Date of Issue 2003/07/03

Product HES Office

HES

HES
D 2008-03
B REV1
ZINC-ALUMINUM COMPOSITE COATING

1. SCOPE
This standard specifies Zinc-Aluminum Composite Coating {previously titled as DACRO COATING
(hereinafter referred to as the coating)} to be applied to the base surface of small iron parts for the purpose
of anti-corrosion and rust-proof.
Remarks:
1. The units and numerical values in this standard are specified values in accordance with the
International System of Units (SI), and those in { } are specified values based on customary units.
2. Use of hexavalent chromium for the coating treatment shall be prohibited beginning on December 31,
2005. However, use of it before December 31, 2005 shall be decided upon coordination among the parties
concerned.

2. GRADE AND CODE

The grades of the coating and codes shall refer to Table 1.
Table 1
Coating weight No. of coatings
Grade Code 2
Application
(g/dm ) and baking example
Grade 1 HES D2008-1 0.160 min. 2 coatings and
2 bakings (*1)
Grade 2 HES D2008-2 0.200 min.
Note (*1):
a. Parts which cannot satisfy anti-corrosion and heat resistance (100 oC to 300 oC) with Zn plating.
b. Parts on which electroplating cannot be applied due to high tension and high hardness.

3. QUALITY
The quality of the coating shall be determined in accordance with the test methods specified in Section 4.2
and the results shall satisfy the requirements in Attached Table 1.

4. TEST
4.1 General Conditions

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 4.1.1 Test locations
The tests shall be conducted with a temperature of 23+5 oC and humidity of 65+15% in a closed place not
exposed to direct sunlight, and free from draft, gas, vapor, and dust harmful to the tests.
4.1.2 Testing materials, apparatuses, and reagents
As a rule, materials, apparatuses, and reagents to be used in the tests shall be those specified in JIS.
4.1.3 Test Sample (Test piece)
As a rule, the test samples shall be selected at random from a lot. However, for those parts whose coating
weight cannot be measured (*2) or those parts which do not allow adhesion test (*3), test pieces which
have been pretreated and coated as those parts may be used only for the coating weight and adhesion tests
if the purchaser approves. The number of test samples and the shape and dimensions thereof shall be as
agreed upon by the purchaser and supplier.
Notes:
(*2) Those parts with a complex shape, for which the total surface area cannot be measured, or those
parts whose weight surpasses 100 g each.
(*3) Those parts having no space for a grid.
4.1.4. Pretreatment on test samples
The test samples shall be thoroughly cleaned using alcohol or benzine and dried with a clean, soft cloth.
4.2 Test Methods
4.2.1 Appearance test
The coated surface of the test samples shall be visually checked under diffused daylight (*4) and to be
checked against the requirements specified in Attached Table 1.
Note (*4): Diffused daylight means the light (not direct sunlight) coming from a window facing north
between three hours after sunrise and three hours before sunset. However, the standard light C defined in
JIS Z 8701 (Color specification-The CIE 1931 standard colorimetric system and the CIE 1964
supplementary standard colorimetric system) can be used.
4.2.2 Coating weight
The coating weight shall be measured according to the following procedure based on the mass law.
a. Measure the mass of a test sample of approximately 50 to 100 g (*5) down to 0.00l g (the result shall
be A).
b. Immerse the test sample in 20 % NaOH (*6) solution (liquid temperature of 70 to 80 oC) until the
coating is completely dissolved.
c. When the coating is completely dissolved, remove the test sample from the solution and rinse well,
and then dry quickly before measuring mass as mentioned in above a. (the result shall be B).
d. Calculate the coating weight using the following formula.

A (g) - B (g) 2
2
Coating weight (g/dm )
Total surface area (dm ) of test sample (test piece)
Notes:
(*5) Parts of less than 50 g in mass shall be measured together up to 50 to 100 g simultaneously. For
single part of more than 100 g in mass or those parts whose mass is difficult to measure, test samples of no
more than 100 g to which the coating has been applied at the same time with the parts shall be tested.
(*6) This shall conform to JIS K 8576 (Sodium hydroxide).

