Chrysler Group LLG Document Number: PS-8955 Process Standard Date Published: 2010-04-13 Category Code: H-1 Change Level: Z EASL Requirement: Yes Restricted: No ZINC ALLOY ELECTRODEPOSITED COATINGS 1.0 GENERAL 1.4 Purpose This standard specifies the plating and perfarmance requirements for various zine-cobalt, zinc-nickel and zinc-iron alloy electrodeposits and their associated chromate coatings, used for enhanced corrasion resistance on ferrous parts. 1.2 Part Drawings 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. Because this standard covers more than one zinc alloy, the chemical symbol of the alloying element must be added as a suffix after the process standard number to designate the specific alloy desired. For example, *PS-8955 Ni" far zinc-nickel, ‘PS-8955 Co for zinc-cobalt, and *PS-8955 Fe" for zinc-iron alloy Ma sufic's nat specfted, any ofthe alloys covered by this standard may be used atthe ccretion of the vendor, A. The desired deposit thickness must be specified after the process standard nurtBer using a “Code” designation. For example, the designatian "PS-8955 Ni Code 30" means a zinc-nickel alloy deposit with a thickness of 8 micrometers or 0.00030 inch. B. Parts with a hardness of Rockwell HRC 82 or greater require a mandatary bake for hydrogen embrittlement reliaf according to Process Standard PS-9500- (Hydrogen Embrittlement Relief) 2.0 PROCESS 2.1 Electroplating Process Both acid and alkaline zinc alloy plating processes are covered by this process standard 2.2 Finish Requirements on Significant Surfaces The requirements of this Standard apply to the significant surfaces of a part. Unless otherwise specified on the part drawing, significant surfaces for plating thickness and corrosion resistance daterminatian are all surfaces that can be touched by a 19 mm (0.75 in) diameter sphere. The threads of threaded fasteners are not classified as significant surfaces. However, the entire head area of screws and bolts, and the unthreaded shanks of bolts are significant surfaces. 2.3 Workmanship The plating shall be smooth, adherent, and free of blisters, pits, nadules, and other functional defects. Coverage shall be complete and uniform in appearance on significant surfaces, with respect to the electroplated deposit. Iridescence in the chromite finish is expected and acceptable. PS-8955, Change Z, 2010-04-13, Page 1 Copyright Chrysler Group LLC tennes5)2.4 Alloy Composition The amount of alloying element present in the zinc alloy elecirodeposits covered by this standard is different for each alloy. The concentration limits for the varius alloys are listed in TABLE 1 NOTE: Zinc-nickel alloy deposits may be obtained from alkaline or mildly acidic plating solutions. The acidic plating processes generally produce higher nickel content alloys than the alkaline systems, however alkaline systems are available which offer the same alloy content as acid syst ems. The corrosion resistance of zinc-nickel allays is a function of both the alloy nickal content as well as the particular chromite conversion coating employed, in general, zinc-nickal alloy deposits containing @ higher percent nickel within limits provide better corrasion protection than alloys with less nickel. However, the quality of the chromite is crucial. Accurate contral of the allay composition within the limits given in TABLE 1 is essential for optimum corrosion protection TABLE 1: ALLOYING COMPOSITIONS AND PERMISSIBLE CONCENTRATION RANGE WT.% RANGE OF ALLOVING | NOMINAL WT.