TEST REPORT

Test Report No.: 210827

Customer: Hyundai WIA India Pvt Ltd.

No. 48; Sur No: 18-80 Kandamangalam
Mr. Park Jihoon
Sengadu Post
Sriperumbudur TK, Tamil Nadu 602105
India

Contract / Date: 4600020632 / 25.06.2021

Quotation No.: 211285

Sub-order: none

Archival storage: 4 weeks

Test specimen: Drive Shaft

Test objective: Component testing according to DBL 7381,

Product version 10 and 12

Origin of sample: Sample sent by customer

Date of receipt: 08.07.2021

Test start date: 12.07.2021

Test end date: 26.08.2021

Laboratory: Application Technology

Scope of testing: Coating thickness (DIN EN ISO 2178)

Technical-mechanical tests 2 (MBN 10494-5)
Condensation-water atmosphere (DIN EN ISO 6270-2)
Corrosion cycle test (DIN EN ISO 11997-1)
Resistance to test fuels (MBN 10494-7)
Resistance to process and service products (MBN 10494-7)

Number of pages 21 signed *) testing d *) testing methods are not a

Fichtestraße 29 Stadtspk. Magdeburg Geschäftsführer:

D-39112 Magdeburg IBAN: DE06 8105 3272 0034 3722 60 Dr. Ulrich Westerwelle
Tel: +49 (0)391 6090-0 BIC: NOLADE21MDG USt-IdNr.:DE163828357
Fax: +49 (0)391 6090-217 Nord/LB Magdeburg Sitz der Gesellschaft:
contact@ilf-magdeburg.de IBAN: DE33 2505 0000 0122 0340 36 Magdeburg
www.ilf-magdeburg.de BIC: NOLADE2H AG Stendal HRB 107162
 Test Report No.210827

Test result summary

Tripod
Single components of the Drive shaft: Outer race Shaft
housing
Characteristics OK NOK OK NOK OK NOK
Coating thickness n/a n/a n/a n/a n/a n/a
Adhesion (As-received condition)
Cross-cut X X X
Scratch test X X X
Multi impact test (method B) - - X - -
Condensation-water atmosphere
Blistering X X X
Cross-cut X X X
Scratch test X X X
Multi impact test (method B) - X -
Corrosion cycle test (Steel)
Surface corrosion X X X
Edge corrosion X X X
Blistering X X X
Cross-cut X X X
Scratch test X X X
Sub-surface corrosion U/2 X X X
Resistance to test fuels
FAM X X X
Resistance to process and service
products
Hydraulic fluid / servo-oil X X X
Brake fluid X X X
Cold cleaning solvent X X X
Preservative X X* X

*borderline (OK after 24 h regeneration time).

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1. Test specimen

The customer delivered original components with the following designation.

Table 1: Designation Assembly component

Designation iLF Designation customer

Drive Shaft
P 1.1 – P 1.13
A 25443300200

Table 2: Designation Single components with legend

Designation iLF Single component Coating Test objective

P 1.1_O – P 1.13_O Outer race Powder coating DBL 7381.10

P 1.1_S – P 1.13_S Shaft Electrocoating DBL 7381.12

P 1.1_T– P 1.13_T Tripod housing Powder coating DBL 7381.10

Outer race Shaft Tripod housing

DBL 7381.10 DBL 7381.12 DBL 7381.10

Figure 1: Drive Shaft

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2. Test procedure in accordance with DBL 7381;

Product version 10 and 12
2.1. Dry film thickness

Test procedure: Determination of Dry film thickness according to DIN EN ISO 2178 as well as
MBN 10494-5
• single measuring points
• overall measurement

Table 3: Result Determination of dry film thickness

– single measuring points (MP)

Outer race Tripod housing

MP 1 MP 2 MP 3 MP 1 MP 2 MP 3
Sample – no. Sample – no.
[µm] [µm] [µm] [µm] [µm] [µm]
P 1.1_O [µm]
82,8 92,6 94,0 P 1.1_T [µm]
87,8 84,1 87,0
P 1.2_O 79,9 76,1 80,3 P 1.2_T 77,5 76,7 68,2
P 1.3 _O 87,8 77,1 81,8 P 1.3_T 78,9 79,5 73,8
P 1.4_O 87,6 92,7 90,1 P 1.4_T 84,4 87,5 86,8
P 1.5_O 85,7 78,6 82,2 P 1.5_T 86,5 97,7 84,4
P 1.6_O 83,7 78,3 83,8 P 1.6_T 95,2 94,7 95,3
P 1.7_O 82,0 84,7 87,4 P 1.7_T 92,3 83,8 98,3
P 1.8_O 79,3 79,0 72,3 P 1.8_T 79,3 88,3 81,9

