Jaguar Cars & Land Rover - Engineering Standard Standard: STJLR.50.

5041
Issue: 1
Date: 12 November 2009
Title: Coatings, Steel Sheet Page: 1 of 9

A INDEX
A Index
B Scope
C Object
D Review
E Related Documents
F Standard Requirements for Production Materials
G Material Approval
H Weldability, Formability, Paintability
I Rinses
J Coating: Zinc Based Materials
K Coating: Other Metallic
L Coating: Organic-Zinc Rich Primer
M Coating: Tri Cationic Phosphate
N Coil Coated Final Product Identification
O Coating Designation
P Initial Supplier Approval
Q Coating Thickness
R Method of Specifying
Z Change History

B SCOPE

This specification applies to coil coatings on steel sheet. These coatings comprise 4 categories:
• Zinc Based Metallic (i.e. Zinc, Zinc/Iron, Zinc/Nickel and other Zinc/Alloy)
• Other Metallic (i.e. Nickel, Tin)
• Organic (i.e. Zinc Rich Primer)
• Phosphate (Upon request from the Stamping Plant to the responsible Materials
Engineering Activity, there is the option of using prephosphated material to aid
formability).

Such coatings shall be specified in conjunction with the appropriate base steel sheet

C OBJECT

1 This specification defines the requirements for coil coatings on sheet steel material used for
automobile body and chassis parts requiring corrosion resistance. The category of Other Metallic
Coatings was incorporated originally for fuel systems parts requiring corrosion resistance.

2 The presence of a coating will influence the properties of the final coated product, compared to the
uncoated base steel sheet.
This document is approved for use by both Jaguar Cars and Land Rover.
Prepared by: Robert Crow Authorised by: Andrew Haggie
cdsid: rcrow4 cdsid: ahaggie

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Issue: 1
Date: 12 November 2009
Title: Coatings, Steel Sheet Page: 2 of 9

D REVIEW

This document must be reviewed at least every three years from the date of the last review or
update.

E RELATED DOCUMENTS

STJLR.51.5226 ISO 4587

ASTM A90 ISO 2808

SAE J1523 ASTM A630

ASTM B530 ASTM B571

ASTM A924M ASTM A591

SAE J1523 ISO 4587

F STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS

Material suppliers and part producers must conform to the company's Standard Requirements for
Production Materials (STJLR.51.5226).

G MATERIAL APPROVAL

Jaguar Land Rover (JLR) Materials Engineering must be contacted by the supplier to determine
the required approval process.

H WELDABILITY, FORMABILITY AND PAINTABILITY

1 The weldability, formability and paintability requirements are specified in the appropriate Base
Steel Sheet material specification.

2 If specified, paintability depends upon the critical factors of chemical cleanliness and crystalline
integrity of the phosphate coating.

I RINSES

Rinses used during the coating process must be hexavalent chromium free.

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Date: 12 November 2009
Title: Coatings, Steel Sheet Page: 3 of 9

J COATING: ZINC BASED METALLIC

1 Coating Mass

Table 1. Coating thickness designations tested to ASTM A90

2
Coating Mass Coating Mass Coating Mass Per Side g/m
a
Designation Single Spot min/max

Hot Dippedb Electrolyticb

00 NA 0
20 20/50 20/30
30 30/60 30/45
40 40/70 40/55
45 45/75 45/60
50 50/80 50/70
55 55/85 55/75
60 60/90 60/80
70 70/100 70/90
98 100/130 100/130
In some instances, coatings that are produced to tighter coating mass ranges than shown above
may be available. These shall be designated as 'Restricted Coating' (Symbol 'C') and shall be
detailed on the appropriate Engineering Drawing as follows:

Table 2. Restricted coating thickness designations tested to ASTM A90

Coating Mass Coating Mass Per Side g/m2
Coating Mass
Single Spot min/maxa
Designation
Hot Dippedb Electrolyticb

50 50/70 50/65
55 55/75 55/70
60 60/80 60/75
70 70/90 -
98 100/125 -
a
ASTM A 90 shall be suitably modified to allow coating mass determinations on individual sides.
b
Where these tolerances cannot be met, exceptions must be approved by the responsible activity
and specified on the Engineering Drawing. Differentially coated products and higher strength
coated products generally have greater coating mass ranges than those stated.

2 Coating Composition (Electrolytic)

Unless an alloy coating is chosen, the primary deposit shall be Zinc. Electrolytic Zinc/Nickel shall
contain 10.5% - 13.5% Nickel. Electrolytic Zinc/Iron shall contain 12% - 18% Iron. The frequency of
testing and the analytical method shall form part of the control plan.

3 Coating Composition (Hot Dipped)

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Unless an alloy coating is chosen, the primary deposit shall be Zinc. The frequency of testing and
the analytical method shall form part of the control plan.

