TM-5001 140701 Cataphoretic Electrocoat

TM-5001 TESLA MOTORS STANDARD
TM-5001
Material Specification: Cataphoretic Electrocoat
version 01
Cataphoretic Electrocoat
MATERIAL SPECIFICATION | VERSION 01
0 Overview & Guidance

This specification establishes standards of composition, quality and performance for cataphoretically-
deposited organic primer coat systems delivered to Tesla Motors or its suppliers for the coating of
metallic substrates. Based on application, coating systems approved to this specification must meet
all grade-affiliated criteria defined herein, subject to the following terms and conditions.
0.1 Laws. This specification shall never supersede applicable laws and regulations. All materials
must meet legal requirements valid in the country of usage.
0.2 Language. Only the English language version of this text shall be binding.
0.3 Process Accreditation. All materials testing must be conducted by a laboratory or facility
accredited to ISO 17025 by an established third-party auditor.
0.4 Standard Obsolescence. It is the responsibility of the supplier to ensure that the most current
versions of all cited standards are employed.
0.5 Initial Source Approval. Delivery of production goods shall not be accepted until representative
initial production samples have been verified for compliance to this specification by Tesla
Materials Engineering.
0.6 Materials Equivalency. Materials or parts approved and purchased to this specification must be
equivalent in every respect to the initial samples verified and approved by Tesla Materials
Engineering. The right to characterize material is reserved.
0.7 Change Reporting. The supplier is exclusively responsible for reporting all product changes
(including, but not limited to, material formulation, material performance or production process)
to Tesla Materials Engineering. Materials must be retested as if for initial release unless agreed
otherwise.
0.8 Quality Control. Test frequency and sample size for process control and product continuous
compliance monitoring must meet the agreed quantities and frequencies defined in this
document and the Control Plan, DFMEA, PFMEA and PPAP packages submitted and approved
by Tesla SQA or Tesla suppliers that use and deliver parts covered by this specification.
0.9 Part Validation. Materials suitability for service in a particular application may only be confirmed
by component-, system- or vehicle-level testing. It is the responsibility of the release engineer to
outline part performance requirements in a design verification plan or related specification.
0.10 Drawing Precedence. In case of conflict, the requirements listed on the engineering part drawing
shall take precedence over the terms and conditions of this specification.
0.11 Product Appearance. All materials, components and assemblies deemed as "appearance items"
must match the corresponding master sample for color, gloss and texture as indicated on the
applicable released engineering information as approved by Tesla Design & Styling and in
accordance with the Appearance Approval procedure.
0.12 IMDS Submission. All materials, components and processes used to produce parts under this
specification and delivered to Tesla Motors, or to be part of products delivered to Tesla Motors
as part of the assembled vehicle, must be registered to the International Material Data System
prior to being supplied for production usage.
Printed copies are uncontrolled. Controlled documents reside electronically. Individuals in possession of an uncontrolled copy are
responsible for ensuring that they are using the latest revision of this document.
© 2014 Tesla Motors, Inc. Proprietary and confidential.
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version 01 Material Specification: Cataphoretic Electrocoat
1 Scope
Materials defined by this specification are cataphoretically-deposited organic primer coat systems
intended for application on metallic substrates, both ferrous and non-ferrous. These coatings may be
variously and interchangeably denoted as electrocoats, e-coats, or electrodeposition/electrophoretic
primers, coatings, or paints; they provide improved resistance to corrosion and chipping and may be
succeeded by other coating systems. The materials specified herein are suitable for interior and
exterior applications, per the guidelines below.
Chemical pretreatment of the substrate surface is often necessary to achieve adequate adhesion
performance of the total coating system. For parts coated externally, direction to use such a
pretreatment system may be specified on the part drawing.
Based on application, material approved to a grade may require compliance with affiliated criteria
agreed upon by Tesla Motors and its suppliers. Deviations from the test requirements noted herein
must be explicitly agreed upon by Tesla Motors and the appropriate supplier.
2 References
