JED-257 Stand 2009-03 engl.

Specification 2009-03
Class: Surface protection Class No.:50
 Zinc and zinc alloy coatings with passivation on

ferrous materials JED
257
Previous Edition Part name (for databases)
2006-03 Passivation, Zn-all..-steel 852 002 570 4
JED-257-0 replacement for JED-101 P1
1 Scope
The specification refers to the corrosion protection on parts of ferrous materials that are moderately
stressed with regards to corrosion, i.e. parts which are exposed to the indoor atmosphere (e.g.
condensed water within an object). All coatings must be free from Chromium VI.
There are the following types:
JED-257-0 Coatings of zinc (Zn) or zinc-iron (Zn/Fe) coatings with subsequent black or colour-less
thick-layer passivation are allowed. An additional sealing is allowed if the function of
the parts is not negatively influenced.
JED-257-1 Same requirements as for JED-257-0 apply, this number not to be used for new
designs.
If JED-257 or JED-257-1 is indicated on the drawing, JED-257-0 shall be applied.
Thermal range of application of the surface protected parts:
-60 °C to +80 °C
Normative reference: ISO 2081 Metallic coatings – Electroplated coatings of zinc

on iron or steel
ISO 4042 Threaded components – Electroplated coatings
2 Requirements
2.1 Requirements on the substrate
The parts to be protected shall be free from surface, treatment, or other defects adversely affecting
the corrosion protection or the adhesion of the coating to the substrate. These are for instance slag
inclusions, laps, score marks with a depth of more than 0,2 mm, pore clusters, sink marks, weld
marks, whirls and bubbles.
Parts with cracks or with material separations transversal to the force shall not be used.
Continuation page 2 to 4
Compiler Approved Product Group: 4961
Doc. Code Language Rev.
E. Gawin H. Voß - en - K
008
JED.dot – Template version 03
JED-257 : 2009-03 Page 2
2.2 Requirements on the coating

The significant surfaces of the parts shall have a dense and homogeneous coating. Significant
surfaces are areas of the surface for which the specified coating is essential for serviceability and
appearance, and that can be touched by a ball 20 mm in diameter.
Zn/Fe coatings are alloyed coatings on the basis of zinc containing 0,4 to 1,0 % iron.
Organic and inorganic coatings consist of organic and inorganic binders which usually contain
zinc or zinc and aluminium particles. These coatings are baked at temperatures specific to type. The
baking temperature has to be such that the strength of the parts is not reduced.
The coatings shall not have any defects affecting corrosion protection, as for instance pores, cracks,
roughness, stains or damages. The coatings shall firmly adhere to the substrate and shall not spall
in case of slight deformation.
The process conditions shall be chosen so as to not affect the usability of the finished part. Parts
with an electroplated coating and a strength of more than 1000 N/mm² (Corresponding hardness: 30
HRC, 295 HV, 280 HB) shall be heat treated prior to chromating to avoid hydrogen embrittlement.
The parts surface protection included shall be within the tolerances provided on the standard
sheets or drawings, with special consideration given to the thread dimensions.
The coating thicknesses specified on the following pages apply to the significant surfaces defined
above.
Measuring areas for the coating thickness on screws and nuts
The significant surface on screws is the approximate center of the head surface or the approximate
center of the end provided that the coating thickness in these areas approximates that in the first
turn of the thread for screws with a length exceeding 5 d (figures 1 to 5).
If necessary, special agreements shall be reached concerning the measuring areas for screws the
length of which exceeds 5 d, and for special parts.
In case of screws with internal drive the coating thickness is measured in the center of the remaining
head surface or in the approximate center of the end (figures 2 to 5).
The coating thickness on nuts is measured in the center of a wrench surface (figure 6).
Examples of measuring areas:
X X X X X X
Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6
Note
There are no requirements for the thickness of the protective coating for areas which cannot be
measured by means of a ball 20 mm in diameter because a controllable coating cannot be achieved
under normal conditions.
 Specification
JED-257 : 2009-03 Page 3
2.3 Coefficients of friction of threaded parts

