EMCV STANDARD NO: ES-VE-064

Pithampur
EMCV Rev No.:0
ETB ETB Standard Date of Issue:
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CLASSIFICATION: SCOPE OF APPLICATION: Zinc Plating and ISSUED BY:

PRODUCT DESIGN &
DESIGN STANDARD Chromate Films on Iron and Steel DEVELOPMENT
TITLE: Specification − Zinc Plating and Chromate Films on Iron and Steel

CONTENTS:-
1. SCOPE
2. DEFINITION OF TYPES AND GRADES
3. TYPES AND GRADES
4. QUALITY
5. TESTS
6. SALT SPRAY TEST
7. INSPECTIONS
8. HYDROGEN EMBRITTLEMENT
9. DRAWING NOTATION
10.REFERRENCE

A ECO-12-0384 NEW RELEASE ALL 01.05.2012 Mahesh Chandra

Rev E.O No. Revision Pages Date Checked By
Name Date Sign
Prepared by: Mahendra P. S. Jadon 26.04.2012
Checked by: Mahesh Chandra 01.05.2012
Approved By Mahesh Chandra 01.05.2012
 EMCV STANDARD NO: ES-VE-064
Pithampur
EMCV Rev No.:0
ETB ETB Standard Date of Issue:
Pithampur
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1. SCOPE
This Standard describes electroplated coatings of zinc plating and chromate films hereinafter
referred to as plating that are applied to iron and steel for corrosion protection and appearance.
Remarks:
1. This Standard applies to the significant surface that is defined as the surface for which the plating is most
important. Corrosion protective qualities, for parts other than the significant surface, shall be determined
by agreement between the parties concerned.
2. The significant surface shall be as specified by the drawing or the inspection standard.

2. DEFINITION OF TERMS
Major terms used in this Standard shall be defined as follows:
(2.1) Yellow chromate
Chromate film, intended for corrosion protection, is yellow. Therefore, the corrosion protective
chromate film is called yellow chromate. Its color tone may change depending on the
composition of chromium chromate (xCr2O3/yCrO3/zH2O), a major component of the film.
(2.2) Bright (clear) chromate
Chromate processing creates a corrosion protective film on a zinc plating while also acting as a
chemical polishing agent. This chemical polishing action is used to give gloss to plating. Methods
of treatment are classified into chemical polishing and alkali liquid treatment. In the chemical
polishing method, the creation of corrosion protective film is rather suppressed. In the alkali
treating method a corrosion protective film is produced and then treated by the alkali solution
to have a glossy surface. The corrosion protective performance of this bright chromate is
inferior to the yellow chromate.
(2.3) Black chromate
After plating, the chromate film is formed with a processing solution containing chromic acid
and an additive of black color treatment chemical (silver nitrate, etc.). Black chromate does not
provide any significant abrasion resistance.
(2.4) Olive (green) chromate
After plating, a chromate processing solution containing special anions is used. A thick film-type
coating can be obtained with good resistance to corrosion. The coating is also called green
chromate.
(2.5) Interference fringe on the surface
With a thin chromate film, a transparent, invisible thin film remains on the plating. When white
light illuminates this surface, rainbow color is created as a result of interference between
reflected light from the surfaces of the coating film and plating. This fringe pattern is called
interference fringe.
(2.6) Dispersion of color on the surface
The color tone of the yellow chromate varies depending on the composition of the coating. The
composition may fluctuate due to variations in the chromate processing solution and operating
conditions. Therefore, even among the same lot of parts, the color tone of each part often
becomes different. Even on the same surface, uniform color tone cannot be obtained very
easily; therefore, there may be color irregularities.
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(2.7) White corrosion products

The corrosion products of zinc consist mainly of white compounds such as zinc carbonate. When zinc
is exposed to a corrosive environment while the chromate film is broken, such corrosion products
(zinc rust) are created.
(2.8) Trivalent clear chromate
The film of the trivalent clear chromate is a film intending to be free from hexavalent chromium
which is generated by processing with liquid of trivalent chrome and silica as main components
after plating. The color tone is similar to that of the bright chromate.
(2.9) Trivalent black chromate
Trivalent black chromate film is a black chromate that is free of hexavalent chromium. After the
plating, the film is formed by a treatment liquid that consists of trivalent chrome and silica
doped with black process chemicals (oxide, such as iron, cobalt, etc.).

