NAVISTAR, INC.

NUMBER:
Material, Parts, and Process Specifications
MPAPS G-22
(MPAPS) Former Designation: CEMS G-22

TITLE: CURRENT REV No.: DATE:

Zinc-Nickel Plating 1710 Oct. 2017

WRITTEN/EDITED BY: APPROVED BY: SUPERSEDES:

W. Cook R. Goluch 1703 - Mar. 2017
PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION
This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of
the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the
applicability of regulatory limits prior to use.

1.0 APPLICATION
Zinc-nickel plating is used primarily for corrosion resistance of ferrous metal parts (fasteners, fittings,
clips, brackets, etc.) where levels of corrosion resistance greater than standard zinc plating are required.
The alkaline zinc-nickel plating process (rather than acid zinc-nickel plating) is preferred for parts
supplied to this specification, since it provides better coating ductility, minimal flaking, and higher
corrosion resistance. A trivalent chromium passivate will be applied to the zinc-nickel plating.
Supplementary sealers/topcoats may be applied, depending on the specified plating class and
performance requirements. Plated parts should not come in contact with stressed polyamides 6 or 66,
due to the potential for stress cracking in the presence of road salts. The service temperature range of
zinc-nickel plated parts is -50 to 120◦C (-58 to 248◦F). This coating is not intended for electrical
grounding applications- See MPAPS G-23.

2.0 SCOPE
This specification covers the Corporation’s requirements for hex-chrome-free zinc-nickel plating on
steel substrates.

2.1 Restricted Chemical Substances

Effective January 1, 2007, all product supplied to the requirements of this specification must comply
with the requirements of the MPAPS B-50 specification.

3.0 REFERENCE DOCUMENTS

Unless otherwise specified, the latest issue of all referenced standards shall apply. The following
standards, specifications and regulations are referenced in this specification.
Quality System Standard ISO 9001 or TS-16949 ASTM B 117 ASTM B 499
NAVISTAR Supplier Packing and Shipping Std. D-13 ASTM B 201 ASTM D 6492
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CFR Title 29, Part 1910 ASTM B 487 SAE/USCAR-11

NAVISTAR MPAPS GT-31 MPAPS B-50 ASTM D 523
SAE/USCAR-7 MPAPS G-23 ASTM B 659

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 NUMBER: TITLE: REVISION:
MPAPS G-22 ZINC-NICKEL PLATING 1710

4.0 REQUIREMENTS
This specification covers zinc-nickel coatings on ferrous metal substrates. The coating composition is
essentially zinc, with 5-15% nickel by weight (Type A) or 10-17% nickel (Type B) (for alkaline
plating). Type B coating provides higher corrosion performance than Type A. All required base metal
heat treatments and forming/bending operations will be completed prior to performance of the coating
operation. Uncoated parts will be thoroughly cleaned and free from rust, scale, oil and other foreign
matter detrimental to the quality and performance of the zinc-nickel coating. Supplementary
sealers/topcoats should be applied based on the performance requirements of the coating class.
Requirements for each class of coating are given in Table 1.
4.1 Passivation Treatment
A trivalent chromium passivation treatment will be applied to the zinc-nickel plated surface in order to
enhance corrosion resistance. Hexavalent chromate conversion coatings are not permitted on zinc-nickel
plated parts used on NAVISTAR products.
4.2 Appearance
The clear/blue/silvery/gray color characteristic of trivalent chromium passivation coatings will be
provided for C Class codes (e.g., Class ZNi-C1). If black is desired, a B class code (e.g., Class ZNi-B1)
can be specified. If other colors are required, it must be specified on the drawing or purchase order.
Black parts plated to Class ZNi-B1 or ZNi-B2 should exhibit a harmonious deep black appearance when
subjected to natural light, and not show lighter areas or areas of iridescence not consistent with a deep
black color. When Class ZNi-B2 is used, particularly for black cosmetic applications, parts will be
subjected to 48 hr salt spray testing after which no white blush will be observed.
4.3 Corrosion Resistance
Parts plated according to the requirements of this specification will be capable of withstanding neutral salt
spray testing for the required minimum number of hours for the plating class designated in Table 1. The
performance expectation assumes that the part will be used as plated and that there is no “handling
damage” to the coating or post-plating forming of the parts. The corrosion performance of parts subjected
to additional fabrication or forming, or which are part of an assembly when tested after plating shall be by
agreement with supplier and appropriately documented.

