Is 1573 - Zinc Plating On Iron & Steel PDF
Is 1573 - Zinc Plating On Iron & Steel PDF
Is 1573 - Zinc Plating On Iron & Steel PDF
( Reaffirmed 2006 )
Indian Standard
SPECIFICATION FOR
ELECTROPLATED COATINGS OF
ZINC ON IRON AND STEEL
( Second Revision /
Second Reprint-SEPTEMBER 1994
UDC
669.587:669.1:621.357
@ Copyright 1974
BUREAU
-OF INDIAN
STANDARDS
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002
Grs
May 1974
IS : 1573-1986
Indian Standard
SPECIFICATION FOR
ELECTROPLATED COATINGS OF
ZINC ON IRON AND STEEL
(
Metallic
Second Revision )
and Non-metallic
Finishes
Sectional
Committee,
SMDC
23
Representing
Chairman
DR R. C. SHARMA
Eveready Flashlight
Company,
Lucknow
Members
Ministry of Defence ( R & D )
SHRI G. S. BHATTACHARJEE
SHR.II. N. BH~\TIA( Alternate )
Premier Automobiles Ltd, Bombay
Stuu A. T. BORATE
SHKI A. G.PKABKU ( Alternate )
Premier Metal Finishers ( P ) Ltd, Calcutta
SIIHI M. S. CHAKRAVORTY
SHRI R. K. CHATTEKJEE
( Alfernal e )
CHEMIST& METALLUWIST-I, RDSO, Ministry of Railways
LUCKNOW
CHEMIST& METALLURGIST.ICF.
MADKAS ( Alternate )
SHRI JAYENDRAK. DALAL
DK R. P. DAMBAL
SHKI E. D. DHAKMARAJ
SHI~IKAUSHIK G~KALDAS
DR S. GURUViAH
SHRI S. KONGOVI
SHRI P. R. RAO ( Alterrzate )
DR S. KRISHNAMURTHY
Copyright 1987
OF INDIAN
STANDARDS
This publication is protected under the Indian Copyright Act ( XIV of 1957 ) and
reproduction in whole or in part by any means except with written permission of the
publisher shall be deemed to be an infringement of copyright under the said Act.
IS : 1573- 1986
( Continuedfrom page i )
Representing
Members
SHRI V. S. KULKARN~
SHRI Susan GOINKA ( Alternate )
HMT Ltd, Bangalore
SHRI M. ERABHAKAR MAHANDALB
SHR~K. R. SATHYANARAYANA ( Afternate )
Ministry of Defence ( DGI )
SHRI R. C. MATHUR
SHRI M. R. GHOSH( Alternate )
T.I. Cycles of India, Ambattur, Madras
SHRI K. L. MUTHU
National
Metallurgical
Laboratory
( CSIR ),
DR S. K. NARANG
Jamshedpur
Development Commissioner ( Small Industries
SHRI R. S. RAGHAVAN
Services Institute ), New Delhi
Bharat Electronics Ltd, Bangalore
SHRI R. S~MASEKHARA
SHRI K. NAGE~H( Alternate)
Peico Electronics and Electricals Ltd, Pune
DR J. VAID
Director General, BIS ( Ex-o_#icio Member )
Smu K. RAOHAVENDRAN,
Director ( Strut 8c Met )
Secretary
SHRIS. K.
GUPTA
IS : 1573- 1986
Indian Standard
SPECIFICATION FOR
ELECTROPLATED COATINGS OF
ZINC ON IRON AND STEEL
( Second Revision)
0. FOREWORD
0.1 This Indian Standard ( Second Revision 1 was adopted by the Indian
Standards Institution on 10 September 1986, after the draft finalized by the
Metallic and Non-metallic Finishes Sectional Committee had been approved
by the Structural and Metals Division Council.
0.2 This standard was first published in 1960, revised in 1970 and covered
three types of zinc plating depending on the coating thickness. In the first
revision of the standard, grades of thickness were revised keeping in view
the utility of the coatings and the trade practices followed in the country.