Figure 2: Dry film thickness measurement points Figure 3: Dry film thickness measurement points
- Outer race - - Tripod housing -

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Table 4: Result Determination of dry film thickness

– single measuring points (MP)

Shaft
MP 1 MP 2 MP 3
Sample – no.
[µm] [µm] [µm]
P 1.1_S [µm]
32,8 32,7 34,5
P 1.2_ S 31,9 32,6 32,4
P 1.3 _ S 33,6 33,2 34,1
P 1.4_ S 33,4 32,6 33,8
P 1.5_ S 32,1 32,0 33,9
P 1.6_ S 33,8 32,9 33,5
P 1.7_ S 32,7 32,5 33,1
P 1.8_ S 33,9 33,8 34,3

Figure 4: Dry film thickness measurement points

- Shaft -

Table 5: Result Determination of dry film thickness – overall measurement

Sample no. Mean value Standard- Maximum Minimum

[µm] deviation [µm] [µm] [µm]
P 1.1_0 – P 1.8_0 83,32 5,59 94,0 72,3

P 1.1_S – P 1.8_S 33,18 0,75 34,5 31,9

P 1.1_T – P 1.8_T 85,35 7,62 98,3 68,2

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2.2. Adhesion (as-received)

Test procedure: Cross-cut test (DIN EN ISO 2409)

• Tesa tape 4657
Scratch test (MBN 10494-5)

Table 6: Result Adhesion

Sample no. Cross-cut Scratch test

Set value: ≤ Gt 1 ≤K2

P 1.1_0 Gt 0 K 1-2

P 1.1_S Gt 0 K2

P 1.1_T Gt 0 K 1-2

P 1.2_0 Gt 0 K 1-2

P 1.2_S Gt 0 K2

P 1.2_T Gt 0 K 1-2

Figure 5: P 1.1_S – Cross-cut Figure 6: P 1.2_O – Cross-cut

Figure 7: P 1.2_T – Cross-cut

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2.3. Multi impact test

Test procedure: Multiple impact test according to DIN EN ISO 20567-1, method B
• Tesa tape 4657

Test condition: Multi Grit Tester 508 MC (company Erichsen)

Angle between grit-blasting shaft and specimen: 54°
Working pressure: 2 bar
Shot: Steel-grit (sharp-edged, size 3,55-5 mm)
Time for feeding shot: 10 sec / 0.5 kg
Shot volume: 2 x 500g

Table 7: Result Multi impact test

Sample – no. Rating Degree of rusting

Set value: ≤ parameter 2 ≤ parameter 1

P 1.1_S parameter 1,5 parameter 1,0

P 1.2_S parameter 1,5 parameter 1,0

Figure 8: P 1.1_S – Multi impact

Figure 9: P 1.2_S – Multi impact

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2.4. Condensation atmosphere with constant humidity

Test procedure: Determination of resistance to humidity according to DIN EN ISO 6270-2 (CH)
as well as MBN 10494-6

Test time: 240 h

Evaluation: directly
Blistering (DIN EN ISO 4628-2)

after 24 h
Cross-cut test (DIN EN ISO 2409)
• Tesa tape 4657
Scratch test (MBN 10494-5)
Multiple impact test (DIN EN ISO 20567-1, method B)
• Tesa tape 4657

Figure 10: Test position in CH device

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Table 8: Result Resistant to humidity (CH)

Sample – no. Blistering Cross-cut Scratch test

Set value: 0 (S0) ≤ Gt 1 ≤K2

P 1.3_0 1 0(S0) Gt 0 K 1-2

P 1.3_S 0(S0) Gt 0 K2

P 1.3_T 0(S0) Gt 0 K 1-2

P 1.4_0 0(S0) Gt 0 K 1-2

P 1.4_S 0(S0) Gt 0 K2

P 1.4_T 2 0(S0) Gt 0 K1
1,2
Test position (Figure 10):
- (1) Outer race is pointing upwards
- (2) Tripod housing is pointing upwards

