Mercedes-Benz DBL 8440

Company Standard Date published: 2018-11

Transition period: 0 months
Total no. of pages (including Annex): 11
Person in charge: Dr. Clemens Franz
E-mail: [email protected]
Plant: 010; Dept.: PT/TWL
Date of translation: 01/2019 Phone: +49 (0) 711 1723506

Parts Manufactured from Ferrous Materials

with Inorganic Coating
(Zinc Flake Coatings)

Foreword

This supply specification describes the requirements for component parts that are protected from
corrosion using zinc flake coatings.

Changes

In comparison with edition 2013-02, the following changes have been made:

Primarily:
- Concrete specification for the demarcation of threaded parts with zinc flake coatings
- Updated normative references
- Special instructions for handling with Cr(VI)-containing surfaces omitted
- Application portfolio DBL-AA 8440.60 re-aligned
- Section 6.6 Handling with deviations from the regular case of threaded parts described
- Section 7.2 Corrosion resistance test supplemented with instructions

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Note: This translation is for information purpose only.

The German version shall prevail above all others.

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Contents

1 Scope of application...............................................................................................................3
2 Normative references.............................................................................................................3
3 Terms and definitions.............................................................................................................4
4 General requirements ............................................................................................................4
5 Abbreviated material designation for documentation .............................................................5
6 Technical Data .......................................................................................................................5
6.1 Process description................................................................................................................5
6.2 Basic materials.......................................................................................................................5
6.2.1 Materials in the strength range 1000 MPa ...........................................................................6
6.3 Coatings .................................................................................................................................6
6.3.1 Source materials ....................................................................................................................6
6.3.2 Fully hardened coatings .........................................................................................................6
6.4 Special component requirements ..........................................................................................7
6.5 Tolerances .............................................................................................................................7
6.6 Coefficients of friction / Sliding behavior ................................................................................8
7 Tests ......................................................................................................................................8
7.1 Dimensional accuracy test .....................................................................................................8
7.2 Corrosion resistance test .......................................................................................................8
7.3 Testing for cathodic protection capability ...............................................................................9
7.4 Layer adhesion test..............................................................................................................10
8 Samples ...............................................................................................................................10
9 Deliveries .............................................................................................................................10
10 Packaging and transportation ..............................................................................................10
11 Shelf life ...............................................................................................................................10
Annex A (Normative) Corrosion protection requirements ...................................................................11

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1 Scope of application
This DBL describes special requirements and properties as well as the characteristic data of parts that are
coated with zinc flakes (ZF coatings) primarily due to corrosion protection reasons. Table 1 shows the
overview of all product versions.
The usage of ZF coatings for screws and nuts with defined friction properties is specified in DBL 9440,
DBL 9441 and DBL 9460. The threaded parts described in this DBL 8440 are normally sheet-metal
molded parts or other large parts where undetachable nut or screw threads have been used.

Table 1: Product versions, overview

Zinc flake coatings (inorganic)
Coating
Application example
Component parts with
Sheet-metal molded parts
Parts category / parts without exceptionally stringent
with undetachable
Color thread requirements for corrosion
threads, e.g. clip nuts
protection

Silver gray 1) .20 .30 .60

Black 2) .21 .31

1): Standard finish

2): Black finishes only for special cases

Usage prerequisite for product version 8440.60

The specification of a surface treatment of components with coating according to 8440.60, as well as a
change of coater, pre-treatment technology or product(s), coating material(s), coating system or location
during the product development phase is not permissible without prior approval by the development
departments responsible for the component, by the responsible corrosion specialists in the development
department as well as the materials engineering specialists and during the series supply phase by the QM
departments of the plants of Daimler AG.

2 Normative references
The following referenced documents are required for the application of this document. For dated
references, only the referenced edition applies. For undated references, the latest edition of the cited
document (including any changes) applies.

