Inhouse Standard: Coatings Powder Coating With Epoxy Resin and Polyester Resin

Systeme für Schienenfahrzeuge
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N12005 - P02
Rev. 10 - en
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Ausdrucke unterliegen nicht dem Aenderungsdienst.
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Inhouse standard
5/7/2019, confidential / vertraulich
Printed copies are uncontrolled.
Coatings
Powder coating with epoxy resin and

polyester resin
Created: 19.08.2015 Checked: 14.10.2015

Date Date
Schnell Gobmeier
Name Name
MUC - R/VST3 MUC-R/IEO

Department Department
Approved: 09.11.2016 Translated: 07/2017

Date Date
Kraus AMPLEXOR Deutschland GmbH

Name Name
MUC - R/VST3 R/LST2

Department Department
bekikl, Turkey - Findikli - Istanbul, e-NORM Knorr-Bremse

Coatings
Inhouse standard Doc. No.: N12005 - P02
Revision: 10 - en
Contact address
Knorr-Bremse Systeme für Schienenfahrzeuge GmbH
Moosacher Str. 80
80809 Munich, Germany
Phone: +49 (89) 3547-0
www.knorr-bremse.com
Preface
This inhouse standard was drawn up by:
MUC – R/IEO - Mr. Gobmeier
The content of this inhouse standard was approved by:

MUC – R/ASU - Mr Pröll
MUC – R/ASD - Dr Merkel
MUC – R/BCD - Dr Anton
MUC – R/BED - Dr Elstorpff
MUC – R/HYD - Mr Wermund
MUC – R/QM2 - Mr Hommers
Previous editions
N12005-P2: 1983-12; 1986-09; 1988-08; 1991-10; 2000-05; 2002-11; 2005-05; 2005-06; 2005-08;
2010-01
Change history
The following changes have been made from revision 09:
Section Description of the change
Rev. 09 Rev. 10
a) New layout, title changed
b) 4.1.1; 4.1.3; 4.1.5; Updating the applicable
Tables 3, 4 and 5 standard
Copyright © Knorr-Bremse AG. All rights reserved, including industrial property rights applications.
Knorr-Bremse AG retains any power of disposal, such as copying and transferring.
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Coatings
Revision: 10 - en
Referenced/additional standards and other documents

Doc. no. Title
DIN EN 286 - 3 Simple unheated steel air reservoir for air or nitrogen - air reservoir
of steel
DIN EN 286 - 4 Simple unheated air reservoir for air or nitrogen - air reservoir of
aluminium alloys
N12005 Coatings - system of designations and use of standards

BN 918340 Powder coatings for external and internal parts of rail vehicles –
technical delivery conditions
DIN EN ISO 2409 Coating materials – Cross-cut test

DIN EN ISO 2813 Determination of the reflectometer values of coatings (except for
metallic coatings) under 20°, 60° and 85°
DIN EN ISO 4628-3 Coating materials – Evaluation of defective coatings – Designation
of quantity and size of defects, and of intensity of changes in the
uniformity of appearance – Part 3: Evaluation of the degree of
rusting
DIN EN ISO 9227 Corrosion tests in artificial atmospheres - Salt spray tests
The document was originally written in German.
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Coatings
Revision: 10 - en
Contents
1 Scope and purpose 5

1.1 New cylinder housings 5
1.2 Repaired cylinders 5
1.3 Sheet metal deep-drawn parts, pistons, compression springs subjected to a static load;
not for piston running surfaces! 5
1.4 Air reservoir to EN 286 Part 3 and Part 4 5

1.5 Micromesh oil filter 5
1.6 Casings, covers, hoods 5

2 Entries in drawings 5
3 Powder 6
3.1 Powder qualities 6
3.2 Purchasing and testing the powder 7
4 Working steps 7
4.1 Pre-treatment 7
4.1.1 Parts to Section 1.1 7
4.2 Powder coating 8
4.2.1 Method 8
4.2.2 Conditions - parts to Section 1.1 to 1.3 8
4.2.3 Coating thicknesses 9
4.2.4 Surface 9
4.3 Reconditioning 9
4.4 Corrosion protection and packaging 9
4.4.1 Corrosion protection 9
4.4.2 Test instructions and requirements 10
4.4.3 Packaging 10
5 Certificate 11
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Coatings
Revision: 10 - en
1 Scope and purpose
This standard concerns coatings on the following parts:
1.1 New cylinder housings
1.2 Repaired cylinders

