‘Tress Kim A kimress@feagroup.com ‘thor Z 5 8 § ‘Author Department hhesse@pfeagroup.com g Supervisor g 3 3 3 5 5 FCAUSLLC Document Number: PS-8955 Process Standard Date Published: 2015-08-24 Category Code: H-1 Change Level: AD EASL Requirement: Yes Contact: Kim Tress A. Restricted: No Phone: 248 512.2442 Department Number: 5840 Document Owner Group: CoC/Organic Materials Engineering ZINC ALLOY ELECTRODEPOSITED COATINGS CARRYOVER ONLY NOTE: This standard is being phased out and shall be used on carryover parts/programs only, If there is a new document to refer to, that document number is PS:50034 DO NOT USE THIS STANDARD ON NEW PARTS/PROGRAMS or add this standard as a change to any model. This standard may be retained on CATIA/NX models revisions, if it was included at the beginning of the program. Contact the originating department identified with this standard for the proper replacement standard. PS-8955, Change AD, 2015-08-24 Copyright FOA US LLCChrysler Group LLC Document Number: PS-8955 Process Standard Date Published: 2012-11-27 Category Code: H-1 Change Level: AB EASL Requirement: Yes Restricled: No ZINC ALLOY ELECTRODEPOSITED COATINGS, 1.0 GENERAL 1.4 Purpose ‘This standard specifies the plating and performance requirements for various 2inc-cobalt, zinc-nickel and zinc-iran alloy electrodeposits and their associated passivate coatings and topcoats, used for enhanced Corrosion resistance on ferrous parts, 1.2. Requirements on Part Drawings ‘Specific requirements shown on the part drawing shall take precederice 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 cfiemical symbol of the alloying element must be added as a suffix after the process standard number to designate the specific alloy desired. Table 1 lists the allowable alloys and the proper designation. ‘ALLOY DESIGNATION DESCRIPTION. Ni Deposit: Zing-Nickel Allo NEHA Deposit: Zinc-Nickel High-Alloy FE, Deposit:Zinc-Iron Alloy co Deposit: Zinc-Cobalt Allo THICKNESS DESIGNATION | DESCRIPTION Code 20, Thickness: 5 micrometers (0.00020 inch) Code 30, Thickness: 8 micrometers (0.00030 inch) PASSIVATE DESIGNATION. | DESCRIPTION Clear (| Passivate: Clear, blue-bright, or colorless Black Passivate: Black NOTE 1; PS-B955 CO alloy is used for “CARRY-OVER ONLY.” This application is being phased out by the end of December 2012. PS- ‘8955 Ni-Code 20 shall be the replacement. ‘A. The desired deposit thickness must be specified after the process standard number using a "Cod: designation. For example, the designation "PS-8955 NI Code 30° means a zinc-nickel alloy deposit with a thickness of 8 micrometers (0.00030 inch) minimum on significant surfaces. 8. The default alloy for the plated deposit is PS-8955 NI unless otherwise noted on the drawing C. The default thickness for the plated deposit is Code 30 unless otherwise noted on the drawing. ©. The default clr fo tn homie or passvateis deat niees chemise nod on ne craving, EB PS-8955, Change AB, 2012-11-27, Page 1 Copyright Crysler Group LLC (ox0s200nE. The use of topcoats or sealers is recommended to enhance corrosion resistance except when the properties or performance of the part will be negatively affected, such as torque or electrical conductivity. F. Parts requiring extra high corrosion resistance must be specified after the process standard number using "Ni-HA" designation. G. Parts with hardness of Rockwell HRC 32 or greater require a mandatory bake for hydrogen embrittlement relief according to Process Standard PS-9500 (Hydrogen Embrittlement Relief) 2.0 PROCESS 2.4 Electroplating Process Both acid and alkaline zinc alloy plating processes are covered by thi®process standard for the “NI” designation. Only alkaline zinc nickel alloy plating processes are acceptable for the "NI-HA" designation. 