The “ES91500-02 Electrical Terminals and Surface Treatments” standard, developed by Hyundai Motor Company and Kia Corporation, is a specialized engineering standard for automotive electrical terminals, busbar systems, and conductive metal components. This standard specifies the technical requirements for surface treatment, coating quality, corrosion resistance, and reliability of electrical contact parts used in Hyundai and Kia vehicles.
Numerous Hyundai/Kia engineering drawings, supplier documents, and connector specifications refer to the ES91500-02 standard as the applicable standard for electrical terminal surface treatments and coating performance.
Modern devices contain hundreds of electrical connectors. The performance of these connectors largely depends on the quality of the terminal coating. The ES91500-02 standard guarantees that electrical terminals provide the following:
This standard helps ensure long-term electrical reliability under demanding operating conditions.
The ES91500-02 standard generally applies to the following:
Mechanical fasteners such as bolts and nuts are generally covered by a different Hyundai specification (MS611-15 standard). The ES91500-02 standard, on the other hand, specifically regulates terminals and busbar systems. This distinction is clearly shown in Hyundai engineering drawings.
The ES91500-02 standard includes typical requirements in the following areas:
The choice depends on the following:
Thickness is typically verified using the following:
Excessive resistance can cause the following:
These tests simulate years of vehicle service.
Typical materials covered by the ES91500-02 standard include:
This standard specifies compatible coating systems for these base metals.
The test methods defined under the ES91500-02 standard are as follows:
The ES91500-02 standard is commonly used for components including the following:
The ES91500-02 standard works in conjunction with various Hyundai Motor engineering standards:
Engineering drawings generally require terminals to conform to the ES91500-02 standard and connectors to the MS611-15 standard.
Although the ES91500-02 standard is specific to Hyundai/Kia, its objectives are comparable to internationally accepted standards, including:
Connector manufacturers typically design their products to comply with the ES91500-02 standard, as well as SAE/USCAR and other automotive requirements.
Consequently, vehicle electrical systems are increasingly reliant on reliable, low-resistance connections. Even a minor degradation of the terminal coating can lead to voltage loss, overheating, intermittent failures, or complete connector failure. The ES91500-02 standard defines expectations for coating quality, corrosion resistance, durability, and electrical reliability, providing standardized requirements that help suppliers deliver consistent electrical performance in Hyundai and Kia vehicles. In short, this standard supports long-term vehicle safety, durability, and warranty performance.
The main sections of this standard are as follows:
For many years, our organization, with its competent and experienced staff, has been understanding the needs of its clients, providing the advanced testing services they require, and assisting them in the establishment, implementation, and improvement of management systems. Within this framework, we also provide testing services compliant with the ES91500-02 standard.
To get an appointment, to get more detailed information or to request an evaluation, you can ask us to fill in our form and reach you.
