DEUTSCHE NORM July 2008

DIN 50979
D
ICS 25.220.40

Metallic coatings –
Electroplated zinc and zinc- alloy coatings on iron or steel with
supplementary Cr(VI)-free treatment
Metallische Überzüge –
Galvanische Zink- und Zinklegierungsüberzüge auf Eisenwerkstoffen mit zusätzlichen
Cr(VI)-freien Behandlungen
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Document comprises 22 pages

Translation by DIN-Sprachendienst.
In case of doubt, the German-language original should be consulted as the authoritative text.

© No part of this translation may be reproduced without prior permission of

DIN Deutsches Institut für Normung e. V., Berlin. Beuth Verlag GmbH, 10772 Berlin, Germany,
has the exclusive right of sale for German Standards (DIN-Normen).
English price group 9
www.din.de !$Y21"
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 DIN 50979:2008-07

A comma is used as the decimal marker.

Contents

Page

Foreword..............................................................................................................................................................3

1 Scope ......................................................................................................................................................3
2 Normative references ............................................................................................................................3

3 Designation.............................................................................................................................................4
3.1 Electrodeposited coatings ....................................................................................................................4
3.2 Passivation .............................................................................................................................................4
3.3 Sealing agents........................................................................................................................................4
3.4 Significant (functional) surfaces ..........................................................................................................5
3.5 Examples of designations.....................................................................................................................5
4 Information to be supplied by the purchaser to the electroplater ....................................................5
5 Basic materials.......................................................................................................................................6
6 Coating and processing ........................................................................................................................6
6.1 Surface preparation and deposition of zinc or zinc-alloy coating ....................................................6
6.2 Supplementary treatments....................................................................................................................6
6.2.1 Passivation .............................................................................................................................................6
6.2.2 Sealing ....................................................................................................................................................7
6.3 Barrel/rack plating (handling of parts).................................................................................................7
6.3.1 Barrel electroplating ..............................................................................................................................7
6.3.2 Rack electroplating ...............................................................................................................................7
6.4 Hydrogen embrittlement .......................................................................................................................7
6.4.1 Basic factors...........................................................................................................................................7
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6.4.2 Choice of procedure ..............................................................................................................................8

7 Requirements to be met by coatings and test methods ....................................................................9
7.1 Thickness................................................................................................................................................9
7.2 Adhesion .................................................................................................................................................9
7.3 Absence of Cr(VI) .................................................................................................................................10
7.4 Accelerated corrosion testing ............................................................................................................10
7.4.1 General ..................................................................................................................................................10
7.4.2 Minimum corrosion resistance of passivated zinc and zinc-alloy coatings..................................10
8 Test report ............................................................................................................................................12
8.1 General information .............................................................................................................................12
2
8.2 Coatings on materials having a tensile strength ≥ 1 000 N/mm ....................................................13
8.3 Test results ...........................................................................................................................................13
Bibliography ......................................................................................................................................................14

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 DIN 50979:2008-07

Foreword

This standard has been prepared by Working Committee NA 062-01-76 AA Galvanische Überzüge of the
Normenausschuss Materialprüfung (Materials Testing Standards Committee).

1 Scope

This standard applies to electrodeposited zinc and zinc-alloy coatings on iron and steel with Cr(VI)-free
passivation. The zinc-alloy coatings contain nickel or iron as alloying agents (referred to as zinc/nickel and
zinc/iron coatings, respectively).

The main purpose of the coatings or coating systems is to protect iron and steel components against
corrosion.

The standard prescribes the designations to be used for the above coating systems and specifies minimum
corrosion resistances to be achieved in specified test procedures and the minimum coating thicknesses
required to achieve them.

2 Normative references

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

E DIN 50969-1:2008-02, Prevention of hydrogen-induced brittle fracture of high-strength steel building

1)
elements — Part 1: Advice on the prevention

DIN EN 1403, Corrosion protection of metals — Electrodeposited coatings — Method of specifying general
requirements
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DIN EN 15205, Determination of hexavalent chromium in corrosion protection layers — Qualitative analysis

DIN EN ISO 3497, Metallic coatings — Measurement of coating thickness — X-ray spectrometric methods

DIN EN ISO 9227, Corrosion tests in artificial atmospheres — Salt spray tests

_____________

1) Another test standard is under preparation.