1.3 Sheet metal deep-drawn parts, pistons, compression springs subjected to a static load; not
for piston running surfaces!
1.4 Air reservoir to EN 286 Part 3 and Part 4
1.5 Micromesh oil filter
1.6 Casings, covers, hoods
2 Entries in drawings
In addition to the designation listed in N12005, for this coating the code digit of the powder quality
must be complied with.
The coating of a part with powder quality 1 (see Table 1), is entered as follows:
Coating N12005 --- P02 --- 1
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Coatings
Revision: 10 - en
3 Powder
3.1 Powder qualities
The powder qualities that may be used are those which in terms of their composition, colour hue and
manufacturer are approved by KNORR-BREMSE SfS GmbH, Moosacher Str. 80, 80809 Munich.
Table 1
Code
Purpose Powder - normal case Powder - optional
digit
1 Parts to Section 1.1 Flamulit ES EP42, black matt Flamulit ES EPR, green
2
3 Parts to Section 1.3 Flamulit ES EP42, black matt Dupont Al2494-85
RAL9005, black matt
4 Parts to Section 1.4 KOP 7−687 industrial flat, RAL7030
stone grey,
Degree of gloss 40−65% at 60°
umber grey,
jet black,
7 Parts to Section 1.5 AF8005/AF8025, industrial flat,
RAL7032 pebble grey, degree
of gloss 70−95% at 60°
RAL7021 charcoal grey, degree
RAL7024 graphite grey, degree
RAL7044 silk grey, degree
844 storm grey, degree of gloss
70−95% at 60°
12 Parts to Section 1.5 CEWEPOL 13 82396, flat,
RAL5012 light blue
13 Parts to Section 1.6 See data sheet N12005−P02−13
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Coatings
Revision: 10 - en
3.2 Purchasing and testing the powder

The coating company should purchase powder of the approved quality in batches sufficient for at least
a quarter year’s requirements.
It must be ensured that the amount of powder purchased all originates from the same manufacturing
batch.
The coating company should take a sample from each amount that is purchased and use it to coat two
sample plates. These sample plates, together with a factory certificate from the coating company, must
be sent to KNORR-BREMSE SfS GmbH stating the following data:
• Manufacturer
•
Type
• Batch number of the powder

• Day of coating
• Oven residence time
• Oven temperature
The relevant amount of powder may be used for parts in series production only once the samples
have been tested and approved by KNORR-BREMSE SfS GmbH.
Note:
For parts to 1.4 the specified quantity of sample plates, with the corresponding documentation, are
also required. However, these are only subject to an explicit test when there are problems regarding
the product quality. The product qualification documentation by BZA Minden on the basis of
BN 918340 must however accompany every production batch. This is a precondition for the use
of the powder concerned.
For parts to 1.5 the applicable instructions are analogous to those for parts to 1.4. Exception:
A separate product qualification by an external test location is not required.
The basis for the quality of the product is the suitability according to BN 918340, which must be
documented appropriately.
4 Working steps
4.1 Pre-treatment
4.1.1 Parts to Section 1.1

Steel parts are degreased with organic or alkaline cleaning solutions, pickled and zinc phosphated.
Aluminium parts are degreased with organic or alkaline cleaning solutions and passivated to
N12005-P25

The parts are degreased with organic or alkaline cleaning solutions, stripped of paint and cleaned
of rust, where necessary any running surfaces are ground out and levelled, then phosphated.
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Coatings
Revision: 10 - en

Steel parts are degreased with organic or alkaline cleaning solutions, pickled and manganese/zinc
phosphated.
Compression springs are only degreased and zinc phosphated.
Aluminium parts are degreased with organic or alkaline cleaning solutions and passivated to
N12005-P25.

Steel and aluminium surfaces require surface treatment to BN 918340. If deviations occur, these
must be specified within the scope of the product qualification¹) and require certification by
BZA Minden.