DBL 8585 General Requirements – Environmental Protection, Hazardous

Substances, Dangerous Goods – Negative Substance List for the
Selection of Materials
DBL 9440 Fasteners with metric thread; surface protection
and supplementary technical delivery conditions
DBL 9441 Surface protection of fasteners for direct bolting into sheet metal and
plastics
DBL 9460 Supply Specification; Screws, Bolts and Studs with Micro-Encapsulated
Liquid Adhesive
VDA 235-101 VDA test sheet - friction coefficient adjustment of mechanical fasteners
with metric thread
DIN EN ISO 6270-2 Coating materials - Determination of resistance to moisture - Part 2:
condensation (loading in a climatic chamber with heated water tank)
DIN EN ISO 9227 Corrosion tests in artificial atmospheres - salt spray tests

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DIN 50969-1 Avoidance of hydrogen-induced brittle fractures in high-strength steel

components due to production conditions - Part 1: preventive measures
DIN 50969-2 Avoidance of hydrogen-induced brittle fractures in high-strength steel
components due to production conditions - Part 2: tests
DIN 50969-3 Avoidance of hydrogen-induced brittle fractures in high-strength steel
components due to production conditions - Part 3: subsequent operational
influences and extended tests
DIN EN ISO 15330 Fasteners - tensile test for the detection of hydrogen embrittlement -
method with parallel support surfaces
DIN EN ISO 10683 Fasteners - non-electrolytic application of zinc flake coating systems
DIN EN ISO 20567-1 Paints and Varnishes – Determination of Stone-Chip Resistance of
Coatings – Part 1: Multi-Impact Testing
MBN 10513 Parts Manufactured from Ferrous Materials with Inorganic Coatings and
Black Surface Finish - Assessment of Corrosion Onset
10494-7 Paint Test Methods – Part 7: Resistance to Chemicals, Test Mixtures and
Test Concentrates

3 Terms and definitions

PV: Product version according to this DBL, e.g. DBL 8440.20

Zinc flake
coating (ZF): Primarily inorganic, thin coating with a very high corrosion protection effect and the
capability of cathodic corrosion protection is characterized in that zinc and, to a
lesser extent, aluminum flakes from a dispersion are applied to a component
surface. The liquid components evaporate as a result of subsequent baking. In
order to achieve optimum corrosion protection, the coating shall normally be applied
and baked at least twice. Instead of using multiple zinc flake base coating layers
(base coat), it is also customary to combine one or more zinc flake base layer(s)
with one or more organic or inorganic cover layers (top coats) of other composition,
which may also contain metal flakes.

Sealants: Sealing in the sense of this DBL is the production of an organic or inorganic
protective layer with a thickness of about 0.5 μm to approximately 2 μm. The
sealing agent may be provided with pigments for coloration (black).

Top layers: A top layer in the sense of this DBL is an organic or inorganic protective layer with
layer thicknesses > 2 μm. The top layer can also contain zinc and/or aluminum as
solid particles and can be provided with pigments for coloring (silver or black).

4 General requirements
With regard to safety requirements and product quality, as well as to fulfill certification requirements, all
relevant statutory regulations and laws shall be complied with. In addition, the relevant requirements of the
Daimler Group shall apply.
In terms of ingredients and recyclability, materials, procedure and process engineering, components and
systems shall comply with all applicable legal requirements.
DBL 8585 shall be observed.
Due to the detection problems of chromium(VI) in ZF coatings, the use of chromium-containing
compounds of other grades in ZF coatings is not permitted.

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For components according to DBL 8440.60, the coating company, the location of the coating plant and the
products to be used shall additionally be specified in the drawing block / in the field "Notes and Remarks"
of the master data of the 3 D model.
Example: Coating AG, Plant D4711 Anyplace,
coated with zinc flake base coat, type "Base1“ Company A.N.Other
and top coat, type Top2, Company A.N.Other

5 Abbreviated material designation for documentation

Not applicable.