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3 Designation

3.1 Electrodeposited coatings

The electrodeposited coatings shall be composed of zinc or zinc-alloys as listed in Table 1.

Table 1 — Designation of electrodeposited coatings

Symbol Definition

Zn Zinc coating without alloying partner

ZnFe Zinc-alloy coating containing 0,3 % to 1,0 % iron by mass

ZnNi Zinc-alloy coating containing 12 % to 16 % nickel by mass

3.2 Passivation

In this standard, passivation is the production of conversion coatings by treating coatings with suitable Cr(VI)-
free solutions in order to improve their corrosion resistance. The conversion coating may optionally be dyed.

Since the Cr(VI)-free passivations are new coating systems, the new nomenclature listed in Table 2 has been
introduced to describe them.

Table 2 – Passivations

Coloration,
Type of passivation Code a Notes
surface appearance

Transparent An Colourless to Often referred to as

coloured and iridescent “thin-layer passivation”

Iridescent Cn Coloured and iridescent Often referred to as

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“thick-layer passivation”

Black Fn Black

a
Tints are permissible.

3.3 Sealing agents

Sealing agents increase corrosion resistance and take the form of a layer normally up to 2 µm thick and are
composed of Cr(VI)-free organic and/or inorganic compounds.

Coatings that can be removed with cold cleaning agents, such as those with an oil, grease or wax base, are
not considered as sealing agents in the context of this standard.

How sealing agents affect component properties such as contact resistance, weldability, compatibility with
fuels, performance in bonded joints, etc., when in service shall be assessed on a case by case basis.

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Since the range of surface modifications is very large, the use of sealing agents and their type shall be agreed
in the case of surfaces that are subject to particular requirements.

NOTE Sealing agents normally remove the interference colours produced by passivation.

Table 3 – Sealing agents

Symbol Meaning
T0 No sealing agent
T2 Sealed

3.4 Significant (functional) surfaces

Components with complex shapes, particularly those having cavities, may not be capable of meeting the
corrosion resistance and minimum thickness criteria required in the accelerated corrosion tests at all the
points on the electroplated surface. In such cases, the significant surfaces for the coating system shall be
indicated on the drawing by a dot-and-dash line.

If the purchaser does not specify a significant surface, the definition given in DIN EN 1403 shall apply.

3.5 Examples of designations

Designation of a zinc/nickel-alloy coating on a steel (Fe) component having a minimum local coating thickness
of 8 µm (8) and iridescent passivation (Cn):
Electroplated coating DIN 50979 – Fe//ZnNi8//Cn//T0

Designation of a zinc/iron-alloy coating on a steel (Fe) component having a minimum local coating thickness
of 8 µm (8) and sealed black passivation (Fn):
Electroplated coating DIN 50979 – Fe//ZnFe8//Fn//T2
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See DIN EN 1403 for further information on designation.

4 Information to be supplied by the purchaser to the electroplater

The minimum information to be provided by the purchaser to the electroplater shall comprise:
a) the tensile strength of the component (to enable the requirements in 6.4 to be taken into account);

b) component information (basic material, production method, heat treatment);

c) information on significant surfaces as required by 3.4;

d) designation of coating to be applied (see 3.5).

If need be, further requirements, such as appearance, friction properties, and media resistance, may be
imposed on the properties of the coatings to be applied and the testing extended accordingly.

If necessary, additional information relating to requirements or restrictions to be imposed on the coating

process shall be provided.

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5 Basic materials

The application of coatings complying with this standard to low-alloyed steels is state of the art. In the case of
other iron-based materials such as cast iron or sintered materials, materials with a substantial content of
passivatable alloying elements or materials with special strength properties, it may be necessary to specially
adapt the treatment processes (pre-treatment, coating, supplementary treatment) and possibly to take
additional measures in order to fulfil the requirements of this standard. For this reason, the electroplater will
need detailed information about the composition, properties and production of the components to be coated.
2
If steel components having tensile strengths of 1 000 N/mm and over are to be coated, steps will have to be
taken even at the early stages of production (e.g. when choosing the material, the hardening process, and the
assembly procedure) to eliminate with a high degree of reliability the possibility of damage resulting from
delayed hydrogen embrittlement.

