Corrosion protection of purchased parts Created by: P. Kießling, PEQAC Replace: 2013-06 Content 1. Scope 2. General 3. Coating 3.1 Coating of thermally not affected engine parts 3.2 Coating of thermally stressed engine parts 3.3 Coating of cover plates 3.4 Coating of oil pans and base frames 3.5 Coating of turbo charger parts 3.6 Cathodic electrophoretic deposition (Cathodic EPD) 3.7 Powder coating 4. Preservation 4.1 Volatile corrosion inhibition (VCI) 5. Testing and documentation Annex 1 Curing test for two-component coating systems Annex 2 Drawing 11.50004-0110 Corrosion protection of cast parts (turbo charger) 1. Scope This standard describes the requirements for the corrosion protection of components and assembly groups which MAN Diesel & Turbo SE (MDT) places on their suppliers. The regulations have general application when is requested by the order text and as long as no further order information, drawing specification or quality standard claims a special coating or preservation or rather claims to discard a coating. 2. General The responsibility for the correct execution of all corrosion protection measures and for providing a corrosion and damage free delivery, rests with the supplier. In addition to the described preservation measures the supplier therefore has to carry out a suitable packaging which ensures easy transportation and protects the purchased part against damages and environmental influences (e.g. moisture). Advisory support by the manufacturer is obligatory for first-time application of the required products like cleaner, paint, preservatives, VCI carrier or special packaging materials. Coating and preserving must be carried out by qualified personnel. In any case the supplier has to take care that solvents completely evaporated out of the coating or preservative and coatings are fully dry before packing. MAN Diesel & Turbo SE Copyrights and utilization only allowed with obligation of MAN Diesel & Turbo SE 1/10
3. Coating All unmachined cast iron areas and steel surfaces which are endangered by corrosion need to be coated as long as they are no sealing or mounting area. It s only allowed to use the specific coating systems tested by MDT and given by this standard. In exceptional circumstances, deviating products are allowed after they got approved by MDT quality department (EQAC) in writing. In case of hard-to-access inner areas where no safe coating and subsequently no reliable quality check can be ensured by the supplier, MDT must be consulted. In individual cases it can be agreed not to coat this space but to apply a preservation as explained in paragraph 4. Prior to coating a sufficient surface preparation is required. The surface designed for painting must be dry, free of dirt and any residues, completely degreased as well as free of scale and any traces of corrosion. In circumstances and after consultation and written approval from MDT, shop primers can remain on the substrate. The surface roughness must meet the requirements of the respective coating system. When used properly, all coating materials given by this standard fulfill the MDT requirements regarding the corrosion, heat and chemical resistance as well as the overcoatability. Along with a proper adhesion on the substrate, which can be achieved by an appropriate surface preparation, it is also important to ensure the complete polymerization of two-component paint systems. When fully cured, the mentioned twocomponent coatings are resistant against their corresponding thinner. While rubbing with a soaked cloth, the coating should not significantly get affected (curing test). More details on the curing test are given in the annex. The respective working instructions supplied by the paint manufacturer are to be observed. Paint application has to be performed according to the manufacturer s instructions and with the intended equipment. The demanded dry film thickness (DFT) for each coating system is defined by the nominal dry film thickness (NDFT) and the maximum dry film thickness according to DIN EN ISO 12944-5:2008-01. To determine the film thickness, a correction value referring to the surface roughness must be taken into account. Any uncertainties must be clarified depending on the problem either with MDT or with the paint manufacturer. 3.1 Coating of thermally not affected engine parts The following coating system must be applied: 90 µm NDFT, 140 µm maximum dry film thickness 2K Ultra-High Solid Rostbarriere SL-2306, RAL 7040 MAN Diesel & Turbo SE Copyrights and utilization only allowed with obligation of MAN Diesel & Turbo SE 2/10
