WORLDWIDE Material Specification

ENGINEERING GMW3359
Finish
STANDARDS

Non-Electrolytically Applied Zinc Rich Coating

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2 References
1 Scope Note: Only the latest approved standards are
This standard covers the basic requirements for a applicable unless otherwise specified.
corrosion resistant non-electrolytically applied zinc 2.1 External Standards/Specifications.
rich coating. Besides corrosion protection, the
SAE/USCAR-5 ISO 16047
coating also provides color identification and
lubrication by using an additional topcoat with SAE/USCAR-11 SAE/USCAR-1
integrated lubricant such as wax or ISO 1463 VDA 621-415
polytetrafluoroethylene (PTFE). 2.2 GM Standards/Specifications.
1.1 Material Description. The material to this 9981062 GMW3059
specification covers organic or inorganic zinc flake
9984094 GMW3286
coating with and without organic topcoat. This
coating system must be free of hexavalent 9985670 GMW14333
chromium, with no hexavalent chromium in final GM9509P GMW14729
product per GMW3059 requirements. GMW3034 GMI 60266 GMW14829
will be used as a referee test. This coating process GMW3001 GMW14872
does not generate hydrogen; however, GMW3034 GMW15272
pretreatment processes, i.e., acid pickling could
cause hydrogen adsorption. Non-electrolytically
applied zinc rich coating has high permeability, 3 Requirements
which allows effusion of hydrogen during curing 3.1 Coefficient of friction/torque tension values in
which might have been absorbed during acid this specification are also determined at ambient
pickling. temperatures. New applications for this finish
1.2 Typical Applications. This coating is suitable should be tested to confirm performance under
for externally and internally threaded parts (size application specific operating conditions.
greater than or equal to M6) and non-threaded 3.2 Finishes conforming to the requirements of this
ferrous parts where high level of corrosion specification can be used in the application range
protection and freedom from hydrogen of -50 to 120C. For applications outside of this
embrittlement are required. This is not temperature range, consult your local
recommended for the following: Material/Fastener Engineering group.
1.2.1 Bolts and nuts of sizes < M6. 3.3 The following types are covered by this
1.2.2 Parts with internal drive recess. specification. The Engineering drawing with
GMW3359 without any type shall default to
1.2.3 Against magnesium surfaces.
GMW3359 Type B.
1.2.4 Loose washers of all sizes.
3.3.1 Type A: High Corrosion Resistant
1.2.5 Parts where electrical conductivity is Coating. Mainly to be used in areas with severe
required. high corrosion environment and in areas with high
1.3 Remarks. Use of this coating system on visibility.
threaded surface and/or bearing surface of joints 3.3.2 Type B: Medium/High Corrosion Resistant
could affect the torque-tension relationship. It is Coating. To be used in areas with severe
recommended that a torque-tension study of the high/severe medium corrosion environment.
fastener joint be performed before releasing this
3.3.3. Type C: Medium/Low Corrosion Resistant
finish on any new application.
Coating. For exterior applications only permissible
in areas with severe low corrosion environment.
Note: For severity definition see GMW15272.