Figure 11: P 1.3_T – Cross-cut Figure 12: P 1.4_O – Cross-cut

Figure 13: P 1.3_S – Cross-cut

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Table 9: Result Multi impact test (subsequent to Resistance to humidity)

Sample – no. Rating Degree of rusting

Set value: ≤ parameter 2 ≤ parameter 1

P 1.3_S parameter 1,5 parameter 1,5

P 1.4_S parameter 1,5 parameter 1,0-1,5

Figure 14: P 1.3_S – Multi impact

Figure 15: P 1.4_S – Multi impact

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2.5. Corrosion cycle test

Test procedure: Corrosion cycle test according to DIN EN ISO 11997-1, method B as well as
DBL 7381

Test time: 6 cycles

Evaluation: Surface corrosion (DIN EN ISO 4628-3)

Edge corrosion (MBN 10494-6)
Blistering (DIN EN ISO 4628-2)
Cross-cut (DIN EN ISO 2409)
• Tesa tape 4657
Scratch test (MBN 10494-5)
Subsurface corrosion (MBN 10494-6)
• SIkkens scribing tool (1.0 mm)

Figure 16: Position 70° (± 5°) in the testing device

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Table 10: Result Corrosion cycle test

Blistering Surface Edge
Sample no.
corrosion corrosion
Set value: < 2 (S2) ≤ Ri 1 ≤ KR 2 (30%)
P 1.5_0 1 0 (S0) Ri 0 KR 0

P 1.5_S 2 (S3) Ri 1 KR 0

P 1.5_T 0 (S0) Ri 0 KR 1

P 1.6_0 1 0 (S0) Ri 0 KR 0

P 1.6_S 2 (S3) Ri 1 KR 0

P 1.6_T 0 (S0) Ri 0 KR 0

P 1.7_0 0 (S0) Ri 0 KR 0

P 1.7_S 2 (S3) Ri 1 KR 0

P 1.7_T 2 0 (S0) Ri 0 KR 0

P 1.8_0 0 (S0) Ri 0 KR 0

P 1.8_S 2 (S3) Ri 1 KR 0

P 1.8_T 2 0 (S0) Ri 0 KR 0
1,2
Test position (Figure 16):
- (1) Outer race is pointing upwards
- (2) Tripod housing is pointing upwards

Figure 17: P 1.5_S – Blistering/Corrosion

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Figure 18: P 1.6_S – Blistering/Corrosion

Figure 19: P 1.7_S – Blistering/Corrosion Figure 20: P 1.7_S (10 times magnified)

Figure 21: P 1.8_S – Blistering/Corrosion

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Table 11: Result Corrosion cycle test

Sub surface Cross-cut Scratch test
Sample no.
corrosion U/2
Set value: ≤ 2 mm ≤ Gt 1 ≤K2

P 1.5_0 1 U/2 = 2,3 mm 3 Gt 0 K 1-2

P 1.5_S U/2 = 1,1 mm Gt 0 K2

P 1.5_T U/2 = 2,7 mm Gt 0 K2

P 1.6_0 1 U/2 = 2,3 mm 3 Gt 0 K 1-2

P 1.6_S U/2 = 1,0 mm Gt 0 K2

P 1.6_T U/2 = 2,5 mm Gt 0 K2

P 1.7_0 U/2 = 2,0 mm 3 Gt 0 K 1-2

P 1.7_S U/2 = 0,7 mm Gt 0 K2

P 1.7_T 2 U/2 = 2,5 mm Gt 0 K2

P 1.8_0 U/2 = 2,2 mm 3 Gt 0 K 1-2

P 1.8_S U/2 = 0,9 mm Gt 0 K2

P 1.8_T 2 U/2 = 2,9 mm Gt 0 K2

1,2 3
Test position (Figure 16): Mean value of two small scribed lines.
- (1) Outer race is pointing upwards
- (2) Tripod housing is pointing upwards

Figure 22: P 1.5_O – Sub surface corrosion U no.1/2 Figure 23: P 1.5_O – Sub surface corrosion U no.1/2
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Figure 24: P 1.5_S – Sub surface corrosion U/2 Figure 25: P 1.5_T – Sub surface corrosion U/2

Figure 26: P 1.6_O – Sub surface corrosion U no.1/2 Figure 27: P 1.6_O – Sub surface corrosion U no.1/2

