TOYOTA ENGINEERING STANDARD

NO.: TSH7702G

TITLE: Zinc-aluminum composite resin coating (hexavalent-chrome free)

CLASS: C2
Established/Revised: Rev. 6 ( Jan. 2020 )

This standard has been revised as a result of the following changes:

(1) a note concerning TSZ0001G has been changed for thorough management of product chemical
substances (Section 1);
(2) “adhering mass” which is the required quality for water-based composite coating has been
changed to “average film thickness” (Table 1, Section 4.2 and Section 5.2); and
(3) test method for “adhering mass” has been changed (Section 5.3.1).

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 TOYOTA ENGINEERING STANDARD TSH7702G C2
Zinc-aluminum composite resin coating (hexavalent-chrome free)

1. Scope
This standard covers zinc-aluminum composite resin coating (hereinafter referred to as "composite
coating") to be used on steel automobile parts for corrosion prevention and for protection of top
coating provided over this coating. The part made of materials provided by this standard shall
comply with TSZ0001G. The materials shall meet the quality requirements specified in Section 4 and
their use shall be approved in advance by the department ordering the parts.

2. Materials of Composite Coating and Coating Film Formation Method

The major materials of composite coating include flakes of metallic zinc and aluminum. The
composite coating is applied uniformly over the parts to be treated and baked. Over the composite
coating film, top coating is applied as necessary.

3. Classification of Composite Coating and Top coating

Composite coating is classified as shown in Table 1 and Table 2, according to the number of coating
and baking repetitions and the type of top coating.

Table 1
Composite coating Top coating
Anti-corrosive coating
Average film Adhering Application
Code Coating/ Coating/ Color example (composite
Type thickness mass example
baking baking coating + top coating)
( m) (g/m2)
Variety of small
TSH7702G-A 2C2B 5.6 min. None Silver Geomet720HP + none
parts
Trans- Geomet720HP +
TSH7702G-AS 2C2B 5.6 min. 1C1B 2 min. Hose clip
parent Plus10
Geomet720HP +
TSH7702G-AT 2C2B 5.6 min. 2C2B 10 min. Black Hose clip
TC101
Geomet720HP +
TSH7702G-AU 2C2B 5.6 min. 2C2B 10 min. Silver Hose clip
HC-Silver
Iron-made
Geomet720HP + JL
TSH7702G-AG 2C2B 6.1 min. 2C2B 8 min. Black machine
Black
screw, bolt, nut
TSH7702G-B Water- 2C2B 6.1 min. None Silver Geomet720HP Bolt, nut
based 2 to 10 Pale Geomet720HP +
TSH7702G-BH 2C2B 6.1 min. 1C1B Bolt, nut
2 min. blue HB100, Protrust A20
Pale Geomet720HP + High-strength
TSH7702G-BM 2C2B 6.1 min. 1C1B 2 to 10
green HB110 bolt, nut
TSH7702G-C 1C1B 4.1 min. None Silver Geomet720HP Hub bolt
Stainless
Geomet720HP + JL
TSH7702G-CG 1C1B 4.1 min. 2C2B 8 min. Black steel-made
Black
machine screw
Geomet720HP +
3 min.
Pale e-TORQUER High-strength
TSH7702G-E (1)
2C2B 6.1 min. 1C1B
purple Geomet720 + bolt, nut
2 min.
Protrust A09

Note (1): When applying the top coating TSH7702G-E, specify its use in design drawing together with
the use of TSH7903G-F.

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 TOYOTA ENGINEERING STANDARD TSH7702G

Table 2
Composite coating Top coating
Anti-corrosive coating
Adhering Adhering Application
Code Coating/ Coating/ Color example (composite
Type mass mass example
baking baking coating + top coating)
(g/m2) (g/m2)
Variety of small
TSH7702G-D 1C1B 24 min. 1C1B 8 min. Silver Magni565(B06JA+B18)
parts
Iron-made
Magni568 Black
TSH7702G-DG 2C2B(2) 24 min. 2C2B 8 min. Black machine screw,
Solvent- (B06JA + B37)
bolt, nut
based
Magni568
TSH7702G-DH 2C2B 24 min. 1C1B 8 min. Silver Bolt, nut
(B06JA + B18CC)
Pale Magni568 High-strength
TSH7702G-DM 2C2B 24 min. 1C1B(3) 8 min.
red (B06JA + B18LT) bolt, nut

Notes:
(2) Although the number of coating and baking repetitions for the composite coating TSH7702G-DG is
basically 2C2B, 1C1B is also acceptable when sufficient anti-corrosion performance is ensured.
(3) When the top coating TSH7702G-DM is selected, do not specify the use of TSH7903G-D in design
drawing.

Remark: “1C1B” denotes one time each of coating application and baking; “2C2B” two times each.

Major components of typical top coatings are shown in Table 3.