3. TYPES AND GRADES

The types and grades of plating shall be classified by the methods of surface treatment and plating
thicknesses as shown in Table 1.
Table 1 (Types)

Plating
Type Rating Symbol thickness Example of application Reference
1 Application
µm ( )
Class 1 (On iron)
For mainly, interior parts
1 MFZn 3C 3 Screw, washer, small shaft
requiring discrimination
Screw, washer, grease-nipple,
For mainly, interior parts
2 MFZn 5C 5 small case, general structural
requiring corrosion resistance
parts
For mainly, interior & exterior Case, retainer, lamp body,
Yellow
Type 1 3 MFZn 8C 8 parts requiring corrosion general structural parts, brake
chromate
resistance pipe
For mainly, interior & exterior Case, retainer, lamp body,
4 MFZn 13C 13 parts particularly requiring general structural parts,
corrosion resistance mechanical parts, bracket
For mainly exterior parts
5 MFZn 25C 25 Brake tube, etc.
requiring special rust prevention
For mainly, interior parts
1 MFZn 3B 3 Screw, washer, small case, etc.
requiring discrimination
For mainly, interior parts
2 MFZn 5B 5 Screw, washer, small case, etc.
Bright requiring beauty discrimination
Type 2 For mainly, interior parts
chromate 3 MFZn 8B 8 Screw, washer, small case, etc.
requiring beauty
Case, retainer, lamp body,
For mainly, exterior parts
4 MFZn 13B 13 general
requiring gloss
constituent, mechanical parts
Black For mainly interior parts
Type 3 1 MFZn 3K 3 Screw, washer, etc
chromate requiring discrimination
For mainly interior parts
2 MFZn 5K 5 requiring black for design, and Screw, washer, etc
corrosion resistance
Screw, washer, small shaft,
For mainly interior and exterior
case, retainer, lamp body
3 MFZn 8K 8 parts requiring black for design,
general structural parts,
and corrosion resistance
mechanical parts, brackets
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Case, retainer, structural parts,

4 MFZn 13K 13 High corrosion protection parts
mechanical parts, brackets
High corrosion protection
1 MFZn 3G 3 Screw, washer, etc
general parts
High corrosion protection
2 MFZn 5G 5 general screw parts and interior Screw, washer, etc
parts
Screw, washer, small shaft,
Olive High corrosion protection case, retainer, lamp body
Type 4 3 MFZn 8G 8
chromate exterior parts and screw parts general structural parts,
mechanical parts, brackets
Case, retainer, structural parts,
4 MFZn 13G 13 High corrosion protection parts
mechanical parts, brackets
For mainly exterior parts
5 MFZn 25G 25 Brake tube, etc.
requiring special rust prevention
For mainly, interior parts
1 MFZn 3TC 3 Screw, washer, small shaft
requiring discrimination
Screw, washer, grease-nipple,
For mainly, interior parts
2 MFZn 5TC 5 small case, general structural Substitute
requiring corrosion resistance
parts material to
Trivalent
For mainly, interior & exterior Case, retainer, lamp body, hexavalent
Type 5 clear
3 MFZn 8TC 8 parts requiring corrosion general structural parts, brake chromium in
chromate
resistance pipe Types 1 and
For mainly, interior & exterior Case, retainer, lamp body, 2
4 MFZn 13TC 13 parts particularly requiring general structural parts,
corrosion resistance mechanical parts, bracket
For mainly exterior parts
5 MFZn 25TC 25 Brake tube, etc.
requiring special rust prevention
For mainly interior parts
1 MFZn 3TK 3 Screw, washer, etc
requiring discrimination
For mainly interior parts
2 MFZn 5TK 5 requiring black for design, and Screw, washer, etc Substitute
Trivalent corrosion resistance material for
Type 6 black Screw, washer, small shaft, hexavalent
For mainly interior and exterior
chromate case, retainer, lamp body chromium in
3 MFZn 8TK 8 parts requiring black for design,
general structural parts, Type 3
and corrosion resistance
mechanical parts, brackets
Case, retainer, structural parts,
4 MFZn 13TK 13 High corrosion protection parts
mechanical parts, brackets
Class 2 (On Copper and Copper alloy)
On For mainly, interior & exterior Screws, small mechanical
1 MBZn 2 2
Copper parts not requiring beauty parts
Type 7 and
Copper For mainly, interior & exterior Screws, small mechanical
2 MBZn 2B 2
alloy parts mainly requiring beauty parts

Note:
1
( ) The plating thicknesses show minimum values.