Figure 28: P 1.6_S – Sub surface corrosion U/2 Figure 29: P 1.6_T – Sub surface corrosion U/2

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Figure 30: P 1.7_O – Sub surface corrosion U no.1/2 Figure 31: P 1.7_O – Sub surface corrosion U no.1/2

Figure 32: P 1.7_S – Sub surface corrosion U/2 Figure 33: P 1.7_T – Sub surface corrosion U/2

Figure 34: P 1.8_O – Sub surface corrosion U no.1/2 Figure 35: P 1.8_O – Sub surface corrosion U no.1/2

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Figure 36: P 1.8_S – Sub surface corrosion U/2 Figure 37: P 1.8_T – Sub surface corrosion U/2

2.6. Resistance to test fuels

Test procedure: Resistance to test fuels according to MBN 10494-7

Test medium: FAM test fluid A

• Exposure time: 10 min at 23°C

Evaluation: Visual assessment according to DIN EN ISO 4628-1 (Table 3)

• Regeneration time: 16 h

Table 12: Size of defects and intensity of changes after exposure

- Table 3 (DIN EN ISO 4628-1)

Parameter Intensity of change

0 Unchanged, no perceptible change
1 Very marginal, barely perceptible change
2 Marginal, clear perceptible change
3 Medium, very clear perceptible change
4 Strong, distinct change
5 Very strong change

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Table 13: Result Resistance to FAM-test fuel

Sample no. Visual Assessment

Set value: No swelling or discoloration after 16 h

P 1.9_0 Parameter 3; brightening

P 1.9_S Parameter 0

P 1.9_T Parameter 3; brightening

P 1.10_0 1 Parameter 3; brightening

P 1.10_S Parameter 0

P 1.10_T Parameter 3; brightening

Figure 38: P 1-9_T - FAM fluid (10 min/RT; after 16 h)

Figure 39: P 1-10_O - FAM fluid (10 min/RT; after 16 h)

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2.7. Resistance to process materials and service products

Test procedure: Resistance to process and service products according to MBN 10494-7

Test medium: 1. Hydraulic fluid

• Exposure time: 16 h at 23°C
2. Brake fluid
• Exposure time: 10 min at 23°C
3. Colt cleaning solvent
• Exposure time: 1 h at 23°C
4. Preservative
• Exposure time: 1 h at 23°C

Evaluation: Visual assessment according to DIN EN ISO 4628-1 (Table 3) as well as the
requirement of DBL 7381, table 20.

Table 14: Result Resistance to process materials and service products

Test medium Assessment Visual Assessment

after
Set value: = Requirement of table 20
P 1.11_O P 1.11_S P 1.11_T
Sample no.
P 1.12_O P 1.12_S P 1.12_T

1h
Hydraulic fluid Parameter 0 Parameter 0 Parameter 0
24 h

Parameter 3 Parameter 3
1h Brightening; Parameter 0 Brightening;
Swelling Swelling
Brake fluid
Parameter 2 Parameter 2
24 h Brightening; Parameter 0 Brightening;
Swelling Swelling

1h
Colt cleaning
Parameter 0 Parameter 0 Parameter 0
solvent
24 h
Parameter 1
1h
Parameter 3 Brightening Parameter 3
Preservative
Brightening Brightening
24 h Parameter 0

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Figure 40: P 1.11_O - Brake fluid (10 min/RT; after 1 h)

Figure 41: P 1.11_O - Brake fluid (10 min/RT; after 24 h)

Figure 42: P 1.12_T - Preservative (1 h/23°C; after 24 h)

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Table 15: Overview of used standard and date of issue

Standard Date of issue

DBL 7381 2021

DIN EN ISO 2178 2016

DIN EN ISO 2409 2020

DIN EN ISO 4628-2 2016

DIN EN ISO 4628-3 2016

DIN EN ISO 6270-2 2018

DIN EN ISO 11997-1 2018

MBN 10494-5 2021

MBN 10494-6 2021

MBN 10494-7 2016

Magdeburg, 30 August 2021

iLF Magdeburg GmbH

Dipl.-Chem. Cornelia Dreyer Dipl.-Ing. (FH) Carsten Passiel

Head Application Technology Laboratory person in charge

Note:
The test results refer only to the subjects of testing.
This test report is a shortened version that does not describe all test conditions given by the standards
applied.
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