Mercedes-Benz DBL 7381

Company Standard Date published: 2021-01

Transition period: 0 months
Total no. of pages (including Notes): 32
Person in charge: Irina Moreno de Struwe
Email: irina.de_struwe@daimler.com
Plant: 050 Dept.: PP/KB
Phone: +49 176 30958659
Date of translation: 04/2021

Organic coating for metallic parts on the outer side

and underside of the vehicle and in the engine
compartment

Foreword
This DBL specifies the requirements for the coating quality of coated metallic parts which are used in vehicle
exteriors, on the underfloor, and in the engine compartment, and describes the testing methods. These
coatings are final coatings. No further additional coating will be carried out in the receiving plant.

This edition replaces the previous edition of this Standard.

Changes
In comparison with edition 2020-11, the following changes have been made: Refer to Annex B
The product versions, which were not set to the status 'Not for new designs’ starting from this edition, are
listed in Annex C Table 25.

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Note: This translation is for information purpose only.

The German version shall prevail above all others.

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Table of contents
1 Scope of application..........................................................................................................................3
2 Normative references........................................................................................................................4
3 Terms and definitions........................................................................................................................4
4 General requirements .......................................................................................................................5
5 Abbreviated material designation for documentation ........................................................................5
6 General properties of materials, raw materials and delivery condition .............................................5
6.1 All product versions...........................................................................................................................5
6.2 Changes (material, process) .............................................................................................................7
6.3 Assemblies........................................................................................................................................7
6.4 Mechanical pre-treatment method ....................................................................................................7
6.5 MAG- + MIG weld seams / heat-affected zone .................................................................................7
6.6 Punched and cut edges ....................................................................................................................7
6.7 CED material and pre-treatment .......................................................................................................7
6.8 Cavity coating ...................................................................................................................................8
6.9 Repair of faults in CED coating on SP body parts and SP component parts ...................................8
6.10 Layer thicknesses .............................................................................................................................8
6.11 Special considerations for product versions with light alloys as base material .................................8
7 Dimensions and tolerances/ form of supply ......................................................................................9
8 Technical Data ..................................................................................................................................9
9 Duties of the supplier ........................................................................................................................9
9.1 General requirements .......................................................................................................................9
9.2 Initial sampling ..................................................................................................................................9
Annex A (normative) Tests with set / target values ................................................................................11
A.1 Definition of the test method classes ..............................................................................................11
A.2 General requirements .....................................................................................................................11
A.3 Testing of paints in wet condition ....................................................................................................11
A.4 Processing tests..............................................................................................................................12
A.5 Visual inspections ...........................................................................................................................12
A.6 Technical-mechanical tests.............................................................................................................13
A.7 Climatic tests...................................................................................................................................16
A.8 Resistance to chemicals, test mixtures and test concentrates .......................................................28
A.9 Analytical tests ................................................................................................................................30
Annex B (informative) Changes in comparison with the last edition ......................................................31
Annex C (informative) Product versions with the status 'not for new designs' .......................................32

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1 Scope of application
This Standard applies to the Mercedes-Benz Cars & VAN divisions. It applies to all metallic base materials
on the exterior and underside of the vehicle and within the engine compartment, as well as for the actual
body, which receive an organic coating or are coated with a paintwork structure.

Depending on the purpose, the organic coatings or paintwork structures can be divided into exposure groups
that represent the respective product versions in this standard. An overview of the permissible product
versions can be found in Table 1 below.

This DBL does not apply to metallic component parts installed in the vehicle interior. DBL 7382 shall apply
to these.
This DBL does not apply to body replacement and follow-up drawn parts. DBL 7383 shall apply to these.

Table 1: Product Versions, Overview

Medium corrosive stress

Heavy corrosive stress

Moderate corrosive

Decorative effect
Product version

Type of coating Application examples

Thermal load
stress

00 X Single or multicoat finish, CED, powder, etc.

Only for special cases, agreement required.
01 X X Thermally stable single or multicoat finish

10 X Single or multicoat finish, CED, powder, etc.

Component parts in the engine compartment
11 X X Thermally stable single or multicoat finish and on the underbody, which are subject to a
medium corrosive stress and do not fall in the
Multicoat finish or powder coating with category of PV 20/22/40.
12 X
stonechip primer
All component parts in the underbody with
20 X CED cavities, or components subject to particularly
high corrosive stress
Body parts e.g. underbody, engine
22 X CED
compartment wall, etc.

Decorative and weather-resistant baked Decorative or functional parts, e.g. Parktronic

30 X X multicoat finish or powder coating, co- sensors, moldings, roof trim strips, wipers,
extrudate, and other coatings emblems, etc.

Body, body parts, or detachable parts such as

Decorative and weather-resistant baked
31 X X trunk lids, engine hood, doors, flaps, front
multicoat finish
module, etc.
For component parts that are subject to very
Single or multicoat paint, powder, etc. extreme corrosive stress due to where they are
40 X
non-decorative installed and are not CED coated, such as
hinges, various holders, etc.

Decorative and weather-resistant baked

Aluminum wheels, wheel cover on aluminum
50 X X multicoat finish or powder coating, and
substrate
other coatings on aluminum wheels

The necessary additional coatings or cavity preservation should be documented in the data record for
product versions PV 10/20.
Components of product versions PV 10/20, which are documented with additional coatings or cavity
preservation in the data record, should be tested with and without additional measures and the respective
limit values should be considered, see Chapter 6.1.4

For product versions 20/22, the responsible specialist department for coating shall be contacted in the event
of a constant thermal load > 130 °C.
Single or multicoat finish: all common coating systems, provided that they comply with the requirements of
this DBL.

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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.

A1690034299 Implementation regulation for surface treatment

A 0080043099 Paint surfaces for wheels
DBL 5425 Coating / Paintwork of Plastic Parts in the Vehicle Exterior
DBL 6714 Negative List – Constituents of Process Materials
DBL 6905 Supply Specification; Protective Agent for Underbody, Cavities and Engine
Compartment
DBL 7292 Supply Specification; Electrophoretic Primer for Bodies and Add-On Parts
DBL 7382 Supply Specification; Coating/Painting of Metallic Parts in the Vehicle Interior
DBL 7383 Supply Specification for Coating-Painting of Body Replacement and Follow-Up
Drawn Parts
DBL 8585 General Requirements – Environmental Protection, Hazardous Substances,
Dangerous Goods – Negative Substance List for the Selection of Materials
DIN 55635 Paints and Varnishes – Cyclic Corrosion Testing of Coating Systems on Materials
and Component Parts in Automotive Construction
DIN EN ISO 2813 Paints and Varnishes - Determination of Gloss Value at 20°, 60° and 85°
EN ISO 9001 Quality Management Systems - Requirements
ISO/IEC 17025 General Requirements for the Competence of Testing and Calibration Laboratories
MBN 10300 Standard Designation of Materials for Technical Documentation
MBN 10473-1 Measurement of Colors
MBN 10473-2 Technical Data for Color Measurement
MBN 10476 Visual Color Assessment of Painted Bodies, Add-On Parts and Metal Sheets in the
Exterior
MBN 10494-1 Paint Test Methods – Part 1: General Requirements
MBN 10494-4 Paint Test Methods – Part 4: Optical Tests
MBN 10494-5 Paint Test Methods – Part 5: Technical-Mechanical Tests
MBN 10494-6 Paint Test Methods – Part 6: Climatic Tests
MBN 10494-7 Paint Test Methods – Part 7: Resistance to Chemicals, Test Mixtures and Test
Concentrates
VDA 250 Material laboratory assessment (for more in-depth assessment based on ISO/TS
16949)
VDA Volume 2 Quality Management in the Automotive Industry – Securing the Quality of Supplies
– Production Process and Product Approval (PPA)
WEB V100 WEB V100 laboratory requirements WEB2020+
WEB V300 Guidelines for initial material sampling
WEB V301 Guidelines for laboratories
WEB V500 Sample card types Sample card duration WEB