2.2 Solution Control ‘The plating conditions and process control ranges shall be mionitored and recorded as described by the AIAG CQI-11: Special Process: Plating System Assessment, Process Table A: Zinc and Zinc Alloy Plating. Additional requirements specified in this standard or on the part drawing shall take precedence over the CQI-11 controls. Rinse overflows, bath dump schedules, chemical concentrations, operating parameters, and maintenance shall be controlled according to the chemical supplier's recommendations, Approval of the plating process, and any proposed changes shall be obtained from the Chrysler Organic Materials Engineering Department. 2.3 Hydrogen Embrittlement Relief High strengthinigh hardness steel paris 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 Embritlentent Relief, within one hour after plating and at specified temperature within two hours after plating:cThe bake operation may be done after trivalent chromite or passivate post dip, provided it can be showarthat there is no detrimental effect on the corrosion resistance. 2.4 Finish Requirements on Significant Surfaces. ‘The requirements ofthis Standard apply to the significant surfaces of a part. Unless otherwise specified on the part drawing; significant surfaces for plating thickness and corrosion resistance determination 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. 2.5 Workmanship ‘The plating shall be smooth, adherent, and free of blisters, pits, nodules, and other functional defects. Coverage shall be complete and uniform in appearance on significant surfaces, with respect to the electroplated deposit. In the zinc nickel deposit, the presence of microcracks reaching the base metal is allowed provided that they do not compromise the resistance to corrosion. Passivates, topcoats and/or sealers shall completely cover the plated surfaces, be adherent and dry-to-touch but not powdery. PS-8955, Change AB, 2012-11-27, Page 2 Copyright Crysler Group LLC (ox0s200nlridescence in the finish is expected and acceptable. 3.0 PERFORMANCE REQUIREMENTS 3.1. Alloy Composition ‘The amount of alloying element present in the zinc alloy electrodeposits covered by this standard is different for each alloy. The concentration limits for the various alloys are listed in TABLE 2. NOTE: Zinc-nickel alloy deposits may be obtained from alkaline or mildly acidic plating Solutions. The Corrosion resistance of zinc-nickel alloys is a function of both the alloy nickel content as well as the particular chromite conversion coating employed. In general, zinc-nickehalloy deposits containing a higher percent nickel within limits provide better corrosion protection than alloys with less nickel. However, the quaity of the passivate is crucial. Accurate contol ofthe alloy composition within the limits given in TABLE 2 is essential for optimum corrosion protection. TABLE 2: ALLOYING COMPOSITIONS AND PERMISSIBLE CONCENTRATION RANGE ceroarnuor | MTRMSSSE OMS] MO RE ‘ikaline zine nickel 5.0 10 16.0% Ni 8.0% Ni ‘eid zine-nickel 9.0 to 16.0% Ni 12.0% Ni ‘Alkaline zine-nickel high alloy | 120 17% Ni 14% Ni Zincsiron 03t008%Fe 0.5% Fe Zine-cobalt 0.4 0 1.0% Co, 0.6% Co CARRY-OVER ONLY 3.2 Plate Thickness on Significant Surfaces ‘The plate thickness on significant surfates must meet the minimum thicknesses as specified by the ‘Code" designation. Unless otherwige- specified on the part drawing, significant surfaces are all surfaces that can be touched by a 19 mm (0,751n) 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 suffaces. ‘The following ASTM Standard Methods are recommended for determining the coating thickness: - ASTM B487 Microscopi Cross Section - ASTM B568 X-Ray Method - ASTM B499 Magnetic Method - ASTM B504 Coulometric Method Except for the'ricroscopic method, itis essential to calibrate the test instrument with an alloy of the same composition as that being measured. To insure compliance with the 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 B697, B602, and B762 or equivalents. Control charts and records documenting compliance with the minimum thickness requirements of this standard shall be prepared and maintained. PS-8955, Change AB, 2012-11-27, Page 3 Copyright Crysler Group LLC (ox0s200n3.2.1 Minimum Deposit Thickness ‘The minimum coating thicknesses on significant surfaces 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 inch) minimum Code 30 '8 micrometers (0.00030 inch) minimum Deposit thicknesses greater than Code 30 are generally not recommended. If itig Yetermined that thicknesses less than Code 20 or greater than Code 30 are necessary for a particular application, drawing notes shall be used to designate the required thickness. If no “Code” is specified on the drawing, the default is ‘Code 30”. 