6 Technical Data

6.1 Process description

When cured, ZF coatings must consist predominantly of metallic components. They contain zinc (≥ 65%)
and up to 10% aluminum flakes.
Before coating with zinc flakes, the component surface is pre-treated (e.g. cleaning, blasting, phosphating
or a combination of various processes) to ensure perfect adhesion of the coating. Evidence of the
suitability of the pre-treatment method for the parts to be coated shall be provided by means of state-of-
the-art examinations.
The ZF coating is applied to small parts by immersion in drums in a Zn(-Al) flake dispersion and, in the
case of larger parts, hanging on suitable frames, by spraying or dipping into the dispersion. As a rule, the
excess dispersion is then centrifuged off (especially in the case of smaller parts) and the coating baked
on, during which the liquid components of the dispersion evaporate and metallic contact is formed
between the flakes and between the flakes and the substrate. This produces an inorganic surface coating
which additionally ensures cathodic protection of the component. This does not mean that these coatings
are generally suitable for electrical contacting.
In order to eliminate defects and increase corrosion protection, the process of dipping, baking and
centrifuging is carried out at least twice or even more frequently.
In the case of larger components, centrifugation of excess coating material may be omitted. However, it
may be necessary to use a suitable blow-off technique, possibly prolonged suspension after immersion, to
ensure that there are no impermissible layer accumulations, especially on functional areas such as screw
contact surfaces.
Flakes aligned parallel to the surface enhance the corrosion protection quality and reduce the settling of
screw joints.
The overall coating properties can be specifically adapted to visual (e.g. black color) or functional
requirements by using special products, with or without metallic components, for the top layer(s). Thus,
the friction behavior can be specifically influenced by the incorporation of lubricant additives, but also by
the inclusion of friction-enhancing substances. The relatively low resistance of ZF base coatings to acids
and alkalis (e.g. rim cleaner) can be increased by an additional organic top coat.
Since the white zinc corrosion products produced on black surfaces tend to attract more negative attention
than on the silver-colored ones, black surfaces according to this DBL are only applicable in special cases
and only if it is proven that the required coating quality can also be achieved on the concrete components.
Also see the reference in section 7.2 for this purpose.
The baking temperature must be ≥ 180 °C; negative impairment of the base material properties must be
avoided. Unless otherwise agreed for a specific component, coating methods, in which the baking
temperature does not exceed 240 °C, must be selected for threads which have been final rolled to
increase the fatigue strength.

6.2 Basic materials

The components to be coated must not have any material, processing or surface defects which would
adversely affect the corrosion protection and/or the appearance of the coatings.
Any contamination on the surface of the parts to be treated (corrosion products or scale, oil, grease, dirt
etc.) shall be completely removable with the commonly used automatic cleaning and pre-treatment
facilities.
The coater must ensure at suitable intervals that there are no impurities such as abrasive residues on the
component surfaces to be coated which could impair the adhesive strength and/or the coating quality. For

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parts with cavities and surface areas lying inside, destructive methods shall be used for this purpose, if
necessary.
Weld seams and heat-affected zones must be pre-treated such that silicate, slag and oxide residues are
removed so well that pre-treatment/coating is possible without weakening adhesion.

6.2.1 Materials in the strength range 1000 MPa

When coating components with strengths ≥ 1000 MPa (possibly also locally limited, e.g. case-hardened or
cold-formed structures or in weld seam areas), it must be ensured that there is no damage due to delayed
hydrogen-induced brittle fracture (hydrogen embrittlement) and due to the coating process (pre-
treatment/coating/post-treatment).
A feature of ZF coatings is that, unlike galvanic processes, no hydrogen is produced during the coating
process which could be absorbed by the components to be coated. Therefore, there is generally no risk of
hydrogen embrittlement during the coating process, even if cleaning processes that do not produce atomic
hydrogen (e.g. alkaline cleaning and/or blasting of the surface) are used during pre-treatment. If acid
cleaning is absolutely necessary for functional reasons, only acids with suitable inhibitors may be used for
pre-treatment/cleaning. The supplier of the inhibitor shall confirm its suitability in writing. The time between
pre-treatment and coating as well as the dipping time in the acid shall be kept as short as possible. Where
acids are used during component cleaning, heat treatment for hydrogen effusion is required. The specific
parameters required for reliable hydrogen effusion (temperature, time) shall be determined by means of
tests. If necessary, due to the high hydrogen permeability of ZF coatings, the heat input during the baking
processes can also be used for successful hydrogen effusion from the base material.
The instructions given in DIN 50969-1, DIN 50969-2 and DIN 50969-3 must be observed. In addition, a
detailed process evaluation (process FMEA) must be carried out by the coater for all partial steps in which
hydrogen can penetrate into the material structure.
Process assessment shall be validated by component tests. From this, measures are derived which safely
minimize the amount of hydrogen penetrating into the material during treatment and enable regular
monitoring of the effectiveness of the measures. The coater must prove the safe, uncritical process control
by additional stress tests during production (according to DIN 50969 or DIN EN ISO 15330). The
frequency shall be determined according to the process FMEA.
The treatment of incorrect coatings (removal of coatings and new coatings) shall be specified.