3 Terms and definitions

PV Product version
AAW Work instruction
conditionally OK conditionally OK
BQF Approval of procurement source
DBL Daimler-Benz Supply Specification
CH Test of condensed water constant climate
ISIR Initial sample inspection report
EP/PES Epoxide resin/Polyester
SP Spare parts
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GE Gloss unit
OK Correct, corresponding to required quality
CED Cathodic dip paint (cathodic electro deposition)
CCT Corrosion cycle test
MAG Metal active gas welding
MIG Metal-inert gas welding
PES Polyester
PLP Production control plan
Rep. Paint repair
SQMS Supplier Quality Management System
TG Glass transition temperature
CASS copper-accelerated acetic acid salt spray
ZGS Drawing date

4 General requirements
To guarantee product safety and product quality, and to meet 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 components and recyclability, materials, process engineering, component parts and systems
shall comply with all applicable legal requirements.

DBL 8585 and DBL 6714 shall be observed.

5 Abbreviated material designation for documentation

The material designation is shown, for example, in Table 2 for the PV10.

Table 2: Structure of abbreviated material designation (see MBN 10300)

Material data Description of final condition
a. Material b. Material c. Material d. Abbreviated e. DBL f. Processing g. Binding Daimler-
group standard number material material condition Benz Supply
designation Specification
Steel DIN EN 10130 1.0338 DBL 7381.10

String, for example, according to MBN 10300:

e.g.: Steel DIN EN 10130-1.0338 + DBL 7381.10
Alternatively, the specification can be indicated in the drawing.

6 General properties of materials, raw materials and delivery condition

6.1 All product versions

6.1.1 General requirements

In case of initial samples and modifications, the materials used for pre-treatment prior to coating (cleaning
and phosphating agents), the types of binding agents and pigmentation used for the paint system, and the
coating and drying processes shall be reported to the Daimler Group's customer plant. This stipulation is
intended to facilitate, in particular within the framework of development processes, general material
assessment and compliance with any necessary technical and/or personal protective measures for the
processing of painted component parts (e.g. grinding, welding). The pre-treatments and coatings shall be
free of heavy metals such as arsenic, cadmium, compounds containing chromium (VI), lead or their
compounds. Pre-treatment, coating material and coating methods as well as layer thickness shall be
selected by the part supplier so as to fulfill the requirements of this DBL. Residues which could promote
corrosion and/or impair adhesion of the coatings, in particular on weld seams or laser-cut edges (flux, scale
or similar), shall be removed chemically or mechanically.
Corrosion-prone edges, corners, overlaps and difficult-to-reach areas shall be treated with particular care.
The surface of the coating shall be free of any visible pre-treatment markings, roughness, craters, dust
inclusions, etc.

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6.1.2 PV 30: Decorative and weather-resistant baked multicoat finish or powder coating, co-
extrudate, and other coatings
A painting system approval is required for this product version.
For coated co-extrudate, only the CASS test is carried out as part of this DBL; all other tests are checked in
accordance with DBL 5425.
Requirements for scratch resistance (Amtec / Crockmeter) in Table 5 as well as those for weather and
chemical resistance in Tables 20 and 21 are applicable for flat applied contrast colors on the outer car
body skin (e.g. in-mold coatings, foils, contrast colors for roofs, flaps).

6.1.3 PV 22/31: Decorative and weather-resistant CED / baked multicoat finish

All materials used for this PV shall have been approved according to the applicable material DBL and have
a BQF. For example cataphoretic dip coating in accordance with DBL 7292

6.1.4 PV 10/20: Single or multicoat finish, CED, powder, etc. with medium corrosion stress / CED
with heavy corrosion stress
Additional measures such as an additional coating on weld seams, edges and surfaces at a risk of
corrosion as well as areas with special stone chip stress or cavity preservation should be documented in
the data record of the component.
All materials used as additional coating for this PV shall have been approved according to DBL 7305 and
have a BQF.
All materials used as cavity preservation for this PV shall have been approved according to DBL 6905 and
have a BQF.
The following scopes shall be tested for initial material sampling of components with additional coatings or
cavity preservation:
1. Component only CED coated
2. CED coated component with documented additional measures according to the given BQF of DBL
7305 or DBL 6905
The Tier 1 supplier must ensure the adhesion between CED and any additional coating, document it and
prove it (see 9.2.1).

6.1.5 PV 50: Baked multicoat finish or coating for aluminum wheels

This product version requires a material policy approval as well as a painting system approval. Both
approvals are issued by the Paint Development team. Epoxy-polyester hybrid powder coatings shall be
used as a primer. The required gloss level for the primer shall be > 80 gloss units, measured under a 60°
measuring angle geometry, as per DIN EN ISO 2813 (layer thickness 90 ± 5 µm, curing conditions 10 min /
200°C object holding time, Q-Panel brushed aluminum substrate).
To create coatings on test panels for the chemical resistance and artificially accelerated weathering tests,
the lower curing limit (UEG) and the minimum layer thickness of the varnish layer shall be applied (total
layer thickness 200 µm). Paintwork compatibility with the competitor shall be ensured. Complete repair
structures and test procedures shall be agreed with the specialist department. All the results should be
documented exactly with values, illustrations, graphs, etc.
The minimum layer thicknesses and paint systems for wheels are stored in the “Implementation regulation
for surface treatment A 169 003 4299” or under document number “Paint surfaces for wheels” A 008 004
30 99 in DocMaster and shall be complied with in accordance with the drawing geometry status.

6.1.6 Aluminum alloys PV 10,11,12,20

For purchased parts of e-coated aluminum alloys with strong and medium corrosion strains, the test time
for the CASS test (see Table 16) can be reduced by one test level in exceptional cases only and in
consultation with the specialist department. The results, along with the corresponding testing times, shall be
provided.

6.1.7 Substrates
For steel and galvanized steel substrate: CCT 2 (Tables 13 and 14) should be applied for new designs for
PVs 10, 11, 12, 20, 22, 30 and 31. CCT 1 can be used in exceptional cases in consultation with the specialist
department
For aluminum alloys: CCT 2 (Table 15) should be additionally applied for new designs for PVs 10, 11, 12,
20, 22, 30 and 31 as an approval-relevant corrosion test.

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6.2 Changes (material, process)

According to VDA Volume 2, all material and process changes shall be reported to the Daimler Group's
customer plant in good time and initial samples shall be taken and approved before series production begins.

