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AEROSPACE AMS2477 REV. A

MATERIAL
Issued 2005-02
SPECIFICATION Revised 2010-04

Superseding AMS2477
Conversion Coating for Aluminum Alloys
Low Electrical Resistance Coating

RATIONALE

AMS2477A results from a Five Year Review and update of this specification.

1. SCOPE

1.1 Purpose

This specification covers the requirements for a low-electrical-resistance chemical conversion coating on aluminum and
aluminum alloy parts.

1.2 Application

This process has been used typically to provide aluminum with a thin inorganic film that improves corrosion resistance
and adhesion of organic coatings and possesses low electrical resistance, but usage Is not limited to such applications.

1.3 Safety - Hazardous Materials

No further reproduction or networking is permitted.

While the materials, methods, applications, and processes described or referenced in this specification may involve the
use of hazardous materials, this specification does not address the hazards which may be involved in such use. It is the
responsibility of the user to ensure familiarity with the safe and proper use of any hazardous materials and to take
necessary precautionary measures to ensure the health and safety of all personnel involved.

2. APPLICABLE DOCUMENTS

The issue of the following documents in effect on the date of the purchase order forms a part of this specification to the
extent specified herein. The supplier may work to a subsequent revision of a document unless a specific document issue
is specified. When the referenced document has been cancelled and no superseding document has been specified, the
last published issue of that document shall apply.

2.1 SAE Publications

Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside
USA and Canada) or 724-776-4970 (outside USA), www.sae.org.

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AMS4027 Aluminum Alloy, Sheet and Plate, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061; -T6 Sheet, -T651 Plate),
Solution and Precipitation Heat Treated

__________________________________________________________________________________________________________________________________________
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entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.”
SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.
Copyright © 2010 SAE International
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of SAE.
TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) SAE values your input. To provide feedback
Tel: +1 724-776-4970 (outside USA) on this Technical Report, please visit
Fax: 724-776-0790 http://www.sae.org/technical/standards/AMS2477A
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SAE AMS2477A Page 2 of 6

2.2 ASTM Publications

Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshocken, PA 15248-2959, Tel: 610-
832-9585, www.astm.org.

ASTM B 117 Operating Salt Spray (Fog) Apparatus

ASTM D 3359 Test Methods for Measuring Adhesion by Tape Test

2.3 U.S. Government Publications

Available from the Document Automation and Production Service (DAPS), Building 4/D, 700 Robbins Avenue,
Philadelphia, PA 19111-5044, Tel: 215-697-6257, http://assist.daps.dla.mil/quicksearch/.

MIL-PRF-23377 Primer Coatings: Epoxy High-Solids

MIL-P-53022 Primer, Epoxy Coating, Corrosion Inhibiting, Lead and Chromate Free
MIL-P-53030 Primer Coating, Epoxy, Water Reducible, Lead and Chromate Free
MIL-PRF-85582 Primer Coatings: Epoxy, Waterborne

3. TECHNICAL REQUIREMENTS

3.1 Preparation

3.1.1 Location of racking points shall be on areas not to be coated or where acceptable to the cognizant engineering
organization.

No further reproduction or networking is permitted.

3.1.2 The coating shall be applied over a surface free from water breaks. The cleaning procedure shall not produce
pitting or intergranular attack of the basis metal and shall preserve dimensional requirements. See 8.5.

3.2 Procedure

3.2.1 The application process shall consist of immersion, spray, pen, or brush (swab) application of a solution capable
of generating a coating compliant with the requirements of this specification. See 8.6.

3.2.2 Touchup

Unless otherwise specified by the cognizant engineering organization, areas from which the coating has been removed
may be touched up provided the area touched-up does not exceed 5 percent of the total surface area of the part.

3.3 Properties

Coated surfaces shall conform to the following requirements:

3.3.1 Electrical contact resistance of the coated product shall not exceed 0.005 ohm (5 milliohm) per square inch when

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tested in accordance with a procedure acceptable to the cognizant engineering organization See 8.11.

3.3.2 Corrosion Resistance

The basis metal shall not show evidence of corrosion beyond the limits specified below after exposure to 168 hours ± 1 to
salt spray corrosion testing in accordance with ASTM B 117 with the exposed surface of test panels inclined back
approximately 6 degrees from vertical.

3.3.2.1 No specimen shall show more than five isolated spots or pits, none larger than 1/32 inch (0.79 mm) in diameter.
Areas within 0.25 inch (6.4 mm) from the edges, identification markings, and racking points shall be excluded.
Loss of color shall not be cause for rejection. See 8.8.
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SAE AMS2477A Page 3 of 6

3.3.2.2 No more than 15 isolated spots or pits, none larger than 1/32 inch (0.79 mm) in diameter, on the combined
surface area of all five test panels. See 8.8.

