DAIMLERCHRYSLER CORPORATION No: PS-8956

Process Standard Date Published: 2003-03-13

Category Code: H-1 Change: N
EASL Req. Yes

CONDUCTIVE PLATED COATINGS FOR ELECTRICAL CONNECTORS AND CORROSION

PROTECTION

1.0 GENERAL

1.1 Purpose

This standard specifies the requirements for electroplated or mechanically plated tin-zinc deposits and
their associated chromate coatings. These coatings are intended for corrosion resistance and electrical
conductivity, and are also suitable for general corrosion protection of non-electrical components.

1.2 Coverage of this Standard

This standard specifies the plating process and performance requirements for electrodeposited and
mechanically plated tin-zinc coatings, and their associated chromate coatings, for use primarily on
fasteners used for electrical grounding and other electrically conductive components (e.g., lamp sockets),
when these automotive elements are used in corrosive environments. These coatings may also be used
for corrosion protection of non-electrical components.

2.0 REQUIREMENTS ON PART DRAWINGS

A. When this process standard is specified, an ΑE≅ or ΑM≅ suffix shall be added to the process standard
number to indicate the method of coating application. That is, E for electroplate or M for Mechanical plate.
If a suffix is not added, either method of application may be used.

B. The desired deposit thickness must be specified after the process standard number using a Αcode”
designation, e.g., PS-8956E Code 30 means an electroplated deposit with a thickness of 8 micrometers.

C. Specific requirements shown on the part drawing shall take precedence over related requirements
specified in this standard, or may be in addition to the requirements of this standard.

D. The notation Α<D> QAR per PS-7300" shall appear in the Part Drawing Standards Block.

3.0 REQUIREMENTS

3.1 Application, Finish and Workmanship

3.1.1 Method of Application

This standard covers both electroplating and mechanical plating. Parts susceptible to hydrogen
embrittlement, as defined in PS-9500, may be either electroplated or mechanically plated. However,
whenever practical (as determined by part size, shape, etc.), mechanical plating is preferred to avoid the
possibility of hydrogen embrittlement. Hardened electroplated parts are subject to the requirements of the
Hydrogen Embrittlement Relief Process Standard PS-9500.

3.1.2 Finish Requirements on Significant Surfaces

The requirements of this standard apply to the significant surfaces of a part. Unless otherwise specified,

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significant surfaces for plating thickness and corrosion resistance are all surfaces that can be touched by a
19 mm (0.75 in) diameter sphere. Threads of electroplated threaded parts are not considered significant
surfaces. Heads of screws, bolts and unthreaded shanks of bolts are significant surfaces. On
mechanically plated parts, significant surfaces are all surfaces that are readily accessible to the proper
size impact media.

3.1.3 Workmanship

The plating shall be smooth and free from blisters, pits, nodules and other harmful defects. Coverage
shall be uniform in appearance and complete except in deep recesses or small diameter holes.

3.1.4 Alloy Composition

The following table summarizes the permissible alloy compositions covered by this process standard.

TABLE 1: ALLOY COMPOSITIONS AND PERMISSIBLE CONCENTRATION RANGE

TYPE OF DEPOSIT PERCENT TIN PERCENT ZINC

PS-8956E, Electroplated Alloy 70 +/- 10 30 +/- 10

PS-8956M, Mechanically Plated Alloy 30 +/- 5 70 +/- 5
PS-8956L, Mechanically Plated Alloy, 2.5 micrometers (0.0001 in) 8.0 micrometers (0.0003 in)
Layered Deposit tin top layer zinc bottom layer

4.0 PRETREATMENT PROCESS - PARTS TO BE ELECTROPLATED OR MECHANICALLY PLATED

4.1 Alkaline Cleaning

Light soils may be removed by soaking parts in a heated alkaline cleaner. Electrocleaning, with the parts
made anodic (positive polarity), may also be used. Parts subject to hydrogen embrittlement shall not be
cleaned cathodically (negative).

4.2 Rust and Scale Removal

The preferred procedures for the removal of heat treat scale or rust on high strength/high hardness parts
are tumbling, vibratory finishing or blasting with a fine abrasive. Alkaline rust removers and de-scalers
may also be used.

