Process Specification 98021.: Powder Coating of Purchased Motorcycle Parts

Technology Surface
Process Specification 98021.

Powder Coating of purchased
Motorcycle Parts.
Model: All
Plant: Suppliers
Development status: Series
In case of dispute the German wording is valid.
Doc. No. Issued Revised Creator Approval

version (GL) (AL) (HAL)
TP-331 TP-331 TP-33 TP-3
98021-01 1998-10-01 2017-05-04 Waldhoer Kohls Stiegler Stoegmeier
Page 1 of 10
REVISION PROCESS SPECIFICATION.
Date Version Page Description of change Creator
1998-10-01 E See archival PS! Noppe
2017-05-04 1 all Adaption of lay-out to actual CI and Waldhoer
fundamental revision of contents.
Process Specification 98021 Version 01

Powder Coating of purchased Motorcycle Parts Page 2 of 19
CONTENT.
REVISION PROCESS SPECIFICATION. .................................................................................................................... 2
CONTENT. ........................................................................................................................................................... 3
FUNDAMENTALS. ................................................................................................................................................ 4
SCOPE OF APPLICATION. ..................................................................................................................................... 4
REQUIREMENTS AND STANDARDS ...................................................................................................................... 4
NORMATIVE REFERENCES. .................................................................................................................................. 5
1. SUBSTRATES. ............................................................................................................................................ 6
1.1 STEEL (GALVANIZED OR NOT). ........................................................................................................................... 6
1.2 ALUMINIUM ALLOYS (CASTING, FORGING AND WROUGHT ALLOYS)............................................................................ 6
1.3 MAGNESIUM ALLOYS. ...................................................................................................................................... 6
1.4 CARBON FIBER REINFORCED PLASTICS. .............................................................................................................. 6
2. PRIMING. .................................................................................................................................................... 7
2.1 PRIMING OF METAL PARTS. .............................................................................................................................. 7
2.2 PRIMING OF PLASTIC PARTS. ............................................................................................................................ 7
3. POWDER TOP COAT SYSTEMS. .................................................................................................................. 8
3.1 ONE-LAYER SYSTEMS. .................................................................................................................................... 8
3.2 TWO-LAYER SYSTEMS. ................................................................................................................................. 11
3.3 CLEAR COAT FOR VISIBLE CFRP SURFACES....................................................................................................... 12
4. REFINISH. ................................................................................................................................................. 13
4.1 REFINISHING SAND-THROUGH SPOTS. .............................................................................................................. 13
4.2 TOP COAT SYSTEMS FOR SPOT REPAIR ............................................................................................................ 14
4.3 RECOATING. ................................................................................................................................................ 18
4.4 PAINT STRIPPING. ........................................................................................................................................ 18
5. ANNOTATIONS AND ADDITIONS. .............................................................................................................. 19
5.1 STOVING CONDITIONS. .................................................................................................................................. 19
5.2 FILM BUILD. ................................................................................................................................................ 19
5.3 COLOUR MATCH. ......................................................................................................................................... 19
5.4 RECYCLING. ................................................................................................................................................ 19
5.5 PROCESS MONITORING OF SERIES PRODUCTION ................................................................................................ 19

FUNDAMENTALS.
This process specification contains all powder top coats tested and approved which are currently or have been
employed in series coating of purchased parts. Their material-specific properties meet the requirements of the
corresponding BMW Group Standard (please see below). When employing the powder coatings indicated here,
these criteria (i.e. resistance against chemicals, dry scratches and UV radiation) do not need to be tested once
again.
If a qualification of further process materials should be indicated due to technical or economical reasons, the
BMW contact person who is responsible for the component’s quality has to discuss this with the issuer of this
process specification at an early stage.
Also, this process specification contains all tested and approved liquid refinish materials for smart repair before
delivery.
SCOPE OF APPLICATION.
This process specification is part of the drawing and applies to all components with a corresponding reference on
the drawing. . The drawing entry should read as follows:
“Surface painted according to PS 98021 in {colour code, colour name}”. Quality specifications regarding the
paintwork are fully described in the BMW Group Standards and need not be entered on the drawing again.
Employing paint materials which are fundamentally approved resp. listed in this process specification does not
dispense the component supplier from part coating approval or introduction of initial samples. These have to be
accomplished in accordance with the responsible BMW contact person who is responsible for the component’s
quality.
REQUIREMENTS AND STANDARDS

The coating of the parts must fulfill the visual and functional requirements of all relevant BMW Group Standards
and of possible additional, component specific quality specifications. The component supplier has to prove this
to the BMW contact person who is responsible for the component’s quality.
The BMW Group Standards define the visual and functional requirements to be met by the whole paintwork. Its
properties, adhesion in particular, are depending not only from the coating materials employed, but also from the
process and the substrate. This is why the corresponding tests are to be conducted with parts which have been
coated under series condition or at least close-to-production conditions.