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 4.2.3 Corrosion resistance test
The test shall be performed in accordance with Section 4.3.1 Salt Spray Test (hereafter referred to as SST)
or Section 4.3.3 Cycle Corrosion Test (hereafter referred to as CCT) in HES D 6001 (GENERAL TEST
METHODS FOR PLATING). The test time and criteria shall conform to Attached Table 1.
4.2.4 Accelerated weathering test
a. The test shall be performed for the specified time as in Attached Table 1 in accordance with
accelerated weathering test (WAN) (*7).
b. The test sample shall be removed from the test equipment and left to stand in a room until it dries.
c. After the test sample is dried, the following tests shall be performed to check if the sample satisfies
the requirements specified in Attached Table 1.
Note (*7): Accelerated weathering test (WAN) shall conform to JIS D 0205 (Test method of
weatherability for automotive parts).
1) Appearance test
The appearance test shall be performed in accordance with the procedure specified in Section 4.2.1 in this
standard and the results shall be checked against the requirements specified in Attached Table 1.
2) Adhesion test
After the above test, the adhesion test shall be performed in accordance with the procedure specified in
Section 4.2.10 and the results shall be checked against the requirements specified in Attached Table 1.
4.2.5 Water resistance test
a. Fill a constant-temperature bath with fresh distilled or deionized water (*8) and maintain it at 40 to 45
oC.
b. Keep test samples as straight as possible (*9) with 1/2 to 2/3 of the sample immersed in the water.
c. Perform the test for a specified time in Attached Table 1, and then remove the sample from the bath.
d. After leaving the sample to stand in a room to dry, check the film surface visually against the
requirements specified in Attached Table 1.
Notes:
(*8) Use fresh distilled or deionized water for every test.
(*9) Two or more test samples, if tested simultaneously, shall be spaced at least 15 mm apart. (This
requirement shall also apply to the tests below.)
4.2.6 Humidity resistance test
a. Place a test sample in a thermo-hygrostat of 50+2 oC and 98+2 % RH, and tilt it 15 to 30 degrees.
b. Perform the test for a specified time in Attached Table 1, and then remove the sample from the
thermo-hygrostat.
c. After leaving the sample to stand in a room to dry, check the film surface visually against the
requirements specified in Attached Table 1.
4.2.7 Gasoline resistance test
a. Pour test volatile solution No. 3 (*10) into a glass container, as a rule, and keep it at 20+5 degrees.
b. Place test samples as straight as possible with 1/2 to 2/3 of the samples immersed in the solution.
c. Perform the test for a specified time in Attached Table 1, and then remove the sample from the
container.
d. After leaving the sample to stand in a room to dry, check the film surface visually against the
requirements specified in Attached Table 1.
Note (*10): The volatile solution No. 3 for the test shall conform to the following.
Petroleum benzine : toluene = 8 : 2 (by volume)
1) Petroleum benzine shall conform to JIS K 8594 (Petroleum Benzine).
2) Toluene shall conform to JIS K 8680 (Toluene).

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 4.2.8 Oil resistance test
a. Pour Honda Ultra Oil S (*11) into a container and keep it at 100+3 oC.
b. Keep the test samples as straight as possible with 1/2 to 2/3 of the sample immersed in the oil.
c. Perform the test for a specified time in Attached Table 1, and then remove the samples from the
container.
d. Wipe the oil off the surface with absorbent cotton soaked with ethyl alcohol (*12). Then check the
film surface of the sample visually against the requirements specified in Attached Table 1.
Notes:
(*11) Honda 4 cycle gasoline engine oil 10W-30 or equivalent.
(*12) Conform to JIS K 8102 : 94 (Ethanol) (95) (Ethyl alcohol).
4.2.9 Alkali resistance test
a. Pour 1/10N of 20% sodium hydroxide solution (*6) into a container and keep it at 20+5 oC.
b. Keep test samples as straight as possible with 1/2 to 2/3 of the samples immersed in the solution.
c. Perform the test for a specified time in Attached Table 1, and remove the test sample from the
container.
d. Wash the sample with water, leave it to stand in a room to dry, and check the film surface of the
sample visually against the requirements specified in Attached Table 1.
4.2.10 Adhesion test
The adhesion test shall performed by cross-cut test as the procedure described below.
a. Place a single-blade knife (*13) on the test sample at a right angle. Then, tilt the knife blade
approximately 30 degrees to the effective surface and cross cut the sample surface to make a grid with 100
squares of 1 mm reaching to the base material.
b. Thoroughly bond (*15) 12 mm-wide adhesive cellophane tape (*14) to the squares on the test sample.
c. Immediately after bonding, pull the tape off of the coated surface quickly holding an edge of the tape
at a right angle to the coated surface.
Notes (*13): Use the single-blade knife illustrated in Fig. 2, or its equivalent.
Unit: mm
Apprx.18