3.3.2.3 Electrical contact resistance after salt fog exposure shall not exceed 0.010 ohm (10 milliohm) per square inch
when tested in accordance with a procedure acceptable to the cognizant engineering organization. See 8.11.

3.3.3 Color

Coating shall be any distinctive color that distinguishes coated from the uncoated items. See 8.9.

3.3.4 Primer Adhesion

Primer in accordance with MIL-P-53022, MIL-P-53030, MIL-PRF-23377, or MIL-PRF-85582 applied over the conversion
coating and cured in accordance with manufacturer’s instructions shall show no separation between the primer and the
conversion coating when tested in accordance with ASTM D 3359 dry tape method

3.4 Quality

3.4.1 The coating, as received by purchaser, shall be continuous, adherent to basis metal, and visually free from
powdery residue, pin holes, pits, and other imperfections detrimental to usage of the parts. Appearance shall be
uniform although slight variations in color are permissible.

4. QUALITY ASSURANCE PROVISIONS

No further reproduction or networking is permitted.

4.1 Responsibility for Inspection

The processor shall supply all samples for processor’s tests and shall be responsible for performance of all required tests.
When parts are to be tested, the parts shall be supplied by purchaser. The cognizant engineering organization reserves
the right to sample and to perform any confirmatory testing deemed necessary to ensure that processing conforms to
specified requirements.

4.2 Classification of Tests

4.2.1 Acceptance Tests

Color (3.3.3) and quality (3.4) are acceptance tests and shall be performed on parts, or samples representing parts when
permitted, from each lot. See 4.3.3.

4.2.2 Periodic Tests

Corrosion resistance (3.3.2) and primer adhesion (3.3.4) are periodic tests and shall be performed monthly unless
frequency of testing is specified by the cognizant engineering organization. Tests of cleaning and coating solutions are
periodic tests and shall be performed at a frequency established by the processor unless frequency of testing is specified

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by the cognizant engineering organization. See 8.4.

4.2.2.1 Periodic testing may be suspended in any month when parts are not processed, however, preproduction testing
may be required by the cognizant quality organization upon resumption of processing.

4.2.3 Preproduction Tests

All property verification tests (section 3.3) are preproduction tests shall be performed prior to production and when the
cognizant engineering organization deems confirmatory testing to be required.
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SAE AMS2477A Page 4 of 6

4.3 Sampling for Testing

4.3.1 Acceptance Tests

Test samples shall be randomly selected from all parts in the lot. A lot shall be all parts of the same part number coated in
the same set of solutions in each consecutive 24 hours of operation, and presented for processor’s inspection at one
time. Unless the cognizant engineering organization provides a sampling plan, the minimum number of samples shall be
as shown in Table 1.

TABLE 1 - Sampling For Acceptance Tests

Number of Parts Quality and
in Lot Color
up to 6 All
7 to 15 7
16 to 40 10
41 to 110 15
111 to 300 25
301 to 500 35
501 to 700 50
701 to 1200 75
over 1200 125

4.3.2 Periodic Tests

No further reproduction or networking is permitted.

Five test panels are required for corrosion resistance tests. Two test panels are required for primer adhesion tests.

4.3.3 Sample Configuration

4.3.3.1 AMS4027 (6061-T6) test panels for corrosion and electrical resistance testing shall be cleaned and processed
with parts. Dimensions, number of test panels, and number and location of readings shall be in accordance with
the test procedure. See 3.3.1.

4.4 Approval

4.4.1 The process and control factors or a preproduction part, or both, whichever is specified, shall be approved by the
cognizant engineering organization before production parts are supplied.

4.4.2 If the processor makes a significant change to any material, process, or control factor from that which was used
for process approval, all preproduction tests shall be performed and the results submitted to the cognizant
engineering organization for process reapproval unless the change is approved by the cognizant engineering
organization. A significant change is one which, in the judgment of the cognizant engineering organization, could
affect the properties or performance of the parts.

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4.4.3 Control factors shall include, but not be limited to the following:

Surface preparation and cleaning methods

Coating material trade name and manufacturer
Coating bath composition and composition control limits
Coating bath temperature limits and controls
Primer application and adhesion test procedure
Electrical contact resistance test procedure
Stripping procedure, when applicable
Periodic test plan for cleaning and processing solutions. See 8.4.
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SAE AMS2477A Page 5 of 6

4.5 Reports

The processor shall furnish with each shipment a report stating that the parts have been processed and tested in
accordance with the specified requirements and that they conform to the acceptance test requirements. This report shall
include the purchase order number, AMS2477A, part number, and quantity.

4.6 Resampling and Retesting

4.6.1 If any acceptance test fails to meet specified test requirements, the parts in that lot may be stripped, pretreated,
coated, and post treated as defined herein and retested. Alternatively, all parts in the lot may be inspected for the
nonconforming attribute, and the nonconforming parts may be stripped, pretreated, coated, and post treated as
defined herein, and retested. After stripping and recoating, parts shall meet the dimensions on the drawing.