4.3 Acid Cleaning

Acid Cleaning is the least desirable of the available cleaning methods for hardened steel parts because it
can contribute to hydrogen embrittlement. Consequently, if fasteners or hardened steel parts with high
hardness, as defined in PS-9500 are acid cleaned, it is required that an inhibited, maximum 5% sulfuric
acid based acid be used and the parts limited to a maximum of 10 minutes exposure. Controls must be
implemented and records must be kept on the type and strength of inhibitor. Steps must also be taken to
remove the parts from the acid bath during plant shutdown due to mechanical or power failure in less than
the 10 minute maximum acid exposure time.

5.0 MECHANICAL PLATING PROCESS

Mechanically plated coatings are to applied to Code 40 (10 micrometers, 0.0004 in) thickness unless
otherwise specified and shall consist of a uniform mixture of about 70 percent zinc and 30 percent tin.
Alternatively, 8 micrometers (0.0003 in) of mechanically deposited zinc, can be overplated with 2.5
micrometers (0.0001 in) of mechanically deposited tin. A yellow or bronze chromate coating shall also be

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provided, and is considered an integral part of the deposit and this standard.

5.1 Media Size

The selection of impact media has an important effect on the quality of the plating obtained. On some part
types, such as cross-recess head screws, one media size will become lodged. The plater must carefully
select a media mix that will not lodge in the recess, threaded area or under free spinning washers. For
some parts the best alternative is to use straight 50 mesh to 100 mesh with no larger media.

5.2 Mechanical Plate Water Polish

Mechanically plated parts must be suitably burnished by Αwater polishing” to consolidate the coating and
minimize loose surface particles prior to chromating.

5.3 Chromate Type Conversion Coatings

FOR PARTS PRIOR TO JANUARY 1, 2007, the zinc alloy deposits of this standard are to be yellow or
bronze chromated followed by an approved leachant-sealant until the yellow is nearly gone. This should
be done immediately after plating and while the parts are still wet.

FOR PARTS TO BE SUPPLIED ON JANUARY 1, 2007 and beyond, hexavalent chromium is no longer
allowed. “Clear” colored trivalent chromate systems with equivalent or improved corrosion resistances are
permitted. Topcoats or sealers are not allowed on fasteners or other threaded parts unless approved by
Fastener Engineering. Slight color variations and iridescence are permitted.

5.4 Leachant/Sealant

Mechanically plated fasteners shall additionally be coated with an approved, proprietary leachant/sealant
after chromating. The leachant/sealant shall be maintained and applied according to the
recommendations of the leachant/sealant vendor. The approved leachant/sealants are listed as an
addendum to this standard.

6.0 ELECTROPLATING PROCESS

The operation of the alloy tin-zinc electroplating bath shall be carried out in accordance with the
instructions of the proprietary chemical supplier of the plating process, and shall produce the alloy
composition listed in Section 3.1.4.

6.1 Requirements for Parts to be Electroplated

6.1.1 Minimum Electroplated Thicknesses

The minimum electroplated thickness is specified by the Code Number suffix appearing after the process
standard number as follows:

CODE TABLE 2: THICKNESS

20 5 micrometers (0.00020 in)

30 8 micrometers (0.00030 in)
40 10 micrometers (0.00040 in)
50 13 micrometers (0.00050 in)

Deposit thicknesses greater than Code 50 are generally not recommended. If it is determined that
electroplated thicknesses less than Code 20 or greater than Code 50 are necessary for a particular
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application, drawing notes shall be used to designate the required thickness.

6.2 Plate Thickness on Significant Surfaces

To insure compliance with the minimum thickness requirements of this standard, the plating thicknesses
shall be measured on a regular and frequent basis using acceptable sampling plans, such as
recommended in ASTM B-697 and B-762 or equivalents. Control charts and records documenting
compliance with the minimum thickness requirements of this standard shall be prepared and maintained.

The plate thickness on significant surfaces must meet the minimum thickness as specified by the ΑCode”
designation (refer to Section 3.5.1).

The following ASTM Standard Methods are recommended for determining the coating thickness:

ASTM B 487 Microscopic Cross Section

ASTM B 568 X-Ray Method
ASTM B 499 Magnetic Method

Except for the microscopic method, it is essential to calibrate the test instrument with an alloy or mixture of
the same composition as that being measured.

6.3 Chromate Coatings

A chromate type passivate is considered an integral part of the electrodeposited tin-zinc alloy of this
process standard. Chromated coatings significantly enhance the overall corrosion resistance of the
deposit. The tin-zinc alloy electrodeposit, covered by this process standard, require a hexavalent or
trivalent chromate conversion coating that is formulated for the particular alloy.