Blade angle; 13 to 16
Thickness; 0.25 to 0.27
Apprx.39.5 Hardness ; HV870 to 890
(Load: 4.9N{500 gf})
Blade angle
Fig. 2
(*14) Refer to JIS Z 1522 (Pressure sensitive adhesive cellophane tapes).
(*15) Rub with fingers forcefully, but do not rub with fingernails.
4.2.11 Heat resistance test
a. Place a test sample in a constant-temperature bath at 250+3 oC for a specified time in Attached Table
1.
b. Remove the sample from the bath and allow it to cool in a room. Then, perform the following tests to
ensure that the sample satisfies the
requirements specified in Attached Table 1.
1) Appearance test
The appearance test shall be performed in accordance with Section 4.2.1. Check to see if the test sample

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 satisfies the requirements specified in Attached Table 1.
2) Corrosion resistance test
Following the appearance test, the sample shall be tested in accordance with Section 4.2.3. Test duration
and criteria shall conform to Attached Table 1.

5. INSPECTION
After being subjected to the test in accordance with Section 4, the coating shall satisfy the quality
requirements specified in Section 3 and an agreement made by the purchaser and supplier concerned.

6. DRAWING INDICATION
The drawing indications for the coating shall be as follows.
Grade Current drawing indication method Drawing indication method
Grade 1 DACRO COATING : D 2008 GRADE 1 HES D2008-1
Grade 2 HES D2008-2

Remarks: Use of Grade 1 or 2 of the coating shall be decided among the parties concerned depending on
the use environment and purpose of the product.

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 Attached Table 1
Item Test duration Criteria
The coating shall be of gray metallic color and shall be
Appearance free from blisters, exposed base material, discoloration,
banks, or other defects.
2
Grade/Coating Grade 1 0.160 g/dm min.
weight 2
Grade 2 0.200 g/dm min.
No. of coatings
2 coatings and 2 bakings
and bakings
Grade 1 480 h (*17)
SST
Corrosion Grade 2 1500 h
No brown rust allowed.
resistance (*16) Grade 1
CCT
Grade 2 40 cycles
Appearance test No rust, cracks, blisters, or peeling
Accelerated
The coating shall not peel off the base
weathering 200h
Adhesion test material surface or from between the
property
layers. (*18)
Water
No blisters, peeling, or other defects shall be allowed.
resistance
240h
Humidity No blisters, wrinkles, crazing, peeling, rust or other
resistance defects shall be allowed.
Volatile solution No blisters, peeling, softening of film, etc. shall be
resistance allowed.
No blisters, peeling, softening of film, or other defects
Oil resistance 7h
shall be allowed.
Alkali
No blisters, peeling, or elution shall be allowed.
resistance
Adhesion The coating shall not peel off form the base material or
(Cross-cut test) from between layers.

No blisters, exposed base material,

Appearance
peeling, cracks, or other defects shall
test
Heat be allowed.
12h
resistance Brown rust shall not be allowed for
SST Grade 1 (after 240 h) or Grade 2
(after 1200 h).
Notes:
(*16) Use SST or CCT for Grade 2.
(*17) Test duration of SST for Grade 1 can be 240 h upon coordination among the parties concerned.
(*18) Adhesion of silver powder on the adhesive tape is allowed.

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 Applicable Standards
HES D 6001-03 GENERAL TEST METHODS FOR PLATING
JIS D 0205 : 87 Test method of weatherability for automotive parts
JIS K 8102 : 94 Ethanol (95) (Ethyl alcohol)
JIS K 8576 : 94 Sodium hydroxide
JIS K 8594 : 96 Petroleum benzine
JIS K 8680 : 96 Toluene
JIS Z 1522 : 94 Pressure sensitive adhesive cellophane tapes
JIS Z 8701 : 99 Color specification-The CIE 1931 standard colorimetric system and the CIE 1964
supplementary standard colorimetric system

Reference Standards
JIS D 0202 : 88 General rules of coating films for automobile parts
JIS K 5400 : 90 Testing methods for paints

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 Revision Record
Year Rec Issue NewsNo Prep Conf Appvl Remarks
79 EST 79/08/23 79012 Shimane Kurokawa Asano
79 Rewrite 87/03/02 ----- Oooka Tomino Katagiri Data transfer to W/P
79 Rewrite 91/11/12 910036 Tanaka Goudo Morita Introduction of SI 2nd stage
79 Rewrite 95/06/08 ----- Kimura Shimada Yamada Data transfer to PC
79 Rewrite 98/06/30 ----- Tashiro Shimada Honda Data transfer to Notes DB
99 Correctio 99/12/24 99017 Tomonaga Naya Tomino Correction of errors
n
03 REV1 03/07/03 03007-3 Aoyama Tomino Suganuma Additions of use limitation of hexavalent
chromium and coating grade 2

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