6.3 Assemblies
Note that DBL 7381 can apply to the testing of either single parts or assemblies. Accordingly, the specified
tests shall also be carried out on either the single part or on the assembly. This shall be coordinated with
the specialist department.

6.4 Mechanical pre-treatment method

The determination of the mechanical pre-treatment method shall be selected such that a sufficient cleaning
of the surfaces is guaranteed, without negatively affecting other component part properties.
Entry of noble particles into the surface of component parts shall be excluded (e.g. no shot-blasting of
aluminum with steel or stainless steel). Conventional sandblasting is not permissible.

6.5 MAG- + MIG weld seams / heat-affected zone

Weld seams / Heat-affected zone shall be pre-treated so that silicate and slag residues are removed to an
extent that allows proper pre-treatment (e.g. phosphating). The heat-affected zone shall be treated in the
same way, if it is accessible. Reliable processes for removing residues resulting during welding shall be
requested from the responsible specialist department. Currently approved methods are: ceramic blasting,
barrel finishing, dry ice blasting, pickling (only on steel), water jets. The processes shall be selected so as
to fulfill the requirements of this DBL. In special cases, an additional coating on the weld seams is also
possible.
Process optimization in weld spatters: Weld spatter shall be avoided as much as possible in the process
since it can lead to surface corrosion.
Slag and silicate residues on the weld seam, which do not lead to a reduction of the specified component
properties, are not a defect, as long as they do not cause any corrosion according to the corrosion test, see
Figure1.

Figure1: Coating defects occur due to silicate residues caused by MAG welding

6.6 Punched and cut edges

Punched and cut edges shall be designed such that compliance with the edge protection required in the
relevant PV is ensured. The following rework methods can be used to improve edge protection: grinding,
brushing, barrel finishing, shot-blasting etc. If a lack of burrs is specified on the drawing, it is recommended
that the edges be embossed, if possible. If the parts are laser cut, a gas cut without active gas shall be
chosen. Where this is not possible, the edges shall be reworked as described above.

6.7 CED material and pre-treatment

The supplier shall ensure that the phosphate content in the CED bath does not exceed 100 ppm, as
corrosion protection deteriorates significantly with increasing phosphate content. The designated specialist
department of the customer plant shall be notified in writing if the CED materials are changed following
sampling with regard to binding agent/solids ratio, or if measures are taken which might affect the flow.
A nickel content of 0,8 – 1,2 g/l shall be maintained during phosphating when galvanized sheets are used.
When using aluminum during a coat-forming phosphating process, care shall be taken to ensure that the
free fluoride content is closer to the lower tolerance limit (just barely any coat formation) than the upper
tolerance limit.
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The demonstration of a closed phosphate coat by analysis as well as the demonstration of monitoring
the pre-treatment and CED parameter should be attached with the ISIR (see 9.2.1).

6.8 Cavity coating

The minimum layer thickness of e-coatings in cavities shall be 12 µm. A complete flow through the parts
shall be ensured for the CED coating of cavities. If air bubbles cannot be avoided, they shall be shifted to
areas which are non-critical with regard to corrosion and functionality by suspending the parts appropriately.
If required, additional measures (e.g. waxing) shall be taken.

6.9 Repair of faults in CED coating on SP body parts and SP component parts

6.9.1 General requirements

In the event of defects in CED coatings, these shall be rectified by suppliers (contract coaters) with repair
primer (2K epoxy, black). The repair primer requires MB approval. If these defects in the CED coating are
rectified, the repaired areas of these component parts shall reach a surface corrosion value of Ri 0. This
applies to all product versions except for PV 31.

6.9.2 PV 30: Decorative and weather-resistant baked multicoat finish or powder coating, co-
extrudate, and other coatings
Spot repair is not permissible, only complete repair.

6.9.3 PV 31: Decorative and weather-resistant baked multicoat finish

The guidelines for repairing areas where the coating has been partially or completely abraded and repairing
the paintwork structure on car bodies can be obtained from the Paint Development Department at the
production plants.

6.9.4 Rewelded, e-coated component parts

The following process is required for re-welded, e-coated component parts:
- Completely remove any weld residues from welded areas
- Remove welding burrs with angle grinder
- Re-sand using 80 grit sanding paper
- Clean using commercially available silicone remover
- Apply MB-approved repair primer
- Ensure mixing ratio, layer thickness and drying according to the manufacturer's specifications
- Re-finish with 2K epoxy primer, black with spray can or 1kg container with spray gun
- Two spray passes, air drying

6.9.5 PV 50: Baked multicoat finish or coating for aluminum wheels

Spot repair is not permissible, only complete repair.

6.10 Layer thicknesses

Supplier-specified coat thicknesses which comply with the requirements of this material-specific DBL shall
be observed. If specifications are indicated on the drawing, they shall be observed; see Table 3: Layer
thicknesses.

For PV50: The minimum layer thicknesses and paint systems for wheels are stored in the “Implementation
regulation for surface treatment A 169 003 4299” or under document number “Paint surfaces for wheels” A
008 004 30 99 in DocMaster and shall be complied with in accordance with the drawing geometry status.

6.11 Special considerations for product versions with light alloys as base material

6.11.1 Extruded aluminum parts/ rolled aluminum/ cast aluminum (pressure, sand, ingot molds)
The CASS test (see Table 16) shall be performed as an approval-relevant corrosion test. In addition,
filiform corrosion test (see Table 17) can be required.

6.11.2 Mirror-turned / polished aluminum wheels

The following tests are performed as approval-relevant corrosion tests for the mirror-turned parts: the
filiform corrosion test (see Table 17) and the CASS test (see Table 16) for the three-layer structure or full-
painted area.

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6.11.3 Magnesium die casting / zinc die casting

The corrosion cycle test 1 (see Table 12) shall be performed as the approval-relevant corrosion test. To
check the closure of the surface, the CASS test (see Table 16) can be used as a quick test. Do not scribe
the surface for this test.

7 Dimensions and tolerances/ form of supply

According to drawing and approved sample

8 Technical Data
For requirements of the approval-relevant tests with set values or target values, refer to Annex A.

Preliminary remark:
In addition to the quality of the coating material itself, the material, pre-treatment and shape of the parts to
be coated may also be crucial to compliance with the following requirements. The tests shall therefore be
conducted on finished parts. If necessary, the Global Material Sampling team shall be consulted prior to
testing.
If, due to their size, component parts are sawn into pieces, the cut surfaces shall be protected, e.g. with a
green polyester adhesive tape (source of procurement should be requested from the specialist department)
or with wax. The selected method shall reliably protect the edges from the moisture of the corrosive media
being drained without affecting the surrounding areas to be tested.
For underbody components, at least two parts shall be tested, the underside of the component parts in the
installation position forming the upper side in the test cell and vice versa. This is required in order to be able
to assess any effects resulting from the reverse situation.
A test angle of 70° is desirable for the main surface.