In this revision, efforts have been made to include many details to make
this standard a comprehensive one. Additional terms are included under
terminology, limitations are referred to regarding finish and appearance
under coating requirements. More details are furnished under information
to be given by the purchaser and the manufacturer regarding chromate
passivation, test for coatings, handling, inspection, packaging and service
life of the coatings.
0.3 Unlike cadmium, zinc is of low toxicity and zinc coatings are widely
used but prolonged contsict with some liquids or damp foodstuffs which
are acidic or liable to become acidic, should be avoided.
0.4 Zinc protects steels cathodically, that is by sacrXcia1 protection in
most environments and this protection is given to steel even at discontinuities in thecoatings. But zinc plating looses its initial bright appearance
due to environmental conditions like dust, condensed moisture at high
relative humidities, acidity, high ambient temperatures,
etc, and forms
bulky, white corrosion products, usually of basic zinc carbonate. One of
the best methods of retarding this type of corrosion is by the application
of inhibitive chromate passivation films. Passivation by chromate conversion coatings gives additional protection against corrosion and should be
3
0.5This standard includes the whole range of iron and steel products as
basis metals. Designers are advised, however, that all forms of iron and
steel are not equally readily electroplated. Many castings can be satisfactorily plated but are apt to be more difficult than forgings. Acid zinc
plating baths or neutral chloride baths are available commercially to plate
satisfactorily the carbo-nitrided
steel castings and other difficult-to-plate
iron and steel substrates. Conventional cyanide and low cyanide baths may
also be used with adequate precleaning steps.
0.5.1 Attention is also drawn to the effects
to be plated. In general, the requirements for
only to those portions of the article which can
surfaces. It helps to reduce process costs if the
part consults a platin g specialist before the
production.
Is:1573-1!&6
1.2 Requirements are specified for appearance, thickness, adhesion, heat
treatment before or after plating, precleaning standards, and if the coating
is chromate-passivated,
the corrosion resistance.
2. TERMINOLOGY
2.0 For the purpose of this standard; the following definitions shall apply.
2.1 Surface work.
The part
has to
at a
IS:1573 -1986
2.8 Hydrogco Embrittlemknt hydrogen into a metal.
Embrittlement
caused by the
entry
of
test, if required;
treatment,
the
minimum
local thickness
of
zinc
in
!
j
Is:1573-1986
TABLE I SUPPLEMENTARY
(CIauses3.1.1,~3.3.2.4.1,2,4.5.1
SL No.
APPROXIMATE
FILM DENSITY
TyPICAL
APPEARANCE
TYPE
(2)
-41)
1.
TRBATMIINTS
und9.2.3 )
Colourless
B Bleached
C Iridescent
(3)
g/m
[Transparent
clear,~sometimes with a
bluish tinge
up to 0.5
Transparent
with slight
1 iridescence
[itel;
iri-
up to
1.0
5 to 10
o-5 to 1.5
50 to loo
More than
1.5
100 to 2oc
Coloured
D Opaque
;;;d;ny.
I
2.
Phosphate Coatings:
E
brown
bronze
Phosphate
to
or
conversion
the nature
of conversion
coatings
4. COATING REQUIREMENTS
4.1 Finish and Appearance
4.1.1 Over the significant surface, the plated article shall be free from
clearly visible plating defects such as blisters, pits, roughness, nodules,
cracks, burning or unplated areas :\nd shall not be stained or discoloured.
On articles, usually where a contact mark is inevitable, this contact mark is
excluded for inspection of appearance. Superficial stains that result from
7
ls:ls73-1986
rinsing or slight discolouration resulting from drying or heating operation
to relieve hydrogen embrittlement shall not be the cause for rejection.
NOTE1 - Unless otherwise specified, the finish shall be bright, semi-bright or
dull. The~plated article shall, however, be clean and free from any damage.