3.2 Coating of thermally stressed engine parts This includes parts of the assembly group 289 (material numbers 11.289xx-yyyy; exhaust pipe, but not the cover plates) as well as parts which are exposed to a temperature of more than 200 C (see drawing details). The following coating system must be applied: 40 µm NDFT, 80 µm maximum dry film thickness Wetterwart Silico Therm 655E 3.3 Coating of cover plates Exhaust pipe covers of the assembly group 289 and 292 (material numbers e.g. 11.289xx-yyyy) and charge air cooler of the assembly group 322 must be coated with: 50 µm NDFT, 80 µm maximum dry film thickness 2K-Thermo Acryl-Lack, RAL 9006 Pump chamber covers (assembly group 073) must be coated in the particular color of the engine. In this case, the same coating system is to be applied but in the required color. The color of the engine is either mentioned in the order or can be inquired of MDT purchase department. 3.4 Coating of oil pans and base frames For oil pans and base frames the following coating system must be applied: 90 µm NDFT, 140 µm maximum dry film thickness 2K Ultra-High Solid Rostbarriere SL-2306 For inner areas the RAL color 7040 must be applied. The color of the outer areas of oil pans depends on the respective engine color. The engine color is either mentioned in the order or can be inquired of MDT purchase department. If the engine is intended to receive the standard color RAL 9006, the outer areas of the oil pan are supposed to be painted in RAL 9006, too. The outer oil pan areas are supposed to be RAL 9005, when the engine will have any other color than the standard RAL 9006. The color of the outer areas of base frames is project specific. The applicable color shade is either mentioned in the order or can be inquired of MDT purchase department. MAN Diesel & Turbo SE Copyrights and utilization only allowed with obligation of MAN Diesel & Turbo SE 3/10
3.5 Coating of turbo charger parts Turbo charger parts belong to the assembly group 500 (material numbers e.g. 11.500xx-yyyy). Cast iron parts need to be coated according to the details of the drawing number 11.50004-0110 (annex 2) with the following system: 40 µm NDFT, 80 µm maximum dry film thickness Wetterwart Silico Therm 655E Components made of sheet steel as well as stainless small parts need to be coated with: 50 µm NDFT, 80 µm maximum dry film thickness 2K-Thermo Acryl-Lack, RAL 9006 Inner areas of silencers need to be coated with: 70 µm NDFT, 140 µm maximum dry film thickness 2K Ultra-High Solid Rostbarriere SL-2306, RAL 7040 Purchased parts destined for the turbo charger production will not receive an additional cover coat by MDT. The coating applied by the supplier already represents the cover coat of the final product. Thus, any damages of the coating (e.g. during the carriage) must be avoided. 3.6 Cathodic electrophoretic deposition (Cathodic EPD) For cases in which a cathodic EPD base coat is requested, the following system is admitted: 25 µm NDFT, 45 µm maximum dry film thickness PPG Powercron 6200HE Cathodic epoxy electrocoat www.ppg.com To repair small paint damages and only for non-media-bearing areas, the following product is admitted: PPG KTL-Reparation-Spray SPR 51133-ZL P166-6200-EE3 Acrylic paint, silk gloss, black www.ppg.com MAN Diesel & Turbo SE Copyrights and utilization only allowed with obligation of MAN Diesel & Turbo SE 4/10
3.7 Powder coating If the drawing requests a powder coat on cathodic EPD primed areas, the following coating system is admitted: 70 µm NDFT, 130 µm maximum dry film thickness Pulverit polyester resin powder coat, series 50 Pulverit Deutschland GmbH, 73560 Böbingen / Rems 4. Preservation All metal surfaces which are endangered by corrosion must be well protected against a corrosive attack. The corrosion protection must be ensured during the transportation and while a subsequent storage for at least 12 month. For shipment and storage industrial climate conditions need to be assumed. The corrosion protection methods mentioned in this standard are designed for continental transport. For intercontinental shipment individual protection methods must be arranged with MDT. This also applies in cases when a protection period of more than 12 month is requested. Prior to preservation the parts must be cleaned. Surfaces need to be dry, free of dirt and any residues, completely degreased as well as free of any traces of corrosion. Bare metal surfaces must not come into contact with hand or body perspiration. Gloves must always be worn when handling the parts. With all applied corrosion protection methods and products it must be possible to use the purchased part without previous removal of the preservative agent. It s only allowed for very big parts (e.g. crankcase, base frame, or crankshaft) and only after consultation and written approval from MDT, to apply preservative agents which