Zinc or aluminium die-cast parts are degreased with organic or alkaline cleaning solutions and
passivated to N12005–P25.
4.2 Powder coating
4.2.1 Method
Unless specified otherwise on the drawing in respect of the coating process, parts must be coated
inside and outside using an electrostatic powder coating plant.
Threads, sealing surfaces and where necessary bores1) must be masked.
4.2.2 Conditions - parts to Section 1.1 to 1.3

Table 2
Powder quality Curing temperature °C for the object Curing time in minutes
Flamulit ES EPR, green 180 to 200 approx. 15
Flamulit ES EP42, black matt 180 to 200 approx. 15
The curing time is reckoned from the time when the object reached the specified temperature.
Parts to Section 1.4: no restrictive conditions
Parts to Section 1.5: no restrictive conditions
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Coatings
Revision: 10 - en
4.2.3 Coating thicknesses

For parts to Sections 1.1 and 1.2 in the area of the piston running surface¹) 80 ± 30 µm. All other
surfaces and parts to Section 1.3 30 to 110 µm. Exceptions from this, such as coatings in the area
of Circlip grooves, must be specified on the drawing.
Parts to Section 1.4 are specified with a coating thickness of 100 ± 30 µm.
Parts to Section 1.5 exhibit a minimum coating thickness of 80 µm. The maximum coating thickness
must not exceed 120 µm.
4.2.4 Surface
For coatings for applications to Section 1.1 and 1.2: Powder Flamulit ES EPR green Rz=25 µm,
powder Flamulit ES EP42 black matt: Rz=15 µm. The surface should have a uniform structure, free
from pores, craters and projections.

See the specifications of BN 918340 for coatings for applications to Sections 1.4 and 1.5. In general
a surface roughness of Rz=50 µm should not be exceeded.
¹) To exclude misunderstandings, sealing surfaces, piston running surfaces and dead areas should be identified on the drawing
with appropriate wording.
4.3 Reconditioning
If the surface is too rough the following rework is permissible:
The cylinder running surface may be rubbed down with abrasive paper of 180 grit, then finished with
abrasive paper of 240 grit. Permissible roughness: Rz=35 µm.
4.4 Corrosion protection and packaging
4.4.1 Corrosion protection

Parts to Section 1.1 to 1.3
Threads, sealing surfaces and bores are zinc phosphated (during the pre-treatment). Any untreated
surfaces are protected with Rust-Ban 395 (N12005-W06), Tectyl 506EH (N12005-W05), or Hölterol
MF 1420 gold (N12005-W03)t.
Parts to Section 1.4

Steel reservoirs are generally protected on the inner surfaces and threads with Tectyl 506EH
(N12005-W05), irrespective of the pre-treatment (as a rule, inner surfaces are not pre-treated).
Aluminium pressure vessels require no internal protection.

Special corrosion protection need not be provided for aluminium or zinc die-cast parts.
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Coatings
Revision: 10 - en
4.4.2 Test instructions and requirements

Parts to Section 1.1 to 1.3
Table 3
Corrosion resistance Coat thickness Notes
Test Instructions Requirements μm
Salt spray test as per DIN EN at least 500 h without red rust as ≥ 90 Unless otherwise
ISO 9227–NSS per DIN EN ISO 4628–3 Ri 0 visible stated in the drawing
subsurface corrosion on the scribe
mark to DIN EN ISO 4628–8 /
5 mm
Cross cut in accordance with Gt 0-1

DIN EN ISO 2409
Corrosion resistance Coat thickness Notes

Test Instructions Requirements μm
Salt spray test as per at least 400 h degree of rust Ri0 80 ± 30 For piston running
DIN EN ISO 9227–NSS to DIN EN ISO 4628–3 surfaces
Adhesion test to Gt 0-1 30 to 110 Adhesion test of parts
DIN EN ISO 2409 to Section 1.3 and to
DIN EN ISO 9227

The test instructions and requirements of BN 918340 Section 2.4.1 (outer parts) are applicable here.
Exception: Degree of gloss
Table 4
BN 9183410 To N12005 – P02 (mandatory)
20° reflectometer value ≥ 85 to 60° reflectometer value 65 ≥ x ≥ 20 to
DIN EN ISO 2813 DIN EN ISO 2813