Nope 2 - Defects on :he surface of the basic metal, such as scratches, porosity,
pits, inclusions, cracks, roll marks and die marks may adversely affect the appearance
of coatings applied thereto,-despite the observance of the best electroplating practices.
-- _ Accordingly, the electroplaters responsibility for defects in the coating resulting from
such conditions shall be waived.
Appearance
of supplementary
treat-
is designated
CLASWICATION
cNFj
(3)
(4)
Irm
38
;:
Fe/Zn 25
18
125
3
Fe/Zn 12.5
1.5
12
2
FelZn 7.5
8
5
1
Fe/Zn 5
NOTE 1 - In any particular environment, the protective value of a zinc coating is
directly proportional to its mass per unit area. Therefore, a coating of 40 pm minimum thickness and 60 pm average thickness may also be used for special purposes.
When very long service life is required, for example, on structural steel components,
the thicker zinc coatings required are usually applied by hot-dip galvanizing or by
zinc spraying.
NOTE2 - Barrel-plated items like screws, nuts, bolts, etc, are usually plated
according to classification Fe/Zn 5 and FelZn 7.5. Tolerances and inspectionprocedure shall be as agreed mutually.
NOTES- Average thickness is determined for small parts and fasteners where
minimum local thickness cannot be determined.
4
IS : 1573 - 1986
Nope 2 - The failure of the test is defined as the first appearance of the white
corrosion products on surfaces visible to the unaided eye at normal reading distance.
However, appearance of black spots and white corrosion products on very low
current density areas, sheared Fdges, formed edges, very near pierced/tapped/blind
h$iaGesizs, contact/wiring pomts, bases of angles, curves and threaded portions shall
NATE3 - Bimetal contact points/inside of blind holes shall be protected suitably
against galvanic corrosioos.
5. BASIS METAL
5.1 Cleaning of Basis Metal - Proper preparatory
procedures
and
thorough cleaning of the basis metal are essential to ensure satisfactory
adhesion and corrosion resistance performance of the coating. The cleaning
shall be done in accordance with the method prescribed in IS : 3194-198Ot.
5.2 Unless otherwise specified, high-strength steels having a tensile strength
greater than 1,500 MPa ( corresponding hardness 45 HRC. 440 WV or
*Methods of testing corrosion resistance of electroplated and anodized ahnninium
coatin~.p.by neutral salt spray test.
tRecommcn&d practice for clianing metals prior to electroplating (first rev&&m).
9
IS : 1573 - 1986
415 HB approx ) should not be electroplated
methods.
6. HEAT TREATMENT
6.1 Heat treatment shall be performed on certain basis metals to reduce
the risk of damage by hydrogen embrittlement. In all cases, the duration
of heat treatment shall commence from the time at which the whole of each
part attains the specified temperature.
6.1.1 Parts made from steels with maximum specified iensile strengths
of 1 050 MPa or higher ( corresponding hardness values of approximately
34 HRC, 340 HV or 325 HB ) and surface-hardened
parts shall require
heat treatment. It is recommended that unless otherwise specified, steels
having tensile strength greater than 1 450 MPa ( corresponding hardness
45 HRC, 440 HV or 415 HB ) should not be electroplated with zinc by
conventional methods.
6.2 With the exception of surface-hardened
parts, the heat treatment
conditions shall be selected on the basis of the specified maximum tensile
strength. Steels shall be categorized according to specified maximum tensile
strength according to Table 3. If the steel specification is only in terms of
minimum tensile strength, the corresponding
maximum tensile strength
shall be determined from Table 3.
TABLE 3 CATEGORIES OF STEELS AND MAXIMUM TENSILE STRENGTH
CORRESPONDING TO SPECIFIED MINIMUM TENSILE STRENGTH
SL No.
(1)
3
ii)
iii)
iv)
MINIMUM
SPECIFIJID
TENSILE
STRENGTH,
Rm
Min
(2)
MPa
CORRESPONDING
MAXIMUM
TENSILESI-REPKX~,Rm
Max
(3)
MPa
IS:1573-
1986
guide, they may be heat-treated at the highest temperature within the limit
imposed by~the tempering temperature for 30 minutes or maintained at a
temperature of 190 to 220C for not less than I hour.