4.6.1.1 When stripping is performed, the method shall be acceptable to the the cognizant engineering organization and
shall not roughen, pit, or embrittle the basis metal or adversely affect part dimensions. When parts have been
stripped and recoated, the purchaser shall be informed.

4.6.2 If any periodic test fails to meet specified test requirements, the process is nonconforming. No additional parts
shall be coated until the process is corrected and new specimens are coated and tested. Results of all tests shall
be recorded and, when requested, reported. Purchasers shall be notified of all parts coated since the last
acceptable test.

5. PREPARATION FOR DELIVERY

5.1 Parts shall be handled and packaged in such a manner as will ensure that the required physical characteristics and
properties of the coating are preserved.

No further reproduction or networking is permitted.

5.2 Packages of coated parts shall be prepared for shipment in accordance with commercial practice and in
compliance with applicable rules and regulations pertaining to the handling, packaging, and transportation of the
parts to ensure carrier acceptance and safe delivery.

6. ACKNOWLEDGMENT

The processor shall mention AMS2477A in all quotations and when acknowledging purchase orders.

7. REJECTIONS

Parts on which coating does not conform to this specification or to modifications authorized by the cognizant engineering
organization will be subject to rejection.

8. NOTES

8.1 The change bar (|) located in the left margin is for convenience of the user in locating areas where technical
revisions, not editorial changes, have been made to the previous issue of this document. An (R) symbol to the left

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of the document title indicates a complete revision of the document including technical revisions, change bars and
(R) are not used in original publications, nor in documents that contain editorial changes only.

8.2 Part manufacturing operations, such as heat treatment, forming, joining, and media finishing, can affect the
condition of the substrate, or, if performed after coating, could adversely affect the coating. Achieving a durable,
low-electrical-resistance assembled bond joint typically requires removal of all coatings down to bare aluminum,
brush application of the conversion coating to a specific contact area, drying, and sealing of the joint. The
sequencing of operations and the maximum joint resistance should be specified by the cognizant engineering
organization and is not controlled by this specification.
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SAE AMS2477A Page 6 of 6

8.3 The parts manufacturer should ensure that the surfaces of the metal parts supplied to the processor are free from
blemishes, pits, tool marks, and other irregularities that will affect the quality of the finished parts. Defects and
variations in appearance that arise from surface conditions of the substrate, such as porosity, scratches, or
inclusions, that persist in the coating despite the observance of accepted industry practices shall not be cause for
rejection.

8.4 ARP4992, Periodic Test Plan for Process Solutions, is recommended to satisfy the requirements for the control of
processing solutions.

8.5 A commercial deoxidizer is typically used to produce a clean, slightly etched surface. Alkaline etching can result in
intergranular attack. Alkaline residues should be removed by thorough rinsing in order to extend the life of the
deoxidizer and/or conversion coating solution.

8.6 The coating raw material is typically supplied in powder form by a specialty chemical firm which provides mixing
and operating instructions.

8.7 Exposure of the applied coating to temperatures above 140 °F (60 °C) may degrade corrosion resistance.

8.8 A corrosion pit or spot can usually be distinguished from other indications by a tail or line of corrosion product under
the pit or spot. Pit size may be determined by either direct dimensional measurement or by comparison to known
references.

8.9 Brownish and dark yellow coatings do not typically have low electrical resistance and may not meet corrosion
resistance requirements. Optimal characteristics are typically obtained with a light coloration. Alloy, surface

No further reproduction or networking is permitted.

roughness, and composition of the solution will determine the exact coloration.

8.10 Conversion coating covered by this specification has poor abrasion resistance. Proper material handling methods
and care during subsequent operations will help avoid damage.

8.11 The electrical resistivity testing procedure should comply with MIL-DTL-81706. Use of self-aligning, gimballed
probes has been found to enhance repeatability and minimize data scatter. Probe and panel surface roughness
should not exceed 32 AA microinch because rough surfaces can yield erroneously low readings. To keep bulk
resistance to a minimum, panel thickness should not exceed 0.025 inch. Use of noble-metal probes is not required.
Contact pressure should be approximately 200 psi.

8.12 Terms used in AMS are defined in ARP1917.

8.13 Dimensions and properties in inch/pound units and the Fahrenheit temperatures are primary: dimensions and
properties in SI units and the Celsius temperatures are shown as the approximate equivalents of the primary units
and are presented only for information.

8.14 Purchase documents should specify not less than the following:

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AMS2477A
Paint and application process, if applicable (3.3.4)
Material and Temper
Part number and quantity of pieces to be processed
Electrical Resistance Test Procedure (3.3.1).

PREPARED BY AMS COMMITTEE “B”