The test instructions and requirements analogous to BN 918340 Section 2.4.1 (outer parts) are
applicable here. Exception: Degree of gloss
Table 5
BN 9183410 To N12005 – P02 (mandatory)
20° reflectometer value ≥ 85 to 60° reflectometer value 95 ≥ x ≥ 75 to
DIN EN ISO 2813 DIN EN ISO 2813
4.4.3 Packaging
For protection against damage
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Coatings
Revision: 10 - en
5 Certificate
Each production batch must be accompanied by a factory certificate provided by the coating
company, showing the following:
Manufacturer of the powder

Day of coating
Oven temperature
Oven residence time
Object temperature
Coat thickness in the piston running surface area: minimum and maximum
Object designation (such as BZ......., drawing no......., Parts list no........)
Qty.
Parts to Section 1.1 to 1.3 additionally

Coat thickness in the piston running surface area: minimum and maximum
For parts to Section 1.4 additionally (see also Section 3.2)

Every production batch must also be accompanied by the product qualification documentation
issued by BZA Minden on the basis of BN 918340.
For parts to Section 1.5

There is no requirement for separate certification (factory certificate, product qualification).
Page 11 / 11

Inhouse Standard: Coatings Powder Coating With Epoxy Resin and Polyester Resin

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Systeme für Schienenfahrzeuge

Powder coating with epoxy resin and

Created: 19.08.2015 Checked: 14.10.2015

MUC - R/VST3 MUC-R/IEO

Approved: 09.11.2016 Translated: 07/2017

Kraus AMPLEXOR Deutschland GmbH

MUC - R/VST3 R/LST2

bekikl, Turkey - Findikli - Istanbul, e-NORM Knorr-Bremse

MUC – R/IEO - Mr. Gobmeier

The content of this inhouse standard was approved by:

Section Description of the change

bekikl, Turkey - Findikli - Istanbul, e-NORM Knorr-Bremse

Referenced/additional standards and other documents

N12005 Coatings - system of designations and use of standards

DIN EN ISO 2409 Coating materials – Cross-cut test

The document was originally written in German.

bekikl, Turkey - Findikli - Istanbul, e-NORM Knorr-Bremse

1 Scope and purpose 5

1.4 Air reservoir to EN 286 Part 3 and Part 4 5

1.6 Casings, covers, hoods 5

bekikl, Turkey - Findikli - Istanbul, e-NORM Knorr-Bremse

1 Scope and purpose

This standard concerns coatings on the following parts:

1.1 New cylinder housings

1.2 Repaired cylinders

1.4 Air reservoir to EN 286 Part 3 and Part 4

1.5 Micromesh oil filter

1.6 Casings, covers, hoods

Coating N12005 --- P02 --- 1

bekikl, Turkey - Findikli - Istanbul, e-NORM Knorr-Bremse

3.1 Powder qualities

bekikl, Turkey - Findikli - Istanbul, e-NORM Knorr-Bremse

3.2 Purchasing and testing the powder

be sent to KNORR-BREMSE SfS GmbH stating the following data:

• Batch number of the powder

4.1.1 Parts to Section 1.1

4.1.2 Parts to Section 1.2

bekikl, Turkey - Findikli - Istanbul, e-NORM Knorr-Bremse

4.1.3 Parts to Section 1.3

4.1.4 Parts to Section 1.4

4.1.5 Parts to Section 1.5

4.2 Powder coating

4.2.2 Conditions - parts to Section 1.1 to 1.3

Parts to Section 1.4: no restrictive conditions

Parts to Section 1.5: no restrictive conditions

bekikl, Turkey - Findikli - Istanbul, e-NORM Knorr-Bremse

4.2.3 Coating thicknesses

from pores, craters and projections.

4.4 Corrosion protection and packaging

4.4.1 Corrosion protection

Parts to Section 1.4

Parts to Section 1.5

bekikl, Turkey - Findikli - Istanbul, e-NORM Knorr-Bremse

4.4.2 Test instructions and requirements

Cross cut in accordance with Gt 0-1

Corrosion resistance Coat thickness Notes

Parts to Section 1.4

Parts to Section 1.5

bekikl, Turkey - Findikli - Istanbul, e-NORM Knorr-Bremse

Manufacturer of the powder

Parts to Section 1.1 to 1.3 additionally

For parts to Section 1.4 additionally (see also Section 3.2)

For parts to Section 1.5