After the specified minimum hours of test, there will be no zinc oxidation products or base metal corrosion
(red rust) on significant surfaces. Significant surfaces for evaluation of fasteners will be defined as all
exposed surfaces of fastener(s) when installed, including but not limited to fastener heads, socket recesses,
SEMS washers, and external surfaces of nuts. Threads and points are excluded unless otherwise specified
on drawing. On parts other than threaded fasteners, significant surfaces will include all plated surfaces;
deep recesses, blind holes, edges, and tubing interiors are excluded unless otherwise specified on drawing.
See Section 6.2.2 for corrosion test method.
(Note that the salt spray test is used to verify that the plating meets the requirements of the specification.
The test shall not be assumed to have any correlation to actual service life or performance of the part.)
4.4 Plating Thickness
Thickness of zinc-nickel plating on parts supplied to this specification shall meet the minimum plating
requirements for the applicable class as specified in Table 1. Coating thickness will be sufficient to
provide corrosion performance requirements as specified for the given Class. Use of a zinc strike layer is
not permitted. Thickness of the passivation coating and other supplementary coatings (sealers, topcoats,
waxes, etc.) is not included in thickness measurements. Coated fasteners must pass all appropriate Thread
Go gages for thread sizing. Threads may be produced undersized prior to plating providing that the finished
This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. 2017 by Navistar, Inc.
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MPAPS G-22 ZINC-NICKEL PLATING 1710

threaded part meets all mechanical property requirements specified for the part. See section 6.2.1 for
plating thickness test methods.

Table 1 – CLASSIFICATION AND REQUIREMENTS FOR ZN-NI COATINGS

Min Neutral Salt Spray Test Additional Sealer/
NAVISTAR Minimum plating
Hours Topcoat*
Designation thickness
(ASTM B 117)
Zinc
Class Code m Red Rust
Oxidation
CLEAR -
ZNi-C1 5 120 480 Optional
ZNi-C2 5 168 620 Req’d
ZNi-C3 8 120 600 Optional
ZNi-C4 8 168 840 Req’d
ZNi-C5 8 240 1000 Req’d

BLACK -
ZNi-B1 5 168 620 Req’d
ZNi-B2 8 240 1000 Req’d
*For threaded fasteners when controlled lubricity is required, a torque-tension control fluid may be added to the
sealer/topcoat. The suffix L will be added to the class code on part drawings (e.g., ZNi-C2-L). (see Section 6.8)
For controlled lubricity, a friction range of 0.14 ±0.03 m is assumed, unless otherwise specified.

4.5 Adhesion
Coating on parts will not blister, chip, flake, or peel after adhesion testing as described in Section 6.2.3.
4.6 Paintability

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Parts plated to this specification shall provide good adhesion to paint and be compatible with plant paint
systems.
4.7 Weathering Resistance
Black zinc-nickel coated parts specified to Class ZNi-B1 or B2 shall provide UV resistance, and be tested
for weatherability as described in Section 6.2.5. After 500 hr testing, parts shall show no blistering,
peeling, cracking, loss of adhesion, fading, discoloration, or red rust. Tested parts will have a gloss level
of 3 or higher (20-degree gloss meter per ASTM D 523).
4.8 Torque – Tension Requirement
Threaded fasteners M6 and larger requiring torque-tension control will be specified on the part drawing
by the addition of the suffix L to the plating class code. These fasteners will be subject to torque-tension
test monitoring through the use of surrogate M10 x 1.5 test bolts. Torque-tension will be monitored per
SAE/USCAR-11, except tightening speed shall be 30 ± 3 rpm. The six sigma torque range value must
be 40-56 Nm with a clamp load of 28.3 kN. Testing is required for initial approval of the finish,
applicators, and PPAP submissions, and will be part of the applicator’s statistical process control.
.
5.0 QUALITY
The zinc-nickel coating will be dense and uniform, free from porosity, pinholes and blisters, and
substantially free from other defects that may affect the appearance or corrosion protective value of the
coating. The plating will have no gray or burned area and will not flake off.
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MPAPS G-22 ZINC-NICKEL PLATING 1710

5.1 Hydrogen Embrittlement

Some processes used to produce zinc-nickel coatings may induce hydrogen embrittlement in parts with
high hardness. It will be the responsibility of the supplier to ensure that supplied parts are free of hydrogen
embrittlement and to see that such parts are baked within one hour of electroplating (but before any
supplementary coatings are applied) to relieve hydrogen embrittlement. Steel parts having core hardness
greater than 32 HRC or surface hardness of 35 HRC, as well as all highly stressed cold worked parts, may
be subject to embrittlement because of hydrogen absorption. Generally, the bake operation will involve
heating in an oven until the part core temperature (not oven temperature) reaches 205-215C (400-420F),
and holding at this temperature for 4 hrs minimum. Likewise, hardened parts which have been tempered
at less than 175C (350F) should be heated at 150C (300F) for at least 8 hours. Refer to SAE/USCAR-
7 for test methods used to detect hydrogen embrittlement of steel parts.
5.2 Sampling Procedure
Select for test one or more random samples from each shipment, or from authorized test specimens. The
number of samples to be selected from each size lot will be agreed upon between the supplier and the
purchaser. If results fall below the test requirements, the shipment may be rejected.