Remarks:
1. Chromate treatment shall generally apply to plating.
2. Type 1 is mainly intended for corrosion protection, applying yellow chromate treatment after plating.
3. Type 2 means the bright chromate treatment after plating, but its corrosion resistance is inferior to Type 1.
4. Type 3 and Type 6 are used mainly for decorative purposes. This type shall not be applied to parts touched by
hands usually.
5. Type 4 means olive chromate treatment after plating and is used for high corrosion resistance.
6. Type 5 is mainly intended for corrosion protection, applying trivalent clear chromate treatment after plating.
7. The interior parts mean those mounted in the body of a car and not subjected to direct or indirect wind or rain.
8. The following cases shall be exempt from application:
(1) Parts coated with grease in use and not requiring protection from corrosion.
 EMCV STANDARD NO: ES-VE-064
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(2) Parts not visible and not requiring plating but actually plated in the manufacturing process.
(3) Parts treated for rust prevention by another treatment due to a machining reason such as caulking.
7. The interior parts mean those mounted in the body of a car and not subjected to direct or indirect wind or rain.
8. The following cases shall be exempt from application:
(1) Parts coated with grease in use and not requiring protection from corrosion.
(2) Parts not visible and not requiring plating but actually plated in the manufacturing process.
(3) Parts treated for rust prevention by another treatment due to a machining reason such as caulking.
9. The major constituents of the hexavalent chromate film are generally expressed by xCr2O3, yCrO3 and zH2O.
The crystal water in this coating is vaporized when exposed to temperatures higher than 80°C, resulting in
deterioration of the coating and poor resistance to corrosion. Therefore, care shall be taken.

4. QUALITY
4.1 Appearance
The appearance of the plating shall be smooth and free from burn deposits, blisters or exposure
2
of substrate ( ) or any other defects detrimental to use. However, slight interference fringes or
color irregularities, as a result of the chromate treatment, are acceptable.
2
Note: ( ) Where the substrate contains defects that are not detected by a normal method, the defects may
sometimes appear after plating as plating defects.
4.2 Plating thickness
Plating thicknesses shall conform to Table 1.
4.3 Corrosion resistance of coating
The corrosion resistance of the coating shall conform to Table 2 when tested by JIS Z 2371
(Methods of Salt Spray Testing).
 EMCV STANDARD NO: ES-VE-064
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Table 2 (Minimum Corrosion resistance SST life)

Chromate Plating Trivalent + (L) lacquer Top Coat
Plating Time before any Time before any
white corrosion Time before any white corrosion Time before any
Type Rating Symbol thickness iron oxide iron oxide(red
material appears material appears
µm (red rust) rust) appears
3 appears (hours)
3 (hours)
( ) (hours) ( ) (hours)
1 MFZn 3C 3 96 - -
2 MFZn 5C 5 144 - -
Yellow
Type 1 3 MFZn 8C 8 72 192 - -
chromate
4 MFZn 13C 13 240 - -
5 MFZn 25C 25 400 - -
1 MFZn 3B 3 48 - -
Bright 2 MFZn 5B 5 72 - -
Type 2 24
chromate 3 MFZn 8B 8 96 - -
4 MFZn 13B 13 144 - -
1 MFZn 3K 3 96 - -
Black 2 MFZn 5K 5 144 - -
Type 3 72
chromate 3 MFZn 8K 8 192 - -
4 MFZn 13K 13 240 - -
1 MFZn 3G 3 240 - -
2 MFZn 5G 5 288 - -
Olive 3 MFZn 8G 8 360 - -
Type 4 168
chromate
4 MFZn 13G 13 480 - -
5 MFZn 25G 25 480 (5) - -
1 MFZn 3TC 3 96 144
Trivalent 2 MFZn 5TC 5 144 192
5 5
Type 5 clear 3 MFZn 8TC 8 72 ( ) 192 100 ( ) 240
chromate 4 MFZn 13TC 13 240 288
4 MFZn 13TC 13 400 448

1 MFZn 3TK 3 96 144

Trivalent
2 MFZn 5TK 5
5 144
5 192
Type 6 black 72 ( ) 100 ( )
chromate 3 MFZn 8TK 8 192 240
4 MFZn 13TK 13 240 288

Note:
3
( )The black material created before the white corrosion material appears will not be regarded as corrosion.
4
( )Time before any iron oxide (red rust) appears on bent parts such as brake tubes shall be 408 hours.
5
( )Slight whitening of the chromate film shall not be regarded as corrosion.