NORMATIVE REFERENCES.
For all powder coated components, the following references fully apply:
Ref. Title
GS 97010 Surface classification for motorcycles.
GS 93008 Prohibited and declarable substances in materials and components.
For all powder coated metal components, the following reference applies additionally:
Ref. Title
GS 90011 Coatings of parts made of metallic materials by means of organic materials.
For all powder coated plastic components (e.g. CFRP), the following reference applies additionally:
Ref. Title
GS 97079 Painted and dyed plastic parts on motorcycles.
Furthermore, relevant specifications as well as component specific requirements are to be observed.
Hint:
Specifications like BMW Group Standards (GS), quality specifications (QV), process specifications (PS) and
testing instructions (AA) are obtainable via the BMW Group “Partner Portal” under https://b2b.bmw.com and can
be downloaded after registration and clearing.
It is within the user’s responsibility to procure themselves the up to date version of the specifications mentioned
above, relevant at the time of contract.
Visual Quality:
The visible surface quality required for the respective part is specified in BMW Group Standard (GS) 97010.
Colour, gloss level and appearance have to match the corresponding BMW master sample. The colour has to be
evaluated according to GS 97079.
Functional Quality:
Coated metal parts must comply with the requirements of BMW Group Standard (GS) 90011, while coated
plastic parts must comply with those of GS 97079. The component’s supplier has to prove this to the BMW
contact person who is responsible for the component’s quality. The necessary tests can be performed in the
supplier’s lab or in an external lab, commissioned by the supplier. A corresponding lab report must be presented.
BMW reserves the right to cross-check the presented lab results.

1. Substrates.
Powder top coat materials can be applied directly onto chemically pre-treated metal surfaces or onto an organic
layer (E-coat or primer).
Any type of pre-treatment, E-coat and/or primer can be employed provided that the whole paintwork fulfills all
requirements of the relevant BMW Group Standards.
1.1 Steel (galvanized or not).

Cleaning and pre-treatment according to PS 92049 is recommended. According to experience, E-coating prior
to powder coating is necessary especially to meet the requirements of GS 90011 regarding corrosion resistance.
1.2 Aluminium Alloys (Casting, Forging and Wrought Alloys).

Cleaning and pre-treatment according to PS 92049 is recommended. E-coating prior to powder coating is not a
precondition.
According to experience, cuprous alloys are prone to corrosion and should not be employed.
Anodised surfaces can be powder coated after a suitable pre-treatment. An alternating use of anodised surface
and E-coat for the same part is not acceptable for series supply.
The part supplier has to prove that all requirements of the relevant BMW Group Standards regarding the part’s
coating are met.
1.3 Magnesium Alloys.

Cleaning and pre-treatment according to PS 05045 is recommended.
1.4 Carbon Fiber Reinforced Plastics.

Cleaning and pre-treatment according to PS 90032 is recommended.

2. Priming.
2.1 Priming of Metal Parts.

To ensure corrosion protection and adhesion to subsequent paintwork, metal parts are to be chemically pre-
treated in principle. In case of steel parts, a subsequent E-coating is compulsory. The need for a primer (onto
pre-treatment resp. E-coat) depends on the following issues:
a) Primer may be necessary to accomplish the required adhesion to subsequent powder coatings
(functional requirements according to GS 90011)
b) Primer may be necessary to compensate visual surface defects and unevenness of the part-in-white
(visual requirements according to GS 97010)
c) Primer may be necessary to avoid surface defects caused by outgassing castings (e.g. blowholes) by
means of a barrier effect (visual requirements according to GS 97010)
The primer can be a liquid paint or a powder coat. The component supplier decides independently which
primer(s) is/are employed; accordingly, he has to prove that the coated parts meet the visual requirements
according to GS 97010 as well as the functional requirements according to GS 90011.
2.2 Priming of Plastic Parts.