9 Duties of the supplier

9.1 General requirements

As part of the initial sampling, the supplier shall verify that all guidelines of the "Global material sampling"
team are observed. The necessary forms and documents such as test matrix and process data can be
retrieved in DocMaster: WEB V* if Annexes 1, 2 and 3 are not attached. Questions shall be addressed to
the Global material sampling department.
This DBL as well as all other required Daimler standards shall be available to all sub-suppliers in order to
ensure that products are DBL-compliant.
The supplier shall ensure that all relevant documents are available to all those involved in the product
creation process.

9.2 Initial sampling

9.2.1 General requirements

The corrosion-related Initial Sample Inspection Report (ISIR) documents shall be attached in the Global
Sample Release Systems and shall contain the following information:
- Indication of the production and coating location. If the component part is produced or coated at more
than one location, then the locations shall be listed separately and include the following data for each
location. In addition, component parts shall be submitted for sampling at each production/coating
location.
- Pre-treatment materials, product name with product code, supplier
- Coating materials, product name with product code (for CED as well as binding agent and pigment
paste), supplier. The IR correlation coefficient shall be at least 0,97 to the approved reference.
- Process description (flow chart)
- Process parameters, test frequency
- Proof of a closed phosphate coat by SEM image: An overview image at a magnification of 500x as well
as a close-up view at 2000x magnification
- Strict monitoring of pre-treatment and CED process parameters
- Filling Annex 1 Process data for pre-treatment, CED and painting
- Filling Annex 2 Test report requirements
- Filling Annex 3 Test matrix
- Layer thickness, layer thickness measuring points (illustrated documentation), test frequency
- Object stoving temperature (ideal, minimum, maximum)

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- Object temperature curves (at full load), object temperature measuring points (illustrated documentation),
test frequency
- Illustrated corrosion test report, e.g. test position, storage/removal of the test parts in the/from the test
cell
- Adhesion test of overall paint system and individual coats
- Tests on adhesion of CED on the substrate as well as adhesion between CED and possible additional
coatings applied
- Repair paintwork: work instructions, coating materials with product and supplier name
- Corrosion test report for the repair concept (illustrated)
- Testing of CCT1 / CCT2 for steel and CASS / filiform test for aluminum wheels should be performed on
the entire wheels

9.2.2 PV 50 aluminum wheels

In addition to the documents required in 9.2.1, the following documents are required:
- Material policy approval
- Paint system approval, see Section 6.1.5 of this DBL
- Objective evidence of resistance to chemicals, gradient oven test method: Table 21.
- Objective evidence of resistance to test fuels: Table 22
- Objective evidence of resistance to process and operating materials: Table 23
- Tests for material policy approval: consult with the Paint Development Department
- Tests for paint system approval: consult with the Paint Development Department
- Filling Annex 1: Process data for pre-treatment, CED and painting
- Filling Annex 2: Test report requirements

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Annex A (normative)
Tests with set / target values

A.1 Definition of the test method classes

The WEB 2020+ process shall be applicable. The WEB V100, V300, V301, V500 documents should be followed.
The laboratories approved regarding A methods are filed in DocMaster under document number WEB V100. No laboratories are specified for B and C methods.

A.2 General requirements

Preload describes a test that precedes the subsequent evaluations. For example, a component part is first exposed to a condensed water constant climate in order to
then carry out the corresponding evaluations on the component part, such as a cross-cut, etc.

The requirements for the layer thicknesses are specified in Table 3.

Table 3: Layer thicknesses

Affected PVs and their requirements

Evaluation

Test Test method

Preload

00 01 10 11 12 20 22 30 31 40 50

MBN 10494-1
According to the PLP and AAW drawing or approved sample with the tolerances typical of the material, as
X Layer thickness Non-destructive
documented in the ISIR.
layer thickness

Cross-section polish in Cross-section polish as per DIN 2808: Method 6a cross-section polish
X MBN 10494-1
the wedge process
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A.3 Testing of paints in wet condition

Not relevant for this DBL.
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A.4 Processing tests

Not relevant for this DBL.

A.5 Visual inspections

The requirements for the optical properties are given in Table 4.

Table 4: Visual inspection

Affected PVs and their requirements
Evaluation

Test Test method

Preload

00 01 10 11 12 30 31 50

High gloss:
High gloss:
Gloss ≥ 80
In accordance with drawing or approved sample. Gloss ≥80 GE (measuring MBN 10494-4
GE (20 °)
angle 20 °) Gloss
X Gloss evaluation Deviation with respect to reference sample 2-3 measurement
Matt: Gloss
Matt: using a
according to
No requirements for CED-Materials Gloss 23±7 GE (measuring reflectometer
color sample
angle 60 °)
(60 °)

Visual
Deviation with respect to reference sample 3-4 measuring technology: MBN 10494-4
inspection:
X Color assessment MBN 10473-2 MBN 10473-1
MBN
No requirements for CED-Materials visual: MBN 10476 MBN 10473
10476

According
MBN 10514-3 to MBN 10494-4
X Appearance
MBN 10514-4 approved MBN 10514-2
sample
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A.6 Technical-mechanical tests

The requirements for the technical-mechanical tests are given in Table 5, Table 6 and Table 7.
The tests of Table 5 are only necessary for development samples and must be carried out on test plates.
PV31 shall be tested even when a system approval is not mandatory.

Table 5: Technical-mechanical tests 1

Affected PVs and their requirements
Evaluation
Preload

Test Test method

30 31 50

Mandrel bending test

X X ≤ 20 ≤ 20 MBN 10494-5
cylindrical mandrel in mm

OK: ≥ 6 (≥ 3,5*)
X X Cupping in mm conditionally OK: ≥ 5 (≥ 2,5*) 6 MBN 10494-5

Amtec-Kistler: ≥ 70 % before reflow

Scratch resistance
X X Crockmeter: ≥ 70 % before reflow MBN 10494-5
Residual gloss in %

*Paint repair structure

: Horst Feldmann, 2022-09-15

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DBL 7381:2021-01, page 14

Table 6: Technical-mechanical tests 2

Affected PVs and their requirements
Evaluation

Test Test method

Preload

00 01 10 11 12 20 22 40 30 31 50

OK: Gt 1 (Gt 1,5*)

X X Cross-cut Gt 1 Gt 1 Gt 1 conditionally OK: Gt Gt 1 MBN 10494-5
1,5 (Gt 2*)
OK: K 2 (K 2,5*)
X X Scratch test K2 K2 K2 conditionally OK: K2 MBN 10494-5
K 2,5 (K 3*)

Scratch test
X X PV 20: K 2 MBN 10494-5
Cavity

Adhesion test by means

of tape pull-off on PV 20, 22: no loss of
X X No loss of adhesion MBN 10494-5
cataphoretically dip adhesion
coated cavity weld seam
Multiple stone chipping OK: 2 (2,5*)
X X test - Overall damage of PV 12, 101: 2 PV 201: 2 conditionally OK.: 2
component [grade] 2,5 (2,5*)
MBN 10494-5
Multiple stone chipping OK: 0,5 (0,5*)
X X test - Degree of corrosion PV12, 101: 1 PV 201: 1 conditionally OK.: 0,5
[grade] 1 (1*)

*Paint repair structure 1: with additional coating documented in the data record of the
component
: Horst Feldmann, 2022-09-15

