CHRYSLER ENGINEERING STANDARD No; PS-8956 CORPORATION ASL Req'd: Y Vehicle ineering Office PROCESS STANDARD. Char (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 lin-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. NOTE This standard has safety, noise, emission or theft prevention significance only when the appropriate drawing depicts the standard with a safety symbol, itis necessary to review the part drawing to ascertain which portions of a standard have safety, noise, emission or theft prevention significance. 12 Scope 12.4 Applloation ‘This standard is for use in supplying certain parts under purchase orders of Chrysler Corporation or is subsiciares. This standard is limited Inf application to those drawings, CATIA Models, Engineering Graphics ‘of Operation Description Sheets which call out this standard number, or which refer to this standard within ‘some other standard or specification. Original equipment and replacement parts for some vehicles sold by (Chrysler Corporation or ts dealers are not cavered by this standard. Products furnished to Chrysler Corporation and products and processes used by suppliers to manufacture these products must conform to the requirements contained in CS-9008.. 1.23 Coverage of this Standerd This standard specifies the plating process and performance requirements for electrodeposited and mechanially plated tin-zinc coatings, and thelr 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 corrasive envrenments. These coatings may also be used for corrasion protection of non-electrical components. ‘technical change co the paragraph. A triple 09/18/96 Editorial q Updated 0a722/95 Eaitorial F EASL Updated Date zaewed 01/0890 ‘pepe 5820 coneacr AJ. Lash (810) 876.7451 PecREN: Curysler Corporation standards, specifications and drevings are mibject to frequent revision Ee is whe users” resposibiiity to senply with Cortene versions, bicteibetion of avandasae to pertien othe than Ghayaler Corporetion sippiiert, snathar with ar vithow. charges te. for detemation omy. k ‘Mbscription service 1b availanie at reasonable covt, wich will sutemtlcaiiy peoviae tha sabecrises wish Siryeot eteotardo., Sabeeripeion infersation of copies of cacsent suanderde, ave, wntiabie’ toon she Enalncortog seantards © internation dervices Department vehicle Easiveeries office, chryaier somettonn 200-36-n (6-95) Volume: H Section: 1 Page No: 108 (1)CHRYSLER ENGINEERING STANDARD No: PS-8966 ‘CORPORATION ASL Req'd: Y Vehicle Engineering Office PROCESS STANDARD. inge: G 1.2.4 Requirements on Part Drawings A When this process standard is specified, an “E* or “M" suffix shall be added to the process standard umber to indicate the method of coating application. Thats, Electroplate or Mechanical plate. If a sutfixis not added, either method of application may be used. B, The desired deposit thickness must be spectied after the process standard number using a “code” designation, ¢.g., PS-8956E Code 30 means an electroplated deposi with a thickness of 8m (0.0003, in). C. Specific requirements shown on the part drawing shall take pracedence aver related requirements ‘specified in this standard, or may be in addition to the requirements of this standard. D. The symbol has been substituted for the diamond symbol in this standard to identity crical but non-regulatory items that require continuous Statistical Process Control (SPC). Refer to PS-7300, E The notation " QAR per PS-7300" shall appear in the Part Drawing Standards Block. 20 REQUIREMENTS 2.1 Application, Finish and Workmanship 2.41 Method of Aopiication ‘This standard covers both electroplating and mechanical plating. Parts with a Rockwell hardness of C-31 or greater may be either electroplated or mechanically plated. However, whenever practical (as datermined by part size, shape, etc). mechanical plating is preferred to avoid the possiblity of hydrogen embritlement. Hardened electroplated parts are subject to the requirements of the Hydrogen Embrittiement Relief Process ‘Standard PS-500, 242 Binlsh Reauiremente on Slaniicant Surtaces ‘The requirements of this Standard apply to the significant surfaces of a part. Unless otherwise spectiod, ‘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, bolls and the unthreaded shanks of bolts are signtieant surfaces. On mechanically plated parts, significant surfaces are all surfaces that are ready accessible to the proper size impact media. 