The components to be coated shall not exhibit any material, processing or surface defects that may affect the
corrosion protection and/or appearance of the coatings adversely or in an unpredicted way.

It shall be possible to remove any impurities (e.g. corrosion products or scale, oil, grease, dirt, etc.) from the
surface of the components without leaving any residue by the standard cleaning and pre-treatment
procedures.

It may be necessary to draw up an agreement on surface quality.

6 Coating and processing

6.1 Surface preparation and deposition of zinc or zinc-alloy coating

To ensure that the process is reliable and reproducible, the entire pre-treatment and coating cycle, together
with the associated physical data, e.g treatment times and temperatures, and all the processing chemicals,
shall be recorded, documented and, if necessary, optimized. The individual process control limits shall be
defined along with the frequency of monitoring and the analytical procedures. The actions these require shall
be described and recorded by the electroplater.
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A typical process cycle would be as set out below.

a) Alkaline degreasing (adapted to suit the oil- or grease-based films encountered);

b) pickling (usually in hydrochloric acid, inhibited);

c) electrolytic alkaline degreasing (preferably anodic);

d) metal electroplating;

e) supplementary treatment comprising passivation and possibly sealing;

f) drying.

6.2 Supplementary treatments

6.2.1 Passivation

Passivations are conversion coatings produced by dipping components in, or spraying them with, passivation
solutions. The deposited coating reacts with the passivation solution to form a thin film that protects the
metallic coating. Some of the deposited coating is normally dissolved as a result of the reaction.

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6.2.2 Sealing

Sealing is carried out by applying additional organic and/or inorganic substances to, or incorporating them in,
the passivation.

Depending on the geometry of the component and the process, this may result in an accumulation of layers.
The latter shall be kept to a minimum, e.g. by blasting in the case of rack-electroplated components or
agitation in the case of barrel-electroplated components.

6.3 Barrel/rack plating (handling of parts)

6.3.1 Barrel electroplating

Among the parts typically treated in coating barrels are screws, nuts and other small components. After the
parts have been loaded into the barrels in bulk, they are pre-treated and coated with the barrel rotating. The
rotation ensures that the coating of all the components is more or less identical, but it may give rise to surface
damage. This damage can be minimized, for example, by reducing the barrel rotation or the drop height when
the barrels are emptied. The corrosion resistance is normally less than that achieved by rack electroplating.

6.3.2 Rack electroplating

Parts may have to be coated in racks because of their size or shape or possibly because they have to meet
special requirements. In this process the components are placed on racks for coating. The characteristics of
the coatings (especially the thickness of the metallic coating) may vary with the position of the components in
the rack, but optimization may be possible, for example, by designing racks for particular components.

6.4 Hydrogen embrittlement

6.4.1 Basic factors

During processes such as pickling, electrolytic cleaning and electrodeposition of metal coatings, steel parts
coated by the procedure described in this standard may absorb hydrogen as a result of hydrogen diffusing
preferentially through the metal lattice to energetically favourable positions, such as structural defects in the
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lattice and points with high concentrations of stress.

This may result in delayed hydrogen-induced brittle fractures. Particular attention has to be paid to the critical
interaction of

⎯ the material and its characteristics (strength, hardness);

⎯ hydrogen absorption during the pre-treatment and coating processes;

⎯ mechanical stresses in the components, including those that vary locally as a function of shape.

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Figure 1 — Interaction of material, mechanical stress and hydrogen absorption

The crucial material properties are strength and toughness, the risk of hydrogen embrittlement increasing with
the strength of the material.
2
All steel parts having a tensile strength Rm ≥ 1 000 N/mm (even if localized as in case-hardened or cold-
worked structures or in the vicinity of welds) are considered high-strength and classified as critical.

6.4.2 Choice of procedure

2
6.4.2.1 Basic material strength < 1 000 N/mm

The choice of treatment procedures is unrestricted provided the requirements of this standard are fulfilled and
service performance is not adversely affected.
2
6.4.2.2 Basic material strength ≥ 1 000 N/mm
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In coating high-strength components, the prevention of delayed brittle fractures (hydrogen embrittlement) is of
paramount importance.

