AN 400 Part 2 - Corrosion protection for bought-in parts

Company Standard Issue date: 2010-01 

AN 400 Part 2 - Corrosion protection for bought-in parts 

Approved: Hr. Dr. Gehring Replace: 01.08.2009 Replaced by 

1. General 

This standard is a general instruction which is to be applied in all cases where special preservation or 

painting is not required by a quality directive, drawing information, order text or order policy. 

The supplier is responsible for the correct application of corrosion protection and for ensuring that goods 

are delivered in perfect condition without corrosion damage. 

Corrosion protection must be designed to cover transportation, and also be suitable for a period of at least 

12 months. 

In addition to corrosion protection, substantial packaging must be provided which protects the bought-in 

part against damage and the effects of the environment (e.g. moisture). 

As a general rule, only those corrosion protection methods and products which allow the bought-in part to 

be used without first removing the means of preservation are permissible. 

The use of corrosion inhibitors which have to be removed before the bought-in part can be used (high 

viscosity oils, waxes) is only permissible in the case of very large components (e.g. base frame or large 

engine crankcase (≥ 32/40)) and only by agreement with MAN Diesel. 

2. Painting 

All unmachined surfaces must be painted. 

As the requirement profile of the paints to be used is extremely varied, only paints approved by MAN 

Diesel must be used. 

The first listed products should be preferred. These products contain a minimum amount of solvents and 

comply with the requirements of European VOC legislation. 

When applied correctly, the paints specified in this norm fulfil all the requirements relating to temperature 

resistance, media compatibility (e.g. lubricating oil), compatibility with processing media (e.g. cutting fluid) 

and the ability to be painted over (with paint systems used by MAN Diesel). 

The paint manufacturer's processing instructions and the requirements for the surface of the part to be 

coated must be observed. 

The film thickness mentioned in the following chapters is the dry film thickness(DFT) above surface 

roughness. 

MAN Diesel SE Copyrights and utilization only allowed with obligation of MAN Diesel SE 1/10



2.1 Painting of turbocharger parts 

The cast parts to be painted can be seen from Drawing E.11.5004-0110 in the appendix. All other 

turbocharger parts for which painting is required must likewise be painted with the systems stated here, 

provided there is no purchase text or drawing with different requirements. 

The turbocharger parts supplied will not be given an additional top coat by MAN Diesel. The paint applied 

to bought-in parts is the final finish for the turbocharger. It is therefore essential that damage to the coating 

be avoided (e.g. when shipping). 

The following systems are approved: 

• Silicotherm 655E as a one-coat system, DFT 50µm on cast iron, otherwise 30µm 

Manufacturer: Süddeutsches Lackwerk, 85622 Feldkirchen, Germany 

Alternatively: 

• Sigmazinc 158/Sigmatherm 540 as a two-coat system 

Primer: Sigmazinc 158, DFT 75µm 

Top coat: Sigmatherm 540, DFT 25µm 

Manufacturer: Sigma Coatings 

Paints other than those stated are permissible if it can be shown that they fulfil the specification in the 

appendix (as an overall system). A test certificate from an independent laboratory must be submitted to 

MAN Diesel for this purpose. 

2.2 Painting of thermally stressed engine parts 

These include parts of Assembly 289 (exhaust pipe, …), and parts exposed to temperatures above 200°C 

(see drawing). 


• Thermo-Zink AL600+, DFT 50µm 



• Sigmazinc 158, DFT 75µm 



appendix. A test certificate from an independent laboratory must be submitted to MAN Diesel for this 

purpose. 




2.3 Painting of non-thermally stressed engine parts 


• Wetterwart 2K Ultra-High-Solid SL 2304, RAL 7040 



• Wetterwart SL 2233, RAL 7040 


• Sigmacover 435, light grey 


• Sigmacover 456, Colour mid-grey: RAL 7040 or similar 


• Amercoat 385, RAL Colour mid-grey: RAL 7040 or similar 

Manufacturer: PPG Protective and Marine Coatings 

All these coatings have to be applied with a DFT of 90 – 140µm 


appendix. A test certificate from an independent laboratory must be submitted to MAN Diesel for this 

purpose. 




3. Preservation 

All non-painted areas which are at risk of corrosion must be reliably protected against corrosion. 

Only products and systems which do not require the means of preservation to be removed before use are 

permitted for this purpose. 

If corrosion inhibiting oils are used, it must be ensured that these are compatible with the fluids used in 

engines (e.g. lubricating oil). 

The use of waxy corrosion inhibitors is only permitted in the case of very large parts and after prior 

consultation with MAN Diesel. 

A common method of providing temporary corrosion protection which does not require the preservation 

medium to be removed is the use of VCI products. VCI stands for Volatile Corrosion Inhibitor. 

The vapour phase of these products forms a corrosion inhibiting coating on the component to be protected 

which degrades when the VCI carrier is removed. Common VCI carriers include foil, paper, chips and oil. 

This is the recommended method of corrosion protection when shipping overland. 

This is the specified method when shipping overseas. 

Small parts can either be wrapped in VCI foil or in VCI paper and packed in a box. An additional VCI 

carrier (paper, oil, chips) must be used when using foil. 