243° Workmanshie ‘A. The plating shall be smooth and free of blisters, pits, nodules and other harmful defects. Coverage ‘shall be uniform in appearance and complete except in deep recesses or small diameter holes. B. _Chromate coatings are considered an integral part of the metallic deposits covered by this standard and shail completely cover the plated surface. C. —_Chromate costings may exhibit small bare spots on edges and projections as a result of bulk handling damage. Such bare spots are not a cause for rejection, Volume: H Section: 4 Page Ne: 108 (2)CHRYSLER ENGINEERING STANDARD No: PS+8956 CORPORATION ASL Reqd: Y Veticle Engineering Office PROCESS STANDARD. Change: G 21.6 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, 30210 }| Electroplated Tin-Zine Alloy PS-8956M, 725 Mechanically Plated "Alloy Ps-e9s6L, 2.5 um (0.0001 in) Mechanically Plated, Layered Deposit tin top layer zinc bottom layer 22 2.2.1 Alkaline Cleaning Light soils may be removed by soaking parts in a heated alkaline cleaner. Electrocleaning, wth the parts made. anodic (positive polarty), may also be used. Parts subject to hydrogen embrittlement shall not be cleaned cathodically. (Negative). 2.22 Rustand Scale Removal ‘The preferred procedures for the removal of heat treat scale or rust on high strengthvhigh hardness parts are tumbling, vibratory fishing or blasting with a day, fine abrasive. Alkaline rust removers and de-scalers may also be used. 223 Acid Cleaning * ***Acid cleaning is the least desirable of the available cleaning methods tor hardened steel parts because it can contribute to hydrogen embritiement. Consequently If fasteners or hardened steel parte with a Rockwell of HRC 31 or greater are acid cleaned, itis required that an inhibited, maximum 5% sutfurle 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 pawer failure in less than the 10 minute maximum acid expesure time. 23 nical [2 inform mPdure of about 70 percent zinc and 30 percent tn. Alternatively, 8 ym (0.0003 inches) of mecharically deposited zinc, can be averplated wth 2.5 um (0.0001 inches) of mechanically deposted fn. A yellow or bronze chromate coating shall also be provided, and is considered an integral part of the deposit and this standard. 200-26-5 (6-95) Section: 1 Page No: 108 (3)CHRYSLER ENGINEERING STANDARD. No: PS-8956 CORPORATION ASL Req'd: Y Vehcte Engineering Office PROCESS STANDARD. Change: G 2.3.1 Media Size The selection of impact media has an Important effect on the qualty ofthe plating obtained. On some part types, such as cross-recass head serews, one media size wil become lodged. The plater must carefully select ‘a media mix that wil 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. 232 Mechanical Piste Water Polish Mechanically plated parts must be sultably bumished by ‘water polishing* to consolidate the coating and minimize loose surface partcles prior to chromating. 23.3 Chromate ‘The zinc alloy deposits of this standard are to be yellow or bronze chromated followed by an approved leachant-sealant until the yellow is nearty gona, This should be done immediately after plating and while the parts are stil wet. 22.2 Leachant/Seslant ‘Mechanically plated fasteners shall additionally be coated with an approved, proprietary leachant/sealant after chromating. The leachant/sealant shall be maintained and applied according tothe recommendations cf the leachantisealant vendor. The approved leachantisealants are listed as an addendum to this standard. 2.4 — Electroplated Coatings The operation ofthe alloy in-zinc electroplating bath shall be carried out in accordance with the instructions. cof the proprietary chemical supplier of the plating process, and shall produce the alloy composition listed in Sec. a4 Electroplated deposits shall consist of an alloy composed of 70 = 10 percent tin, with zinc comprising the remaining 30 + 10 percent. A yellow or bronze chromate shall also be provided, andiis considered an integral part of the electroplated deposit and this standard. NOTE: Clear chromate coatings shall not be used. 25 Requirements for Parts to be Electroplated 25.1 Minimum Electropiated Thicknesses ‘The minimum coating thickness is specified by the Cods Number suffix appearing after the process standard number as follows: Code 20 5 uum (0.00020 in) ode 30 8 kam (0.00030 in} Code 40 10 um (0.00040 in.) Code 50 43 um (0.00050 in.) Deposit thicknesses greater than Code 50 are generally not recommended. fit is 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. —_— oo 200-26-m (6-95) Volume: H Section: 1 Page No: 108 (4)CHRYSLER ENGINEERING STANDARD No; PS-8956 CORPORATION ASL Reqd: Y Vehicle Engineering Otfice PROCESS STANDARD. Change: G 26 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 8-697, 8-602 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 specitied by the "Code" designation (refer to paragraph 2.5.1). ‘The following ASTM Standard Methods are recommended for determining tha 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 of mixture of the ‘same compostion as that being measured. 27 Chromate Coatings. ‘The tin-zinc electroplated alloy is to be yellow chromated as an integral part of the coating process. 