Powder coat systems can be applied either onto primed surfaces or directly onto pre-treated or activated plastic
surfaces. The component supplier decides independently which primer(s) is/are employed; accordingly, he has
to prove that the coated parts meet the visual requirements according to GS 97010 as well as the functional
requirements according to GS 97079.

3. Powder Top Coat Systems.
The information in this PS regarding dwell time, object temperature and minimum film build are for guidance only. No responsibility is accepted for the
accuracy of this information. Valid are the technical data sheets and other information regarding the application provided by the respective powder
suppliers. It rests with the processor to obtain these.
Process Step Process Materials Supplier: Woerwag Process and Quality Requirements
3.1 One-Layer Colour, gloss level and appearance have to match the
3.1.1 Matt Colours (Woerwag).
Systems. master sample after drying.
Product Line: W850G Dwell / object temperature / minimum film build:
Formulation: 55368 10 min / 200°C / 60 µm
Colour: YA45 Flat Black
Product Line: W850S Dwell / object temperature / minimum film build:
Formulation: 118726 textured 15 min / 200°C / Not specified
Product Line: W888 Dwell / object temperature / minimum film build:
Colour: Deep Black matt

Process Step Process Materials Supplier: Tiger Coatings Process and Quality Requirements
Colour, gloss level and appearance have to match the
3.1 One-Layer 3.1.2 Matt Colours (Tiger Coatings).
master sample after drying.
Systems.
(continued)Einschicht-
Systeme
Product Line: Drylac 230 Dwell / object temperature / minimum film build:
Formulation: 80010A6 15 min / 200°C / 60 µm
Formulation: 90015 finely textured 15 min / 200°C / 70 µm
Colour: WM33 Nuerburg Silver met. matt
Colour: WM4B Agate Grey met. matt
Process Step Process Materials Supplier: Akzo Nobel Process and Quality Requirements
3.1 One-Layer 3.1.3 Matt Colours (Akzo Nobel).
Systems. (continued) Einschicht-Systeme
Product Line: Interpon A 2201 Dwell / object temperature / minimum film build:
Formulation: YN500D / YN505D / YN50KD 10 min / 200°C / 60 µm
Product Line: Interpon A 2205 Dwell / object temperature / minimum film build:
Formulation: YL302GF finely textured 10 min / 200°C / 70 µm
Colour: Dark Grey matt

Process Step Process Materials Supplier: Axalta Process and Quality Requirements
3.1 One-Layer 3.1.4 Matt Colours (Axalta).
Systems. (continued) Einschicht-Systeme
Product Line: Alesta SD Dwell / object temperature / minimum film build:
Formulation: SD030C4900520 finely textured 10-14 min / 200°C / 60-80 µm
Colour: YM3F Deep Black matt (RAL 9005)
3.1 One-Layer 3.1.5 Glossy Colours (Tiger Coatings).
Systems. (continued)
Colour: YM40 Cordoba Blue
Colour: YB15 Light White
Colour: YM36 Racing Red

Process Step Process Materials Supplier: Woerwag Process and Quality Requirements
3.2 Two-Layer Colour, gloss level and appearance have to match the
3.2.1 Matt Colours (Woerwag).
Systems. master sample after drying.
Product Line: W852MC (Powder base coat) Dwell / object temperature / minimum film build:
Colour: M960 Aluminium Silver met. matt
Colour: WM07 Magnesium 2 met. matt
Colour: WM34 Platinum met. matt
Discontinued (for spare parts only):
Colour: WM23 Asphalt Grey 2 met. matt
Product Line: W848H (Powder clear coat) Dwell / object temperature / minimum film build:
Colour: Transparent, silky matt

Process Step Process Materials Process and Quality Requirements
3.2 Two-Layer 3.2.2 Glossy Colours.
Systems. (continued)
Currently, there are no glossy colours in two-layer technology (base coat and clear coat) approved.
3.3 Clear Coat for Glossy, with enhanced UV-resistance for protection of the CFRP’s epoxide. Gloss level > 80 %
visible CFRP Double coating necessary!
Surfaces.
Supplier: Tiger Coatings

Product Line: Powder clear coat (GMA), Dwell / object temperature / minimum film build:
for visible CFRP surfaces
Formulation: Drylac 250/00113 B1 1. Coat (B1): 20 min / 175°C / 60 - 80 µm