6.3 Coatings

6.3.1 Source materials

The manufacturer of the coating materials must ensure, e.g. by means of a process FMEA, that the
technical properties (metal content, size, characteristics of the metal flakes, ratio of zinc to aluminum,
other chemical additives, viscosity, etc.) of the coating materials supplied to the coater only fluctuate within
limits that do not affect the coating quality. The manufacturer of the coating materials shall audit and
assess the suppliers of the source materials.
Before producing the initial samples with the supplier of the coating material, the coater must define the
fluctuation limits in the chemical and physical properties of the liquid coating material within which there is
no influence on the quality of the fully cured coating system. The preparation of the liquid products (e.g.
stirring technology, viscosity, solvent content) must be described and implemented.
In addition, the manufacturer of the coating materials and the coating company are expected to assess all
processes (from incoming goods to dispatch of the treatment process materials and parts) in detail (P-
FMEA conforming to VDA) for all sub-stages of the manufacture of the products and coatings.
The coater must monitor and control the work flows in the entire process chain by measuring the process
parameters. These include, for example, temperature measurements at the various process points,
measurements of the air humidity during the drying processes of water-based zinc flake coatings,
monitoring of the solvent content of the coating liquids by suitable measures.
These measures shall be documented and submitted to Daimler AG on request.

6.3.2 Fully hardened coatings

The coatings must have dense, uniform, dry and non-sticky surfaces. Drops of coating material, sags and
voids due to abrasion are not acceptable where these may impair the correct functioning, the mounting
capability or the properties of the parts or the system.

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Damage to the coating due to improper handling of the parts after coating, e.g. throwing or unsuitable
further processing or transport conditions, must be avoided.
Note: the ductility of ZF coatings is normally limited and may vary depending on the product. When using
these coating systems for parts which are formed after coating (flanging, bending, etc.), it is therefore
necessary to check the formability of the specifically intended coating system and the possible influence of
the forming on the corrosion protection effect (tests according to table 2). The same applies to the
application of zinc flake coatings on resilient components such as clips or springs.
The ZF coatings must adhere well to the base material (see section 7.4). and shall not chip off with the
associated reduction of the corrosion protection effect, neither during proper mounting of the coated parts
(e.g. in the case of clips) nor under tensile or compression stress during operation (e.g. in the case of
springs).
In the cured state, the coating must consist predominantly of inorganic components. The use of sealants
as top coat is permitted provided that there are no functional reasons against it.
Post-treatment of the ZF coating with easily removable oils/greases/waxes to improve the corrosion
protection effect is not permissible, since these substances can be removed in the vehicle by the
application of a cold cleaning agent, which in turn may impair the corrosion protection quality.
The component supplier, in cooperation with the coaters, is expected to define the required minimum
coating system mass (in g/m2) as a guideline value. Compliance with this specification shall be checked
regularly.
In the case of components with interior areas (cavities) not directly visible, the coater must take suitable
measures to ensure that the coating quality in the interior areas also meets the DBL requirement. For this
purpose, components shall be cut open and the tests prescribed in table 2 must be conducted on the
internal surfaces as well and the layer thicknesses specified in section 6.5 must be checked. Particular
attention shall be paid to the freedom of the coatings from voids.
In the case of components in which the component geometry has gaps or Doppler surfaces, chemical
removal and re-coating is only permissible if it can be demonstrated that residues of the decoating
chemical which do not remain in gaps have a negative effect on a high-quality re-coating.

6.4 Special component requirements

If special requirements are placed on the components/surfaces coated in accordance with this DBL, e.g.
adhesion of the surfaces and/or special friction behavior due to special coefficients of friction and/or
formability of the coated component, the suitability of the coating system for fulfilling the special
requirement must be carefully checked. If necessary, the process materials to be used for the surface
protection of the component must be specifically mentioned in the component drawing and, if necessary,
the requirement for corrosion protection deviating from table 2 must also be specified and described in the
drawing.
The lubricants, operating fluids, fuels and cleaners approved by Daimler AG used in the engine
compartment must not damage the coating. The suitability of the intended coating systems must be
proven by tests. For testing the compatibility with hydraulic oil, test fuel, preservative, cold cleaner and
brake fluid, also see MBN 10494-7.