28 Performance Requirements 281 Adhesion, General The deposit shall not peel from itself or from the substrate when tested in accordance with ASTM 8-571, ‘Standard Test Methods for Adhesion of Metalic Coatings. The hardened, aged (for 24 hours) chromate coating ‘hall be fightly adherent to the plated coating and shall not be removed by ordinary handling. 2.82 Mechanical Plate Adhesion Teste Mechanically plated parts shall show no evidence of loosely adherent or poorty consolidated plating when inspected as follows: ‘A. Parts with smooth surfaces shall be subjected to a tape test, The adhesive side of @ strip of ‘transparent tape (e.g., “3M Scotch’ type 810) shall be pressed firmly against the smooth surtaces of {a partto pick up any loosely adherent metallic particles, The test tape is then applied to a clean, white paearfer viewing, Edens of ose partes acherng othe tape sal suit rejecton of he onthe 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 stif wire (e.0., a paper clip) to loosen any poorly consolidated or poorly bonded metal particles, Evidence of dsiodged partcies falling from the drive recass when the fastener |s inverted over and tapped against a hard white surface shall result in rejection of the entire lot of parts. 2.8.3 Dimensional Tolerance Tolerances specified on crawings are fo 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 ol the Chrysler ‘Standards Parts Book for untied threads and Page MZ-2.01 for checking ISO matric screw threads.) —_—_—— 200-36-9 (6-95) Volume: H Section: 1CHRYSLER ENGINEERING STANDARD No: PS-8956 CORPORATION ASL Req: Y Vehicle Engineering Office PROCESS STANDARD. Change: G 2.8.4 Hydrogen Embrittlement Relief Parts mechanically plated to the requirements of this standard must be treated for hydrogen embritiement relief as shown in Table 1 of Process Standard PS-9500, Section 2.1.3, Electroplated, hardened stee! parts with a Rockwell Hardness of HA.31 or higher MUST BE BAKED to the schedule specified in Process Standard PS-9500 Section 2.1.4, Table 2 285 Hydrogen Embrittlement Test ‘The hydrogen embrittiement test shall be performed according to the requirements of Process Standard PS-9500, Section 3.0, Hydrogen Embrittiement Test. 286 Accslersted Corrosion Resistance es in Table 2: Minimum Salt Soray Test Requirements. 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 "Hours to White Rust’ requirement (Table 2). is freedom trom VOLUMINOUS white corrosion products after testing for the number of hours listed. A light white fm or “blush” does not constitute a failure. Table 2, Minimum Salt Spray Test Rsquirements, summarizes the required minimum hours of ‘exposure to salt epray before the formation of while corrosion products, as well as the minimum number of hours to red rust. ‘Also, chromate coatings are inheranty fragie fms and some damage at sharp edges, comers, etc, is to be expected. Small amounts of white corrosion products at such damage sites DO NOT constitute a fallure. ‘TABLE 2: MINIMUM SALT SPRAY TEST REQUIREMENTS — | Method of Coating Minimum Hours to Minimum Hours to pplication White Corrosion Red Rust Volume: H Section; 1 Page No: 108 (6)CHRYSLER ENGINEERING STANDARD No: PS-8956 CORPORATION ASL Regid: Venicl Engingering Off PROCESS STANDARD. (On parts with a surface area greater than 155 om? (24 in), the appearance of one or more red rust spots per each 155 cmé (24 in2) of significant surlace (see Section 2.1.2), that are visible to the unaided eye at normal reading distance or any rust spot originating from an area larger than 1.6 mm (1/16 in) in diametor is considered a failure. On parts smaller than 155 cm? (24 in?), the appearance of more than one rust spot on any significant surface or any rust spot originating from a spot larger than 1.6 mm (1/16 in.) in diameter is & failure. (On threaded fasteners, the formation of corrosion products in the threaded areas DOES NOT constitute a fallure, However, the head and unthreaded shank of a screw or bolt Is considered a significant surtace and ‘must withstand the formation of white and red rust for the minimum times listed in Table 2. 29 Preliminary Process Potential Study A intial production startup ofthe process, the supplier, in conjunction with a Chrysler quality specialist, shall perform a Preliminary Process Capability Study. Refer to the Chrysler, Ford, and General Motors manual, ‘Qualty System Requirements QS-9000. 3.0 PROCESS CAPABILITY STUDY Following successful completion of the Process Potential Study, the supplier shall perform a Process Capabilty Study. Flter to Chrysler, Ford, and General Motors manual, Qualty System Reaurements QS-9000. 40° quauty ‘The supplier's quallty plan shall meet the requirements specified in the Chrysler, Ford, and General Motors ‘manuel, Qualty Sister's Reaurements QS-2000, The suppliers quay plan shall assure that inal production ‘shipments and those made subsequently throughout the model year meet Chrysler's requirements, Volume. ‘producfon must conform fe Chrysler specications and meet or exceed quay and performance levels ofthe ‘most recent samiples approved by Chrysler Corporation. 