3.2.2 Maximum Deposit Thickness Because of various factors such as the part configuration and type of plating process used, the maximum thickness values cannot be defined. The maximum thickness must not interfere with the assembly or performance of the part. When necessary, a maximum thickness may be defined on the print. 3.3 Passivates A trivalent chromite type passivate is considered an integral part of the electrodeposited zinc alloys of this process standard. Chromite 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. ‘Slight color iridescence and color variations are acceptable. Chromium-free passivates may be used if alljperformance requirements are met. 3.4 Topcoats and/or Sealers ‘The use of a topcoat or sealer is re¢ammended on parts other than fasteners, surfaces that will be welded, or components requiring'eiectrical conductivity. The topcoat or sealer must be dry-to-the-touch and pass all fluid compatibility requirements for each application. The topcoat or sealer must not interfere with the assembly or performance of the part. NOTE: No topcoats or sdalers are allowed on fasteners and other threaded parts unless approved by Fastener Engineering 3.5 Adhesion ‘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 chromite coating and topcoat and sealer shall be tightly adherent to the zinc alloy substrate and shall not be removed by ordinary handling 3.6 Hydrogen Embrittlement Test ‘The hydrogen embrittlement testis to be performed according to Process Standard PS-9500. PS-8955, Change AB, 2012-11-27, Page 4 Copyright Crysler Group LLC (ox0s200n3.7 Accelerated Corrosion Resistance’ The test shall be conducted in accordance with ASTM B117 for the times shown in TABLES 3 and 4. The requirements of TABLE 3 represent general performance requirements for all non-threaded fastener components. TABLE 4 shall apply to fasteners, threaded parts or other components where the use of a topcoat or slr may have an adverse fect on fe performan "TABLES rosa goer ‘Sample parts shall be dried and aged for a minimum of 24 hours prior to exposing them to salt spray. TABLES 3, 4JBf@'5 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 ours to red rust A faint white film or “blush” does not constitute a failure. A white “powdery” filrithat does not increase with time is also not a failure. Chromite coatings are inherently fragile fims, 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, Salt spray corrosion test requirements DO NOT apply to deep recesse8, such as small blind holes and the interior of tubing (On parts with a surface area greater than 155 sq cm (24 sq in)cthe appearance of six or more red rust spots per 1000 sq cm (1 sq ft.) of significant surface, 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 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 rust spot originating from a spot larger than 1.6 mm (1/16 in) in diameter is a failure. ‘The corrosion testing of fasteners must follow the procedure as outlined in SAE/USCAR-1, "Salt Spray Testing and Evaluation of Fastener Finishes". 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 4, TABLE 3: MINIMUM SALT SPRAY TEST REQUIREMENTS WITH TRIVALENT CHROMITES AND OPTIONAL SEALER OR TOPCOAT NO TOPCOAT OR SEALERS ARE ALLOWED ON FASTENERS UNLESS APPROVED BY FASTENER ENGINEERING. HOURS UST MITE | HOURS TO RED RUST THICKNESS | TRIVALENT 2 ALLOY Fess | TRNGNaNE | win. <3% unite RACK | BARREL | RACK | BARREL ZINC-NICKEL ¢-20 5 | SHEAR | tg | 120 | reo | 720 BLACK CLEAR ZINC-NICKEL ¢-30 8 | SEAR sae | 120 | ace | to ZINC-NICKEL HIGH 5 CLEAR ALLOY €-20 Black) 240} «216 | 1000 | 720 PS-8955, Change AB, 2012-11-27, Page 5 Copyright Crysler Group LLC (ox0s200nTABLE 3: MINIMUM SALT SPRAY TEST REQUIREMENTS: WITH TRIVALENT CHROMITES AND OPTIONAL SEALER OR TOPCOAT NO TOPCOAT OR SEALERS ARE ALLOWED ON FASTENERS UNLESS APPROVED BY FASTENER ENGINEERING. HOURS TO WHITE, RUST THICKNESS | TRIVALENT < a ONs (ricrometers) | CHROMITE | th 3% white HOURS TO RED RUST eos eee eae PNRILOYC30 8 ce ogo | 216