5. TEST'S
5.1 Pretreatment of test sample
The test part’s surface shall be cleaned to completely remove oils and stains and degreased
using benzene, etc.
5.2 Appearance test
The test shall be performed under bright light source (300 lx and over) when examining for burn
deposits, blisters, exposed substrate, etc.
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5.3 Thickness test

As a general rule, a microscope should be used for measuring the plating thickness. However, a
coulometric thickness gauge or a magnetic thickness gauge may be used at the discretion of the
personnel involved in the testing. However, if the coulometric thickness gauge is used, the
results should be confirmed with a microscope as required.
5.3.1 Microscope method
The sample to be measured for plating thickness shall be cut perpendicular to the plated
surface. Then, the section shall be polished carefully and the plating thickness measured with
the microscope. If the boundary between the substrate and the plating is not clearly visible, the
test sample may be dipped for several seconds in a corrosion solution consisting of 5 mℓ of non-
diluted hydrochloric acid and 95 mℓ of distilled water and then measured. Each test sample
(one part) shall be measured at several locations and the minimum value shall be used as the
thickness measurement of the sample.
5.3.2 Plating thickness measurement using the coulometric thickness gauge
The coulometric thickness gauge is used together with a microscope as a supplementary
measuring method. Use the actual part as the test piece (no test piece cutting is required). Use
the plated metal surface as the anode. Immerse the part in the electrolytic solution. Run a
steady electric current through the electrolytic solution. Electrolysis will result. Initially, a
constant voltage potential will appear between the anode and the cathode, corresponding to
the metal used in the plated part. Immediately following this, complete dissolution of the metal
plating on the part will occur and the base surface of the part will be clearly visible. Two rapid
voltage fluctuations between the anode and the cathode will occur. Note the time of the second
voltage fluctuation. Electrolysis is now complete. Plating thickness is determined based on the
time required for complete electrolysis.
5.3.3 Plating thickness measurement using the magnetic thickness gauge
1. The magnetic thickness gauge is used whenever the actual part, which cannot be damaged, is
used.
2. Use an actual part as the test piece. Measure the plating thickness on a flat and smooth area
of the part as much as possible.

6. SALT SPRAY TEST

The salt spray test shall be performed according to JIS Z 2371 Continuous spraying shall be applied
for the specified time.

7. INSPECTIONS
Plated parts shall be inspected for appearance, the thickness of plated film, and resistance to
corrosion.
1. For sampling, many samples shall be extracted at random from lots of the same parts. The
number of test samples and inspection positions shall be agreed upon between buyer and
supplier.
2. The appearance of the plated film shall be inspected and tested according to Item 5, and the
result shall conform to the specifications of Item 4.
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8. PREVENTION OF HYDROGEN EMBRITTLEMENT

1. Removal of stress before plating
The basis metals such as high-strength steel, which has high tensile strength, and case
hardening steel shall be protected from hydrogen embrittlement. To reduce the effect of
hydrogen embrittlement, heat treatment to remove stress before plating is desirable. The
conditions shall be agreed upon between buyer and supplier.
2. Prevention of hydrogen embrittlement after plating
When the steel parts have a hardness of 28 HRC (269 HB) or above or are highly cold-
worked parts, the plated parts shall be protected from hydrogen embrittlement. To protect
from or prevent hydrogen embrittlement, the pretreatment of plating and the plating work
shall be adequately performed. For the parts using spring steel, etc., within 4 hours after
plating, heat treatment shall be conducted to prevent hydrogen embrittlement.

9. DRAWING NOTATION
The number of the Standards and symbols shall be designated on the drawing.
Example: Electroplated zinc coating Type 5 trivalent clear chromate grade 3 with top coat.

10. REFERRENCE
 JIS Z 2371 -Methods of Salt Spray Testing.
 IS 1573:1986- Specification For Electroplated Coatings Of Zinc On Iron And Steel.
 MS82-3701- Electroplated Coatings Of Zinc.
 NES M 4040- Zinc Plating and Chromate Films on Iron and Steel.