The surface treatment shall be performed in such a way as to prevent damage due to delayed hydrogen-
induced brittle fractures with a high degree of certainty. How to deal with potentially defective coating (e.g. by
stripping and re-coating) shall be investigated and the outcome documented.

The steps taken to minimize the risk of delayed hydrogen-induced brittle fractures shall be agreed between
the electroplater and the purchaser.

The necessary process investigation and process testing associated with the manufacture may be performed,
for example, by strain testing an adequate number of suitable hydrogen-sensitive specimens.

The advice given in E DIN 50969-1 shall be borne in mind.

To prevent brittle fractures, heat treatment processes shall be performed after electroplating to promote
hydrogen effusion and possibly even before electroplating to relieve internal component stresses. In this
connection, see 3.4 and 4.4 in E DIN 50969-1:2008-02.

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Particular attention shall be paid to ensuring that the deposited metallic coating does not act as a diffusion
barrier and prevent hydrogen effusion. The properties of the components shall not be adversely affected.

NOTE Guideline values for heat treatment to promote hydrogen effusion are given in Table 4.

Table 4 — Guideline values for heat treatment to promote hydrogen effusion after electroplating as
specified in this standard

Tensile strength, Heat treatment conditions in hot-air circulation oven

Rm Minimum holding time at component temperature (215 ± 15) °C
2
N/mm h

1 000 to 1 250 6

1 251 to 1 450 12

1 451 to 1 600 20

1 601 to 2 000 24

In addition to the measures described above, components potentially subject to hydrogen damage shall be
tested as specified in E DIN 50969-2.

7 Requirements to be met by coatings and test methods

7.1 Thickness

Table 5 shows the minimum coating thicknesses (dmin) provided on significant surfaces by the specified
processes.

The thicknesses of zinc and zinc-alloy coatings shall preferably be determined by X-ray fluorescence as in
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DIN EN ISO 3497.

Examples of other methods that can be used are:

a) microscopic determination as in DIN EN ISO 1463;

b) coulometric determination as in DIN EN ISO 2177;

c) magnetic determination as in DIN EN ISO 2178.

No account is taken of the thicknesses of passivation and sealing layers.

7.2 Adhesion

There shall be no peeling or blistering if the test pieces are kept at (220 ± 10) °C for 30 minutes and then
immediately quenched in water at 15 °C to 25 °C (thermal shock test based on DIN EN ISO 2819).

NOTE Bending or burnishing, if feasible, is recommended as a further adhesion test.

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7.3 Absence of Cr(VI)

The coating deposited shall be free of Cr(VI) when analysed as specified in DIN EN 15205.

7.4 Accelerated corrosion testing

7.4.1 General

The coatings shall be subjected to a DIN EN ISO 9227-NSS salt spray test.

NOTE Since the temperature, humidity, flow conditions, etc. may be very different from the limited test atmospheres
specified in the accelerated corrosion tests, the results of accelerated corrosion tests cannot be used without qualification
to predict the corrosion behaviour of components when in service.

7.4.2 Minimum corrosion resistance of passivated zinc and zinc-alloy coatings

No corrosion products such as white rust in the coating or red rust in the basic material shall appear within the
minimum test times specified for a given coating system and test. The evaluation shall be based on the
significant surfaces of the component.

The minimum corrosion resistances apply in the “coated state” and also after thermal ageing at 120 °C for
24 hours prior to the corrosion test. Thermal ageing is unnecessary for the Zn//An//T0 coating system.

Treatments such as waxing and greasing which have not been agreed but which could improve resistance in
the corrosion test are not permitted.

Operations such as sorting, transportation, assembly or exposure to aggressive media shall be avoided prior
to corrosion testing since they may adversely affect the corrosion resistance properties of the coatings.
Assessment or limitation of such damage is not covered by this standard.

The corrosion resistance that can be achieved by coatings may depend not only on the coating system and
the quality of the coating, but also to a considerable extent on the component to be coated (e.g. on the
material and the geometry). If optimum coating quality cannot readily be achieved in the case of a component
(e.g. because of defects in the material or complicated component geometry), it may be necessary to agree a
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reduced corrosion resistance.