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 GMW3359
3.3.4 For special applications, e.g., where no
lubrication or no topcoat is required, the
information may be added on the individual part
drawing.
3.4 Pre-treatment. The use of acidic cleaners is
not recommended as a pre-treatment for all parts
heat treated or highly cold worked to the specified
core hardness greater than Hardness Rockwell C
Scale (HRC 32) or surface hardness (HRC 35). If,
due to excessive surface scale, acidic cleaners are
used as a pretreatment, then additional care and
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documentation is required in baking and testing for
hydrogen de-embrittlement (see 3.11).
3.5 Appearance. The coating shall have a uniform
appearance and shall be free from tears, sags,
pores, cracks, flakes, blisters, rough spots,
uncoated areas and excess coating which affects
appearance and performance. The coating shall
not be oily or tacky to the touch. During normal
handling practice parts shall not leave particulate
residue on equipment, hands, or gloves. The
coating shall be completely cured and shall have
good adhesion to base metal. The color unless
otherwise specified shall be silver.
3.6 Thickness. When applied to threaded
products, the coating shall not have an adverse
effect on normal installation and removal practices.
At the same time coating thickness shall be
adequate to provide corrosion resistance
performance requirements. Thereby the following
minimum thickness values shall be applied:
Table 1: Coating Thickness
Type
A 12
B 12
C 8
Note: Lower Coating thickness for a chemical
system shall be acceptable, if proven that parts
with lower thickness can meet all other
performance requirements. It will be recorded in
the GM Materials File.
3.6.1 The maximum thickness of coating which
may be applied to threads on threaded products is
limited by the basic thread size (tolerance h or H).
After coating, parts must gage with appropriate
basic size GO thread gages. Threads may be
produced undersize/oversize (before coating) to
accommodate the coating thickness, provided the
finished product (after coating) meets all specified
mechanical properties. Where mechanical
properties are not specified, undersizing/oversizing
is subject to approval by the pertinent engineer and
all undersize/oversize shall be within permissible
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GM WORLDWIDE ENGINEERING STANDARDS
Minimum Thickness[µm]
© Copyright 2007 General Motors Corporation All Rights Reserved
limits as agreed upon. Fastener supplier will
consult with the coating applicator to determine the
appropriate thread size before coating.
3.6.2 The applicator shall monitor the coating
thickness per line per lot. The coating thickness
shall be measured on flat surfaces, minimum
ten (10) samples per lot. Supplementary treatment
is not applicable to thickness measurements. The
individual coating thickness for the full set of
samples shall be equal or greater than the
minimum coating thickness shown in Table 1.
Note: The applicator can use a non-destructive
method to monitor the day to day thickness results;
however, a relation with correct thickness
measured by microscopic test and the readings by
non-destructive test must be established. ISO 1463
microscopic test to measure the thickness of
plating/coating shall be used as a referee test
method.
3.6.3 The maximum coating thickness under the
head of bolts and screws shall not exceed 25 µm.
Supplier shall monitor the thickness and maintain
the test results in file to be submitted when
required.
3.7 Corrosion Resistance. Parts plated to this
specification when neutral salt spray (NSS) tested
GMW3286 shall show no white corrosion products
and no base metal corrosion (red rust) after
exposure for minimum hours specified in Table 2
on significant surfaces.
The corrosion testing of the threaded fasteners
must follow the procedures as outlined in
SAE/USCAR-1.
Table 2: Salt Spray Test Corrosion
Performance
Type White Corrosion Red Rust
Note 1
A 240 h 720 h
B 144 h 480 h
C 72 h 240 h
Note 1: 5 % permissible
Note: The salt spray test is only used to test the
integrity of the finish for quality control. The hours
to white or red corrosion products shall not be
construed as having any correlation to the actual
service life of the part.
3.7.1 For normal production, processes that are in
statistical process control shall yield parts that are
capable of meeting the same salt spray
requirements.
3.7.2 Neutral Salt Spray (NSS) testing shall be
performed on a regular basis to maintain statistical
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 GM WORLDWIDE ENGINEERING STANDARDS
process control. The minimum frequency of
corrosion tests for white and red corrosion with
NSS test hours up to and including 480 h shall be