need to be removed before usage of the part (e.g. high-viscosity oils and greases). When using corrosion preservatives it is obliged to ensure that they are not harmful during normal use and that they are compatible with the operating fluids of the engine (e.g. lube oil). Compatibility is ensured by using the following products: - PrimeServ Protect Fully synthetic, low viscous protection oil; free of VOC, acid, silicone and resin Distributed by: MAN Diesel & Turbo SE, 86224 Augsburg, Germany Phone: +49 821 322-0, Fax: +49 821 322-3382, E-mail: primeserv-aug@mandieselturbo.com - Rivolta K.S.P. 204 non VOC Oily, full synthetic corrosion preservative; VOC- and silicone-free Distributed by: Bremer & Leguil GmbH, Am Burgacker 30-42, 47051 Duisburg, Germany www.bremer-leguil.de - BRANOrol Mineral oil based preservative; free of VOC, resin and silicone Distributed by: BRANOpac GmbH, Gottlieb-Daimler-Str. 18-20, 35423 Lich, Germany www.branopac.de MAN Diesel & Turbo SE Copyrights and utilization only allowed with obligation of MAN Diesel & Turbo SE 5/10
4.1 Volatile corrosion inhibition (VCI) MDT prefers the usage of VCI products for preservation because no depreservation is necessary in this case. VCI stands for volatile corrosion inhibitor and is the term for a method where corrosion preventive active ingredients vaporize from a carrier material within a draught-free enclosed packaging and create a protective layer on the metal surface. After opening the packaging, the active ingredients evaporate and the component part is ready for assembly without any residues. This is the recommended preservation method for continental transportation. For intercontinental transportation the VCI method is prescribed. Typical VCI carriers are coated plastic films, foil bags, VCI impregnated paper, cardboard or pulp boards and corrosion protection oils (e.g. BRANOrol). There is a variety of different producers of VCI products, including international acting companies like for example BRANOpac (www.branopac.de) who is available in the Asian region, too. For big components MDT recommends single wrapping in VCI foil and additional use of one of the protection oils named above to preserve bare metal surfaces and drill holes. Smaller parts and bulk goods can be compiled in reasonable packaging units and either be packed in VCI foil or single wrapped in VCI paper and bundled in a box. VCI packaging units should be designed in a way that allows resealing after a partial taking or rather a repacking after a short removal for example in the context of a quality check. Under these circumstances the protective atmosphere can recover and further preservation is given. Additionally the amount of VCI active component within the packaging can be increased by adding new VCI carrier material. To achieve a reliable corrosion protection by VCI materials, particularly the following points have to be considered: - Only new and intact VCI materials can be used. The use of recyclate is not allowed. - With the choice of a certain foil thickness, the respective capability to block humidity must be taken into consideration. - The utilized VCI materials must be suitable for the respective materials to be protected. - During packing the temperature of the component may not deviate from the ambient temperature. Otherwise there is a risk of condensation. - To strengthen the VCI effect, it is recommended to add additional VCI carrier into the packaging. A given maximum distance between VCI carrier and the surface to be protected must not be exceeded. Depending on the packaging volume, a certain amount of VCI active ingredient must be added. To achieve this, the part could for example first be wrapped in VCI paper and then be packed in VCI foil. - No moisturizing materials like wood, cardboard or untreated fibrous materials are allowed within the packaging. MAN Diesel & Turbo SE Copyrights and utilization only allowed with obligation of MAN Diesel & Turbo SE 6/10
- VCI active ingredients are only able to provide protection within a closed package. Thus, the foil need to be sealed in a way that guarantees draught-free conditions in the packing unit during the requested preservation period and the VCI atmosphere won t evaporate. - After packing, the manufacturer s instructions regarding the waiting time and the temperature must be adhered so that the protection atmosphere can form optimally and preservation is given. - Prerequisite for a reliable preservation is that the foil will not be damaged during transport. This should be achieved by selecting a suitable load carrier and by labeling. - Attention must be paid to weather-proof conditions while transport and storage. - The ambient temperatures for VCI packed goods need to be in the range of -20 to +50 C during transport and storage. In case of momentary deviations, the foil packaging need to stay closed and must not be mechanically stressed. All metal surfaces which are endangered by corrosion need an additional protection by corrosion protection oil to ensure a 12 month corrosion protection period even in case of a damaged VCI packaging. 