Medium-sized and large parts must be packed in VCI foil. Bare surfaces and holes must additionally be 

preserved with a VCI oil. 

Examples of what such protection may look like are shown in the appendix. 

Reliable preservation using VCI products assumes that the packaging is not damaged during shipping. 

This must be ensured by choosing a suitable load carrier or suitable crate and appropriate marking. 

It must be ensured that only VCI products which are compatible with the component material are used. 

Only dry, clean and corrosion-free components may be preserved and packed. Perspiration from the 

hands on bare surfaces must be avoided. The components to be packed must be cooled to ambient 

temperature. Hot components (e.g. after cleaning) must not be packed. 

VCI products must be used before their shelf life has expired. Only VCI products from the original 

packaging may be used. VCI products lose their effectiveness if not stored in the original packaging. VCI 

packaging is non-returnable packaging and must not be reused. 

The packaging must be as air tight as possible. The VCI material is only able to work in a sealed pack. 

It is recommended that the manufacturer's advice be sought when using VCI products for the first time. 

There are various manufacturers of VCI products who are also represented worldwide. An example of 

these is Branopac (www.branopac.com), who are also represented in the Asiatic region. 




Attachment 1 




Attachment 2 

Examples for VCI preservation: 

Small parts: 

Medium sized and large parts: 




Attachment 3: Paint specification 

1. Painting of turbocharger parts 

Surface: blasted SA 2 ½ 

Characteristics Requirements Test Instructions 

Colour silver, RAL 9006 Visual as per RAL colour card 

Gloss matt DIN EN ISO 2813 (60° angle) 

Cross-hatch cut Gt 0 

DIN EN ISO 2409 

Multi-cut unit 1 mm spacing 

Adhesion test (scratch test) 

Original condition 

max. K 1 

(the coating shows good 

adhesion, but shows serrated 

edges) 

The coating is removed down to the 

background by cutting or scraping with a 

knife blade under pressure. To verify the 

bonding between several layers, the 

pressure on the knife blade is reduced as 

necessary. 

Salt-spray test Test duration 500 h DIN EN ISO 9227 

• Bubble build-up max. m0/g0 DIN 53209 

• Adhesion strength 

(scratch test) 

max. K 1 see adhesion test 

• Corrosion degree max. Ri 1 DIN 53210 

Condensed water climate 

test 

Test duration 500 h DIN EN ISO 6270-2 





Resistance to chemicals Test duration 24 h 

Types: see appendix T2A 

preservative 

cutting fluid 

cleaner 

Heat-Resistance 

600°C 

scratch test max. K 1 

cross-hatch cut max. Gt1 

No visible change, e.g. 

swelling or shrinkage 

Slight loss of gloss 

permissible 

test duration 48 h 



DIN EN ISO 2812-1 

Procedure 2 

RT (= Room temperature) 




2. Paint for thermal loaded engine parts 


Colour grey Visual 


DIN EN ISO 2409 

Multi-cut unit 1 mm spacing 

max. K 1 


Adhesion test (scratch test) 

(die Beschichtung haftet sehr 

gut, zeigt jedoch gezackte 


knife blade under pressure. To verify the 


Ränder) / (the coating shows 

good adhesion, but shows 

bonding between several layers, the 

pressure on the knife blade is reduced as 

serrated edges) 

necessary. 








test 







Types: see appendix T2A 

preservative 


cleaner 

Heat-Resistance 

600°C 






permissible 

test duration 48 h 




Procedure 2 





3. Paint for engine parts not thermal loaded 


Colour grey Visual 


DIN EN ISO 2409 Multi-cut unit 1 mm 

spacing 


max. K 1 


Adhesion test (scratch test) (the coating shows good knife blade under pressure. To verify the 


adhesion, but shows bonding between several layers, the 

serrated edges) pressure on the knife blade is reduced as 

necessary. 








test 







Types: see appendix 

Preservative 

lube oil 


Cleaner 

Recoatable with 2K-Epoxy 

Amerlock 2/400 ( dft 60-80 

µm) 




permissible 






Procedure 2 





Chemicals for resistance testing 

Engine oil: mineral oil based middle alkaline lube oil (e. g. Shell Argina X40, BP Energol IC- 

HFX404, Exxon Mobil Mobilgard M440, Chevron Taro 40XL40, Total Aurelia 

TI4040) 

Testing temperature: 80 °C 

Cleaner: alkaline water based spray-cleaner for metal components. Contains surfactants, 

amines, yellow metal inhibitors and anti-corrosion components. pH value 8,5 - 

10,5 (e. g. Eskaphor N6811, Haugg Chemie). 

testing temperature: 60 °C 

Cutting Fluid: watermiscuble cutting fluid containing amines, emulsifiers and corrosion 

inhibitors with a mineral oil content between 10 and 50 % 

(e. g. Castrol Hysol 30 FF) 

Preservative: wax-like preservative with a content of solvent (naphtha) of about 50 % (e. g. 

Valvoline Tectyl 846 oder Fuchs Anticorit BW 366)

AN 400 Part 2 - Corrosion protection for bought-in parts

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