DaimLeRCHRYSLER CORPORATION PROCESS STANDARD NO: PS-8956 Vehicle Engineering Approved Source List Required: Yes Change: Volume: H Section: 1 Page: 108 CONDUCTIVE PLATED COATINGS FOR ELECTRICAL CONNECTORS AND CORROSION PROTECTION 1.0 GENERAL 1.1 Purpose of the Standard ‘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 Purpose of the Process. ‘This standard presents the process for electroplated or mechanically plated tin-zine deposits and thelr associated chromate coatings intended for corrosion resistance. 41.3 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 primariiy 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 “E" or “M" 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. Ia suffix is not added, either method of application may be used 'B. The desirad deposit thickness must be specified after the process standard number using a “code” 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, ©. The notation “ QAR per PS-7300" shall appear in the Part Drawing Standards Block. 3,0 REQUIREMENTS 3.1. Application, Finish and Workmanship 3.4.4. Method of Application This standard covers both electroplating and mechanical plating. Perts with e Rockwell Hardness of HRC 31 or greater may be either electroplated or mechanically plated. However, whenever practical (as, determined by part size, shape, etc.), mechanical piating is preferred to avoid the possibilty of hydrogen PS-8956 , Change L, Page 1embrittlement. Hardened electroplated parts are subject to the requirements of the Hydrogen Embritlement Relief Process Standard PS-9500 3.1.2 Finish Requirements on Significant Surfaces ‘The requirements ofthis standard apply to the significant surfaces of a part. Unless otherwise specified, significant surfaces for plating thickness and corrosion resistance are all surfaces that can be touched by 2.19 mm (0.75 in) diameter sphere, Threads of electroplated threaded parts aro not considered significant surfaces. Heads of screws, bolts and unthreaded shanks of bots are significant surfaces, On mechanically plated parts, significant surfaces are all surfaces that are readily accessible to the proper size impact mecia. 3.1.3 Workmanship ** ‘The plating shall be smooth and free from biisters, pit , Nodules and other harmful defects, Coverage shall be uniform in appearance and complete except 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 ZING, PS-8956E, Elactroplated Alloy 704-10 304/10 PS-8956M, Mechanically Plated Alloy 304-5 704-5 PS-8956L, Mechanically Plated Alloy, | 2.5 micrometers (0.0001 in) | 8.0 micrometers (0.0003 in) Layered Deposit tin top layer Zine bottom layer 4.0 PRETREATMENT PROCESS - PARTS TO BE ELECTROPLATED OR MECHANICALLY PLATED. 4.4 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 end Scale Removal ‘The preferred procedures for the removal of heat treat scale or rust on high strengthvhigh hardness parts are tumbling, vibratory finishing or biasting 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 ‘can contribute to hydrogen embritlement. Consequently, if fasteners or hardened steel parts with a Rockwell Hardness of HRC 31 or greater are acid cleaned, itis 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 pars from the acid bath during plant shutdown due to mechanical or power failure in PS-8986 , Change L, Page 2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 25 ‘micrometers (0.0001 in) of mechanically deposited tin. A yellow or bronze chromate coating shall also be provided, and is considered an integral part of the deposit and this standard. 5.41 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 “water polishing" to consolidate the coating and minimize loose surface particies prior to chromating. 5.3. Chromate Type Conversion Coatings *** FOR PARTS PRIOR TO JULY 1, 2002, the zinc alloy deposits ofthis 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 piating and while the perts are stil wet. FOR PARTS TO BE SUPPLIED ON JULY 4, 2002 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 pleted fasteners shall additionally be coated with an approved, proprietary leachansealant after chromating. The leachant/sealant shall be maintained and applied according to the recommendations of the leachanseaiant vendor. The approved leachant/sealanis 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 Thicknessos ‘The minimum electroplated thickness is specified by the Code Number suffix appearing after the process standard number as follows: PS-8956 , Change L, Page 3CODE THICKNESS 20 5 micrometers (0.00020 in) 30) 8 micrometers (0.00030 in) 40 10 micrometers (0.00040 in) 50. 113 micrometers (0.00080 in) Deposit thicknesses greater than Code 50 are generally not recommended. IF itis determined that electroplated thicknesses less than Code 20 or greater than Code 50 are necessary for a particular 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 ofthis standard shall be prepared and maintained The plate thickness on significant surfaces must meet the minimum thickness as specified by the “Code” designation (refer to Section 3.8.1), ‘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, its 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 ofthis 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 JULY 1, 2002 MAY UTILIZE EITHER A HEXAVALENT OR TRIVALENT CHROMATE. PARTS SUPPLIED BEGINNING JULY 1, 2002 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 7.4 Adhesion, General The deposit shall not pee! from itself or from the substrate when tested