ASTM D1475 ASTM D4399 ISO 9227
ASTM D1735 ASTM D4752 ISO 15184
ASTM D2369B ISO 554 ISO 17872
ASTM D2803 ISO 2808 SAE J2334
ASTM D3170 ISO 2813
ASTM D3359B ISO 4628-8
3 Requirements
3.1 General Guidelines. The electrocoat is to be applied via cathodic deposition. Testing is to be
conducted on the electrocoat as intended for production, which may or may not include an approved
pretreatment. Representative substrates to be electrocoated must be visually regular and defect-free,
without scratches, cracks, porosity or inclusions. Prior to coating, parts must be thoroughly cleaned,
free of grease, sweat, dust, dirt and other residual matter that may impair adhesion, promote
corrosion or affect appearance. For improved adhesion and corrosion resistance, an alkali degreasing
followed by a zinc phosphate or other acceptable pretreatment is suggested (required as noted, see
section 3.2). Final coated parts post-bake must possess a smooth, uniform surface, free from
excessive runs, drips, tears, craters, sags, inclusions, voids, pinholes, or localized build-up.
3.2 Pretreatment. A conversion coating pretreatment may be required prior to electrocoating. Only
zinc phosphate or organometallic silane-based systems are approved for use. Weight shall be
adjusted to suit the substrate and achieve the performance requirements of the total coating system;
the acceptable weight range, as measured by an x-ray fluorescence spectrometer, shall be
determined and disclosed. Pretreatment may be applied by immersion or spray and shall be
compatible with multimaterial systems as required. Prior to conversion, parts must be thoroughly
treated to remove residual matter that may impair the conversion process.
3.3 Composition. In addition to validation testing, the coating supplier is responsible for providing
information on the chemical makeup of the material (including an infrared spectrum analysis) if so
requested by Tesla Motors.
For coatings to be applied off-site by the supplier, all materials information regarding cleaning agents,
pretreatment chemicals, and coating pigment and binder types are to be disclosed to Tesla Motors as
part of the approval process. Information on coating and drying methods is also required.
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With each delivered batch of material supplied as unmixed components to be applied on-site at Tesla,
the supplier shall provide the following batch-specific information: percent solid content by volume
(ASTM D2369B) and density of the products (ASTM D1475).
With each delivered batch of material supplied as pre-mixed product to be applied on-site at Tesla,
the supplier shall provide the following batch-specific information in addition to the above: solution
conductivity (ASTM D4399) and pigment/binder ratio.
3.4 Material Stability. Resin to be used in-house shall be stable and approved for use after 180 days of
storage within the temperature range of +5°C and +35°C. Paste to be used in-house shall be stable
and available for use after 90 days of storage within the temperature range of +5°C and +35°C.
Material for use on site at Tesla Motors must maintain full performance capabilities for 90 days in an
operational tank with proper bath maintenance.
3.5 Testing Protocols. Test samples shall be tested in as-received condition a minimum of 72 hours
after the completion of the baking process. Initial approval data shall come from one lot consisting of 5
specimens per test, unless otherwise specified. Test specimens shall measure 100 mm x 300 mm
unless directed otherwise.
All samples to be tested must be conditioned for at least 24 hours at +23±2°C and 50±5% RH
immediately prior to testing per ISO 554. Default values of temperature and humidity are taken to be
+23±2°C and 50±5% RH. If not specified otherwise, such conditions may be assumed. All prescribed
values of temperature and humidity are target values; variations within ±2°C and ±5% RH of these
values are permissible, unless otherwise noted. Exposure time periods carry a tolerance of ±5
minutes. If a specimen must be transferred from one test environment to another within a given cycle,
this lapse may not last longer than 1 minute.
3.6 Grade Structure. Grade 10 (Table 1) requirements apply to non-decorative interior applications.
Grade 11 (Table 2) requirements apply to decorative interior applications. Grade 20 (Table 3)
requirements apply to exterior and body applications. Grade 30 (Table 4) requirements apply to
powertrain applications.
3.7 Property Requirements. The property requirements that define each grade are listed in the
following tables (over).
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TABLE 1: GRADE 10
UNITS
PROPERTY STANDARD REQUIREMENT
CONDITIONS
Color –– –– per drawing
Gloss 60° ISO 2813 per drawing
15 – 35
Thickness µm ISO 2808
cavities: 12 – 35
Hardness –– ISO 15184 > 2H
surfaces: no corrosion (red/white)