4 Supplementary Coatings

Unless otherwise stated, no supplementary coatings (other than a JLR approved mill oil (rust
preventative oil) or prelube) are permitted.

5 Coating Adhesion

Coated steel shall conform to the coating bend test requirements of ASTM A 924M for hot dipped
and ASTM A 591 for electrolytic coated products. The frequency of testing shall form part of the
control plan.

6 Coating Bend Test

Coated Steel shall conform to the coating bend test requirements of ASTM A 924M for hot dipped
and ASTM A591 for electrolytic coated products. The frequency of testing shall form part of the
control plan.

7 Adhesive Shear Test - For All Coating Types

7.1 When tested according to SAE J1523 or ISO 4587 (0.8 mm thickness specimen; additional
bonding thickness of 0.25 mm.) using a high strength structural epoxy adhesive (1k or 2k),
the coating (i.e. zinc or zinc/alloy) shall remain adherent to the steel substrate up to a
minimum shear strength requirement of 8 MPa.

7.2 The frequency of testing shall be agreed with JLR Materials Engineering and be incorporated
into the control plan

7.3 The supplier shall have the option to seek or decline approval to this sub section. If approval
to is declined, no material shall be supplied for adhesive bonding applications, as defined by
the relevant Engineering Drawings.

7.4 For relevant Engineering Drawings, component engineers shall not specify a minimum shear
strength requirement lower than 8 MPa.

8 Coating Wraparound and Edge Condition

8.1 For one side coated products, traces of coating are allowed on the uncoated side of the sheet
from the edges to 15 mm from coil edges. No coating is allowed on the remainder of the
uncoated side.

8.2 The amount of coating on the strip edge shall be no greater than the maximum stipulated in
sub section 1 and provide sufficient adhesion to prevent flaking during the manufacturing
process.

9 Coating Appearance

For hot dipped products, the coating shall be minimum spangle and when viewed at 1 times
magnification (1X), the individual zinc crystals shall be no longer than 5 mm across the maximum
dimension. The need for a final temper mill reduction to control surface appearance or formability
is to be negotiated between the manufacturing activity and the coater.

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K COATING: OTHER METALLIC

1 Tin

Table 3: Coating Mass

2
Coating Mass Coating Mass Coating Mass Per Side g/m
C
Designation Single Spot min/max
D D
Hot Dipped Electrolytic
20 20/50 20/35
35 35/65 35/50
50 50/80 50/65
65 65/95 65/80

C
ASTM A630 shall be suitably modified to allow coating mass determinations on individual sides in
SI units.
D
Where these tolerances cannot be met, exceptions must be approved by the responsible activity
and specified on the Engineering Drawing. Differentially coated products and higher strength
coated products generally have greater coating mass ranges than those stated.

2 Nickel

Table 4: Coating Mass (ASTM B530 with a multiplication factor of 8.90)

Coating Mass Designation Coating Mass Coating Mass Per Side g/m2
Electrolytic
25 20/50
35 35/65
45 50/80

3 Coating Bend Test

When tested to ASTM B 571 no peeling or flaking of the coating is permitted.

4 Edge Condition

Single side coatings are not anticipated. The amount of coating on the strip edge shall be no
greater than the maximum stipulated Table 3 and Table 4 and of sufficient adhesion to prevent
flaking during the manufacturing process.

5 Coating Appearance

The coating shall not have defects of a nature or degree for the grade and quality ordered that will
be detrimental to the fabrication of the finished part. The need for a final temper mill reduction to
control surface appearance or formability is to be negotiated between the manufacturing activity
and the coater.

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Date: 12 November 2009
Title: Coatings, Steel Sheet Page: 6 of 9

L COATING: ORGANIC - ZINC RICH PRIMER

1 Base Material

Between the appropriate Base Steel Sheet and the Zinc Rich Primer layer shall be a Zinc Based
Metallic layer, usually Electrolytic Zinc/Nickel.

2 Pretreatment Layer

A conductive Inorganic/Zinc Dust complex shall be used to give a satisfactory bond between the
zinc based metallic (usually Electrolytic Zinc/Nickel) layer and the Conductive Organic layer.

3 Coating Weight (as Cr)

0.38 g/m2 + 0.10 g/m2 / - 0.05 g/m2

4 Conductive Organic Layer

This shall comprise an Epoxide Binder (Epoxy Resin) modified with Zinc Particles. The control plan
referred to in Section J3 shall address conductive organic layer composition and consistency of
electrical conductivity.

5 Coating Thickness:

9 µm + 2.5 µm / - 1.5 µm (ISO 2808)

6 Coating Appearance

The coating shall not have defects of a nature or degree for the grade and quality ordered that will
be detrimental to the fabrication of the finished part.