NOTE: PARTS SUBMITTED PRIOR TO JANUARY 1, 2007 MAY UTILIZE EITHER A HEXAVALENT OR
TRIVALENT CHROMATE. PARTS SUPPLIED BEGINNING JANUARY 1, 2007 SHALL USE A
TRIVALENT CHROMATE SYSTEM ONLY. HEXAVALENT CHROMATES WILL NO LONGER BE
ALLOWED AT THAT TIME. NO TOPCOATS ARE ALLOWED ON FASTENERS AND OTHER
THREADED PARTS UNLESS APPROVED BY FASTENER ENGINEERING. SLIGHT COLOR
IRIDESCENCE AND VARIATIONS ARE ACCEPTABLE.

7.0 PERFORMANCE

7.1 Adhesion, General

The deposit shall not peel from itself or from the substrate when tested in accordance with ASTM B 571
(Standard Test Methods for Adhesion of Metallic Coatings). The hardened, aged (for 24 hours) chromate
coating shall be tightly adherent to the plated coating and shall not be removed by ordinary handling.

7.2 Mechanical Plate Adhesion Tests

Mechanically plated parts shall show no evidence of loosely adherent or poorly consolidated plating when
inspected as follows:

A. Parts with smooth surfaces shall be subjected to a tape test. The adhesive side of a strip of
transparent tape (e.g., Α3M Scotch” type 810) shall be pressed firmly against the smooth surfaces of a
part to pick up any loosely adherent metallic particles. The test tape is then applied to a clean, white
paper for viewing. Evidence of loose particles adhering to the tape shall result in rejection of the entire lot
of parts.

B. Internal drive fasteners shall be subjected to a Αprobe test”. The cavity of the drive recess shall be
probed with the end of a stiff wire (e.g., a paper clip) to loosen any poorly consolidated or poorly bonded
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metal particles. Evidence of dislodged particles falling from the drive recess when the fastener is inverted
over and tapped against a hard white surface shall result in rejection of the entire lot of parts.

7.3 Dimensional Tolerance

Tolerances specified on drawings are for the final dimensions unless otherwise indicated. Allowance for
plating build-up may have to be made in the dimensions of threaded fasteners. (See page Z-2.01 for
checking ISO metric screw threads).

7.4 Hydrogen Embrittlement Relief

Parts mechanically plated to the requirements of this standard must be treated for hydrogen embrittlement
relief as shown in Table 1 of Process Standard PS-9500, Section 2.2.3.

Electroplated, hardened steel parts with a Rockwell Hardness of HRC 31 or greater MUST BE BAKED to
the schedule specified in Process Standard PS-9500 Section 2.2.4, Table 2.

7.5 Hydrogen Embrittlement Test

The hydrogen embrittlement test shall be performed according to the requirements of Process Standard
PS-9500, Section 3.0, Hydrogen Embrittlement Test.

7.6 Accelerated Corrosion Resistance

Sample plated and chromated parts shall be dried and aged for 24 hours prior to exposing them to the salt
spray test. The test shall be conducted in accordance with ASTM B 117 for the times shown in Table 2.
Salt spray corrosion test requirements DO NOT apply to deep recesses, such as small blind holes and the
interior of tubing, or to non-significant surfaces.

The objective of the ΑHours to White Rust” requirement (Table 2), is freedom from Voluminous white
corrosion products after testing for the number of hours listed. A light white film or Αblush” does not
constitute a failure. Table 2 summarizes the required minimum hours of exposure to salt spray before the
formation of white corrosion products, as well as the minimum number of hours to red rust.

Also, chromate coatings are inherently fragile films and some damage at sharp edges, corners, etc., is to
be expected. Small amounts of white corrosion products at such damage sites DO NOT constitute a
failure.

TABLE 3: MINIMUM SALT SPRAY TEST REQUIREMENTS

MINIMUM HOURS TO
METHOD OF COATING THICKNESS CODE
WHITE CORROSION RED RUST

Electroplated Code 20 120 300

Electroplated Code 30 120 400
Electroplated Code 40 120 500
Electroplated Code 50 120 600
Mechanically Plated Code 30 120 200
Mechanically Plated Code 40 120 250

On parts with a surface area greater than 155 sq cm (24 sq in), the appearance of one or more red rust
spots per each 155 sq cm (24 sq in) of significant surface (see Section 3.1.2), that are visible to the
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unaided eye at normal reading distance or any rust spot originating from an area larger than 1.6 mm (1/16
in) in diameter is considered a failure. On parts smaller than 155 sq cm (24 sq in), the appearance of
more than one rust spot on any significant surface or any spot originating from a spot larger than 1.6 mm
(1/16 in) in diameter is a failure.