6.0 QUALIFICATION
Engineering qualification of sources is required in advance of production shipments. Suppliers shall
submit samples for approval of finish, luster, color and appearance to the Navistar Industrial Design
Group. Samples shall be accompanied by test data certifying that all requirements of the specification
have been met. Upon approval, styling master samples denoting the minimum level of acceptable
appearance quality shall be developed and retained by the supplier and the quality department of each
using NAVISTAR facility.
6.1 Quality Control Plan
A Quality Control Plan for products supplied to the requirements of this specification will be established
by mutual agreement between NAVISTAR and the supplier. Unless specific exception is noted, the
following characteristics, where applicable*, shall be included in the plan as features for management
by statistical process control.**

Plating Thickness, Adhesion, Torque-Tension

characteristics (fasteners only)
* Other characteristics for inclusion in the control plan may be specified on the engineering
drawing and/or purchase order.
** See NAVISTAR Engineering Design Standard A-16

6.2 Methods Of Test

6.2.1 Plating Thickness
Determine thickness of coating on significant surfaces (see definition in Section 4.4) using the eddy
current (magnetic) method (ASTM B 499), the x-ray method (ASTM B 659), or the microscopic method
(ASTM B 487). The microscopic method will be used as a referee test when necessary.
6.2.2 Corrosion Testing
Perform salt spray testing per ASTM B 117.
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MPAPS G-22 ZINC-NICKEL PLATING 1710

6.2.3 Adhesion
Sample plated parts will be exposed to 220 ± 5C for 30 ± 5 minutes, followed by quenching in water at
room temperature.
6.2.4 Passivation Treatment
Presence of a hex-free chromate coating may be verified per certification by the plater. When necessary
for referee purposes, presence of clear chromate coatings may be determined per ASTM B 201. The
absence of hexavalent chrome may be demonstrated using ASTM D 6492, as required.
6.3.5 Weatherability Testing
Parts requiring UV resistance shall be tested for weatherability using Method A per MPAPS GT-31.

7.0 SOURCE APPROVAL AND QUALITY CONTROL

7.1 Supplier Requirements
All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements.
NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG
PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must
maintain their certification with an accredited registrar and must furnish copies of registration
certificates to their Corporate Buyer upon request.
7.2 Approval
Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all
respects to those samples which were approved by the purchaser. No changes in formulation or
processing practices are permitted without approval. In the event that changes in material, properties,
processing practices, construction, color, or labeling of the product are required, the supplier shall notify
NAVISTAR Materials Engineering and Purchasing and Supplier Development of the proposed
change(s). Test data indicating conformance to all requirements of this specification, test samples, and
new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CFR Title 29,
Part 1910 shall be submitted with the request for change.
7.3 Process Control
The supplier shall either perform and report results of tests on specific lots of parts produced using ISO
9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a state
of statistical control and with a process capable of providing all required properties. The part supplier
and the quality control manager of the using NAVISTAR plant may determine testing and reporting
requirements on specific products.

8.0 SHIPPING AND HANDLING

Shipping and identification shall be in accordance with NAVISTAR Supplier Packing and Shipping
Standard D-13. Parts shall be packaged so as to avoid any damage in shipment detrimental to the
appearance of the part.

This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
Suppliers are required to assume all patent liability. 2017 by Navistar, Inc.
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MPAPS G-22 ZINC-NICKEL PLATING 1710

9.0 DESIGNATION ON DRAWINGS

Example:
Zinc-Nickel Plating, Class ZNi-C1, MPAPS G-22
Zinc-Nickel Plating, Class ZNi-C2-L, MPAPS G-22 (for controlled lubricity)
Zinc-Nickel Plating, Class ZNi-B2, MPAPS G-22

10.0 TECHNICAL INFORMATION

For further information related to the technical Suppliers may purchase controlled copies of
content of this specification, contact: this specification by contacting:
Materials Engineering and Technology Dept. IHS Markit Inc.
10400 W. North Avenue 15 Inverness Way East
Englewood CO 80112-5776
Melrose Park, IL 60160 Phone: 1-800-854-7179
E-mail: MaterialsEngineering@Navistar.com E-mail: Automotive@IHS.com
Website: http://global.ihs.com

A.0 GENERAL INFORMATION

A.1 SUGGESTED PRODUCTS:

For Class ZNi-C5: ZinKlad™ 1000 (MacDermid Inc.)
For Class ZNi-B2: ZinKlad™ 1000B (MacDermid Inc.)
[See http://www.zinklad.com for more information about Zinklad coatings and approved global
applicators.]

REVISION HISTORY

Revision Change Approved by Date

Level Approved
1703 Clarified corrosion performance requirements R. Goluch 3/16/2016

1710 Added reference to MPAPS G-23 for electrical grounding R. Goluch 10/24/2017
applications; fixed typographic error in section 6.2.1.

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Suppliers are required to assume all patent liability. 2017 by Navistar, Inc.
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