If stress-relief is given after shot-peening
Nor~lprocesses, the temperature shall not exceed 22OC.
NOTE2 - Some steels which have been carburized, flame hardened or induction
hardened, and subsequently ground would be impaired by the treatment given in
Note 1 and should instead be stress-relieved at a lower temperature, for example,
at 170C for not less than 1 hour. Guidance is given in Table 4.
SURFACE-HARDENED
PARTS )
TEMPERATURE
MAXIMUM SPECIFIED
TENSILE STRENGTH,
TIME
Rm Max
(1)
i)
ii)
iii)
iv)
(3)
(2)
MPa
Rm Max < 1 050
1 050 < Rm Max < 1 450
1450i:RmMax<1800
1800-c RmMax
(4)
Not required
190-220
190-220
1s
24
1go-220
6.4 Heat-Treatment After Plating Hydrogen Embrittlement Relief Components subject to fatigue or sustained loading stress in service and
made from severely cold-worked steels or nitrided steels or steels of tensile
strength of 1 050 MPa ( corresponding hardness 34 HRC, 340 HV, 325 HB
approx ) or greater should be heat-treated after plating. Guidance is given
in Table 5.
6.4.11 In case the heat-treatment
temperature would be harmful, for
example, to surface-hardened steels ( except for nitrided steels ), it may be
necessary to apply a lower temperature for a longer time.
No-re 1 - The baking should be done as soon as possible after electroplating
and before any supplementary chemical treatment of the plated surfaces. The best
time and temperature in some cases shall be established by experiment.
No1132 - Electroplated springs and other parts subject to flexure shall not be
flexed -before the hydrogen embrittlement relief treatment. Steel springs shall be
treated in boiling water for not less than 2 hours. The spring rating may be affected
at a higher temperature.
11
Is : 1573 - 1986
NOTE 3 - Other conditions of time and temperature may be specified and used
if they have been shown to be effective for the particular part and are acceptable to
the purchaser but parts shall not be heat-treated above their tempering temperature.
(1)
MAXIMUM SPECIFIED
TENSILE STRENGTH,
Rm Max
(2)
TBMPERATURE
MPa
RmMax<lOXI
1 450
1450iRmMaxg1800
1 800 < Rm Max
3)
C
Not required
W-220
190-220
190-270
TXMB
(4)
h
8
IS
24
OF SAMPLES
selected
selected
All the
to in.
8. TEST SPECIMENS
8.1 If separate test specimens are used to represent the coated articles in a
test, the specimens shall be of the same nature, size and number and be
processed as required in the purchasers order.
8.1.1 Unless a need can be demonstrated,
shall not be used in place of production
visual examinations.
IS:1573-1986
8.3 Corrosion Resistance Test Specimens - If separate specimens for
corrosion resistance tests are required, the panels not less than 150 mm in
length;100 mm in width and approximately 1 mm in thickness shallbe used.
8.4 Hydrogen, Embrittlement Test Spechens - If specimens are required,
the configuration shall be specified by the purchaser.
9. TEST METHODS
$Metheds of tests for chromate conversion coatings on zinc and cadmium surfaces.
13
ls:l573-1986
9.2 Thickne!3s
9.2.1 Local Thickness - The local thickness of the
determined by methods as given in IS : 3203-1982*.
coating
may be
NOTE2 - If the coatings are rough or matt, the microscopical and protilometric
methods may give unreliable results, and magnetic/eddy current methods may give
measurements which are somewhat greater than those obtained on smooth coatings
of the same maas.
9.2.3 Thickness measurements of zinc coatings may be made ( for Types
A, B, C, D and E ) after application of the supplementary treatments.