On threaded fasteners, the formation of corrosion products in the threaded areas DOES NOT constitute a
failure. However, the head and unthreaded shank of a screw or bolt is considered a significant surface
and must withstand the formation of white and red rust for the minimum times listed in Table 2.

8.0 QUALITY

Refer to CS-9801 for general quality requirements.

9.0 GENERAL INFORMATION

Three asterisks “***” after the section/paragraph header denotes multiple technical changes to the
section/paragraph. A triple asterisk before and after a string of text (***text***) identifies a single change.

Certain important information relative to this standard has been included in separate standards. To assure
the processes submitted meet all of DaimlerChrysler requirements, it is mandatory that the requirements
in the following standards be met.

CS-9800 - Application of this standard, the subscription service, and approved sources
CS-9003 - Regulated substances and recyclability

Within Engineering Standards, the Regulatory (Government-mandated) requirements are designated by

<S>, <E> and <H> which correspond to Safety, Emission and Homologation Shields respectively. The
DCC-mandated requirements are designated by <D>, <A> and <T> and correspond to the Diamond,
Appearance and Traceability symbols respectively.

For specific information on this document, please refer to the contact person shown in the "Publication
Information" Section of this document. For general information on obtaining Engineering Standards and
Laboratory Procedures, see CS-9800 or contact the Engineering Standards Department at
engstds@dcx.com.

10.0 REFERENCES

CS-9003 CS-9800 CS-9801 PS-809 PS-6239

PS-7300 PS-9500 ASTM B 117 ASTM B 487 ASTM B 499
ASTM B 568 ASTM B 571 ASTM B 602 ASTM B 697 ASTM B 762

11.0 ENGINEERING APPROVED SOURCE LIST

Processes, covered by this standard, shall only be purchased from those sources listed in Table 3 below:

APPROVED MECHANICAL PLATERS, PS-8956M

AMAC Industries, Inc. Mechanical Galv-Plating
Cleveland, OH Sidney, OH
All Service Metal Treating N & W Metal Finishing Inc.
W. Trenton, NJ Cleveland, OH
Cadon Plating Co. Plateco
Wyandotte, MI Reedsburg, WI
Coatings 85 Plant ΑB & D Reilly Plating Corp
Mississauga, Ontario Melvindale, MI

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 APPROVED MECHANICAL PLATERS, PS-8956M
Crest Products, Inc. (Captive Shop) Rotor Clip Co. (Captive Shop)
Lexington, KY Somerset, NJ
Drake Mechanical Plating Sur-Fin
Homer, MI Traverse City, MI
Dyna-Burr Chicago Corp. Quality Rolling and Deburring
Northlake, IL Thomaston, CT
Dyna-Burr Corp, Wisconsin Mechanical Metal Finishing
Rockford, IL Brookfield, WI

APPROVED ELECTROPLATERS, PS-8956E

Ajax Metal Processing Inc.
Detroit, MI
Burbank Plating
Pacoima, CA 91331
Finishing Services Inc.
Ypsilanti, MI
Modern Plating Corp
Plating Technology, Inc.
Columbus, OH 43206
***Roy Metal Finishing
Conetee, SC 29636
Varland Metal Service, Inc.
Cincinatti, OH 45229
Freeport, IL 61032 Whyco Chromium Company, Inc.
Thomaston, CT 06787

SUPPLIERS OF APPROVED PROPRIETARY MECHANICAL PLATING

PROCESSES
MacDermid, Inc. Tru-Plate Process, Inc.
Waterbury, CT Subsidiary of McGean-Rohco, Inc.
Cleveland, OH
Plating Systems & Technologies Mechanical Coatings Corp.
Jackson, MI Sidney, OH

APPROVED LEACHANTS/SEALANTS
SUPPLIER PRODUCT NAME
MacDermid, Inc. JS500
Waterbury, CT Ultraseal
Tru-Plate Process, Inc. Tru-Plate 0470 Clear Seal
Cleveland, OH

12.0 PUBLICATION INFORMATION

Contact/Phone No: R.J. Lash (248) 576-7461

Alternate Contact/Phone No:
Dept. Name & Dept. No./Tech Club/Organization: Body Materials Engineering, Dept 5820
Date Standard Originally (Initially) Issued: 1990-01-08
Date Published: 2003-03-13
Change Notice:
Description of Change: EASL, Removed <D>

#####

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