Table 3
Top coating Major component
Plus10 Sodium silica, surfactant, ion-exchanged water
TC101 Epoxy resin, phenolic resin, black pigment, magnesium silica, diluting solvent
HC-Silver Epoxy resin, phenolic resin, black pigment, magnesium silica, diluting solvent
JL Black Sodium silica, acrylic resin (including lubricating agent), carbon black, ion-exchanged water
HB100 Silicon resin, special urethane-modified acrylic resin, ion-exchanged water, diluting solvent
Silicon resin, special urethane-modified acrylic resin (including lubricating agent),
HB110
ion-exchanged water, diluting solvent
B18 Epoxy resin, metallic flakes
B37 Epoxy resin, metallic flakes, friction-coefficient modifier, black pigment
B18CC Epoxy resin, metallic flakes, high friction-coefficient modifier, pigment
B18LT Epoxy resin, metallic flakes, low friction-coefficient modifier, pigment

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 TOYOTA ENGINEERING STANDARD TSH7702G

4. Quality
4.1 Appearance
When tested in accordance with Section 5.1, appearance shall meet the following requirements:
Coated parts shall exhibit the specified color and their surfaces shall be free from blisters, roughness
and pinholes easily detectable with the naked eye. However, concerning the parts which have no
functional failure, requirements may be specified otherwise on the basis of agreement between the
parties concerned.

4.2 Average Film Thickness

When tested in accordance with Section 5.2, coating shall meet the average film thickness
requirements specified in Table 1. The average value shall be calculated from the values of
smoothing parts excluding edge, screw thread or root, etc. However, it is allowable to substitute the
average film thickness calculated from adhering mass and coating density.
(Average film thickness ( m) = Adhering mass (g/m2) / Coating density (g/cm3)
Besides, requirements may be specified otherwise on the basis of consultation between the parties
concerned if ensuring specified film thickness results in functional failure for parts. However, it is
necessary to describe the specified value in the drawing.

4.3 Adhering Mass

When tested in accordance with Section 5.3, coating shall meet the adhering mass requirements
specified in Table 1 and Table 2. However, requirements shall be specified otherwise on the basis of
consultation between the parties concerned if the application of coating and/or top coating in the
specified mass results in the functional failure of parts such as in the case of machine screws and
nuts.

4.4 Adhesion
When tested in accordance with Section 5.4, the substrate shall not be exposed and the coatings shall
not separate from each other. However, adhesion of a negligible amount of particles including
metallic flakes and black powders to the peeling tape shall not be considered as peeling.

4.5 Corrosion Resistance

When tested in accordance to Section 5.5, coating shall meet the corrosion resistance requirements
specified in Table 4. For the test, use parts that have undergone surface treatment at the
mass-production line. However, requirements shall be specified otherwise on the basis of
consultation between the parties concerned if difficulty lies in determining whether the following
requirements are met or not because of the form of sample part or other similar reasons.

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 TOYOTA ENGINEERING STANDARD TSH7702G

Table 4
Duration before iron rust development
Code Cyclic accelerated
Salt-water spray test
corrosion test
TSH7702G-A
TSH7702G-AS
TSH7702G-AT 1000 h min. 20 cycles min.
TSH7702G-AU
TSH7702G-D
TSH7702G-AG
TSH7702G-DG 1500 h min. 30 cycles min.
TSH7702G-B
TSH7702G-BH
TSH7702G-BM
TSH7702G-DH 1500 h min.(4) 30 cycles min.(4)
TSH7702G-DM
TSH7702G-E
TSH7702G-C
96 h min. ---
TSH7702G-CG

Note (4): Corrosion resistance evaluation for bolts and nuts shall be conducted after appropriate
tightening of the product is made. See TSB0517G for the evaluation method. The
tightening method shall basically follow that of the simulated process, but the details shall be
in accordance with the agreement made among the parties concerned.

4.6 Corrosion Resistance after Heat Aging

After tested in accordance with Section 5.5.3, TSH7702G-BH, TSH7702G-DH, TSH7702G-BM,
TSH7702G-DM and TSH7702G-E shall meet the requirements shown in Table 5. Evaluate the
corrosion resistance after heat aging on the basis of iron rust development. Determine whether to
include or not the discoloration of coating film into evaluation criteria through consultation between the
parties concerned.

Table 5
Code Appearance test Salt-water spray test
TSH7702G-BH
TSH7702G-BM No blisters, exposed substrate,
Iron rust shall not develop
TSH7702G-DH rough surface, cracks and other
up to 1200 h
TSH7702G-DM abnormalities allowed
TSH7702G-E

4.7 Total Friction Coefficient of Screws

When TSH7702G-DM is applied, the coated parts shall meet the quality requirements for
TSH7903G-D specified in TSH7903G, Section 3.1, Total Friction Coefficient for Screws and Section
3.2, Stability.

