Klass.-Nr.

50 24 3
The English translation is believed to be accurate. In case of discrepancies the German version shall govern.

March 2003

Paint Coating on Exterior Plastic Parts

Requirements Konzernnorm Descriptors: paint, varnish, painting, exterior plastic parts, bumper, wheel cover, rear spoiler, trunk lid, fender

TL 211

Changes The following changes have been made as compared to TL 211, 2003-02 issue:

Adhesive tape specifications revised (section 6.2)

Previous issues 1974-11; 1983-10; 1989-07; 1992-08; 1992-09; 1995-03; 1995-10; 1998-06; 2003-02 1 Scope

This technical supply specification (TL standard) specifies requirements for primer coat, single and multicoat painting acc. to color chart or special combination chart on plastic parts (body-mounted parts, e.g. bumper, wheel cover, rear spoiler, trunk lid, fender, etc). 2 Designation

Painting acc. to TL 211 3 3.1 Requirements General Requirements

Approval of first supply and changes according to VW 011 55. Avoidance of hazardous substances according to VW 911 01. In case pretreatment is necessary to activate the substrate, the related method should be specified (e.g. flame exposure, plasma treatment, etc.). The coating/paint, as well as potential re-painting shall exhibit firm adhesion to the substrate or to the original paint coat, respectively. The supplier shall provide the following information for all parts under test: 1. 2. 3. Specification of substrate material (manufacturer designation and VDA designation) Color Paint structure (precise paint specifications, paint supplier), e.g.: Primer coat: 2K primer 01-77008 by Akzo Base coat: 831646 by Du Pont Clear coat: 2K clear coat GP72-0113 by BASF 4. 5. 6. 7.
Form FE 41 - 12.00

Norm vor Anwendung auf Aktualitt prfen / Check standard for current issue prior to usage.

20 m 20 m 22 m

Paint shop worker Paint shop Painting location Painting date

Page 1 of 9
Fachverantwortung/Technical responsibility K-QS-31 Frau Kern Tel:-28507 Frau Dr. Daniel Normung/Standards (EZTD, 1733) Wiesner Tel.: +49-5361-9-49035 Sobanski

Vertraulich. Alle Rechte vorbehalten. Weitergabe oder Vervielfltigung ohne vorherige schriftl. Zustimmung einer Normenabteilung des Volkswagen Konzerns nicht gestattet. Vertragspartner erhalten die Norm nur ber die zustndige Beschaffungsabteilung. Confidential. All rights reserved. No part of this document may be transmitted or reproduced without the prior written permission of a Standards Department of the Volkswagen Group. Parties to a contract can only obtain this standard via the responsible procurement department.

VOLKSWAGEN AG

QUELLE: NOLIS

Page 2 TL 211: 2003-03

3.2

Appearance and haptic characteristics

The parts shall exhibit a uniform appearance on their entire surface; they shall conform to the drawing requirements and to the released sample for gloss and color. Pores, coarse cracks, and other flaws which adversely affect the specified appearance are not permissible. Color and degree of glossiness are documented in the first-sample test report or development sample test report acc. to VW 501 95. 3.3 Open-air weathering

All painted components are tested by the VW Group according to VW 501 185 (open-air weathering: 1 year in moist heat and 1 year in dry heat). The supplier is obligated to remove the cause for complaints occurring during this test and to improve the paint system. 3.4 Painting process

The painting process shall be coordinated by paint shop and paint manufacturer. Both parties will confirm the first-sample test report, meaning that both are responsible for fulfilling the specified requirements. Responsibilities are distributed as follows:

The paint manufacturer provides information on the fulfillment of requirements specified in the relevant TL standards, processing guidelines and support regarding the applied paint method. The paint shop provides information about the substrate (type of the plastic material and its commercial name), checks the requirements as early as possible (this also applies to preproduction series parts: at least for liability), confirms compliance with the processing guidelines of the paint manufacturer and requires support regarding the applied paint method. Conditioning

3.5

All samples delivered for testing shall be pre-conditioned: 7 days at room temperature with narrow air temperature range (18 C to 28 C) or 48 h at 50 C. Prior to individual testing, the parts shall be conditioned for 24 h at 18 C to 28 C acc. to DIN 50 014. 4 4.1 Requirements on structure and paint coat thickness General

Only one single re-painting job is permissible, considering the total paint coat thickness of < 150 m. In principle, the following color combinations are permissible for re-painting: a) first and second coat are of the same color b) permissible first coats for all colors: black, dark blue shades, dark gray shades (also metallic or pearlescent finishes) Other color combinations shall be agreed upon with the relevant release departments of each brand.