6.5 Tolerances
Following coating, the parts shall be within the tolerances specified on the standard sheets or drawings. In
particular, this stipulation applies to threaded parts. Local accumulations of coating material or loose
coating material particles which could impair the function and/or appearance intolerably are not permitted.
Note:
In processes for the mass production application of ZF coatings, different layer thicknesses are achieved
depending on the geometry. If a uniform, dimensionally stable layer thickness is achieved on the
predominant part of the total surface, accumulations of material can occur predominantly in the base of
the thread and in the area of the bearing surfaces with undetachable threads, which exceed the usually
specified tolerance limits, but which do not necessarily lead to the discarding of the parts.
In such cases, the dimensional accuracy of coated threads can no longer be determined by means of
gages, but only by discrete measurement. In the case of tests with thread ring gage, the dimensional
stability of the test specimens is therefore still deemed satisfactory if the thread ring gage can still be
screw-tightened, even if against resistance, but without other aids/tools. For arbitration cases, DIN EN ISO
10683 specifies limit screw-on torques for checking gage accuracy.

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In the case of ZF coatings, large accumulations of material in the area of the contact surfaces must be
avoided in the case of parts with threads, as this can result in pre-tension force losses due to settling.
In the case of components coated in accordance with PV .60, Daimler AG (developer responsible for the
component in cooperation with the responsible quality manager) determines the measuring points at
which the coating thicknesses need to be measured on the basis of tests conducted by the supplier in
accordance with statistical test planning. This specification shall take the form of a work instruction. The
target layer thicknesses, the tolerances at the defined measuring points and the frequency of these
measurements are also determined.
In addition, at least one point shall be defined on the component where a 100% layer thickness
measurement is required after complete coating. At this point, the target layer thickness of the complete
system and the related tolerances shall also be documented. In addition, evidence of a process capability
index of Cpk => 1.33 shall be provided for this point.

6.6 Coefficients of friction / Sliding behavior

As a rule, the surfaces must be supplied in accordance with this DBL without additional lubricants
integrated into the coating or subsequent treatment with grip-dry lubricants.
If a lubricant treatment/selective preservation or a lubricant integrated into the coating is required, this,
together with the special requirements and the determination methods, is specified by Daimler in the
drawing.
For all design types, the requirements for the properties of any additional lubricants applied or integrated
lubricants are given in VDA 235-101.
If zinc flake coatings are used according to this DBL, total friction coefficients (μtot) in the range from 0.13
to 0.2 are expected. Deviations from this are permissible, as are more precise limitations of the very wide
coefficient of friction window compared to fasteners according to DBL 9440, if the coefficients of friction
and the necessary test procedures are documented in the drawing.
In the case of special clips and other resilient components, the use of cover layers with integrated
lubricants or subsequent treatment with non-slip lubricants can facilitate assembly or even out the
assembly properties. For this reason, such lubricant additives are permissible, provided that the functional
properties of the component or system are not negatively affected. The risk of the clip connection
loosening itself as a result of the lubricant treatment of the surface must also be checked and ruled out.
The use if lubricants (integrated in the top layer or as additional lubricant treatment) must be documented.
The same applies to washers to be coated separately for screw connections (mostly used in commercial
vehicles and > M14). The safety of the screw joint is in the foreground in this case. Any subsequent
treatment of washers with lubricants to achieve the required coefficient of friction window during the
assembly of screw joints must be tested and determined separately.
In special cases, the coated component surface must meet special requirements with regard to high
coefficients of friction. The extent to which this can be achieved by adding anti-slip substances to the top
coating layer or whether additional measures on the component surface prior to coating or anti-slip
intermediate layers are suitable for series production must be clarified in advance through practical tests.

7 Tests

7.1 Dimensional accuracy test

The coater shall ensure that the requirements have been fulfilled with suitable action and a sufficiently
large number of random samples. The results shall be documented and archived.