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DBL 7381:2021-01, page 15

Table 7: Technical-mechanical tests 2

Affected PVs and their requirements
Evaluation
Test Test method
Preload

30 31 50

Pressurized water spray

OK: D1 (D1*) No loss of adhesion on St. Andrew's
X X test MBN 10494-5
conditionally OK.: D1,5 (D1,5*) cross
on St. Andrews cross

Pressurized water spray

test D1, minor erosion of existing
X X D1, minor erosion of existing damage MBN 10494-5
for damage due to multi- damage
impact stone chipping -
Process B
Pressurized water spray MBN 10494-5
Only Parktronic sensors: No loss of adhesion on the scratch
X X test on the scratch, pre- . similar to St.
damage with cutter knife Andrews cross

Impact force adhesion on

X X aluminum surfaces: unaged, Average value ≥ 50
in N/cm2

MBN 10494-8
Impact force adhesion on
Average value ≥ 45
X X aluminum surfaces:
No individual value ≤ 20
tempered, in N/cm2
: Horst Feldmann, 2022-09-15

*Paint repair structure

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DBL 7381:2021-01, page 16

A.7 Climatic tests

The requirements for the temperature resistance are specified in Table 8.
The requirements for the constant condensed water climate test are specified in Table 9.
The requirements for the corrosion cycle test 1 for steel are indicated in Table 10.
The requirements for the corrosion cycle test 1 for galvanized steel are indicated in Table 11.
The requirements for the corrosion cycle test 1 for magnesium/ zinc die casting are indicated in Table 12.
The requirements for the corrosion cycle test 2 for steel are indicated in Table 13.
The requirements for the corrosion cycle test 2 for galvanized steel are indicated in Table 14.
The requirements for the corrosion cycle test 2 for aluminum are indicated in Table 15.
The requirements for the CASS test for aluminum substrates are indicated in Table 16.
The requirements for the filiform test are given in Table 17.
The requirements for the test for resistance to low temperature are given in Table 18.
The requirements for the natural outdoor exposure with salt are given in Table 19.
The requirements for the weathering are given in Table 20.

Table 8: Temperature resistance

Affected PVs and their requirements

Evaluation

Test Test method

Preload

00 01

X Temperature resistance 24 h 130 °C

X Cross-cut Gt 1 MBN 10494-5

Scratch test K2 MBN 10494-5

X

Corrosion cycle test on refer to Table 10. MBN 10494-6

: Horst Feldmann, 2022-09-15

X
steel
Corrosion cycle test on refer to Table 11. MBN 10494-6
X
galvanized steel

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Table 9: Constant condensed water climate (CH)

Evaluation Affected PVs and their requirements Test method

Test
Preload

00 01 10 11 12 20 22 40 30 31 50

Condensed water
constant climate (CH)
X MBN 10494-6

Exposure time in h 120 240 240 240 240

Blistering/
X <2 (S2) <2 (S2) <2 (S2) 0 (S0) 0 (S0) MBN 10494-6
Degree of blistering (S)

OK: K 2 (K 2,5*)
X Scratch test after 24 h K2 K2 K2 conditionally OK: K K2 MBN 10494-5/-6
2,5 (K 3*)
OK: Gt 1 (Gt 1,5*)
X Cross-cut after 24 h Gt 1 Gt 1 Gt 1 conditionally OK: Gt 1 MBN 10494-5/-6
Gt 1,5 (Gt2*)
Multiple stone chipping test
X method B – overall damage PV 12, 101: 2 PV201: 2 2 MBN 10494-5
of component [grade]

Multiple stone chipping test

method B – degree of
X PV 12, 101: 1 PV201: 1 0,5 MBN 10494-5
component corrosion
[grade]
: Horst Feldmann, 2022-09-15

Pressurized water spray

X test D1 MBN 10494-5
for damage due to multi-
impact stone chipping - 1
*Paint repair structure
Process B with additional coating documented in the data record of the
component

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DBL 7381:2021-01, page 18

Table 10: Corrosion cycle test 1 for steel
Affected PVs and their requirements

Evaluation
Preload
Test Test method
00 01 10 11 12 20 22 40 30 31

Corrosion cycle test 1 Steel substrates

Steel
X MBN 10494-6
Exposure time in cycles 3 6 10 10

X Surface corrosion Ri 1 Ri 1 Ri 1 Ri 0 MBN 10494-6

KR 2 KR 2
X Edge corrosion** KR 2 KR 1 MBN 10494-6
PV101: KR 1 PV201: KR1
SR 2 SR 2
X Weld seam corrosion SR 2 SR 2 MBN 10494-6
PV101: SR 1 PV201: SR 1
Subsurface corrosion around
X 1,5 2,0 1,5 1,5 MBN 10494-6
a scribe U/2 in mm
Blistering/
X <2 (S2) <2 (S2) <2 (S2) 0 (S0) MBN 10494-6
Degree of blistering (S)

X Scratch test after 24 h K2 K2 K2 K 2 (K 2,5*) MBN 10494-6

X Cross-cut after 24 h Gt 1 Gt 1 Gt 1 Gt 1 (Gt 1,5*) MBN 10494-6

Flange corrosion: Unopened

X No leakage of red rust from the flange MBN 10494-6
evaluation after 3 cycles
Assessment after 3 cycles
Flange corrosion, opened:
X PV102, 202: free of corrosion MBN 10494-6
Assessment after end of test
Cavities: PV 10, 11, 12: Ri 1, K 2 (even in
PV 20, 22: Ri 1, K 2 (even in the
: Horst Feldmann, 2022-09-15

Evaluation after end of test the area of the heat-affected

X area of the heat-affected zone) MBN 10494-6
Surface corrosion Ri, scratch zone)
test K PV202: Ri 0, K 2
PV102: Ri 0, K 2
Cavities:
Evaluation after end of test no loss of adhesion on CED PV 20, 22: no loss of adhesion
X Adhesion test by means of MBN 10494-6
layer on CED layer
tape pull-off on
cataphoretically dip coated
cavity weld seam
*Paint repair structure 1 with additional coating documented in the data record of the

component
**The limit values refer to one edge length. No integration across the whole component 2 with cavity preservation documented in the data record of the component
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DBL 7381:2021-01, page 19

Table 11: Corrosion cycle test 1 for steel, galvanized
Affected PVs and their requirements

Evaluati
Preload
Test Test method
00 01 10 11 12 20 22 40 30 31
on
Galvanized/ galvanized + organic coating / hot-dip aluminized substrates
Corrosion cycle test 1
The values indicated refer to zinc corrosion.
Galvanized steel
X No red rust shall occur in any case (does not apply to SR). MBN 10494-6

Exposure time in cycles 3 6 10 10

X Surface corrosion Ri 1 Ri 1 Ri 1 Ri 0 MBN 10494-6

KR 3 KR 3
X Edge corrosion** KR 3 KR 2 MBN 10494-6
PV101: KR2 PV201: KR2
SR 2 SR 2
X Weld seam corrosion SR 2 SR 2 MBN 10494-6
PV101: SR1 PV201: SR1
Sub-surface corrosion
X 4,0 4,0 4,0 4,0 (4,0*) MBN 10494-6
around a scribe U/2 in mm
Blistering/
X <2 (S 2) <2 (S 2) <2 (S 2) 0 (S 0) MBN 10494-6
Degree of blistering (S)