in accordance with ASTM B 574 (Standard Test Methods for Adhesion of Metallic Coatings), The hardened, aged (for 24 hours) chromate ‘coating shall be tightly adherent to the plated coating end shall not be removed by ordinary handling, PS-8956 , Change L, Page 4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 (¢.g., “3M Scotch” type 810) shall be pressed firmly against the smooth surfaces of a part to pick up any loosely adherent metalic 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 ‘probe test’. The cavity of the drive recess shall be probed with the end of a stiff wire (e.g., a paper cli) to loosen any poorly consolidated or poorly bonded ‘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 Embrittiement Relief Parts mechanically plated to the requirements of this standard must be treated for hydrogen embrittlement relief as shown in Table 1 of Procass 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. 7.8 Hydrogen Embrittlement Test ‘The hydrogen embrittement test shall be performed according to the requirements of Process Standard PS-9500, Section 3.0, Hydrogen Embritiement 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 ofthe “Hours to White Rust” requirement (Table 2), is freedom from Voluminous white corrosion products after testing for the number of hours listed. A light white fim or ‘blush’ does not Constitute a failure. Table 2 summarizes the required minimurn hours of exposure to salt spray before the formation of white corrasion 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, comers, elc., is to be expected. Small amounts of white corrosion products at such damage sites DO NOT constitute a failure, TABLE 2: MINIMUM SALT SPRAY TEST REQUIREMENTS: MINIMUM HOURS TO METHOD OF COATING} THICKNESS CODE PS-8956 , Change L, Page 5WHITE CORROSION RED RUST, Electroplated Code 20 120 300 Eloctroplated 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 om (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 at normal reading distance or any rust spot originating from an area larger than 1.6 mm (1/46 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 feilure. 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 GENERAL INFORMATION Three asterisks “**" after the paragraph header denotes multiple technical changes to the 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, i is mandatory that the requirements in the following standards be met. (CS-9800 - Application of this standard, the subscription service, and approved sources CS-9801 - General quality requirements CS-9003 - Regulated substances ond recyclabilty Within Engineering Standards, the designations , , , , or will be substituted for the Safety, Emission, Noise, Theft Prevention, or Homologation Shields respectively. The designation will be substituted for the Diamond symbol Processes shall only be purchased from those sources listed under Engineering Approved Source List. 9.0 REFERENCES 68-8003 C8-9800 cs-9801 PS-809 PS-6239 PS-7300 P8-9500 ASTMB 117 ASTM B 487 ASTM B 499 ‘ASTM B 568 ASTMB 574 ‘ASTM B 602 ‘ASTM B 697 ASTM B 762, 10.0 ENGINEERING APPROVED SOURCE LIST PS-8956 , Change L, Page 6APPROVED MECHANICAL PLATERS, PS-6956M "AMAG Industries, Ine. Mechanical Gah-Piating Cleveland, OH Sidney, OH ‘All Service Metal Treating NN & W Metal Finishing Inc. W. Trenton, NJ Cleveland, OH Cadon Plating Co. Piateco Wyandotte, Mi Reedsburg, WI Goatings 85 Plant"B &D Reily Plating Corp Mississauga, Ontario Melvindale, Mit Crest Products, Inc. (Caplive Shop) Rotor Clip Co. (Captive Shop) Lexington, KY Somerset, NJ Drake Mechanical Prating ‘SurFin Homer, Ml Traverse City, Ml Dyna-Burr Chicago Corp. ‘Qualify Roliing and Deburring Northlake, IL Thomaston, CT. Dyna-Burr Corp, Wisconsin Mechanical Metal Finishing Rockford, IL Brookfield, WI APPROVED ELECTROPLATERS, PS-8956E ‘Ajax Metal Processing Ine Plating Technology, Inc. Detroit, MI Columbus, OH 43206 Burbank Plating Varland Metal Service, Inc. Pacoima, CA 81331 Cincinatti, OH 45229 Finishing Services Ine Whyeo Chromium Company, In. Ypsilanti, Mi ‘Thomaston, CT 06787 ‘SUPPLIERS OF APPROVED PROPRIETARY MECHANICAL PLATING PROCESSES MacDermid, ine. Tru-Plate Process, inc. Waterbury, CT Subsidiary of McGean-Roheo, Inc. Cleveland, OH Plating Sysiems & Technologies Mechanical Coatings Corp. Jackson, Ml Sidney, OH APPROVED LEACHANTSISEALANTS, SUPPLIER: PRODUCT NAME Wacbermid, Ino. 15550 Waterbury, CT Travel TrsPlato Process, Inc, Tru-Plato 0470 Glear Seal Cleveland, OH PS.8956 , Change L, Page 7APPROVED LEACHANTS/SEALANTS. ‘SUPPLIER PRODUCT NAME ‘MeGean-Rohce, inc. Rogard WG-2 Cleveland, OH Paveo, ine. Paveoat Superseal Cleveland, OH Biating Systems & Technologies Hyperseal 11.0 BIBLIOGRAPHY By entering the names of the approvers listed below, the writer Is stating that the approver has reviewed this Process Standard AS SUBMITTED and concurs with its contents, Date Standard Originally (Initially) Issued: January 08, 1890 Department Name and Number: Body Materials Engineering, Dept. 5820 Current Contact/Phone No: R.J. Lash, (248) 576-7461 Alternate Contact/Phone No: JE. Fillion, (248) 576-7490 X.2 Revision (Technical, Editorial, or Source Change) Required Approvals Date of Change: January 02, 2001 Model Year - Effectivity Code - Disposition Code: 2001 V-2 Authority: 00817-MOS ‘Change Level: L Owning Dept. Supervisor Approval: R.J. Lash Quality and Reliability Approval: Description of Change: Phaseout of hexavalent chromium; Standard updated. aH PS.8956 , Change L, Page 8