% RANGE OF ed ELEMENT ALLOYING ELEMENT Zinc-cobalt 0.4 to 1.0% Co 0.6% Co ‘Alkaline zinc-nickel 5.0 t0 16.0% Ni 8.0% Ni Acid zine-nickel 9.0 10 16.0% Ni 12.0% Ni Zinc-iron 0.3 to 0.8% Fe 0.5% Fe 2.5 Plating Requirements 2.5.1 Plate Thickness on Significant Surfaces The plate thickness on significant surfaces (Section 2.2) must meet the mi by the *Code" designation (refer to Section 2.5.2). um thicknesses as specified The following ASTM Standard Methads are recommended for determining the coating thickness: - ASTM B 487 Microscopic Cross Section - ASTM B 568 X-Ray Method - ASTM B 499 Magnetic Method - ASTM B 504 Coulometric Method Except for the microscopic method, itis essential to calibrate the test instrument with an alloy of the same ‘composition as that being measured. 2.5.2 Minimum Deposit Thickness The minimum coating thicknesses are specified by the Code number suffix after the process standard number as follows: Code 0: Not recommended, use PS-79 or PS-4220 if color identification of parts is required; see PS-PLATING Code 20: 5 micrometers (0.00020 in) Code 30: 8 micrometers (0.00030 in) Deposit thicknesses greater than Gods 30 are generally not recommended. If itis determined that thicknesses less than Cade 20 or greater than Cade 30 are necessary for a particular application, drawing notes shall be used to designate the required thickness. If na "Code" is specified on the drawing, the PS-8985, Change Z, 2010-04-13, Page 2 Copyright Crysler Group LO pone 06.08)default is “Code 30". 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 & 697, B 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. 2.6 Chromite Type Conversion Coatings ‘A trivalent chromite type passivate is considered an integral part of the electrodeposited zinc alloys of this. process standard. Chromited coatings significantly enhance the overall corrosion resistance of the deposit. The zinc alloy electrodeposits covered by this process standard require a trivalent chromite conversion coating that is formulated for the particular alloy NOTE: No topcoats are allowed on fasteners and other threaded parts unless approved by Fastener Engineering. Slight calor iridescence and color variations are acceptable. The effectiveness of the chramite coating is measured by the number of hours of salt spray exposure before the development of voluminous white corrosion products. A faint white film or “blush” does nat constitute a failurs. TABLES 2 and 3 summarize the required minimum hours of salt spray exposure before the formation of white corrosion products for the alloys and chromite coatings covered by this standard, as well as the minimum number of hours to red rust. 2.7 Performance Requirements 2.7.1 Adhesion ‘The deposit shall not peel from itself or from the substrate when tested in accordance with ASTM B 871 {Standard Test Methods far Adhesian of Metallic Coatings). The hardened, aged chromite coating shall be tightly adherent to the zine alloy substrate and shall not be removed by ordinary handling, 2.7.2 Hydrogen Embrittlement Relief High strengtlvhigh hardness steel parts with a Rockwell Hardness of HRC 32 or greater MUST BE PROPERLY BAKED according to the schedule and procedure specified in Process Standard PS- 9500, “Hydrogen Embrittlement Relief", within one hour after plating. The bake operation may be done after trivalent chromate post dip, pravided it can be shown that there is na detrimental effect an the corrosion resistance. 2.7.3 Hydrogen Embritlement Test The hydrogen embrittlement test is to be performed according to Process Standard PS-9500<8> 2.7.4 Accelerated Corrosion Resistance NOTE: The salt spray test is only used to test the integrity of the alloy deposit and the effectiveness of the chromite coating. The hours to white or red rust SHALL NOT be construed as having any correlation to the actual service life of the part! ‘Sample parts shall be dried and aged for 24 hours priar to expesing them to salt spray. The test shall be conducted in accordance with ASTM B-117 for the times shown in TABLES 2. and 3. PS-8955, Change 2, 2010-04-13, Page 3 Copyright Chrysler Group LO (povec6-05)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. ‘Chramite” coatings are inherently