X Scratch test after 24 h K2 K2 K2 K 2 (K 2,5*) MBN 10494-5/-6

X Cross-cut after 24 h Gt 1 Gt 1 Gt 1 Gt 1 (Gt 1,5*) MBN 10494-5/-6

Flange corrosion: Unopened

X No flange corrosion (no zinc corrosion) visible to customer MBN 10494-6
evaluation after 3 cycles
Flange corrosion: Opened: Ri 4 zinc corrosion (no red rust)
X MBN 10494-6
Assessment after end of test PV102, 202: free of corrosion
Cavities:
: Horst Feldmann, 2022-09-15

Evaluation after end of test PV 10, 11, 12: Ri 1 PV 20, 22: Ri 1

X MBN 10494-6
Surface corrosion Ri, scratch PV102: Ri 0, K 2 PV 202: Ri 0, K 2
test K
Cavities:
Evaluation after end of test -
no loss of adhesion on CED PV 20, 22: no loss of adhesion
X Adhesion test by means of MBN 10494-6
tape pull-off on layer on CED layer
cataphoretically dip coated
cavity weld seam
*Paint repair structure 1 with additional coating documented in the data record of the component

**The limit values refer to one edge length. No integration across the whole component 2 with cavity preservation documented in the data record of the component

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DBL 7381:2021-01, page 20

Table 12: Corrosion cycle test 1 Magnesium/ zinc die casting

Evaluation Affected PVs and their requirements

Preload

Test Test method

00 01 10 11 12 20 22 40 30 31

Corrosion cycle test 1

Magnesium /zinc die casting
Magnesium/zinc die casting
X MBN 10494-6

Exposure time in cycles 10

X Surface corrosion** Ri 0 MBN 10494-6

X Edge corrosion KR 2 MBN 10494-6

Blistering/
X 0 (S 0) MBN 10494-6
Degree of blistering (S)

Sub-surface corrosion around

X 1,5 MBN 10494-6
a scribe U/2 in mm

X Scratch test after 24 h K2 K 2 (K 2,5*) MBN 10494-5/-6

: Horst Feldmann, 2022-09-15

X Cross-cut after 24 h Gt 1 Gt 1 (Gt 1,5*) MBN 10494-5/-6

*Paint repair structure

**The limit values refer to one edge length. No integration across the whole component

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DBL 7381:2021-01, page 21

Table 13: Corrosion cycle test 2 for steel (DIN 55635)
Affected PVs and their requirements

Evaluatio
Preload
Test Test method
10 11 12 20 22 30 31
n

Corrosion cycle test 2 Corrosion cycle test 2 must be used for new designs.
Steel substrates CCT 1 can be used in exceptional cases in consultation with the specialist department
X MBN 10494-6
Exposure time in cycles 6 6 6

X Surface corrosion Ri 1 Ri 0 Ri 0 MBN 10494-6

KR 2 KR 2
X Edge corrosion** KR 1 MBN 10494-6
PV 101: KR1 PV 201: KR1
SR 2 SR 1
X Weld seam corrosion SR 2 MBN 10494-6
PV 101: SR 1 PV 201: SR 1
Sub-surface corrosion around
X 5,0 3,5 4,5 (4,5*) MBN 10494-6
a scribe U/2 in mm
Blistering/degree of blistering
X 1 (S1) 1 (S1) 0 (S 0) MBN 10494-6
(S)

X Scratch test after 24 h K2 K2 K 2 (K 2,5*) MBN 10494-5/6

X Cross-cut after 24 h Gt 1 Gt 1 Gt 1 (Gt 1,5*) MBN 10494-5/6

Flange corrosion: Unopened

X No leakage of red rust from the flange MBN 10494-6
evaluation after 3 cycles
Flange corrosion: Opened: PV 20: Ri 1
X PV102: free of corrosion MBN 10494-6
Assessment after end of test PV 202: free of corrosion
Cavities:
PV 10, 11, 12: Ri 1, K 2 (even PV 20, 22, 202: Ri 0, K 2 (even
Evaluation after end of test
X in the area of the heat-affected zone) MBN 10494-6
: Horst Feldmann, 2022-09-15

in the area of the heat-affected

Surface corrosion Ri, scratch
PV102: Ri 0, K2 zone)
test K
Cavities:
Evaluation after end of test -
PV 20, 22: no loss of adhesion
X Adhesion test by means of no loss of adhesion on CED layer MBN 10494-6
on CED layer
tape pull-off on cataphoretically
dip coated cavity weld seam
*Paint repair structure 1 withadditional coating documented in the data record of the component
**The limit values refer to one edge length. No integration across the whole component 2 with cavity preservation documented in the data record of the component

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DBL 7381:2021-01, page 22

Table 14: Corrosion cycle test 2 for steel, galvanized (DIN 55635)
Affected PVs and their requirements

Evaluati
Preload
Test Test method
10 11 12 20 22 30 31
on
Galvanized/ galvanized + organic coating / hot-dip aluminized substrates. The given values refer to zinc
Corrosion cycle test 2 corrosion. No red rust shall occur in any case (does not apply to SR).
Galvanized steel Corrosion cycle test 2 shall be used for new designs. CCT 1 can be used in exceptional cases in consultation
X with the specialist department MBN 10494-6

Exposure time in cycles 6 6 6

X Surface corrosion Ri 1 Ri 0 Ri 0 MBN 10494-6

KR 3 KR 2
X Edge corrosion** KR 1 MBN 10494-6
PV 101: KR2 PV 201: KR2
SR 2 SR 1
X Weld seam corrosion SR 2 MBN 10494-6
PV 101: SR1 PV 201: SR1

X Sub-surface corrosion around 2,0 1,5 2,0 (2,0*) MBN 10494-6

a scribe U/2 in mm
X Blistering/degree of blistering 1 (S1) 1 (S1) 0 (S 0) MBN 10494-6
(S)
X Scratch test after 24 h K2 K2 K 2 (K 2,5*) MBN 10494-5/6

X Cross-cut after 24 h Gt 1 Gt 1 Gt 1 (Gt 1,5*) MBN 10494-5/6

Flange corrosion: Unopened

X No flange corrosion (no zinc corrosion) visible to customer MBN 10494-6
evaluation after 3 cycles
Flange corrosion: Opened: PV20: Ri 1
X PV102: free of corrosion MBN 10494-6
Assessment after end of test PV202: free of corrosion
Cavities:
PV 10, 11, 12: Ri 1, K 2 (even PV 20, 22, 202: Ri 0, K 2 (even
Evaluation after end of test
X in the area of the heat-affected zone) MBN 10494-6
: Horst Feldmann, 2022-09-15

in the area of the heat-affected

Surface corrosion Ri, scratch
PV102: Ri 0, K 2 zone)
test K
Cavities:
Evaluation after end of test -
PV 20, 22: no loss of adhesion
X Adhesion test by means of no loss of adhesion on CED layer MBN 10494-6
on CED layer
tape pull-off on cataphoretically
dip coated cavity weld seam
*Paint repair structure 1 withadditional coating documented in the data record of the component
**The limit values refer to one edge length. No integration across the whole component 2 with cavity preservation documented in the data record of the component