Page 3 TL 211: 2003-03

NOTE: If for technical reasons a larger paint coat thickness is necessary, this shall be agreed upon by the parties involved. However, all other requirements stated in TL 211 shall be fulfilled. Exceptions: only primed parts < 50 m (see section 6.1). Any deviation from this can only be made through a drawing entry or a separate release. 4.2 4.2.1 Structure Base material

Plastic acc. to drawing 4.2.2 Primer coat / filler / primer surfacer (see section 6.1)

If specified (by drawing, release or color standard) or required for technical reasons (depending on substrate). 4.2.3 Top coat or intermediate coat (solid color, metallic, pearlescent finish)

Base coat acc. to color standard or custom color combination chart, free of cadmium or cadmium compounds. 4.2.4 Clear coat (if required for decorative or technical reasons)

Acc. to released sample, testing acc. to IR spectrum. 4.3 Paint systems and layer thicknesses in m

See table 1. Table 1

No. System 1 2 3 4 5 Total layer thickness: Primer surfacer Primer coat/ filler Primer coat 10 to 50 2 to 10 20 to 50 Single-layer Double-layer Multi-layer paint paint paint 20 to 40 20 to 40 30 to 90 2 to 10 or 20 to 50 2 to 10 or 20 to 50 20 to 40 32 to 135 2 to 10 20 to 50 Single-layer piano lacquer 67 to 165 2 to 10 20 to 50 Double-layer piano lacquer 67 to 165 2 to 10 20 to 50

Top coat Intermediate coat Water-based paint Solid color Metallic Pearlescent Clear coat

20 to 40 1)

10 to 35 15 to 35 10 to 35 10 to 35 20 to 40

10 to 35 15 to 35 10 to 35 10 to 35 35 to 45

10 to 35 15 to 35 10 to 35 10 to 35 55 to 70

1) This only applies to parts with base coat/clear coat paint system without primer coat, filler or primer surfacer.

Page 4 TL 211: 2003-03

Properties requirements

See table 2. Table 2 No. 1 1.1 Properties Requirements Visual properties of single-layer and double-layer piano lacquer and premium paint of high-gloss brilliant appearance Gloss acc. to DIN 67 530, 20 Double-layer piano lacquer > 90 Single-layer piano lacquer > 90 Brilliant solid color, pearlescent and > 90 (-5, conditionally up to 10) metallic paints Other paints Acc. to drawing or surface performance specifications LAH 983 018 Color acc. to DIN 5033-4, DIN 6174, DIN Acc. to VW 501 95 6175-2 (applies to first samples and standard production colors only) Structure of measuring system: Wave-scan plus, measurement acc. to manufacturers specifications Double-layer piano lacquer LW < 5; SW < 10 Single-layer piano lacquer LW < 7; SW < 18 Brilliant solid color, pearlescent and LW < 13; SW 10 to 30 metallic paints Other paints acc. to drawing or surface performance specifications LAH 983 018 Adhesion Crosscut test Gt 0 to 1 acc. to DIN EN ISO 2409 and section 6.2 involving tear-off of adhesive tape Behavior in steam jet test No stripping of paintwork acc. to PV 1503 1. Evaluation of blister grade after 30 min acc. Behavior in moisture condensate to DIN 53 209 (m2g2 still permissible) constant climate acc. to DIN 50 017 KK, 2. Evaluation after 24 h, blister grade acc. to test duration 240 h DIN 53 209, m0g0 (in case of prior Subsequent acclimatization for 30 min at blistering, testing of paint adhesion shall be room temperature performed in that same area) 3. Requirements stated in table 2, no. 2 shall still be fulfilled Environmental cycle test No change in the paint surface acc. to PV 2005 A (individual parts) 50 cycles Temperature cycle test behavior Requirements stated in table 2, no. 2 shall still Aging at elevated temperature be fulfilled Aging in mechanically circulated air Test duration 240 h Test temperature (90 2) C Subsequent acclimatization for at least 30 min at room temperature

