 µm to 20 µm. For threaded parts, the specifications shall only
apply to the head and/or to the face and wrench bearing surfaces; for all other surfaces, the
minimum coating thickness is achieved if the anti-corrosion requirements are fulfilled.
Internal drives and threaded areas must not exhibit any accumulations of base coat and/or top coat
that might impair the functional properties.
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TL 245: 2007-06

3.10 Adhesion
A scribing line shall be applied on the basis of DIN EN ISO 9227, component dimensions
permitting. Adhesive tape with an adhesive strength of (10 ± 1) N per 25 mm in width is then used
for the adhesion test. It shall be firmly pressed by hand onto the specimen surface and then
removed with a jerk-like motion perpendicular to the surface. There must be no large-area removal
of the coating. Small particles of the coating that adhere to the tape are permissible.

3.11 Corrosion behavior

3.11.1 Test atmosphere CH acc. to DIN EN ISO 6270-2

This test is only required for the release of new coating systems. Generally, this test is carried out
on coated test panels (test scope see below). Within the framework of a first-sample test, the
moisture resistance can also be proven by a certificate issued by the coating material
manufacturer.
A scribing line shall be applied on the basis of DIN EN ISO 9227. After a test duration of 720 h and
evaluation according to DIN EN ISO 4628-3, the following minimum requirements must be adhered
to at all times:
─ Base metal corrosion on surface: Ri 0.
─ base metal corrosion permissible in the scribing line, but no rust creep.

3.11.2 NSS test acc. to DIN EN ISO 9227

The following requirements apply to parts in the goods reception department of the Volkswagen
Group plant using the parts (e.g. after packing and transport).

3.11.2.1 Requirements for components of a general nature

─ No base metal corrosion (Ri 0) after a test duration of 720 h.
─ No base metal corrosion (Ri 0) after a test duration of 480 h with thermal conditioning (aging at
elevated temperature/mechanically circulated air) 96 h at +180 °C.

3.11.2.2 Requirements for threaded barrel plated goods

─ No base metal corrosion (Ri 0) after a test duration of 600 h without thermal conditioning.
─ No base metal corrosion (Ri 0) after a test duration of 480 h with thermal conditioning (aging at
elevated temperature/mechanically circulated air) 96 h at +180 °C.

3.11.2.3 Requirements for components with the protection types Ofl-t601, Ofl-t610 and
Ofl-t615
─ No base metal corrosion (Ri 0) after a test duration of 480 h without thermal conditioning.

3.12 Resistance to chemicals

The verification of the resistance to chemicals is only required for the release of new coating
systems. Generally, this test is carried out on coated test panels (test scope see below). Within the
framework of a first-sample test, the resistance to chemicals can also be proven by a certificate
issued by the coating material manufacturer.
Test according to VDA 621-412 in the following media:
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TL 245: 2007-06

─ FAM test fuel according to VDA 621-412, test A 4.1.1 Y

─ Diesel fuel according to TL 788 and VDA 621-412, test A 4.1.2 X
─ Biodiesel (FAME) according to DIN EN 14214 and VDA 621-412, test A 4.1.2 X
─ Gasoline, premium unleaded per DIN EN 228 and test according to VDA 621-412, test
A 4.1.3 Y
─ Factory-fill engine oil according to TL 52173 (Burmah Castrol Oil code A97075PBC) and
VDA 621-412 test A 4.1.4 X
─ Hydraulic fluid according to TL 52146 and VDA 621-412, test A 4.1.6 X
─ Automatic transmission fluid according to TL 52162 and VDA 621-412, test A 4.1.7 X
─ Coolant according to TL 774 and VDA 621-412, test A 4.2.2 X
A surface change is not permitted (≤ code 1 acc. to DIN EN ISO 4628-1).
Additionally, tests are performed in the following medium:
─ Brake fluid according to TL 766 and VDA 621-412, test A 4.2.1 X.
The following requirement applies to this medium: Swellings that have corrected themselves after
24 h are permissible.