7.2 Corrosion resistance test

The required corrosion resistance must be achieved upon delivery to the respective Mercedes-Benz
plants. It also follows from this that outgoing tests at the supplier's/coater's premises prove the component
condition required by DBL before shipment to the Mercedes Benz plants.
After the required test period according to DIN EN ISO 9227 NSS, the components are removed from the
test chamber, rinsed with demineralized water and then dried with compressed air, e.g. by soft blowing,
before evaluation.
The corrosion resistance requirements to be fulfilled in accordance with Annex A, table 2 are applicable to
the complete surface, unless surface areas are excluded from the requirements in the drawing.
In the case of components with cavities accessible for coating, the requirements therefore also apply to
cavity surfaces insofar as these may be exposed to corrosion attack. In order to demonstrate the

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necessary coating quality here, additional components must be separated and the internal surfaces
exposed to the prescribed corrosion stresses.
In the case of parts coated in the frame, the requirements also apply to the contact surfaces of the
suspension points which must be kept as small as possible.
The requirement for the test duration without base material corrosion also applies to those parts of the test
where any test medium (scooping areas) accumulates.
It is an additional requirement that the surfaces do not show any blisters or peeling following testing in
accordance with DIN EN 6270-2 CH and DIN EN ISO 9227 NSS.
During the corrosion test of small parts, at least 10 parts per individual type of test must be tested in each
case in order to record fluctuations from component manufacture as well as from the test method. The
number of test pieces can be reduced for larger parts. It is essential that it can be derived from the test
result that all parts from the series coating process meet the requirements of this DBL.
The instructions contained in the relevant test standards with regard to the positioning of the components,
e.g. inclined position for testing in accordance with DIN EN ISO 9227 NSS, shall be observed.
The parts according to this DBL must be tested with and without heat treatment (96h, 180 °C) before the
corrosion loads according to DIN EN ISO 9227 NSS.
Exception: In the case of spring band clamps coated according to product version .20, which are bonded
with elastomer hoses, a heat treatment of 96h at only 160 °C is carried out before the corrosion stresses.
Conducting the corrosion tests beyond the times required by the DBL is recommended in order to gain
knowledge about the extent of difference between the actual coating quality and the required limit and how
the coating quality varies.
Note:
As a rule, silver-colored components with ZF coatings are not visually conspicuous in practice with regard
to zinc corrosion, since the surfaces only turn slightly gray. Proven silver ZL coatings also show a similarly
inconspicuous behavior in the salt spray test according to DIN EN ISO 9227 NSS. Therefore, a
requirement regarding freedom from corrosion is dispensed with for the product versions with a silver
surface as per Table 2. However, If a significant change in the silver-colored surface, possibly with
voluminous zinc corrosion or with strong staining, is found after a salt spray test has been conducted, it is
recommended to check the use of a different zinc flake system and, if necessary, to change the coating
system.
Assessment of the test parts for freedom from base material (Fe) corrosion:
Fe corrosion products resulting from base material corrosion are easily and clearly visible on the silver-
colored ZF surfaces solely due to their brown coloring. The assessment must be carried out under normal
laboratory lighting and normal, possibly corrected visual acuity (glasses) of the assessor. The use of other
optical aids such as a microscope or magnifying glass is not permitted.
Evaluation of black parts for freedom from zinc corrosion:
The test instruction MBN 10513 with the corrosion degree KG 1 shown there gives an indication of how
incipient zinc corrosion on screw heads appears. For black parts without threads, the tolerable changes
are transferable.

7.3 Testing for cathodic protection capability

Zinc flake systems must have the capability of cathodic protection of the steel surface, at least in the event
of damage to the coating system, through electrical contact between the flakes. In order to test this system
property, scratch the coating surfaces down to the base material over a width of 0,5 mm max. using an
appropriate tool. Then store the scratched specimen exposed to a salt spray load in accordance with DIN
EN ISO 9227 NSS. The result is deemed good if no base material corrosion occurs in the vicinity of the
scratch following 72 hours of corrosion exposure.
For the product version .60 of this DBL, a corrosion resistance of the scored component surface up to the
beginning base material corrosion in the 800-h neutral salt spray test is required. For this product version,
the same corrosion resistance is also required following simulated stone chip loads in the stone chip
resistance test according to DIN EN ISO 20567-1, method B, carried out before corrosion exposure.
The supplier shall provide evidence of this cathodic protection capability before initial sampling and
include the results with the ISIR. The coater is also expected to perform this test in-process during series
production at suitable intervals defined by the coater, to document the results and to submit the results on
request. The test frequency shall be defined in the quality plan.

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If the component geometry does not allow the execution and evaluation of the test, the system properties
of the cathodic protection capability shall be verified on other suitable coated components (comparable
base material, identical pretreatment and coating).

