DaimtenC+RYSLER CORPORATION Ne: PS-8956 Process Standard Date Publishes: 2002-06-25 Category Core: Chang FASL Req. Yes CONDUCTIVE PLATED COATINGS FOR ELECTRICAL CONNECTORS AND CORROSION, PROTECTION 1.0 GENERAL 14 Purpese This standare specifies the requiremonts for electroplated or mechanically plated fin-zine deposits and {elt associated chromate coatings, These coatings are intended for corrosion resistance and electneal conducti'y, ind are also suitable for general corrosion protection of noryelectrcal components 1.2 Coverage of this Standarc ‘This standard specifies the plating process and performance requirements for electrodeposited and mechanisily piated tn-zinc coatings, and their associated chromate coatings, for use pray on {fasteners used for electrical grounding and otver electrically conductive components (e.g. lamp sokets), hen these automotive elements are used in corrosive environments, These costings 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 AEs of AMs Suffix shall De added to the process standart ‘number to indicate the method of coating application. That is, Efor electroplate or M for Mechanical plate. If suffix is not added, either method of application may be used. 8. The desired deposit thickness must be specified after the process standard number using 2 Acode” designation. e.9., PS-B956E Code 20 means an electroplated deposit with a thickness of 8 miarometers, G. Specific requirements shown on the part drawing shall take precedence over related requirements Specified i this standard, or may be in addition to te requirements of this standard D. The notation A QAR per PS-7300" shall appear in the Part Drawing Standards Block. 2.0 REQUREMENTS: 3.1 Application, Pin’sh and Workmanship 3.1.1 Method of Application This standerd cvers beth elecrrapiating and mechanical plating. Parts susceptibia o hydrogen embritlerent, as defines in PS-2500, may be either electropialed ot mechanically ciate’. Powever, whenever prescical (as determines by part Size, shape, etc.) mechanical plating s preferred to avoid the Possibility of tudragen embrtlement. Hantened eleetroplatod parts are subject io ine iequiremente of Ne Hydrogen Emtrittlemant Reliaf Process Standard PS-9970, 3.1.2 Finish Requirements on Significent Surfaces PS-8956 , Changs M, 2002-08-26, Page 1 aceon Copyright DaimlerChrysler Corporation 180‘The requirements of this standard apply to the significant surfaces of apart. Unless otherwise speciied. Significant surfeses for plating thickness and corrosion resistance are all surfaces thal ean be touched by a 19 mm (0.75 in) diameter sphere. Threads of electroplated threaded pars are not considereo significant surfaces. Heacs of screws, bolts and unthreaded shanks of bolts are significant eurisces. On ‘mechanically plated parts, significant surfaces are all surfaces that are readily accessible to the proper size impact media, 3.1.3 Workman shia ‘The plating shall be smooth and free fram blisters pts, nodules and other harmful defects, Coverage shall be uniform in appearance and complete except in deep recesses or small diameter holes, 3.14 Alley Compastion The following table summarizes the permissible slloy compositions covered by this process standard, TABLE 1: ALLOY COMPOSITIONS AND PERMISSIBLE CONCENTRATION RANGE TYEE OF DEPOSIT PERCENT TIN PERCENT ZING PS-S9666, Ele aoplated Aly ToweT went0 PSLESEGM, Mechanicaly Plated Alloy mosis Tons PS-B256L, Mechanical Piated Alley, | 2:5 micrometors (00001 a) | 60 micrometers (00008 FH Layered Deposit tin top layer zine bots layer 4.0 PRETREATMENT PROCESS - PARTS TO BE ELECTROPLATED OR MECHANICALLY PLATED 44 Alkaline Cleaning Light soils ray be removed by seaking parts in s heated alkafine cleaner. Electrocieaning, with the parts made anodic (positive polarity), may also be used. Parts subject to hydrogen embritlement shall not be cleaned ethodically (negative). 