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 TOYOTA ENGINEERING STANDARD TSH7702G

5. Test Method
5.1 Appearance
Visually check from a distance of 50 cm from the sample under normal room illumination.

5.2 Film Thickness

(1) Fix the sample part so that the composite coating is perpendicular to synthetic resin, and sand
the sample part at the right angle to coating surface as taking care not to break the coating.
Sand the sample part as changing the sanding papers until the streaks made by former sanding
papers are obliterated.
(2) Zoom in the sample part with a microscope up to optimum magnification, and measure the
thickness of coating.
(3) Measure at least 5 points of smoothing surface excluding edge, screw thread or root, etc., and
calculate average value.
Remark: It is allowable to adopt another measurement method on the basis of consultation between
the parties concerned if the correlation has been secured. However, it is necessary to
describe the test condition when reporting test results.

5.3 Adhering Mass

5.3.1 Adhering Mass

(1) Prepare the number of sample parts so that the surface area of the sample parts is from 0.010 to
0.040 m2.
(2) Measure the surface area of coated sample parts. Measure the mass of the sample parts after
cleaning with alcohol and ether, dry, and use it as A.
(3) To remove their coating, immerse the sample parts in 20 % solution of sodium hydroxide adjusted
to 80 or higher for about 10 min.
(4) Clean the sample parts with diluted water and alcohol, dry, and use it as B.
(5) Obtain the adhering mass by the equation below.

A (g) - B (g)/total surface area of the sample parts (m2) = Adhering mass (g/m2)

5.3.2 Top Coating

(1) Prepare the number of sample parts so that the surface area of the sample parts on which the
base coating is applied is 0.010 to 0.040 m2 and measure the mass in precision of 0.001 g and
use it as A.
(2) Apply top coating.
(3) Check that the sample parts is cooled to approx. room temperature (20 5 ) and measure the
mass in precision of 0.001 g and use it as B.
(4) Obtain the adhering mass by the equation below.

B (g) - A (g)/total surface area of the sample parts (m2) = Adhering mass (g/m2)

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 TOYOTA ENGINEERING STANDARD TSH7702G

5.4 Adhesion
Attach adhesive tape (e.g., Cellophane Tape of Nichiban Co., Ltd.) to the coated part or coated part
with top coating and rub it strongly with fingertips to eliminate bubbles. Thereafter, holding either end
of the tape, rapidly pull the tape in the 180 opposite direction to peel it. In adhering the tape,
make sure that the adhering width is 12 mm and the length 20 mm (5) (Fig. 1).
Note (5): If the size of sample part is smaller than these dimensions, the test may be conducted by
adhering the tape on the maximum possible area. When conducting the test under such
condition, however, take into account the theoretical difference between conducting the test
on the specified area and on the smaller area.

Fig. 1 (Unit: mm)

5.5 Corrosion Resistance

5.5.1 Salt Water Spray Test
Carry out the salt-water spray test specified in Table 4 in accordance with JIS Z 2371 or ASTM B117,
checking for iron rust development.

5.5.2 Cyclic Accelerated Corrosion Test

Carry out the cyclic accelerated corrosion test specified in Table 4 in accordance with TSH1555G to
check for iron rust development. Recommended cycle pattern is method C, but method A is also
acceptable. If interruption is necessary during the test, discuss the problems among the parties
concerned. When setting test pieces in place, be sure to orient the surface to be valuated upward.
During spraying, however, tilt the test pieces 20 to 60 so that salt water does not stay on the
surfaces.
During drying, take due care of air inflow and equipment arrangement so as to ensure full drying.

5.5.3 Corrosion Resistance Test after Heat Aging

(1) Allow the sample to stand for 12 h in a thermostatic chamber adjusted to 250 3 .
(2) Retrieve the sample from the chamber and allow to cool to room temperature (20 5 ).
(3) Conduct appearance test in accordance with Section 5.1.
(4) Immediately after completing (3), conduct salt-water spray test to check for iron rust development.

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 TOYOTA ENGINEERING STANDARD TSH7702G

5.6 Friction Coefficient Test

When TSH7702G-DM is applied, conduct this test in accordance with the test method specified for
TSH7903G-D in TSH7903G, Section 4.2, Friction Coefficient.

6. For Reference
Sintered metal parts shall meet the requirements for fastening reliability specified for the parts.

Applicable Standards
TSB0517G Corrosion resistance test method and film thickness test method for
threaded fasteners
TSH1555G Test method for accelerated corrosion under complex environment
TSH7903G Stabilizing treatments of frictional resistance for screw thread parts and
joint parts
TSZ0001G Control method for substances of environmental concern
JIS Z 2371 Methods of salt spray testing
ASTM B117 Practice for Operating Salt Spray (Fog) Apparatus

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