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DBL 7381:2021-01, page 23

Table 15: Corrosion cycle test 2 for aluminum (DIN 55635)

Affected PVs and their requirements

Evaluati
Preload

Test Test method

10 11 12 20 22 30 31
on

Corrosion cycle test 2 Aluminum

Aluminum Corrosion cycle test 2 shall be used for new designs.
X MBN 10494-6
Exposure time in cycles 6 6 6

X Surface corrosion Ri 0 Ri 0 Ri 0 MBN 10494-6

X Edge corrosion** KR 2 KR 2 KR 1 MBN 10494-6

X Weld seam corrosion SR 2 SR 2 SR 1 MBN 10494-6

Sub-surface corrosion
X 0,5 0,5 0,5 (0,53) MBN 10494-6
around a scribe U/2 in mm

X Longest thread, lF in mm 4,0 4,0 4,0 (6,03) MBN 10494-6

**The limit values refer to one edge length. No integration across the whole component 3 ground
: Horst Feldmann, 2022-09-15

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DBL 7381:2021-01, page 24

Table 16: CASS test
Affected PVs and their requirements

Evaluation
Preload

Test Test method

00 01 10 11 12 20 22 40 30 31 50

CASS test This test will be applied to all aluminum substrates (even cast).
Aluminum For aluminum alloys PV10,11,12, 20, see item 6.1.6.
X MBN 10494-6
Exposure time in h 96 168 240 240

No change in surface of the

X Visual assessment MBN 10494-4
original

X Surface corrosion Ri 1 Ri 0 MBN 10494-6

KR ≤14
X Edge corrosion** KR 2 KR 1 MBN 10494-6
KR 05

Blistering/ 0 (S 0)
X <2 (S 2) 0 (S 0) MBN 10494-6
Degree of blistering (S) after 24 h

Sub-surface corrosion around

X 2,0 1,0 (2,03) 1,0 MBN 10494-6
a scribe U/2 in mm

Infiltration at scratch: Only Parktronic

Pre-damage with cutter knife, sensors MBN 10494-6
X
in mm 1,0
: Horst Feldmann, 2022-09-15

X Scratch test after 24 h K2 K 2 (K 2,5*) K2 MBN 10494-5/-6

X Cross-cut after 24 h Gt 1 Gt 1 (Gt 1,5*) Gt 1 MBN 10494-5/-6

*Repair of paintwork structure 3 Ground

** The limit values refer to one edge length. No integration across the whole component 4 areas with 3 coats or fully painted
5 gloss of rotating edges

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Table 17: Filiform corrosion
Affected PVs and their requirements

Evaluation Test Test method

Preload

30 31 50

Filiform corrosion mirror-turned/polished

Aluminum
Aluminum Aluminum wheels
X MBN 10494-6
Cass test 24 hours +
Exposure time
28 days at 60°C  1°C / 82 %  2 % rel. Humidity

X Visual assessment No gloss decrease, no color change in the original MBN 10494-4

X Surface corrosion Ri 0 MBN 10494-6

X Edge corrosion KR 1 KR 0 MBN 10494-6

Blistering/
X 0 (S 0) 0 (S 0) MBN 10494-6
Degree of blistering (S)

Sub-surface corrosion around

X 2,0 2,0 MBN 10494-6
a scribe U/2 in mm

4,0
X Longest thread lF in mm 4,0 MBN 10494-6
6,03
: Horst Feldmann, 2022-09-15

X Scratch test after 24 h K2 MBN 10494-5/-6

X Cross-cut after 24 h Gt 1 Gt 1 MBN 10494-5/-6

** The limit values refer to one edge length. No integration across the whole component 3 ground

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Table 18: Resistance to low temperatures

Affected PVs and their requirements

Evaluation
Test Test method
Preload

30 31 50

Low-temperature test no cracks

X X MBN 10494-6

Table 19: Natural weathering with salt

Affected PVs and their requirements
Evaluation
Preload

Test Test method

22 31

Natural weathering with salt This test is not relevant for purchased parts.
X MBN 10494-6
Exposure time 12 months with light protection 12 months

X Surface corrosion Ri 0 Ri 0 MBN 10494-6

X Edge corrosion** KR 2 KR 2 MBN 10494-6

Blistering/
X <2 (S 2) 0 (S 0) MBN 10494-6
Degree of blistering (S)

Sub-surface corrosion around

Xa scribe U/2 in mm 2,0 3,0 MBN 10494-6
: Horst Feldmann, 2022-09-15

Steel
Sub-surface corrosion around
X a scribe U/2 in mm 2,0 2,0 MBN 10494-6
Zinc
Sub-surface corrosion around 1,0 1,0
X a scribe U/2 in mm MBN 10494-6
2,03 2,03
Aluminum
** The limit values refer to one edge length. No integration across the whole component 3 ground

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Table 20: Weathering

Affected PVs and their requirements

Evaluation Test Test method

Preload

30 31 50

Proof of compliance with this

requirement by the paint supplier The coating materials used require a separate DBL-approval system
Weathering
shall be sufficient. Reference approval as regards compliance with this item.
sample is a part of the ISIR.

Florida test
MBN 10494-6
X
Test plates
Exposure time min. 3 years min. 2 years

X Visual color assessment Color deviation with respect to unexposed reference sample not greater than characteristic value 3-4 MBN 10494-4

Gloss measurement using a

X Gloss decrease ≥ 20 GE MBN 10494-4/-6
reflectometer

X Visual assessment No cracks, no chalking MBN 10494-6

Artificial weathering SAE J

2527 (CAM 180)
X MBN 10494-6
Exposure time 4000 h 3000 h

X Visual color assessment Color deviation with respect to unexposed reference sample not greater than characteristic value 3-4 MBN 10494-4

Gloss measurement using a

X Gloss decrease ≤15 GE MBN 10494-4/-6
reflectometer

X Visual assessment No cracks, no chalking MBN 10494-6

Constant condensed water

: Horst Feldmann, 2022-09-15

This test shall be performed after artificial and natural weathering

climate
X MBN 10494-6
Exposure time 240 h

X Scratch test after 24 h K 2,5 . MBN 10494-5/-6

X Cross-cut after 24 h Gt 1,5 Gt 2 MBN 10494-5/-6

X Degree of blistering 0 (S0) MBN 10494-6

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A.8 Resistance to chemicals, test mixtures and test concentrates

The requirements for resistance to chemicals using the gradient oven test method are indicated in Table 21.
The requirements for resistance to test fuels are given in Table 22.
The requirements for resistance to process and operating materials are given in Table 23.