7.4 Layer adhesion test

To test the layer adhesion, press an adhesive textile tape with an adhesive force of (7 ± 3) N per 25 mm
width (for PV .60 an adhesive tape with adhesive strength 7 N/cm) firmly onto the component surface by
hand. During the subsequent abrupt stripping perpendicular to the surface, the coating must not be
detached. Small coating material components are permitted to adhere to the adhesive tape. If the
adhesion test cannot be performed and assessed, e.g. due to the component geometry, alternative
meaningful component-related adhesion tests shall be developed, described and performed.

8 Samples
The following information shall be included in the ISIR without further request:
 Specified DBL PV
 Any agreed deviations from the DBL requirements
 Coater applying surface protection, or subcontractor if applicable
 Documentation of the selected surface pre-treatment
 Applied coating processes and applied materials, including manufacturers and product names
 Number of coating layers
 Baking temperature and time (target value and limits)
 Minimum coating system mass to be observed in g/m2
 Information concerning any measures performed to prevent hydrogen embrittlement
 Results of tests as per section 7. After the corrosion tests, the appearance of the test specimens after
the test and the position of the test specimens in the test apparatus must be documented as well as
the pictures must be attached to the initial sample test report.
 Name of the testing bodies (supplier and/or subcontractor and/or testing institute)

In case ofseveral coaters, each coater must provide initial samples with EMPB and in this case special
attention must be given to the same functional and/or assembly characteristics of the parts finished in
different installations. As a rule, this also results in the necessity of using the same products (starting
chemicals) for layer generation.
Similar changes with regard to material and process must be submitted to the customer plant of Daimler
AG in good time and initial sampling must be carried out before series production and must be approved.
The supplier of zinc flake coatings (manufacturer of treatment/coating materials) assumes that the coaters
are regularly audited and the ability of the coaters to produce the required coating quality is tested
according to the requirements of the specified DBL product version. This attestation shall be enclosed with
the ISIR in the delivery of initial samples to Daimler.

9 Deliveries
Ongoing deliveries shall correspond to the approved samples.
For serial deliveries, the supplier shall conduct an in-process quality inspection and make the data
available on request. The data accessible to Daimler AG in this case shall be treated as confidential and
not forwarded to third parties.
All parts shall be delivered free from corrosion products.

10 Packaging and transportation

The components shall be protected against the effects of corrosive media. During transport, the parts may
not damage each other to such an extent that the requirements of this DBL are no longer met.

11 Shelf life
When storing parts until they are required for subsequent processing or assembly, preservation or special
storage conditions may be required.

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Uncontrolled copy when printed TP/G36-4: Vinodh Kumar H, 2019-09-24

Uncontrolled copy when printed

DBL 8440:2018-11, Page 11

Annex A (Normative) Corrosion protection requirements

Table 2: Technical data and requirements
Fasteners with ZF coatings with threads, see DBL 9440, DBL 9441, DBL 9460

PV Coating/ Surface Recommend Parts Acceptance System Note

main ed requirement requirement
components (color) layer DIN EN ISO DIN EN ISO
thickness 9227 NSS 1) 6270-2 CH 2)
[µm] h without h without
corrosion of corrosion of
Zn Fe Zn Fe
inorganic/ without Parts in engine compartment and chassis
.20 Silver max. 30 720 480
Zn, Al thread area
inorganic/ without
.21 black max. 30 240 480 240 480 For special cases only
Zn, Al thread
inorganic/ with
.30 Silver max. 12 720 480 For special cases only
Zn, Al thread
inorganic/ with
.31 black max. 12 240 480 240 480 For special cases only
Zn, Al thread
inorganic/ formed Parts with exceptional stringent
.60 Silver max. 40 3) 1 200 1 200
TP/G36-4: Vinodh Kumar H, 2019-09-24

Zn, Al sheet metal requirements on corrosion protection

properties

1) The tests for corrosion resistance in accordance with DIN EN ISO 9227 NSS must be conducted on parts with and without heat treatment
(96h, 180 °C) prior to corrosion loads. Thermal load with reduced temperature, exception see 7.2.
2) The test in accordance with DIN EN ISO 6270-2 CH is conducted for system release during the initial sample test at the coater’s end and parallel
to the coating production at longer intervals, at least once a year with and without previous heat treatment of the components over 96 hours at
180 °C.
3) Procedure for the specific component-related coating thickness specification (see section 6.5). In the case of threaded connections, watch out for
any settling at the bolting points.

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