4.2 Rust and Scale Removal ‘Tho preferred procedures forthe removal of heal eat scale or rust on high strengtihigh hardness paris are tumbling, vibratery finishing or blasting witn a fine abrasive, Alkaline rust removers and de-scalers may also be used 4.3 Acid Cleanirg Aci¢ Cleaning is the least desirable of the available cleaning methods for hardened stee! parts because it ah contribute to hydrogen embritlement. Consequently, iffasteners or harcened steel parts with haraness, as derined in PS-9500 are acid cleened. its required that an inhibited, maximum 5% sulfurie cid hated arid ho uead and tha parte limited to a manimuin of 10 minutes exposure, Corkcats Must BE implemented and records must be kept on the type and strencth of inhibitor, Steps must also be taken to Femove the parts: from the acid bath during plant shutdown due to mechanical or power failure in less than, the 10 minute maximum acid expasurs ime, 5.0 MECHANICAL PLATING PROCESS: ‘Mechanically plated coatings are to applied to Code 40 (10 micrometers, 0.0004 in) thickness unless PS.8956 , Change M, 2002-06-26, Page 2 ‘Copyright DaimlerChrysler Corporlion 190otherwise spe ified and shall consist of a uniform mixture of about 70 percent zinc and 30 pereent tn, Altematively. # micrometers (0.0003 in) of mechanically deposited zinc, can be overplated with 25 micrometers (0.0001 in) of mechanically Ceposited tin. A yellow or bronze chromate coating shall also be provided, and is considered an integral part of the deposit and thie standard, 5.1 Media Size The selection of impact masts has an impertant effec on the quality af the plating abizined, On some part types. such as cross-rececs head sorews, one media size wil become lodged. The plater mast earetuly ‘select a modia mix that will not lodge in te recess, threaded area or under free spinning washers. For Some parts the best altermative is To Use Svaight 80 mesh 10 100 mesh with no larger media 5.2 Mechanical Plate Water Polish Mechanically plated pars must be sutably burnished by Awater polishing’ to consolidate the coating and mminimize Ico surface panicles prior to ehremating, 3 Chromate Type Conversion Coatings *** FOR PARTS PRIOR TO JANUARY 1, 2007, the zine alloy deposits ofthis standard are to be yellow or bronze chromuted follawed by an approved {eaenant-sealant until the yellow is neatly gone. This ehould be done immestiately afer piating and while the parts are stil wet. FOR PARTS 70 BE SUPPLIED ON JANUARY 1, 2007 and beyand, hexavalent chromium is no longer allowed. “Cle:r” colored trivalent chromate systems with equivalent or improved corrosion resistances are Penmited_Toacoats or sealers are not allowed on fasteners or ather threaded parts unless approved by Fastener Engineering, Slight color vartations and iiescence are permitted 5.4 Leachant’Sealant Mechanicaly pleted fasteners shall additionally be coated with an approved, proprietary leachantiseslant fer chromatirg. The leachant/sealant chall bo maintained and applied according to the recommendations of the leachant/sealant vendor. The approved lechant/sealants are fisted as an ‘addendum to this standard. 6.0 ELECTRCPLATING PROCESS ‘The operation of the alloy fin-zine electroplating bath shall be camied out in accordance with the insuuctions of the proprietary chemical supplier of tie plating process, and snall procuce the alloy composition listed in Section 3.1.4 6.4 Requirements for Parts to be Electroplated 6.1.1 Minimum Electropisted Thickneseas ‘The minimum #lectroplated thickness is specified by the Code Number suffix appearing after the process -seetare FMtOot ao TS, CODE THICKNESS 20 S micrometers (0.00020 in) — 30 8 micrometers (0.00030 in) 40 10 micrometers (0.00040 in) PS-B956 , Change M, 2002-06-26, Page 3 con Copyrighs Doimle-Chrysor Caporaton 180‘ODE THICKNESS 50. 13 micrometers (0.00050 in) Deposit viicknuesses greater inan Code 50 are generally not recommended. If t is determined that electroplated *hicknessas less than Code 20 or greater then Code 50 are necessary for a paricular application, drawing notes shall be used to designate the required thickness. 6.2 Plate Thickness on Significant Surfaces Teinsure compliance with the minimum thickness requi-ements ofthis standard, the plating thicknesses shall be measured on 2 regular and frequent basis using acceptable samoling plans, such 2s secommended in ASTM B-697 and 8-762 or equivalents, Control charts and recerds documenting compliance wth the minimum thickness requirements of thie standard shall be prepared and malniained. ‘The plate thiciness on significant surfaces must meet the minimum thickness as specified by the ACoda’ designation (rafer to Section 3.5.1) ‘The following ASTM Standard Methods are recommended for determining the coating thicknaee: ASTM B 427 Microscopie Cross Section ASTM B 588 X-Ray Method ASTM B 499 Magnetic Method Except for the misrescopic methos, tis essential to calibrate the tes instrument with an alloy or