TOYOTA ENGINEERING STANDARD

NO.: TSH6524G

TITLE: Electroplated zinc coating (hexavalent chrome free)

CLASS: C2
Established/Revised: Rev. 3 ( Mar. 2009 )

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

(1) terms and explanations have been modified in part.
(2) expressions have been reviewed to improve clarity.

Prepared and Written by: Engineering Data Planning Dept.

Paint & Finishing Design Dept. Engineering Data Control and
Vehicle Material Engineering Div. Management Div.
ⒸTOYOTA MOTOR CORPORATION
 CONFIDENTIAL DO NOT REPRODUCE
CLASS
TOYOTA ENGINEERING STANDARD TSH6524G C2
Electroplated zinc coating (hexavalent chrome free)

1. Scope
This standard covers requirements for electroplated zinc coating(1) (hereinafter referred to as
"coatings") applied to iron parts for automobiles for the purpose of corrosion prevention.
The parts made of materials provided by this standard shall conform to prohibitions and restrictions for
substances of environmental concern in TSZ0001G. Exempt uses specified by EU ELV Directive
shall conform to the latest version of the Directive.
Note (1): The coatings also include chromate treatment after zinc coating, which does not contain
hexavalent chrome (hereinafter referred to as "chromate").

2. Treatment Method
After pretreatment (e.g. degreasing, acid pickling, etc.) suitable for the type of the substance and the
surface condition, the substance is electroplated in the bath containing zinc metal salt to create
coating. Chromate treatment, for inhibition of white corrosion products, using chromate without
containing hexavalent chrome, and dehydrogenation, shall also be applied if specified in drawings or
other official documents.

3. Classification
The coatings shall be classified as listed in Table 1 according to the coating thickness (Grade) and the
method of chromate.

Table 1 Classifications
Code
Grade Clear chromating after Black chromating after Use conditions
As plated
plating plating
U TSH6524G-U TSH6524G-UC TSH6524G-UE
Extremely severe
S TSH6524G-S TSH6524G-SC TSH6524G-SE
A TSH6524G-A TSH6524G-AC TSH6524G-AE Severe
B TSH6524G-B TSH6524G-BC TSH6524G-BE Normal

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 3
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Mar. 2009

1 / 4
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSH6524G

4. Quality
4.1 Appearance
The surface of the coating shall be tested with the test method specified in Section 5.1, and be
smooth and free from burning, blisters, and unplated areas that can be detrimental in actual use.
Table 2 shows general color tint of coatings for reference. Specific gloss or tint shall be specified, if
necessary, through an agreement between the parties concerned, including the departments that
have carried out design and have established the standards (participation is not absolutely
necessary).

Table 2 Color Tint of Coatings (Reference)

Type Tint
As plated Zinc metallic color
Clear chromating after plating Yellowish silver gray
Black chromating after plating Black

4.2 Coating Thickness

The coating thickness shall be tested with the test method specified in Section 5.2 and satisfy the
specifications of Table 3. However, this requirement shall not apply to recesses and joints that are
threaded portion or not possible to contact by 12 mm diameter spherical surface and portions that
have been agreed upon between the related parties, including the departments that have carried out
design and have established the standards (participation is not absolutely necessary). Further, the
coating thickness does not include the thickness of post-treatment film.

Table 3 Coating Thickness

Grade Coating thickness ( m)
U 25 min.
S 13 min.
A 8 min.
B 5 min.

4.3 Corrosion Resistance

The corrosion resistance shall be tested with the test method specified in Section 5.3. The corrosion
resistance of the coating as plated shall satisfy the specifications of Table 4. The corrosion
resistance of the coating after chromate treatment (and coating) shall satisfy the specifications of
Table 5.
However, Tables 4 and 5 shall not apply to recesses and joints that are hard for a threaded portion or
12 mm diameter spherical surface to contact and portions that have been agreed upon between the
related parties, including the departments that have carried out design and have established the
standards (participation is not absolutely necessary).

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 3
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Mar. 2009

2 / 4
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSH6524G

Table 4 Corrosion Resistance (as Plated)

Corrosion resistance
Type
Time to formation of iron rust (brown rust) (h)(2)
TSH6524G-U 240 min.
TSH6524G-S 144 min.
TSH6524G-A 96 min.
TSH6524G-B 48 min.

Note (2): Within the specified time, iron rust (brown rust) shall not occur at 3 or more points per
100 cm2 of the area applied with electroplated zinc coating. The zinc-coated area
shall be free from any rust with a diameter of 2 mm or more.

Table 5 Corrosion Resistance (with Chromate Treatment)

Corrosion resistance
Type Time to formation of white Time to formation of iron rust
corrosion products (h)(3) (brown rust) (h)(2)
TSH6524G-UC
312 min.
TSH6524G-UE
TSH6524G-SC
216 min.
TSH6524G-SE
72 min.
TSH6524G-AC
168 min.
TSH6524G-AE
TSH6524G-BC
120 min.
TSH6524G-BE

Note (3): Within the specified time, white powdery corrosion products that are easy to visually
recognize shall not appear in the area applied with electroplated zinc coating.
Decolorization of chromate film and black dots formed on electroplated area shall not
be regarded as the category of corrosion product.

5. Test Methods
5.1 Appearance Test
Appearance shall be checked visually at a distance of 500 mm from the testing surface under room
light.

5.2 Coating Thickness Test

Thickness shall be tested by a microscopical method, or other suitable method like a coulometric
method or fluorescent X-ray method or magnetic induction method may also be used for this test.

5.3 Corrosion Resistance Test

Salt spray test shall be performed in accordance with JIS Z 2371, ASTM B117 or TSH1552G. For
the test, use a specimen that has been let stand for at least 24 h after electroplating.

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 3
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Mar. 2009

3 / 4
 CONFIDENTIAL DO NOT REPRODUCE

TOYOTA ENGINEERING STANDARD TSH6524G

6. Reference
(1) Chromate treatment shall, as a rule, apply after zinc coating.
(2) If the chromated surface is subjected to dehydrogenation, the chromate layer may crack then
reduce the corrosion resistance. Therefore, chromate treatment shall, as a rule, apply after
dehydrogenation.
(3) Dehydrogenation shall be specified according to TSH5105G, if necessary, accompanied with the
standard of zinc coating specified herein.
(4) Ensure that a tightened part systems satisfies the required quality related to fastening reliability.
A special attention should be paid when additional coating is applied after chromate treatment
since it affects friction coefficient.

Applicable Standards
TSH1552G Test method of salt spray
TSH5105G Dehydrogenation treatment
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

NOTES: The recipient of this standard shall undertake the following confidentiality obligations upon the receipt of this standard.
- The recipient shall discard by shredding or fire, or return to Toyota Motor Corporation if appropriate, the documents contained in this standard when they Rev. 3
are no longer necessary due to the termination of the work concerned or the revision of current version of this standard,
- This standard and the technical information related thereto are owned by and under sole control of Toyota Motor Corporation. They shall not be disclosed
in whole nor in part to ant third party without prior written consent of Toyota Motor Corporation..
Mar. 2009

4 / 4