TressKimA-kim.tress@

MARCHIAROGIANCARLO-GIANCARLO.MARCHIARO@CRF.IT

AuthorDepartmentFCAUS--ORGANICMATERIALS-5840Author

Co-AuthorDepartmentCRF.-GroupMaterialsLabsCo-Author

ZINCNICKELALLOY

ELECTRODEPOSITEDCOATINGS

PS.50031FCAItalyClass:NPR

FCAUSDoc.Type:PS

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Date:22-JUN-2015

HARMONIZEDDOCUMENT

Changelevel

Date

Descriptionofchange

-

22-JUN-2015

Initialrelease.Harmonizedversionof9.57409,PS-8955,andPS-12182.

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CONFIDENTIAL

THISDOCUMENTMUSTNOTBEREPRODUCEDORCIRCULATEDTOTHIRDPARTIESWITHOUTPRIORWRITTENCONSENTBYFCAItalyS.p.A.andFCAUSLLC..

INCASEOFDISPUTE,THEONLYVALIDREFERENCEISTHEENGLISHEDITION

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ZINCNICKELALLOYELECTRODEPOSITEDCOATINGS

TABLEOFCONTENTS

1GENERAL 4

1.1Purpose 4

1.2CoverageofthisStandard 4

2REFERENCES 5

3DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS 6

4PROCESSANDPROCESSCONTROLREQUIREMENTS 6

4.1Conditionofthepartpriortoprocessing 6

4.2Procedure 7

4.2.1Cleaning 7

4.2.2Plating 7

4.2.3Passivates 7

4.2.4Topcoatsand/orSealers 7

4.2.5HydrogenEmbrittlementRelief 7

4.3Processcontrol 8

4.4Inspectionrequirements 8

4.4.1FinishRequirementsonSignificantSurfaces 8

4.4.2Workmanship 8

4.4.3AlloyComposition 8

4.4.4PlateThickness 9

MeasurementLocations 9

MethodofMeasurement 9

MaximumDepositThickness 10

ThicknessonFasteners 10

4.4.5Frictioncoefficient 11

4.5Adhesion 11

4.5.1Heatshockmethod 11

4.5.2BendMethod(tobeadoptedonlyonpartsmadeofthinsheetortape) 11

4.6HydrogenEmbrittlementTest 11

4.7AcceleratedCorrosionResistance 11

4.8DrytoTouch 13

4.9CondensingHumidity(fortopcoatsandsealers) 13

4.10GalvanicCompatibility 13

4.11TappingScrewTestProtocol 13

4.12WasherAssemblyBreakawayTorque 13

4.13FastenerHeadFill(Fortopcoatsonly) 13

4.14UVResistance 13

4.15Chromiumpresence 14

4.16Re-process 14

4.17PartMaintenanceRequirements 14

5SPECIALREQUIREMENTS 15

5.1ProcessValidation 15

5.2CoatingBuildCapability 15

6QUALITY 16

7TESTEQUIPMENT 16

7.1TestFacilities 16

7.2TestEquipment 16

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8APPROVEDSOURCELIST 17

9DRAWINGCALLOUTCROSS-REFERENCE 19

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1GENERAL

ThisstandarddefinesharmonizedrequirementsforzincnickelelectroplatedcomponentsforusebyFCAItalyS.p.A.andFCAUSLLC.

ThisdocumentsupersedesFCAItalyProcurementSpecification9.57409andFCAUSProcessStandardsPS-8955andPS-12182.

1.1Purpose

Thisstandardspecifiestheplatingandperformancerequirementsforzinc-nickelalloyelectrodepositsandtheirassociatedpassivatecoatingsandtopcoats.Thiscoatingsystemisusedforenhancedcorrosionresistanceonferrousparts,includingfasteners.

1.2CoverageofthisStandard

Specificrequirementsshownonthepartdrawingshalltakeprecedenceoverrelatedrequirementsspecifiedinthisstandard,ormaybeinadditiontotherequirementsofthisstandard.

Alkalinezincnickelprocessesshallbeusedunlessotherwisenoted.Whenaspecificsubstratecannotbeeffectivelyplatedinalkalinezincnickel,suchascastironcomponents,thesuppliermustobtainapprovalfromMaterialsEngineering.Partsmaybeprocessedinabarrelorrackplatingline.

Becausethisstandardcoversmorethanonefinish,theabbreviateddescriptionmustbeaddedasasuffixaftertheprocessstandardnumbertodesignatethespecificsystem.Table1providesalistoftheavailabledesignations.