mixture of the same compasition 28 that Being measured, 6.3 Chremate Coatings ~~ A chromate tyre passivate is considered an integral part of the electrodeposited tin-zinc allay of this process stendard. Cnromated coatings significantly enhance the overall eeetion resistance of the deposit. The tin-zinc alloy electrodepasit, covered by this process standard, require a hexavaient or ‘tivalent chromate conversion coating that is formulated for the particular allay, NOTE: PARTS SUBMITTED PRIOR TO JANUARY 1, 2007 MaY LITILIZE EITHER A HEXAVALENT OR. TRIVALENT CHROMATE. PARTS SUPPLIED BEGINNING JANUARY 1, 2007 SHALL USE A TRIVALENT CHROMATE SYSTEM ONLY. HEXAVALENT CHRONATES 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 7.4 Adhesion, General Tha daparil shall nat paat from itself or rom the substrate when teslsd In accordance with ASTM 8 $71 (Standard Test Methods fer Achesion of Metallic Coatings). The hardened, aged (for 24 hours) chromate coating shal bs tightly adherent tothe plated coating and shall not be removed by ocdinary handling, 7.2 Mechanical Plate Adhesion Tests Mechanicsily plated parts shall show no evidenee of loosely adherent or pocrly consolidated plating when inspected as fe'lows: P3-8956 , Change M, 2002-06-26, Page ¢ a Copyright DaimlerChrysler Cargoraion 190‘A. Pans with smooth surfaces shall De subjected to a tape test, The adhesive side of a stip of ‘transparent tape (¢.g., ASM Scotch” type 610) shall be pressed fimly against the smooth surfaces of a arto pick up any loosely adherent metalic paricies. The test tape is then applied to a clean, white Bape for view ng. Evidence of loose patteles achering tote tap2 shall resultin relation ofthe entire ot pars. B. internal drive fasteners shall be subjected to a Aproba tost’. The cavity of the drive recess shall be robed with th end of a stiff wire (e.g.. a paper clip) to loesen any pecry consolidated or poorly bonded meiai particles. Evidence of dislodged particles faling from the drive recess when the fastener is over and tapped against a hard write surface shall result In rejection of the entire lot of parts. 7.3 Dimensional Tolerance Tolerences spacified on drawings are for the final dimensions unless obterwise indicated. Allowanes for plating build-up may have to be made in the dimansions of threaded fastenors. (See page Z-2.01 for checking ISO matric serew threads). 7.4 Hydrogen Embritloment Relief Parts mechanically plated to the requirements of this standard must be treated for hydrogen embritlement relief as shows in Table 1 of Process Stancard PS-9500, Seation 2.2.9. Electroploted. hardened steel parts with a Reckwell Hardnass of HRC 31 or grestar MUST BE BAKED to the schedule specified in Process Standard PS-9500 Section 2.2.4, Table 2. 7.8 Hydrogen Embritlement Test, The hydrogen embrittement test shall be performed according to he requirements of Process Standard PS-9500, Section 3.0, Hydrogen Embrtlement Test, 7.6 Accelerated Corrosion Resistance Sample plates and chromated pars shall be died and aged for 24 hours prior to exposing them to the salt Spray test. The test shall ve conducted in accordance witn ASTM B 117 forthe times shown in Table 2. Salt spray cossion test requirements DO NOT apply to deep recesses, such as small bind holes and the interer of tubirg, orto non-significant surfaces, ‘The objective of the AHours to White Rust’ requirement (Table 2), is freedom from Voluminous white corrosion prec sets after testing for the number of hours listed, A fight white fm or Ablush” does not constitute « failure. Table 2 summarizes the required minimum hours of exposure to salt spray before tha formation of white corrosion products, as well as the minimum number af hours to red rust. Algo, ehremats coatings are inherent fragile films and some damage at sharp edges, comers, etc, lo be expected. Small amounts of white corrosion products at such damage sites DO NOT constitute © failure. TABLE 2: MINIMUM SALT SPRAY TEST REQUIREMENTS MINIMUM HOURS TO METHOD OF COATING | THICKNESS CODE WHITE CORROSION RED RUST Electroplatec Code 20 720 300) PS-8956 , Change M, 2002-06-26. Page 5 ceamenp Copyright OcimlarChrysler Corporation 190TABLE 2: MINIMUM SALT SPRAY TEST REQUIREMENTS METHOD OF COATING | THICKNESS CODE MINMUM HOURS TO | WHITE CORROSION | RED AUST Eleetrepiated Code 30 120 09 Elcctoplaied Code a0 730 300 Electropisted Code 50 720 00 Mechanicaly Plated Cede 30 120 200 Mechanicaly