(1. Coat, UV-absorbing)
Intermediate sanding
Drylac 250/00113 A1
(2. Coat, enhanced appearance, 2. Coat (A1): 20 min / 175°C / 60 - 80 µm
fine grinding)

4. Refinish.
4.1 Refinishing Sand-through Spots.
Process Steps Process Materials Process Parameters Process and Quality Requirements
4.1.1 Passivating. Henkel Bonderite NC 100 Apply only if a spot has been Restoring the conversion coating (corrosion protection and
sanded through to the bare adhesion). Apply onto the bare metal spot completely.
metal.
Do not apply to Magnesium
surfaces.
Application according to the
updated version of Henkel’s
technical data sheet.
4.1.2 Priming. Woerwag Woeropur 2K-Hydro-Primer Not necessary if the outer The primer needs to completely cover not only pre-treated bare
W320 (121460) paint layer has been sanded, metal spots, but also the surrounding sanded areas of the
or but not through. paintwork. Isolating these is necessary as visible markings can
BASF Primer Filler Pro, grey: result after painting otherwise.
AB85-7270 (285-270) resp. Application of primers Use black primers for dark top coat colours only.
BASF Primer Filler Pro, black: according to the updated
AB85-9290 (285-290) version of the paint supplier’s
or technical data sheet.
ColorSystem BMW
HS-AM Multi Primer grey
(51 91 2 244 691) resp.
HS-AM Multi Primer black
(51 91 2 221 285).
Use with hardeners and thinners as
indicated in the respective technical
data sheets.

4.2 Top Coat Systems for Spot Repair
4.2.1 One-Layer Woeropur 2K One-layer top coats, To avoid rework, the paint Colour, gloss level and appearance have to match the part’s initial /
Systems. solventborne: spot needs to be blended series coating according to GS 97010.
Supplier: Woerwag carefully into the initial / series
coating.
W761M (B1933)
Colour: Agate Grey met. matt (WM4B) Application according to the
updated version of Woerwag’s
W761M (B1447) technical data sheet.
Colour: Aluminium Silver met. matt
(M960)
W761M (B1729)
Colour: Asphalt Grey 2 met. matt
(WM23)
W761M (B1330)
Colour: Magnesium 2 met. matt
(WM07)
W762M (B1746)
Colour: Nuerburg Silver met. matt
(WM33), finely textured
W761M (B1852)
Colour: Platinum met. matt (WM34)
W761 (B1442)
Colour: Flat Black (YA45)

4.2.1 One-Layer 2K Refinish systems, solventborne: To avoid rework, the paint Colour, gloss level and appearance have to match the part’s initial /
Systems. spot needs to be blended series coating according to GS 97010.
(continued) Glasurit Line 22 carefully into the initial / series
Supplier: BASF coating.
Colours:
All solids (non-metallics), according to Application according to the
mixing formulas updated version of BASF’s
resp. BMW’s technical data
ColorSystem HS-Acryl sheet.
Supplier: BMW
Colours:
All solids (non-metallics), according to
mixing formulas

4.2.2 Two-Layer Woeropur 2K base coat, To avoid rework, the paint Colour, gloss level and appearance have to match the part’s initial /
Systems. solventborne spot needs to be blended series coating according to GS 97010.
Supplier: Woerwag carefully into the initial / series
coating.
R4207 (A2479)
Colour: Platinum met. matt (WM34) Application according to the
updated version of the paint
Use with Woerwag 2K clear coat supplier’s technical data
R3279H (KL 886) sheet.
Refinish systems
(waterborne base coats):
Glasurit Line 90
Supplier: BASF
Colours:
All (solids and metallics), according to
mixing formulas
Use with Glasurit 2K clear coats
ColorSystem HC (Hydrocolor)
Supplier: BMW
Colours:
All (solids and metallics), according to
mixing formulas
Use with ColorSystem BMW 2K clear

coats

4.2.2 Two-Layer OEM Circular pipe materials: To avoid rework, the paint Colour, gloss level and appearance have to match the part’s initial /
Systems. spot needs to be blended series coating according to GS 97010.
(continued) carefully into the initial / series
Supplier: Bollig & Kemper coating.
Waterborne base coat 16-125-3680 Application according to the

Colour: Racing Red (YM36) updated version of Bollig &
Kemper’s resp. BASF’s
Waterborne base coat 16-125-5301 technical data sheet.
Colour: Cordoba Blue (YM40)
2K-Hydro clear coat 16-512-0135

(glossy, waterborne)
Supplier: BASF
Waterborne base coat FV60-0B15

Colour: Light White (YB15)
FF52-0029
2K clear coat Evergloss 8110
(glossy, solventborne)

4.3 Recoating.
A recoating in initial colour is permissible if the maximum total film build specified for a part is not exceeded. The part supplier is obliged to prove that in
this case all requirements of the relevant BMW Group Standards are fulfilled as well.
4.4 Paint Stripping.