and which correspond to Safety and Emission Shields respectively. When applicable, the Chrysler mandated requirements are designated by which correspond te:the Diamond symbol and by for Appearance related objectives, 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@chrysler.com 7.0 REFERENCES hiyeler ASTM SO SAE Federal Standards ‘Standards Standards S| Standards Standards CS-9003, ‘ASTM B117 z ‘SAE/USCAR-1 CS-9800 ‘ASTM B487 CS-2801 ‘ASTM B499 PS-79 ‘ASTM B504 PS.420025> | ASTM B568 PS.8500 | ASTM B571 : PS-PLATING | ASTM B602 ‘ASTM B697 ‘ASTM B762 Quality and Reliability Documents Other Documents “i “AIAG COr-T1 = Available from wwjn,aiag.org PS-8955, Change AB, 2012-11-27, Page 8 Copyright Crysler Group LLC (ox0s200n8.0 ENGINEERING APPROVED SOURCE LIST TABLE 6: ENGINEERING APPROVED SOURCE LIST Materials covered by this standard shall only be purchased from those source(s) listed in this table. r 7 ZING-NICKEL, SUPPLIER ZINC-IRON. ZINC-NICKEL SRN RACK | BARREL | RACK | BARREL | RACK | BARREL CANADA ‘Acadian Platers Lid. % x 315 Rexdale Blvd Rexdale, ON M9W 1R8 ‘Autotek Electroplating, x Inc.20 Huddersfield Rexdale, ON M9W 526 Coatings 85 — Plant B & C x x 6975 Davand Mississauga, ON LST 1L5 | VEE MEXICO Nicro SAde CV i x x Pirul # 33 Col Bella Vista Tlalnepantia Tecniflex Ansorge x x Calle 9, No 6 and 6A Cal. Alce Blanco CP 53370, Naucalpan usA | Ajax Metal Processing x | . x 4651 Bellevue Ave Detroit, MI 48207 BFG Electroplating x x 33 Scott St Hamburg, NY 14075 Cadillac Plating Co. x 23895 Groesbeck Warren, Mi 48089 ‘Chem Plate Industries x x 1250 Morse Ave, Elk Grove Villages 60007 Controlled Plating Tech Xx 1100 Godfrey SW Grand Rapids, MI 49503, DeKalb Metal Finishing x 625 W 18th St Auburn, IN 46706 Erieview Metal Treating x x 4465 Johnston Pkwy Cleveland, OH 44128 PS-8955, Change AB, 2012-11-27, Page 9 Copyright Crysler Group LLC (ox0s200nTABLE 6: 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-NICKEL ZINC-NICKEL HIGH ALLOY RACK | BARREL RACK BARREL RACK BARREL Gatto Industrial Platers| 4620 W Roosevelt Rd Chicago, IL 60644 x x Greystone Induplate 1 Greystone Dr North Providence, Ri.02911 ‘JD Plating Co. 25428 John R St Madison Hts, Ml 48071 KC Jones Plating Co. 321 W 10 Mile Rd Hazel Park, Mi 48030 Marsh Plating Corp. 103 N Grove St Ypsilanti, MI 48198 Medina Plating Corp. 940 Lafayette Rd Medina, OH 44256 ‘Modern Plating 701 S Hancock Freeport, IL 61032 Plating Technology, inc. 800 Frebis Ave Columbus, OH 43206 Plating Technology, Inc. 1525 West River Rd Dayton, OH 45418 Rampart Industries 17241 Ryan Rd Detroit, Mi 48212 Roy Metal Finishing 112 Conestee Rd Conetee, SC 29636 ‘South Holland 26100 S Whiting Way. Monee, IL 60449 Twist inc. 1430 Lavelle Dr Xenia, OH 45385 Varland Metal Service, 3231 Fredonia Ave Cincinnati, OH 45229 Whyco Chromium 670 Waterbury Rd ‘Thomaston, CT 06787 Wolverine Plating Corp 29456 Groesbeck Hwy Roseville, Mi 48066 (ox0s200n PS-8955, Change AB, 2012-11-27, Page 10 Copyright Crysler Group LLC9.0 PUBLICATION INFORMATION ContactPhone Number: K. Tress (248) 512-2442 Atemate ContactPhone Number: JM. Szotek (248) 576-7442 Department Name & Department Number/Tech Club/Organization: Organic Materials Engineering, Department 5840 Date Standard Originally Published: 2001-01-02 Date Published: 2012-11-27 Change Notice: Description of Change: ~ Editorial = Section 1.2: Define new “Plain” finish as no passivates/topcoat requirements.Clariy drawing designation, Section 3.7: Define salt spray performance for new “Plain’ finish anne PS-8955, Change AB, 2012-11-27, Page 11 Copyright Crysler Group LLC (ox0s200n