5.0 CONTROL ‘The supplier shall not ship parts that do not meet the requirements of this standard. ‘Any proposed chanjges to this process must be approved by Chrysler Corporation, Body Materials Engineering Department, before the changes are implemented 5.1 Mechanical plating materiala (including the leachantsealants) shall only be obtained from the ‘suppliers of proprietary plating preducts appearing on the Engineering Approved Source List included as an addendum to this standard. 5.2 Mechanically plated finishes covered by this standard shail only be abtained from sources that appear ‘on the Engineering Approved Source List included as an addendum to this standard. 5.3 All production electro or mechanically plated parts must be capable of passing the following requirements. Laboratory test results obtained by the vendor must be recorded and kept for review by Chiyaier personnel, A. Alloy Composition B. Plate thickness ©. Plateachesion D. Salt Spray Test E, _Hycrogen Embrittement (where applicable) Volume: H ‘Section: 1 Page No: 108 (7)CHRYSLER ENGINEERING STANDARD No: PS-8956 CORPORATION ASL Reqd: Y ring Office, PROCESS STANDARD Change: & 5.4 The supplier shall not ship parts that do not meet the requirements ofthis standard, 5.5 Any contemplated changes in manufacturing process chemistry, materials options and/or heat treatment being considered by a primary or sub-supplier, including these requested by Chrysler user plants, are not permitted wihout fist notifying Purchasing and without prior approval by the responsible Chrysler Engineering Laboratory. Failure to comply may result in the parts being rejected at the producers risk along with any attendant incurred claim costs. 6.0 CONTACTS ‘Questions concerning this standard should be directed to Chrysler Corporation, Vehicle Engineering, Body Materials Engineering Department, Corrosion & Plating Group. 7.0 BEFERENCES Chrysler, Ford, and General Motors manual, Quality System Requirements QS-2000. Chrysier Corporation Process and Characteristic Standards: ASTM Standards: 8117 3.487 5-499 568 B571 8-802 697 8762 aeeee (6-95 Volume: H Section: 1 Page No: 108 (8)Vehicle Engineering Office FOR STANDARD: PS-8956 CHRYSLER CORPORATION ENGINEERING APPROVED SOURCE LIST CONDUCTIVE PLATED COATINGS FOR ELECTRICAL CONNECTORS AND Engineering Standard Title: CORROSION PROTECTION APPROVED SOURCE: Approved Mechanical Platers, PS-6956M: AMAC Ind. n., Cleveland, OH Al Service Metal Treating, W. Trenton, NJ Cadon Plating Co., Wyandotte, Ml Coatings 85 Plant “B", Mississauga, Ontario “Crest Products, nc., Lexington, KY Drake Mechanical Plating, Homer, Ml Dyna-Burr Chicago inc., Northlake, I Dyne-Burr Corp., Rockford, IL Empire Plating Co., Cleveland, OH Mechanical Galv-Piating, Sidney, OH Plateco, Reedsburg, WI Reilly Plating, Melvindale, MI “Rotor Clip Co., Somerset, NJ ‘Sur-Fin, Traverse City. Mi Quality Rolling and Deburring, Thomaston, CT Wisconsin Mechanical Metal Finishing, Brookfield, WI Approved Electroplaters, PS-8956E: “Ajax Metal Processing Inc., Detroft, Ml Finishing Services inc., Ypsilanti, Mi Plating Technology, inc., Columbus, OH 43206 Variand Metal Service inc., Cincinnatt, OH 45229 \Whyco Chromium Company, Inc., Thomaston, CT 06787 _—_—_——$— —— —— ‘the above Chrysler Eaginearing Approved ource List nanes those sources anf gub-sources currently approved ‘the product or procese indicated, by fUrntehing this list to you, Chrysler im no way assumes for che performance of any named suppliors or sub-sources and specifically reserves all Farther, Le should jcurce of sub-source solely because it has net been, iuded in the fae fernished herewith. ‘therefore urged to Eurniah us with the names of any ‘Addletooal sources or sub-sourcen you believe are qualified, for investigation by Chrysler Cerporaticn for poasible approval in accordance with thin peltey. Date Changes and Cancellations. oeR0RS Updated caeans Updated 957290 ‘Source List Added to Standard 200-21-a (6. Volume: H Section: 1 Page No: 108 (9)Vehicle Engineering Office FOR STANDARD: PS-8956 (CHRYSLER CORPORATION ENGINEERING APPROVED SOURCE LIST (Continued) MacDermid, Inc., Waterbury, CT Plating Systems & Technologies, Jackson, Ml ‘Tru-Plate Process, inc., Subsidiary of MeGean-Riohco, Inc., Cleveland, OH Mechanical Coatings Corp. Sidney, OH “Captive Approved LeachanySealants: MacDermid, inc., Waterbury, CT. 4388600 McDermid, Inc., Waterbury, CT Uttraseal™ Tru-Plate Process, nc, Cleveland, OH ‘Tru-Plate 0470 Clear Seal ‘MeGean-Rohco, inc, Cleveland, OH Rogard WG-2 Pavco Ine., Cleveland, OH Pavcoat Superseal Plating Systems & Technologies Hyperseal 200-21-m (6-95) Volume: H Section: 1 Page No: 108 (10)