1.2 1.3

2 2.1

2.2 3

4 5 5.1

Page 5 TL 211: 2003-03

No. 5.1.2

5.2 5.2.1 6 6.1 6.2 7 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11

8.12

Properties Low-temperature aging After aging at elevated temperature, the same specimen shall be exposed to lowtemperature aging Test duration 24 h, Test temperature (-40 3) C Subsequent acclimatization for at least 30 min at room temperature Low-temperature behavior Aging period 24 h Impact test based on ISO 4532, see section 6.3 (-40 3) C Stone impact test Acc. to DIN 55 996-1 Acc. to PV 1217 Resistance to water vapor see section 6.4 Resistance to chemicals acc. to VDA test sheet 621 412 as compared to: FAM test fuel (test A4.1.1Y) Gasoline premium unleaded acc. to DIN EN 228 (test A4.1.3Y) Diesel fuel acc. to TL 788 (test A4.1.2X) Diesel fuel consisting of vegetable oil methyl ester (PME) acc. to DIN 51 606 (test A4.1.1Y) Engine oil acc. to TL 521 73 (test A4.1.4) Brake fluid acc. to TL 766 (test A4.2.2Y, filter layer) Coolant acc. to TL 774 (test A4.2.2X) Polish see section 6.4 (part No. 00V 096 318 001) Bitumen and tar remover see section 6.6 Sealant and sealant remover see sections 6.5 and 6.6 Thinner for plastic primer coat (original: VW-ALV 001 001 10) 10 min at room temperature (applies to primed after-sales parts only) see section 6.7 Thinner for primer coat (original: VW-ALV 015 003 A5) 10 min at room temperature (applies to primed after-sales parts only) see section 6.7

Requirements Requirements stated in table 2, no. 2 shall still be fulfilled

No chipping and no cracks in paint coating

Characteristic value 2.0 For requirements see drawing For requirements see drawing

Reversible swellings permissible, there shall be no changes in the paint surface after 24 h. No change in the paint surface No change in the paint surface No change in the paint surface No change in the paint surface Reversible swellings permissible, there shall be no changes in the paint surface after 24 h No change in the paint surface No change in the paint surface No change in the paint surface No change in the paint surface No change in the paint surface

No change in the paint surface

Page 6 TL 211: 2003-03

No. 8.13

9 10 10.1

10.2

11

12 12.1

12.2

Properties Silicone remover (original: VW-LSE 020 000 A3) 10 min at room temperature (applies to primed after-sales parts only) see section 6.7 Simulated oil soot exposure acc. to VDA 621 408 Light and weather fastness (short-term test method) Weathering in humid heat acc. to PV 3930 (corresponding to Florida) test duration: 1-year cycle Weathering in dry heat acc. to PV 3929 (corresponding to Kalahari and Arizona) test duration: 1-year cycle Resistance of clear coat to UV radiation acc. to PV 1502/12.96 (use specified plastic material) test duration: 600 h for elastic clear coats, e.g. on EPDM Testing of weather fastness (open-air weathering) Weathering in humid heat (corresponding to Florida) acc. to VDA test sheet 621 403 test duration: 24 months Weathering in dry heat (corresponding to Kalahari or Arizona) acc. to VDA test sheet 621 403 test duration: 24 months Notes on testing

Requirements No change in the paint surface

No change in the paint surface

No visible change in gloss and color permissible, see section 6.8 Requirements stated in table 2, no. 2.1 shall still be fulfilled No visible change in gloss and color permissible, see section 6.8 Requirements stated in table 2, no. 2.1 shall still be fulfilled No cracking of the clear coat

(Only for release testing) No visible color change No other change in the paint coat, like e.g. chalking, blistering or cracks No visible color change No other change in the paint coat, like e.g. chalking, blistering or cracks

All sections of parts which are not subject to the requirements stated in this TL standard shall be identified so in the drawing. Prior to testing, the parts shall be conditioned acc. to VDA 621 417. The room temperature with narrow air temperature range stated in this document is 18 C to 28 C acc. to DIN 50 014. 6.1 Primer coat / filler / primer surfacer

Do not use parts coated with top coat for customer service parts that are only primed. Plastic parts which are only primed shall only fulfill the requirements specified in table 2, no. 2 to 6 and 8.11 to 8.13. 6.2 Crosscut test

Please take greater care than with metal substrate to ensure that the cuts made in the crosscut test do enter the substrate, however, do not go too deep. Press the adhesive tape (Tesagewebeband 4657 by Tesa) firmly onto the surface before removing it.