fragile films 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 failure. Awhite "powdery film that dass not increase with time is also nota failure. On parts with a surface area greater than 155 sq em (24. and which correspond to Safety and Emission Shields respectively. When applicable, the PS-8955, Change Z, 2010-04-13, Page 5 Copyright Chrysier Group LLC pove06.)Chrysler mandated requirements are designated by which correspond to the Diamond symbol and by for Appearance related objectives, respectively. For specific information on this document, please refer to the comtact 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@chrysler.com. 6.0 REFERENCES Chrysler ASTM Iso SAE | Federal | Standards Standards Standards | Standards | Standards ‘CS-9003 ASTM B-117 SAE/USCAR-1 ‘€S-9800 ‘ASTM B 487 CS-9801 ‘ASTM B 499 PS79 ASTM B504 PS-4200 ‘ASTM B 568 [Ps-2500<8> ASTM B-571 PS-PLATING ‘ASTM B 602 ‘ASTM B 697 ‘ASTM B 762 ‘Quality and Reliability Documents ‘Other Documents 7.0 ENGINEERING APPROVED SOURCE LIST TABLE 4: ENGINEERING APPROVED SOURCE LIST™* Materials covered by this standard shall only be purchased from those source(s) listed in this table. “ZING-IRON- “ZINC-COBALT ZING-NICKEL SUPPLIER RACK | BARREL) RACK | BARREL| RACK | BARREL ‘Acadian Platers Lid x x Rexdale, Ont. Canada Ajax Metal Processing, Inc. x x x Detroit, Ml AP! Industries x x Elk Grove Village, IL Alas Plating Co. x Cleveland, OH Autotek Electroplating, Inc. x x Rexdale, Ont. Canada, Barber Coleman/Rabert Shah x Rockford, IL PS-8955, Change Z, 2010-04-18, Page 6 Copyright Chrysler Group LLC ceonz-es-08)TABLE 4: ENGINEERING APPROVED SOURCE LIST** Materials covered by this standard shall only be purchased from those source(s) listed in this table. SUPPLIER ‘ZINC-IRON ZINC-COBALT ZINC-NICKEL RACK | BARREL RACK | BARREL RACK BARREL BFG Electroplating Hamburg, NY x x Cadillac Plating Co Warren, Ml Goatings 85 Pint B & C Mississauga, Ontario Controlled Plating Tech Grand Rapids, MI DeKalb Metal Finishing ‘Aubum, IN Eleo industries, Inc. Rockford, IL Erieview Metal Treating Cleveland, OH 44128 Finishing Services Ypsilanti, Mi Gatto Industrial Platers Ghicago, IL Greystone Induplaie North Praviderice, BI Hohman Plating Dayton, OH Howard Plating Industries Madison Heights, Ml JD Plating Go. Madison Heights, MI KC Jones Plating Co. Hazel Park, Ml Marsh Plating Corp Ypsilanti, Ml Medina Plating Carp. | Medina, OH 44256 Modem Plating Freeport, IL Nicro SAdeCV Tlalnepantla, Mexico (ene ce-25) PS.8955, Change Z, 2010-04-13, Page 7 Copyright Chrysler Group LLCTABLE 4: ENGINEERING APPROVED SOURCE LIST** Materials covered by this standard shalll anly be purchased from those source(s) listed in this table. ‘SUPPLIER ZING-IRON ZINC-COBALT ZINC-NICKEL, RACK BARREL RACK BARREL RACK BARREL P &J Plating Toledo, OH Plating Technology, Ine. Dayton, OH Columbus, OH x x x Progressive Plating Indianapolis, IN Rampart Industries Detroit, MI Reilly Plating Co Melvindale, MI Roy Metal Finishing | Conetee, SC 29636 South Holland Monee, IL Superior Plating Co. Minneapolis, MN Tecniflex Naucalpan, Mexico Twist Inc. Xenia, OH Varland Metal Service, Inc. Cincinnati, OH 45229 Whyco Chromium Thomaston, CT Wisconsin Plating Rlacine, WI Wolverine Plating Garp Roseville, Ml 8.0 PUBLICATION INFORMATION** Contact/Phone Number: J.M. Szotek (248) 676-7492 Altermate Contact/Phone Number: Department Name & Department Number/Tech Club/Organization: Organic Materials Engineering, Dept 5840 Date Standard Originally Published: 2001-01-02 Date Published: 2010-04-13 PS-8955, Change Z, 2010-04-13, Page 8 poveceeey Copyright Chrysler Group LLC‘Change Notice: Description af Change: - Sec. 7.0; Consolidate Table #8 into Table #5; Include Tecniflex; - Sec. 8.0: Update contact information ~ Editorial eaeee PS-8855, Change Z, 2010-04-13, Page 9 (Copyright Chrysler Group LLC to ce-06)