4 Referenced standards*
TL 766 Brake Fluid; Material Requirements
TL 774 Ethylene Glycol-Based Coolant Additive; Material Requirements
TL 788 Diesel Fuel, Fuel Requirements
TL 52146 Central Hydraulic System Fluid; Lubricant Requirements
TL 52162 Factory-Fill-for-Life Automatic Transmission Fluid; Lubricant Requirements
TL 52165 Lubricant (Greenish) for Threaded Fasteners; Material Requirements
TL 52173 Factory-Fill Engine Oil SAE 0W-30 with Fuel-Saving Properties for Extended
Oil Change Intervals; Requirement, Testing
VW 01043 Multipoint Socket Profile; Drive Shape for Threaded Parts
VW 010 48 Round Hexagon Socket; Drive Shape for Threaded Parts
VW 01110-1 Threaded Joints, Design, Assembly Instructions (currently only available in
German)
VW 01129 Limit Values for Coefficients of Friction; Mechanical Joining Elements with
Metric ISO Thread
VW 01155 Vehicle Supply Parts; Approval of First Supply and Changes
VW 11624 Metric ISO Thread; Limit Dimensions for 6G/6f Tolerance Zone, Male 6f,
Female 6G
VW 11627 Thread Limit Dimensions for External Threads of Tolerance Class 6e; Metric
ISO Threads
VW 13750 Surface Protection of Metal Parts; Surface Protection Types, Codes
VW 91101 Environmental Standard for Vehicles; Vehicle Parts, Materials, Operating
Fluids; Avoidance of Hazardous Substances
VDA 621-412 Anstrichtechnische Prüfungen; Chemikalienbeständigkeit von Kraftfahrzeug-
Lackierungen (Tests for Coating Methods; Resistance to Chemicals of Motor
Vehicle Paints; only available in German)

*
In this Section, terminological inconsistencies may occur as the original titles are used.
Page 8
TL 245: 2007-06

VDA 235-203 Threading Behavior; Coefficients of friction; Practice- and Mounting-Oriented

Testing (currently only available in German)
DIN 267-27 Fasteners - Part 27: Steel Screws, Bolts and Studs with Adhesive Coating;
Technical Specifications
DIN 267-28 Fasteners - Part 28: Steel Screws, Bolts and Studs with Locking Coating;
Technical Specifications
DIN EN 228 Automotive Fuels – Unleaded Petrol – Requirements and Test Methods
DIN EN 14214 Automotive Fuels – Fatty Acid Methyl Esters (FAME) for Diesel Engines –
Requirements and Test Methods
DIN EN ISO 1463 Metallic and Oxide Coatings – Measurement of Coating Thickness –
Microscopical Method
DIN EN ISO 2064 Metallic and Other Non-Organic Coatings - Definitions and Conventions
Concerning the Measurement of Thickness
DIN EN ISO 2178 Non-Magnetic Coatings on Magnetic Substrates –Measurement of Coating
Thickness – Magnetic Method
DIN EN ISO 4042 Fasteners – Electroplated Coatings
DIN EN ISO 4628-1 Paints and Varnishes – Evaluation of Degradation of Coatings; Designation
of Quantity and Size of Defects, and of Intensity of Uniform Changes in
Appearance – Part 1: General Introduction and Designation System
DIN EN ISO 4628-3 Paints and Varnishes – Evaluation of Degradation of Coatings; Designation
of Quantity and Size of Defects, and of Intensity of Uniform Changes in
Appearance – Part 3: Assessment of Degree of Rusting
DIN EN ISO 4757 Cross Recesses for Screws
DIN EN ISO 6270-2 Paints and varnishes - Determination of Resistance to Humidity - Part 2:
Procedure for Exposing Test Specimens in Condensation-Water
Atmospheres
DIN EN ISO 9227 Corrosion Tests in Artificial Atmospheres - Salt Spray Tests
 Page 9
TL 245: 2007-06

Appendix A (informative)

A.1 Released surface protection systems

A.1.1 Ofl-t601
Any system, e.g.:
DELTA-TONE 9000
DELTA-PROTEKT KL100
GEOMET 321
Magni Flake B46
Magni Flake D90
ZINTEK 200

A.1.2 Ofl-t602
Any system, e.g.:
DELTA-PROTEKT KL100 + DELTA-PROTEKT VH300
GEOMET 321 PLUS 10
ZINTEK 200 + ZINTEK TOP
Magni Flake B46 + Magni Top T06E

A.1.3 Ofl-t610
DELTA-TONE 9000
Magni Flake D90

A.1.4 Ofl-t611
DELTA-PROTEKT KL100 + DELTA-PROTEKT VH300

A.1.5 Ofl-t615
DELTA-TONE 9000 + lubricant (greenish) acc. to TL 52165
Magni Flake D90 + lubricant (greenish) acc. to TL 52165

A.1.6 Ofl-t647
Any system.
However, for joining elements only:
DELTA-PROTEKT KL100 + DELTA-PROTEKT VH301GZ
GEOMET 321 PLUS VL
Magni Flake B46 + Magni Top T06E-GZ
ZINTEK 200 + ZINTEK TOP LV