Table 21: Resistance to chemicals

Affected PVs and their requirements

Evaluation

Test Test method

Preload

30 31 50

Resistance to chemicals
X Proof of compliance with these requirements by the paint supplier is sufficient (test results are part of the ISIR). MBN 10494-7
Gradient oven test method

X Water no surface damage: ≥ 75°C, warning limit ≥ 65°C

X Tree resin no surface damage: ≥ 45°C, warning limit ≥ 40°C

X Pancreatin no surface damage: ≥ 50°C, warning limit ≥ 40°C

MBN 10494-7
X Caustic acid solution no surface damage: ≥ 55°C, warning limit ≥ 45°C

X Sulfuric acid no surface damage: ≥ 45°C, warning limit ≥ 40°C

X Destructive sulfuric acid no destruction of the coat of paint below 55°C

: Horst Feldmann, 2022-09-15

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DBL 7381:2021-01, page 29

Table 22: Resistance to test fuels

Evaluation Affected PVs and their requirements

Test Test method

Preload

00 01 10 11 12 20 22 40 30 31 50

X Resistance to test fuels Proof of compliance with these requirements by the paint supplier is sufficient (test results are part of the ISIR). MBN 10494-7

X FAM test substance 23°C/10 min: no swelling or discoloration after regeneration time of 16 hours, scratch test: KR2 MBN 10494 part 7

Table 23: Resistance to process and service products

Affected PVs and their requirements
Evaluation

Test Test method

Preload

00 01 10 11 12 20 22 40 30 31 50

Resistance to process and

X Proof of compliance with these requirements by the paint supplier is sufficient (test results are part of the ISIR). MBN 10494-7
operating materials

16 h/23°C: no visible change in surface

X Hydraulic fluid/servo-oil MBN 10494-7
PV31: 4 h/50°C: no visible change in surface

23°C/10 min: no swelling or discoloration

X Brake fluid MBN 10494-7
PV31: 23°C/10 min: no swelling or discoloration after regeneration time of 16 hours
: Horst Feldmann, 2022-09-15

23°C/1 h: no swelling or discoloration

X Cold cleaning solvent MBN 10494-7
PV31:23°C/10 min: no swelling or discoloration after regeneration time of 16 hours

X Preservative 23  2°C/60 min: no swelling or discoloration, except PV31 MBN 10494-7

X Wheel cleaner PV50: RT/16 h: no swelling or discoloration, no gloss change MBN 10494-7

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A.9 Analytical tests

The requirements for Film-Tg and the degree of hardness are specified in Table 24.

Table 24: Thermal analysis

Affected PVs and their requirements
Evaluation

Test Test method

Preload

50

Glass transition temperature Film-Tg:

Clear acrylic powder ≥68°C (20 min /170°C)

X Film-Tg Clear PES powder ≥ 67°C (15 min/170°C) (powder oven) MBN 10494-1
EP/PES hybrid primer ≥ 60°C (20 min/170°C)
Reactive EP/PES hybrid primer ≥ 60°C (17 min/150°C)

X Degree of hardness Film-Tg Film-Tg:  1,5 °C MBN 10494-1

: Horst Feldmann, 2022-09-15

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Annex B (informative)
Changes in comparison with the last edition
In comparison with edition 2020-11, the following changes have been made:
- PV 21, 23 and 24. Cancelled and get new status: Not for new designs.
- Table 1: Columns “Cavity preservation” and “Stone-chip primer” deleted, for PV12 “with stone-
chip primer” adopted under “Type of coating”, for PV 20, changed from CED black to CED, for
PV31 “OEM body painting at the supplier” replaced by baked multicoat finish.
- Adopted in the area of use: The necessary additional coatings or cavity preservation should be
documented in the data record for product versions PV 10/20. Components of production
versions PV 10/20, which are documented with additional coatings or cavity preservation in the
data record, should be tested with and without additional measures, see Chapter 6.1.4
- Table 25 with PV ‘Not for new designs’ which had PV 21,23,24 was adopted
- Section 6.1.2.: Sentence for flat applied contrast colors on the outer body skin adopted.
- Section 6.1.4.: PV10/20 with and without additional coating, completely revised
- Section 6.1.5. adopted: Complete repair structures and scopes of test shall be agreed with the
specialist department. All the results should be documented exactly with values, illustrations,
graphs, etc., document number “Paint surfaces for wheels” A 008 004 30 99.
- Sec. 6.1.7. New: Substrate: Steel, galvanized steel and aluminum: Corrosion cycle test 2 shall
be used for new designs. CCT 1 can be used in exceptional cases in consultation with the
specialist department
- Section 6.5 Water jets adopted. The processes shall be selected so as to fulfill the requirements
of this DBL. In special cases, an additional coating on the weld seams is also possible. Process
optimization for weld spatters recorded in
- Section 6.7: The proof of a closed phosphate coat by analysis as well as the proof of monitoring
the pre-treatment and CED parameters should be attached with the ISIR. (see 9.2.1)
- Section 6.10. adopted: under the document number “Paint surfaces for wheels” A 008 004 30
99. in the future. Deleted: The other applicable document is the material approval list for alloy
wheel surfaces.
- Section 9.2.1 adopted: Proof of a closed phosphate coat by SEM image: An overview image at
a magnification of 500x as well as a close-up view at 2000x magnification, strict monitoring of
pre-treatment and CED process parameters, Filling Annex 1, Filling Annex 2, Filling Annex 3,
Adhesion test of overall paint system and individual coats, Tests on adhesion of CED on the
substrate as well as adhesion between CED and possible additional coatings applied, CCT1 /
CCT2 test for steel and CASS / filiform test for aluminum wheels should be conducted on the
entire wheels.
- Section 9.2.2: Filling Annex 1: Process data for pre-treatment, CED and painting, Filling Annex
2: Test report requirements
- Tables 6, 9, 10, 11: Specifications for PV10/20 with additional measures adopted
- Table 22: Values for resistance to test fuels specified
- Table 23: Brake fluid 10 minutes at 100 °C not applicable
- Table 24: Requirements adopted
- Deleted in all tables: Additional % corrosion surface in brackets to the corrosion evaluations (Ri,
KR, SR), “k.A.” information. Changed: Half grades of corrosion evaluations (Ri, KR, SR)
changed to full grades.
- For evaluation of edge corrosion: The limit values refer to one edge length. No integration
across the whole component.
- New tables 13, 14, 15 with CCT 2 requirements for PV 10,11,12, 20, 22, 30 and 31 for steel,
galvanized steel and aluminum.
- Annex A.1. deleted: Description of test method classes. Adopted: The WEB 2020+ process
shall be applicable. The WEB V 100, 300, 301, 500 documents should be followed.

Copyright Daimler AG

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 DBL 7381:2021-01, page 32

Annex C (informative)
Product versions with the status 'not for new designs'

The product versions, which were not set to the status ‘Not for new designs’ starting from this
edition, are listed in Table 25.

Table 25: Product versions with the status not for new designs, overview
Medium corrosive stress

Heavy corrosive stress

Cavity preservation
Moderate corrosive

Stone-chip primer

Decorative effect
Product version

Type of coating Application examples

Thermal load
stress

All component parts in the

CED black +
underbody with cavities, or
21 X X Stone impact resistant
components subject to particularly
coating
high corrosive stress
CED black + cavity All component parts in the
23 X X underbody with cavities, or
preservation
component parts that are subject to
CED black + cavity particularly high corrosion loads and
24 X X X preservation + stone impact also have a cavity preservation
resistant coating agent applied

Copyright Daimler AG

Uncontrolled copy when printed : Horst Feldmann, 2022-09-15