Page 7 TL 211: 2003-03

6.3

Impact test

Impact test acc. to DIN ISO 4532, however, a specified testing force of 90 N on a rigid base plate shall be used. 6.4 Resistance to water vapor

The painted surface of the part under test shall be placed over a steaming water surface for 2 min at a distance of 5 cm. 6.5 Polish

Apply polish (part no. 00V 096 318 001) with a cellulose pad, let dry and polish off subsequently with cellulose. 6.6 Bitumen and tar remover

Mix 5 g Panmex bitumen "85/25" by Esso with 5 ml petroleum ether to yield a paste. Thoroughly cover an area with a diamter of approx. 3 cm with this paste. After an exposure period of 1 h, the part is cleaned of the tar paste with a tar cleaner (No. 000 096 501 A 001). 6.7 1. 2. Sealant Sealant AKR 321 W 30 (product designations: W 550-2, Pfinders, Bblingen, Germany or CA 66 D Caramba, Duisburg, Germany) and Acrylate sealant AKR 318 A 20 (product designation Tempal KSL, Sahm Chemie, Dillenburg, Germany). Sealant remover

6.8

One section is coated with sealant by immersion. After conditioning the part for 24 h at room temperature, the wax layer shall be washed off by agitating the part in hot (80 C) kerosene for 3 min. 6.9 Thinner and silicone remover

Depth filters (diameter 3.6 cm, item no. 08960, by Seitz-Filter-Werke, Bad Kreuznach, Germany) shall be immersed in thinner or silicone remover (until they are well soaked); after the excess liquid has dripped off, they subsequently shall be placed on the primer coat of the plastic part and immediately covered by a petri dish or a crucible.

6.10

Changes in color and gloss

Clean all coatings prior to evaluation. Clean matte black paint coatings only with water to which a commercially available detergent has been added. Clean solid color and metallic paint coatings with a paint cleaner (00V 096 305 001).

Page 8 TL 211: 2003-03

7 TL 766 TL 774 TL 788

Referenced standards1 Brake Fluid; Material Requirements Ethylene Glycol-Based Coolant Additive; Material Requirements Diesel Fuel, Fuel Requirements Factory Fill Engine Oil SAE 0W-30 with Fuel-Saving Properties for Extended Oil Change Intervals; Requirements, Testing Clear Coat in Dual Layer Metallic Paint Coatings; Test of Resistance to Cracking Paint Coating of Non-Metallic Materials; Paint Adhesion, Steam Jet Test Vehicle Parts; Testing of Resistance to Environmental Cycle Test Non-Metallic Materials; Weather Aging in Dry, Hot Climate Non-Metallic Materials; Weathering in Humid Heat Vehicle Supply Parts, General; Approval of First Supply and Changes Vehicle Components; Resistance to Open Air Weathering Colorimetric Evaluation of Automobile Paint Coatings Vehicle Environmental Standard; Vehicle Parts, Materials, Operating Fluids; Avoidance of Hazardous Substances Colorimetry; Spectrophotometric Method Colorimetric Evaluation of Color Differences of Surface Colors According to the CIELAB Formula Tolerances for Automotive Paints; Part 2: Goniochromatic Paints Climates and their Technical Application; Standard Atmospheres Climates and their Technical Application; Condensated Water-Containing Climates Designation of Degree of Blistering of Paint Coatings Paints and Varnishes; Stone Chip Resistance Test for Coatings, Part 1: Multi Impact Test Reflectometer as a Means for Gloss Assessment of Plane Surfaces of Paint Coatings and Plastics Automotive Fuels; Unleaded Petrol; Requirements and Test Methods Automotive Fuels; Fatty Acid Methyl Esters (FAME) for Diesel Engines; Requirements and Test Methods Paints and Varnishes, Crosscut Test Vitreous and Porcelain Enamels, Determination of the Resistance of Enameled Articles to Impact; Pistol Test Tests for Coating Methods, Testing of Weather Fastness (Open-Air Weathering) Tests for Coating Methods; Test of Paint Coatings for Color Change by Simulated Oil Soot Exposure

TL 521 73 PV 1502 PV 1503 PV 2005 PV 3929 PV 3930 VW 011 55 VW 501 85 VW 501 95 VW 911 01 DIN 5033-4 DIN 6174 DIN 6175-2 DIN 50 014 DIN 50 017 DIN 53 209 DIN 55 996-1 DIN 67 530 DIN EN 228 DIN EN 14 214 DIN EN ISO 2409 DIN ISO 4532 VDA 621 403 VDA 621 408

In this section terminological inconsistencies may occur as the original titles are used.

Page 9 TL 211: 2003-03

VDA 621 412 VDA 621 417

Tests for Coating Methods; Resistance to Chemicals of Automotive Paints Tests for Coating Methods; Conditioning of Plastic Coatings Prior to Start of Testing