On threaded parts to be used with preformed threads in the counterpart, plating shall be carried out
in such a way that total coefficients of friction from 0,12 to 0,18, if measured according to ISO
16047, are met. This does not apply to thread-forming screws (see JED-835 and 836). In cases
where a different coefficient range is defined in the drawing, that has to be used. Uneven, rough or
too thick coatings shall be avoided in the threaded area.
Coatings with a thickness of more than 8 µm usually peel when the screw is tightened. This leads to
uncontrollable extreme coefficients of friction and to insufficient prestress within the screwed joint.
The coefficients of friction of screws and nuts shall be measured using screw testing equipment that
permits uniform slow tightening and release of the screwed connection.
2.4 Requirements for the protection against corrosion
2.4.1 Test of passivation coating inclusive sealing, if applicable
Corrosion protection requirements Test method
≥ 72 h
no zinc corrosion ISO 9227

max. of 3 % zinc corrosion permitted if treated NSS test
in drums
2.4.2 Test of complete coating (inclusive testing time according to 2.4.1)

Unthreaded rack Threaded parts and Test method
Requirements parts drum parts
≥ 3 cycles (2) ≥ 2 cycles ISO 3231 / 2l SO2
≥ 120 h (72) ≥ 72 h ISO 9227 NSS test
no corrosion of the basis metal
(): exceptional requirements
Parts being subject to the exceptional requirements:
– shank and threaded area on screws with a thread pitch ≤ 1

– shank and threaded area on screws with a length exceeding 10 x d
– areas that were formed after surface treatment
2.5 Thickness of the coating

In general, the required resistance is achieved with the nominal thicknesses specified below:
Parts, not subsequently sealed Parts, subsequently sealed

(only zinc and zinc alloys)
Unthreaded parts ≥ 7 µm ≥ 4 µm
Threaded parts ≥ 4 µm ≥ 3 µm
2.6 Test for hexavalent chromium

Hexavalent Chromium must not be present in the coating.
The test to prove that no hexavalent chromium is present has to be done according to EN 15205
“Determination of hexavalent chromium in corrosion protection layers”. If the concentration of
hexavalent chromium is below 0,1 µg/cm² according to this test, the parts are regarded as being free
from hexavalent chromium.
JED-257 : 2009-03 Page 4
2.7 Resistance to media

Zinc and zinc alloy coatings according to this specification are not resistant to acids and strong
alkaline materials, as for instance cleansing agents.
2.8 Test of brittle fracture tendency

The parts are subjected to a mechanical load approximating or exactly corresponding to the type of
load intended. In this condition, the part is exposed to -40 °C for 24 hours. Fracture shall not occur.
2.9 Test of adhesion

The parts are stored 30 minutes at +220 °C ± 10 °C in air and immediately afterwards immersed in
water with a temperature of +15 °C to +25 °C. No sp alling or blistering of the coating may occur.
2.10 Colour of coating

A slight yellow, blue or green coloration is accepted for silver colour. There are no requirements for
the gloss.
All mentioned colours can have yellow, blue or green iridescence. Identical parts from one process
must have a homogeneous appearance.
3 Guarantee
3.1 General
The manufacturer is obliged to prove by regular random test that the requirements specified in
chapter 2 are observed, and to keep the inspection documents accessible to the customer.
3.2 Initial sample
Together with each initial delivery several initial samples and the initial sample inspection report
shall be submitted for the inspection of dimensions and material.
3.3 Guarantee
The current supplies must conform to the released sample, to the requirements defined in this
specification and to the drawings.
The Engineering Department and the Quality Assurance must be informed about any modifications.
This applies also to planned modifications of the pretreatment and of the types of electrodes. In
these cases, a new sampling and written release is required.

JED-257 Stand 2009-03 engl.

Uploaded by

Copyright:

Available Formats

JED-257 Stand 2009-03 engl.

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

JED-257 Stand 2009-03 engl.

Uploaded by

Copyright:

Available Formats

Specification 2009-03

Class: Surface protection Class No.:50

 Zinc and zinc alloy coatings with passivation on

JED-257-0 replacement for JED-101 P1

There are the following types:

If JED-257 or JED-257-1 is indicated on the drawing, JED-257-0 shall be applied.

Thermal range of application of the surface protected parts:

Normative reference: ISO 2081 Metallic coatings – Electroplated coatings of zinc

ISO 4042 Threaded components – Electroplated coatings

2.2 Requirements on the coating

Measuring areas for the coating thickness on screws and nuts

Examples of measuring areas:

Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6

2.3 Coefficients of friction of threaded parts

no zinc corrosion ISO 9227

2.4.2 Test of complete coating (inclusive testing time according to 2.4.1)

Parts being subject to the exceptional requirements:

– shank and threaded area on screws with a thread pitch ≤ 1

2.5 Thickness of the coating

Parts, not subsequently sealed Parts, subsequently sealed

2.6 Test for hexavalent chromium

2.7 Resistance to media

2.8 Test of brittle fracture tendency

2.9 Test of adhesion

2.10 Colour of coating

You might also like