Stripping the paint from faulty coated parts for the purpose of a renewed complete series coating is permissible.
The part supplier is responsible for these parts fulfilling all requirements of the relevant BMW Group Standards as well.
The part supplier has to prove this at BMW’s request.

5. Annotations and Additions.
5.1 Stoving Conditions.

In order to ensure the appropriate stoving conditions oven curves of the powder coat drying oven have to be recorded regularly. The measurement
results have to be filed for documentation purposes. Due to individual plant layout and shape of the parts appropriate object temperature and dwell time
can vary from the data indicated by the powder supplier. When in doubt, the degree of crosslinking of the part’s cured powder film has to be determined
whether it is compliant with the requirements (e.g. by means of a DSC analysis).
Colour, gloss level and appearance are very much influenced by the part’s actual shape of the heat-up curve (object temperature).
Therefore a part-specific optimization of the stoving process needs to be performed in order to ensure the desired colour match with the master sample.
5.2 Film Build.

All given film build figures in this process specification refer to dry film build. If not specified otherwise, the permitted maximum total film build in visible
areas is:
Non-outgassing parts: 250 µm

Outgassing parts: 450 µm
Bolt head contact surface areas: 150 µm
Specified areas: as indicated (part-specific)
5.3 Colour Match.

The official BMW master sample is the mandatory guideline for colour, gloss level and appearance and can be ordered from Thierry, Stuttgart:
(http://www.thierry-gmbh.de). The user must ensure the master sample’s functionality by adequate handling and storage at any time. At the time of use,
the master sample needs to be within the permitted tolerance.
5.4 Recycling.
Recycling of powder is permitted as long as this process is continuous and all optical, chemical and functional requirements are achieved reliably and
demonstrably.
5.5 Process Monitoring of Series Production

The component’s supplier defines the necessary test methods and test frequency to ensure a continuous o.k. series quality and aligns this with the
BMW contact person who is responsible for the component’s quality.


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Technology Surface

Process Specification 98021.

Development status: Series

In case of dispute the German wording is valid.

Doc. No. Issued Revised Creator Approval

Process Specification 98021 Version 01

Process Specification 98021 Version 01

REQUIREMENTS AND STANDARDS

Process Specification 98021 Version 01

Furthermore, relevant specifications as well as component specific requirements are to be observed.

Process Specification 98021 Version 01

1.1 Steel (galvanized or not).

1.2 Aluminium Alloys (Casting, Forging and Wrought Alloys).

1.3 Magnesium Alloys.

1.4 Carbon Fiber Reinforced Plastics.

Process Specification 98021 Version 01

2.1 Priming of Metal Parts.

2.2 Priming of Plastic Parts.

Process Specification 98021 Version 01

Process Specification 98021 Version 01

Process Specification 98021 Version 01

Process Specification 98021 Version 01

Process Specification 98021 Version 01

Supplier: Tiger Coatings

Formulation: Drylac 250/00113 B1 1. Coat (B1): 20 min / 175°C / 60 - 80 µm

Process Specification 98021 Version 01

4.1 Refinishing Sand-through Spots.

Process Specification 98021 Version 01

Process Specification 98021 Version 01

Process Specification 98021 Version 01

Use with Glasurit 2K clear coats

Use with ColorSystem BMW 2K clear

Process Specification 98021 Version 01

Waterborne base coat 16-125-3680 Application according to the

2K-Hydro clear coat 16-512-0135

Waterborne base coat FV60-0B15

Process Specification 98021 Version 01

4.4 Paint Stripping.

Process Specification 98021 Version 01

5.1 Stoving Conditions.

5.2 Film Build.

Non-outgassing parts: 250 µm

5.3 Colour Match.

5.5 Process Monitoring of Series Production

Process Specification 98021 Version 01

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