edges: < 5% red/white
Corrosion
96 hours ISO 9227 welds: < 5% red/white
resistance
scribe creep: < 3 mm max (CRS < 5)
blistering: none
as-received ASTM D3359B 4B
ASTM D1735 4B
Adhesion 240 h humidity
ASTM D3359B no blistering or corrosion
following corrosion
ASTM D3359B 4B
test
MEK, 20 double rubs ASTM D4752 no visual changes

Solvent
resistance acetone, 20 double
ASTM D4752 no visual changes
rubs
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TABLE 2: GRADE 11
UNITS
CONDITIONS
15 – 35
cavities: 12 – 35
ISO 17872 no surface, edge or weld corrosion

Corrosion
96 hours ISO 9227 no blistering
resistance
ISO 4628-8 scribe creep: c < 3 mm (CRS < 5)
ASTM D1735 4B
following corrosion
ASTM D3359B 4B
test

Solvent
rubs
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TABLE 3: GRADE 20
UNITS
CONDITIONS
20 – 35
cavities: 15 – 35
surfaces: no corrosion (red/white)

ISO 17872 edges: < 15% red, < 40% white
Corrosion
50 cycles SAE J2334 welds: < 15% red/white
resistance
ISO 4628-8 scribe creep: c < 3 mm max (CRS < 5)
blistering: none
Corrosion mm, 1000 h
ASTM D2803 <3
resistance (aluminum only)
ASTM D1735 4B
following cyclic
ASTM D3359B 4B
corrosion
mm, –18°C
Chip resistance ASTM D3170 chip size < 1.5
(underbody only)

Solvent
rubs
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TABLE 4: GRADE 30
UNITS
CONDITIONS
20 – 35
cavities: 15 – 35
aluminum, CRS, HRS

840 h ISO 9227 3
max blister size, mm
aluminum, CRS, HRS
ISO 17872
line scribe
ISO 9227 c<3
840 h
ISO 4628-8
Corrosion max creepage, mm
resistance galvanneal steel
480h ISO 9227 3
max blister size, mm
galvanneal steel
ISO 17872
line scribe
ISO 9227 c<5
480h
ISO 4628-8
max creepage, mm
ASTM D1735 4B
following corrosion
ASTM D3359B 4B
test
mm, –18°C
Chip resistance ASTM D3170 chip size < 1.5
(underbody only)

Solvent
rubs
4 Document History
VERSION ISSUER DATE DESCRIPTION OF CHANGE
01 A. Pezeshkian 2014-07 Initial Release
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TM-5001 TESLA MOTORS STANDARD

0 Overview & Guidance

Color –– –– per drawing

Gloss 60° ISO 2813 per drawing

Hardness –– ISO 15184 > 2H

surfaces: no corrosion (red/white)

as-received ASTM D3359B 4B

MEK, 20 double rubs ASTM D4752 no visual changes

Color –– –– per drawing

Gloss 60° ISO 2813 per drawing

Hardness –– ISO 15184 > 2H

ISO 17872 no surface, edge or weld corrosion

as-received ASTM D3359B 4B

MEK, 20 double rubs ASTM D4752 no visual changes

Color –– –– per drawing

Gloss 60° ISO 2813 per drawing

Hardness –– ISO 15184 > 2H

surfaces: no corrosion (red/white)

as-received ASTM D3359B 4B

MEK, 20 double rubs ASTM D4752 no visual changes

Color –– –– per drawing

Gloss 60° ISO 2813 per drawing

Hardness –– ISO 15184 > 2H

aluminum, CRS, HRS

as-received ASTM D3359B 4B

MEK, 20 double rubs ASTM D4752 no visual changes

VERSION ISSUER DATE DESCRIPTION OF CHANGE

01 A. Pezeshkian 2014-07 Initial Release

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