When BNF jet test method as given in IS : 3203-1982* is used, the
supplementary treatment prior to testing shall be removed. The chromate
film may be removed from Types A, B, C and D as given in Table 1 by
using a very mild abrasive (as paste of levigated alumina rubbed on with
the finger). Type E coating may be treated with a concentrated ( 28 percent )
ammonia solution to quickly dissolve the ph0sphat.e coating without
affecting the underlying zinc.
9.3 Adhesion - Adhesion of the coating shtill be such that when examined
in accordance with Appendix F, the coating shall not show separation
from the basis metal at the interface.
9.4 Corrosion
14
+.
to this specification
or to authorized modi-
Mark
15
or producers
may be obtained
IS: 1573-1986
APPENDIX
( Clause 3.2 )
EXAMPLES
A-l. SERVICE
OF SERVICE
GRADE NUMBER
CONDITIONS
GRADE NUMBER 3
A-2.1 Severe involving indoor exposures and prone to scratching and abrasive wear to some extent. Example of articles subjected to such conditions
are tools, zippers, machine parts, etc.
A-3. SERVICE
GRADE NUMBER 2
GRADE NUMBER
APPENDIX
and subjected
( Clause 3.1.1 )
RECOMMENDED
B-l. SERVICE
LIEE OF ZINC
B-l.1 .The service life of zinc coating is a function of thickness and the
type of environment to which it is exposed. -Though it is not possible to
predict-the exact life, guidelines ( very approximate ) are available on the
basis of world-wide collection of corrosion data.
16
Atnzosphm
5.6 pm /year
l-5 pm/year
Industrial
Urban. non-industrial
or marine
Suburban
Rural
Indoors
NOTE 1 - The mean corrosion
and are relative values only.
NOTE
2 -The
include corrosion
1986
mean
corrosion
1.3 pm/year
0.8 pm/year
Considerably less than
0.5 pm/year
rates given above are subjected to wide variations
rates
are
applicable
to
APPENDIX
C.
( Clause 9.1.1.2 )
HUMIDITY TEST
C-l. APPARATUS
A heat-insulated chamber. A fan to circulate air in the chamber and
non-corrosive support for the specimen near the centre of the chamber
constitute the humidity chamber.
C-2. TEMPERATURE OF THE TEST
The test shall be conducted at a temperature
cooling to 30C.
of 55 i: 2C followed by
C-3. HUMIDITY
The relative humidity shall not be less than 95 percent.
C-4. TEST CYCLE
The article shall be subjected to the above mentioned temperature and
humidity conditions for 16 hours continuously. The source of heat shall
then be turned off. Circulation of the air shall be maintained. The temperature shall be allowed to fall to 30%. The article shall be kept at this
temperature for 5 hours. The article shall be examined after each cycle.
17
IS : 1573 - 1986
APPENDIX
( Clause 9.1.1.3 )
a)
b)
4
d)
Distilled water
Glacial acetic acid
Diphenyl carbozide
Wetting agent ( sulphonated
alcohol type )
Concentrated
hydrochloric acid
e)
( relative density l-16 )
f) Sodium hypochlorite ( 10-15
percent solution )
g) Hydrogen peroxide ( 100 vol )
15ml
30 ml
5 ml
NOTE- The reagents shall be added in the above order and the resulting solution kft in an open beaker for about 24 hours in order to allow excess chlorine to
escape before use.
D-2. _PROCEDURE
A drop of the test solution shall be applied to the coated sample. The
formation of a red or purple colouration within five minutes of applying
the drop denotes the-presence of the chromate film. In case of bleached or
colourless coatings, the colour will be less intense.
APPENDIX
( Clause 9.2.2 )
METHOD FOR DETERMINATION OF AVERAGE THICKNESS
E-l. STRWPING SOLUTION
Dissolve
hydrochloric
test.
E-3. CALCULATION
where
~21 - original mass in g of the sample,
IIT?= final mass in g of the sample, and
A ZZ area in mm2 of coating.
NOTE -
APPENDIX
( Clause 9.3 )
BURNISHING
F-l. Rub an area of not more than 650 mm2 of the plated
surface, selected
and firmly with a smooth metal
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