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
[email protected].
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)