at least once per week. The minimum frequency of
corrosion tests for red corrosion with NSS test
hours greater than 480 h shall be at least once per
month. The sample size shall be three (3) pieces
minimum per lot for each test requirement. Use
actual part for NSS testing unless the use of other
parts (surrogate or other parts) is agreed by GM
Engineering. The supplier shall maintain the test
results in a file to be submitted when required by
GM unless otherwise agreed between the
purchaser and supplier.
3.7.3 Significant surfaces for test evaluation of
fasteners shall be all exposed surfaces of the
fastener when installed, including but not limited to
fastener heads, socket recess, sems washers and
external surface of nuts. Fastener threads and
point are excluded unless otherwise specified on
the drawing.
3.7.4 Significant surfaces on parts other than
threaded fasteners shall be all surfaces. Deep
recesses, such as blind holes and the interior of
tubes are excluded unless otherwise specified on
the drawing.
3.7.5 Temperature Resistance. After heating the
parts for 3 h at 150°C (part temperature), the
corrosion resistance requirements as specified in
3.7 shall still be met. This test requirement is only
for initial approval of the finish material.
3.7.6 Accelerated Corrosion. After heating the
parts for 3 h at 150°C (part temperature) the
corrosion resistance requirements as specified in
3.7 shall still be met. This test requirement is only
for initial approval of the finish material.
3.7.7 Accelerated Corrosion. The coatings to this
specification shall be exposed per GMW 14872:
• Type A: EXT All, 4 s, Method SH/SM/SL,
Exposure D.
• Type B: EXT All, 4 s, Method SH/SM/SL,
Exposure C.
• Type C: UH All, 4 s, Method SH/SM,
Exposure B.
3.7.7.1 After exposure, there shall be no red rust
on significant surfaces.
Note: This test shall be run with initial approval of
chemicals/process and applicator approvals.
Applicators are required to perform this test
(GMW14872) on processed parts, minimum of one
time per year. Parts performance records shall be
retained for minimum 3 years for potential review.
This test shall be run at the frequency deemed
appropriate by the applicator, such that a
© Copyright 2007 General Motors Corporation All Rights Reserved
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GMW3359
confidence in passing the requirements is
developed.
Note: Verband Der Automobilindustrie (VDA)
621-415 Cyclic Corrosion Test could be used as an
alternate test method to GMW14872 test by GME.
The coating to this specification shall be exposed
to VDA 621-415 Cyclic Corrosion test.
• Type A 10 cycles
• Type B 6 cycles
• Type C 2 cycles
3.7.7.2 After test cycles, the screw heads shall
exhibit no red rust.
3.7.8 Cathodic Protection. The cathodic
protection capability of the coating can be tested
by NSS test per GMW3286 with a specimen which
is scratched to the base metal, the scratch having
a width of 0.5 mm maximum. After the 96 h NSS
test, there shall be no red rust in the area of the
scratch. This test is required only for initial
approval of finish material.
3.8 Flexibility and Chip Resistance. The coating
must withstand the normal extension, flexing and
compression encountered by springs and spring
clips during product assembly without evidence of
flaking or loss of adhesion from the base metal. It
shall withstand normal handling and storage
conditions without chipping or flaking.
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3.9 Adhesion Characteristics. Parts coated to
this specification shall show no evidence of
blistering or other appearance changes, other than
a whitish blush, after exposure to humidity testing
per GMW14729 for 96 h minimum. When tape is
tested per GMW14829, 10 minutes after removal
from humidity test there shall be minimum 99.0%
of coating (topcoat) retention after the tape
adhesion test. When removing the tape, a slight
adherence of the coating is permissible since this
has no influence on the corrosion resistance. In
case of small fasteners when the surface area of
the part is not large enough to run the test, steel
panels 50 x 50 mm shall be processed with
fasteners and used for adhesion test.
3.9.1 Parts shall be tested to meet the adhesion
requirements for initial approval. This test shall be
conducted on a periodic basis per the applicator’s
control plan.
3.10 Chemical Resistance. Coated parts in the
as-received condition shall be tested against the
following chemicals per the respective test
methods shown.
3.10.1 Windshield washer solvent, 9985670 or
similar if approved by engineering GM9509P.
3.10.2 GM fabric cleaner, 9981062 or similar if
approved by engineering.GM9509P.
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 GMW3359 GM WORLDWIDE ENGINEERING STANDARDS