5. Testing and documentation Apart from the information in the order text, on drawings, in quality standards and the AN s, all written agreements regarding the preservation made between the supplier and MDT need to be stored by the supplier in paper or scanned and saved as a PDF file for at least 10 years. If required, the documents shall be provided to MDT. For compulsory labeled parts (parts with COC-number or other concrete component label), the supplier is obliged to determine the DFT according to ISO 19840 and to document the values. While doing this, the specific correction value determined according to ISO 19840 Annex D must be used. The test report should be created following Annex E of ISO 19840. For compulsory labeled parts the supplier is additionally obliged to document all applicable points of the following list clearly assigned to the respective part. Together with the DFT test report this information must be stored by the supplier in paper or scanned and saved as a PDF file for at least 10 years. If required, the documents shall be provided to MDT. Details of surface preparation - Surface roughness R y5 (mean maximum peak-to valley height in µm) according to DIN EN ISO 8503-1:2013-05 - Used cleaning agents - Is the surface preparation grade Sa 2½ according to DIN EN ISO 12944-4 reached? (yes / no) - Got the surface tension determined? (yes / no) If so, which result was achieved? (mn/m) MAN Diesel & Turbo SE Copyrights and utilization only allowed with obligation of MAN Diesel & Turbo SE 7/10
Details of coating for each coating material and each coating step - Is it a base coat or a second or third layer? - Name of the coating material - Manufacturer of the coating material - Shade of color - Lot number component A - Lot number component B - Mixing ratio and information if it was mixed by weight or volume - Name of the thinner - Lot number of the thinner - Share of the thinner (%) - Description of the applicator - Relative air humidity - Surface temperature - Ambient temperature - Dew point - Description of the drying conditions - Date - Name of the painter - Was a curing test performed? (yes / no) If so, was no residue, a minor or a significant residue visible? - When and by whom the goods got released for packaging and shipping? (date, name) Details of preservation for each preservation agent - Which area got treated - Name of the preservative - Manufacturer of the preservative - Lot number of the preservative - Details about additional used substances (e.g. thinner) - Name of the executing worker - Date - Description of the drying conditions To determine the surface tension by test inks (e.g. from arcotest GmbH, Mönsheim, Germany) and to perform a curing test can be demanded by the order text. MAN Diesel & Turbo SE Copyrights and utilization only allowed with obligation of MAN Diesel & Turbo SE 8/10
Annex 1 Curing test to determine the cross linking of a two component coating system If performed accurately and after an accordant drying, the requested two component coating systems are resistant against their respective thinner. The grade of cross linking can easily and cheap be determined by performing a curing test. On the basis of the curing test, the coating quality at a certain time can be determined. Test procedure: - A white, robust, absorbent, disposable cloth (e.g. Kimberly-Clark Wypall X70) is soaked with the respective thinner of the tested coating system. - This cloth is than rubbed along the coated surface with medium pressure and over a distance of approx. 30 cm for three times back and forth. - The abrasion residue on the cloth is inspected and documented by taking a picture of it. Evaluation: no residue minor residue significant residue acceptable acceptable not acceptable In many cases black abrasions appear when metal pigmented (e.g. aluminum) coatings are tested. Those abrasions must not be confused with the residues of binder dissolved by the thinner. Factual bad results are characterized by a sticky and weak surface which thwarts the wiping. MAN Diesel & Turbo SE Copyrights and utilization only allowed with obligation of MAN Diesel & Turbo SE 9/10
Annex 2 Drawing 11.5000-40110 - Corrosion protection of cast parts (turbo charger) MAN Diesel & Turbo SE Copyrights and utilization only allowed with obligation of MAN Diesel & Turbo SE 10/10