7 Coating Bend Test

When tested in accordance to ASTM B 571 no peeling, flaking or interlayer separation of the
coating is permitted.

M COATING: TRI-CATIONIC PHOSPHATE

1 Base Material

Between the appropriate Base Steel Sheet and the Phosphate layer shall be a Zinc based Metallic
layer, usually Electrolytic Zinc or Hot Dipped Zinc/Iron.

2 Phosphate Layer

When approved by the responsible Materials Engineering Activity, a suitable Tri-Cationic

(Zinc/Nickel/Manganese) Automotive Quality Phosphate shall be used. Such phosphating shall not
be detrimental to any other part of this specification

2.1 Coating Weight 1.5 g/m2 ± 0.3 g/m2

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Date: 12 November 2009
Title: Coatings, Steel Sheet Page: 7 of 9

N COIL COATED FINAL PRODUCT IDENTIFICATION

1 The coated coil final product shall be identified as follows:

1.1 This information shall be marked on the more heavily coated side of a one-sided or
differentially coated product and on the unexposed side of equally coated products for
exposed surfaces and shall be repeated at 1 m intervals.
• Steel Company Name and Location
• Coater's Name (if different from above)
• Date Coated.

O COATING DESIGNATION

1 In addition to the Base Steel Sheet specification, Engineering Drawings shall show a coating
designation which identifies the coating mass of each side, the coating composition of each side
and the method of coating (Electrolytic and/or Hot Dipped) as follows:

1.1 1st and 2nd characters: The coating mass designation of one side (the unexposed side or
heavier coated side).

1.2 3rd character: The coating composition of the unexposed side or heavier coated side where
G = Zinc, A = Zinc/Iron, N = Zinc/Nickel, T = Tin, K = Nickel and X = other than G, A, N, T or
K.

1.3 4th and 5th characters: The coating mass designation of the opposite side (the exposed side
or lighter coated side).

1.4 6th character: The coating composition of the opposite side where G = Zinc, A = Zinc/Iron, N
= Zinc/Nickel, T = Tin, K = Nickel and X = Other than G, A, N, T or K.

1.5 7th and 8th characters: When "EL" is specified, the coil shall be continuously coated by
Electrolytic deposition. When "HD" is specified, the coil shall be continuously coated by Hot
Dipping. When "EL/HD" appears in the 7th and 8th character positions, the coating may be
continuously coated by Electrolytic deposition or Hot Dipping as desired by the respective
JLR Purchasing activity.

1.6 9th character: C = Restricted Coating Mass

1.7 10th character: P = Phosphate

2 For additional clarification where it is not self evident, the exposed side or lighter coated side shall
be clearly identified on the Engineering Drawing. Trade names shall not be used on the
Engineering Drawing.

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P INITIAL SUPPLIER APPROVAL

1 For initial approval, the supplier shall supply the following information for each coating
designation/coating line combination.

1.1 A plan detailing how each of the requirements contained in this standard will be controlled on
a continuing production basis.

1.2 Test results from a typical production sample.

1.3 Test results from typical production samples for paintability requirements.

1.4 Typical coating chemical analysis. For products coated by Hot Dipping, coating composition
shall be determined by analysis of samples taken from the molten bath. For Electrodeposited
coatings, composition shall be as deposited.

1.5 Coating mass histogram including mean and standard deviation values. Data shall consist of
a minimum of 500 mass measurements randomly taken from each side of a minimum of 20
coils while the process is operating in statistical control.

Q COATING THICKNESS

1 To estimate the thickness of the coating from the coating mass, the following factors (per side)
shall be used:

1.1 Zinc (Hot Dipped or Electrolytic) 7.14 g/m2 = 1 µm

2
1.2 Zinc/Nickel (Electrolytic) 7.35 g/m = 1 µm

1.3 Zinc/Iron (Electrolytic) 7.25 g/m2 = 1 µm

2
1.4 Zinc/Iron (Hot Dipped) 7.21 g/m = 1 µm

1.5 Tin 7.30 g/m2 = 1 µm

1.6 Nickel 8.90 g/m2 = 1 µm

R METHOD OF SPECIFYING

The specification on the Engineering Drawing shall include, if applicable, the coating defined by
STJLR.50.5041.

e.g MS4 coated with hot dip galvanized zinc to 50 g/m2 for a skin panel application shall be
specified thus:

Steel to STJLR.50.5172 MS4, coated to STJLR.50.5041: Z100, class 1

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Date: 12 November 2009
Title: Coatings, Steel Sheet Page: 9 of 9

Z CHANGE HISTORY
Issue Date Description of Change

1 11 Nov 2009 First Issue – replaces WSS-M1P94-A

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