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Table 5 — Minimum coating thicknesses and minimum test times for passivated transparent or
iridescent zinc and zinc-alloy coatings subjected to the DIN EN ISO 9227-NSS test

Minimum test time,

h

Without basic material

Type of surface Coating Type of
corrosion (as a function of
protection coating designation electroplating Without
Zn or Zn-alloy coating
coating
thickness)
corrosion
5 µm 8 µm 12 µm

Transparent-passivated Zn//An//T0 Barrel 8 48 72 96

electroplated zinc coating
Rack 16 72 96 120

Iridescent-passivated Zn//Cn//T0 Barrel 72 144 216 288

electroplated zinc coating
Rack 120 192 264 336

Iridescent-passivated and Zn//Cn//T2 Barrel 120 192 264 360

sealed electroplated zinc
coating Rack 168 264 360 480

Iridescent-passivated ZnFe//Cn//T0 Barrel 96 168 240 312

electroplated zinc-iron-
alloy coating Rack 168 240 312 384

Iridescent-passivated and ZnFe//Cn//T2 Barrel 144 216 288 384

sealed electroplated
zinc-iron-alloy coating Rack 216 312 408 528
a
Iridescent-passivated ZnNi/Cn//T0 Barrel 120 480 720 720
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electroplated zinc-nickel-
a
alloy coating Rack 192 600 720 720
a
Iridescent-passivated and ZnNi//Cn//T2 Barrel 168 600 720 720
sealed electroplated
a a
zinc-nickel-alloy coating Rack 360 720 720 720

a
To limit the testing costs, the requirement has been reduced to 720 hours.

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Table 6 — Minimum coating thicknesses and test times for passivated black zinc and zinc-alloy
coatings subjected to the DIN EN ISO 9227-NSS test

Minimum test time,

h

Without basic material

Type of surface Coating Type of corrosion
protection coating designation electroplating Without (as a function of Zn or
coating Zn-alloy
corrosion coating thickness)

5 µm 8 µm 12 µm

Black-passivated and ZnFe//Fn//T2 Barrel 120 192 264 360

sealed electroplated
zinc-iron-alloy coating Rack 168 264 360 480
a
Black-passivated and ZnNi//Fn//T2 Barrel 168 480 720 720
sealed electroplated
a
zinc-nickel-alloy coating Rack 240 600 720 720
a
Black-passivated ZnNi//Fn/T0 Barrel 48 480 720 720
electroplated zinc-
a
nickel-alloy coating Rack 72 600 720 720

a
To limit the testing costs, the requirement has been reduced to 720 hours.

Faint visual variations (a hazy grey veil) that are not voluminous in nature are permitted and do not adversely
affect the corrosion protection layer.

No generally recognized corrosion resistance figures are as yet available for electroplated black-passivated
and sealed electroplated zinc coatings (Zn//Fn//T2).
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8 Test report

8.1 General information

The electroplater shall provide a report that:

a) refers to this standard (i.e. DIN 50979);

b) certifies conformance with the requirements of this standard;

c) gives the name of the electroplater;

d) records process details (rack or barrel plating and coating system deposited).

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8.2 Coatings on materials having a tensile strength ≥ 1 000 N/mm2

The report shall certify that designated steps have been taken to minimize the risk of delayed hydrogen-
induced brittle fracture.

8.3 Test results

The tests in 7.2, 7.3 and 7.4 shall be carried out concurrently with the process.

The test report shall include the following details:

a) the results of the technological tests specified in clause 7 of this standard;

b) by whom the tests were performed (the supplier and/or subcontractor and/or an independent testing
laboratory).
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Bibliography

DIN EN ISO 1463, Metallic and oxide coatings — Measurement of coating thickness — Microscopical method

DIN EN ISO 2177, Metallic coatings — Measurement of coating thickness — Coulometric method by anodic
dissolution

DIN EN ISO 2178, Non-magnetic coatings on magnetic substrates — Measurement of coating thickness —
Magnetic method

DIN EN ISO 2819, Metallic coatings on metallic substrates — Electrodeposited and chemically deposited
coatings — Review of methods available for testing adhesion
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