3.10.3 Resistance to Gasoline. To 3.12 Torque-Tension. Metric threaded fasteners

GMW14333 - A - Rating 2. M6 and larger shall be subject to torque-tension
3.10.4 Resistance to Cleaning Agents. To monitoring through the use of surrogate M10 x 1.5
GMI 60266 - Rating 2. test bolts. Ten (10) surrogate bolts shall be
processed with the production parts. A minimum of
3.10.5 There shall be no discoloration of the
ten (10) bolts per finish line per shift shall be
surface.
monitored per SAE/USCAR-11, except tightening
Note: Chemical resistance tests are required at speed shall be 30 ± 3 RPM. The tests shall be
chemical approval only. frequently run to maintain statistical quality control.
3.11 Hydrogen Embrittlement. All parts heat The test results shall be regularly plotted and
treated or highly cold worked to the specified core maintained in file to be submitted when required.
hardness greater than HRC 32 or surface The six (6) sigma torque range value must be
hardness HRC 35, which are processed through within the listed range (Table 3).
hydrogen generating process, shall be processed
per SAE/USCAR-5.

Table 3: Torque- Tension Test Parts and Requirements

Thread Size Surrogate Test Nut Test Washer Torque (Nm) Tension (kN) Coefficient
Bolt Part Part Number Part Number of Friction
Number
M10 x 1.5 11516105 11516090 11502644 48 ± 8 28.3 0.13 ± 0.03
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3.13 Coefficient of Friction. The coefficient of 3.16 Physiological Safety. The coating material
friction of threaded fasteners shall be 0.13 ± 0.03 must not cause any health hazard either to line
(six sigma values) when tested per ISO 16047 with operators or customers.
the following exceptions: Tightening speed shall be
30 ± 3 RPM. 4 Manufacturing Process
Note: Torque-Tension Test and Coefficient of Not applicable.
Friction Tests are required for the initial approval of
the finish material. Suppliers/applicators shall also
5 Rules and Regulations
run either Torque-tension Test or Coefficient of
Friction Test for regular quality control. 5.1 All materials supplied to this standard must
comply with the requirements of GMW3001, Rules
3.14 Bearing Surface Characteristics. Special
and Regulations for Material Specifications.
M10 heavy hex bolts (parts number 11570102 or
equivalent) shall be tested per SAE/USCAR-11 5.2 All materials supplied to this standard must
with the following requirements: Tightening speed comply with the requirements of GMW3059,
shall be 30 ± 3 RPM. Test nut shall be 11516090. Restricted and Reportable Substances for
Tension load shall be 24 kN. Test shall be Parts.
conducted with ELPO coated test washers
(11515490 except unhardened and coated with 6 Approved Sources
9984094, medium build ELPO) and aluminum test Engineering qualifications of an approved source
washers (3.0 mm minimum thick, 10.25 to 10.50 are required for this standard. Only sources listed
hole size, AA6063T52 aluminum). The six (6) in the GM Materials File (i.e., GM Supply Power)
sigma torque range shall lie within 35 to 52 Nm for under this standard number have been qualified by
ten (10) samples tested for both the ELPO and engineering as meeting the requirements of this
aluminum bearing surfaces. These tests are standard.
required for the initial approval of the finish
For other GM locations, the responsible
material.
engineering group should be contacted to obtain
3.15 Recyclability. Parts with this coating shall not the approved source in that individual country.
have any negative effect on recyclability of the
parts.
7 Notes
7.1 Glossary. Not applicable.

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 GM WORLDWIDE ENGINEERING STANDARDS GMW3359

7.2 Acronyms, Abbreviations, and Symbols. 9 Release and Revisions

ELPO Electrodeposition Primer 9.1 Release. This standard originated in October
EXT Exterior 1999. It was first approved by GMW Finish Team
HRC Hardness Rockwell C scale in February 2000. It was first published June 2000.
NSS Neutral Salt Spray 9.2 Revisions.
PPAP Production Part Approval Process Rev Approval Description (Organization)
PTFE Polytetrafluoroethylene Date
RPM Revolutions per Minute B JUN 2004 Rewrote in New GMW
SH Severe – High template, revised 2.1, 2.2,
3.3.1, 3.3.4, 3.3.5, 3.3.7 3.5
SL Severe – Low
and 7 and added 3.3.8 (GMW
SM Severe – Moderate Finish Team)
UH Underhood
C JUL 2007 Added 1.3.1, 1.3.2 and 3.1.
VDA Verband Der Automobilindustrie
Added new coating types,
complete revision of wording
8 Coding System 1.1, 1.3.2, 1.3.2, 1.3.3, 1.3.4,
This standard shall be referenced in other 1.3.5, 3.3.(ff), 3.4 (ff), 3.6,
documents, drawings, etc. as follows: 3.6.1, 3.7, 3.10, 3.11 Bolt
GMW3359 A changed. (GMW Finish Team)
GMW3359 A Black

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