Pated Code 40 720 250 On parts with a surface area greater than 155 sa cm (24 sq in), the appearance of one or more red rust ‘spots per each 155 sq em (24 sq in) of significant surface (See Section 3.1.2), that are visible to the unaided eye 21 nermal reading distance of any rust spot ofiginating rom an area larger tan 1.6 mm (1/18 in) in diameter is considered 2 failure. On parts smaller than 185 sq em (26 sq in), the appearance of more than on¢- rust spot on any significant surface or any spect originating from a spet larger than 1.8 mm. (1/16 iny in diarnster is a failure. (On threaded fasteners, the formation of corrosion products in the threaded areas DOES NOT constitute @ failure. However, the head and unthreaded shank of a screw or bolts considered a sienificant surface and must withstand the formation of white and red rust for the minimum times listed in Tabla 2, 8.0 QUALITY Refer to CS-9201 for general quality requirements. 8.0 GENERA. INFORMATION ‘Three asterisks “after the section/paragraph header denotes multiple technical changes te the sectaniporagraph. A viple asterisk before and after a sting of text (“~text™") identifies 2 single change. Cenain important information relative to this standard has been included in separate standards. To escure the processes submitted meet all of DaimlerChrysler requirements, itis mandatary thal the requirements in the following standerds be met. ‘CS-2800 - Application of this standard, the subscription service, and approved sources C5-2003 - Renurated substances and recyciability ‘Within Engineering Standards. the Regulatory (Government-mandatad) raquiramonts are designated by <$>, and which correspond ta Safety, Emission and Homelagation Shields respectively. The DC C-mandater requirements are designated by , and and correspene to the Diamond, Appearance ond Traceability aymbals respectively. For specific information on this document, please refer te the contact person shown in the "Publication lefarmation” Saction of thie document. Fer general information on obtaining Engineering Stancards ond Laboratory Proredures, see CS-9800 or contact the Engineering Standards Department st engstds@ccx.com, 10.0 REFERENCES PS-8956 , Change M, 2002-08-26, Page § (Conarght aimts:Chrelae Caremton 190CS-2005 CS-9800 CS-9801 PS-809 PS-6239 PS-7300 PS-9500 ASTMB 117 ASTM B 487 ASTM 8499 ASTM B 868 ASTM 8571 ASTM B 602 AStw 8 697 ASTM 8 762 11,0 ENGINEERING APPROVED SOURCE LIST Processes, covered by this standard, shall only be purchased from these sourcas fistad in Table 3 below: TABLE 3: ENGINEERING APPROVED SOURCE LIST APPROVED MECHANICAL PLATERS, PS-895EM ANAC Industies, Ine. Mochanieal Gaiv-Plating Cleveland, OH Sidney, OH ‘Al Service Metal Treating N& W Metal Finishing inc W. Trenton, NJ Cleveland, OH Calon Plating Co. Pisteco Wyandotte, Mi Reedsburg, WI Coatings 85 Plant AB &D Reilly Plating Corp Micsissauga. Ontario Malvindale, MI ‘Crest Products, Inc. (Captive Shop) Rator Clip Go, (Captive Shop) 71 Lexingson, KY. Somerset, NU Drake Wechanical Plating SunFin Hoiner, Mi Traverse City, Ml Dyria-Hurr Chicago Corp, ‘Quality Roling and Déburting Novthiske, Ik ‘Thomaston, CT Dynaciiur Corp, ‘Wisconsin Mechanical Metal Finning Rockford, IL Brookfield, WI ‘ABPROVED ELECTROPLATERS, PS-BO56E, ‘Alas Watal Processing Ine. Detrot, Ml Burbank Pating Pacoima, CA 91331 Piating Tecnnoisay. Inc Columbus, OH 43205 snd Metal Service Inc incinatti, OH 48229 Finishing Servicas Ine. Yesilart, MI Whyeo Chromium Company, ine, ‘Thomaston, CT 06767 Moder Plaing Corp Fresport IL 61032 F'5-5956 , Change M, 2002-06-26, Page 7 ‘Copyragm DaimlerChrysler Corporation 190,‘SUPPLIERS OF APPROVED PROPRIETARY MECHANICAL PLATING PROCESSES MeeBirmid, Ine Tre Plale Process, ne, Weatertury, CT ‘Subsidiary of MeGean-Roheo, Ine. Cleveland, OF | Pits} Systems & Technolegies | Mecharical Coatings Com Jackson. ME Sidney, OH APPROVED LEACHANTSSEALA SUPPLIER PRODUCT NAME | TaeLigemia, Ine S500 Wateroury. CT pases Tia ie Process, Ie, Tru-Plate 0470 Cleat Seal Claveland, 04 12.0 PUBLICATION INFORMATION ContactiPhone Not Ral. Lash (248) 876-7461 Akernate ContieyPhone Ni Dept, Name & Dept. No./Tach Club/Orgsnization: Body Materials Engineering, Dept $820 Date Standard Originally (Initially) Issuee: 1990-07-08 Date Published: 2002-06-26 Change Notice. Description of change: Editorial aeeRE PS-2856 , Change M, 2002-06-26, Page & Copyright DeimlerChrysler Corporation 180