Table1-DesignationsforDrawings

Thickness(1)

Description

8

Thickness:8micrometers(0.00030inch)minimum

12

Thickness:12micrometers(0.00050inch)minimum

Passivate(2)

Description

Plain

Nopassivates,topcoat,orsealer

Clear

Thick-layerhexavalentchromium-freeiridescentpassivation

Black

Hexavalentchromium-freeblackpassivationsystem

PostTreatment(2)

Description

ST

Sealerortopcoatforenhancingcorrosionresistance

LUB(3)

Lubricatedsealerortopcoatforenhancingcorrosionresistanceandforfrictioncoefficientcontrol

TAP

Specifictopcoatsoptimizedforuseontappingscrews

NOTE(1):High-strengthsteelshavingatensilestrengthof1040N/mm2orgreater,orhardnessofHRc32orgreater,shallnotbespecifiedtothicknessgreaterthan8micrometers.

Forfastenersandthreadedelementsshallbespecified8micrometersthicknessonly.

NOTE(2):InordertocomplywiththeDirective2000/53/CEallthepassivationandsealingtreatmentsusedmustbefreeofhexavalentchromium,cadmium,leadandmercury.

NOTE(3):Thecoefficientoffrictionshallbespecified.Unlessotherwisespecified,thecoefficientoffrictionshallbe0.10to

0.16.(seealso4.4.5)

A.Forexample,thedesignation“DOCNO8BlackLUBCf=0.10to0.16”requiresablackfinalappearancewithalubricatingsealerthatprovidesacoefficientoffrictionof0.10to0.16,aspersection4.4.5.Ifthereisnothingnotedonthedrawing,thedefaultthicknessfortheplateddepositis8micrometersminimumandthedefaultcolorforthechromiteorpassivateisclear.

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B.Theuseoftopcoatsorsealersisrecommendedtoenhancecorrosionresistanceexceptwhenthepropertiesorperformanceofthepartwillbenegativelyaffected,suchastorqueorelectricalconductivity,orpartsthatmustsubsequentlybepaintedbycataphoresis(ecoat),orsmallblocksreinforcementsandbushingsintendedforrubber-metalconnection.

C.WhenspecifyingthiscoatingforcomponentstobeprocessedthroughtheBodyInWhite(BIW),the“Plain”designationshallbeused,unlessotherwisenotedonthedrawing.Thisdesignationisonlyrecommendedforcomponentsthatwillbesubsequentlypaintedorsubjecttofurtherprocessingwherethepassivatefilmisnotcompatible.

D.Platedpartswithtensilestrengthof1040orgreater,orhardnessofRockwellHRC32orgreater,andallpropertyclass9.8and10.9boltsrequireconformancetotherequirementsofProcessStandardPS.50023<S>HydrogenEmbrittlementRelief.

E.Zincnickelalloycoatingshallnotbeusedforsteelpartswithresistancetotensilestress(R)>1500N/mm2regardlessofpartclassification,norforsteelpartswithR≥1220N/mm2forwhichfunctionalclass1(refertoStandard00160)isprescribed.

F.Castironcomponents,suchasbrakecalipers,maybeplatedineitheracidzincnickelsystemsorinaduplex(acidzincandsubsequentalkalinezincnickel)system.

2REFERENCES

Table2-References

DocumentNumber

DocumentTitle

00160

ServiceClasses–AssignmentofThreeServiceClassestoMotorVehicleComponents

9.01102

SupplyQuality–FCAAutomobilesS.p.A.

9.01103

ProductQualityandConformityCertificate

9.01107

UseProvisionsfortheI.M.D.S.System

9.52605/01

NormalandSpecialServiceThreadedFasteners

7.G0114

FastenerFrictionTest

ISO3613

MetallicandOtherInorganicCoatings–ChromateConversionCoatingsonZinc,Cadmium,Aluminium-ZincAlloysandZinc-AluminiumAlloys–Test

Methods

CS-9003

SupplierRequirementsforVehicleandServiceParts:MaterialContentReporting,Marking,andRecyclability

CS-9800

GeneralInformation

CS-9801

QualityRequirements

PS.50023<S>

HydrogenEmbrittlementRelief

AIAGCQI-11Version2

SpecialProcess:PlatingSystemAssessment

ASTMB117

StandardPracticeforOperatingSaltSpray(Fog)Apparatus

ASTMB487

StandardTestMethodforMeasurementofMetalandOxideCoatingThicknessbyMicroscopicalExaminationofCrossSection

ASTMB499

StandardTestMethodforMeasurementofCoatingThicknessbyMagneticMethod:NonmagneticCoatingsonMagneticBasisMetals

ASTMB504

StandardTestMethodforMeasurementofThicknessofMetallicCoatingsbytheCoulometricMethod

ASTMB568

StandardTestMethodforMeasurementofCoatingThicknessbyX-RaySpectrometry

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Table2-References

DocumentNumber

DocumentTitle

ASTMB602

StandardTestMethodforAttributeSamplingofMetallicandInorganicCoatings

ASTMB697

StandardGuideforSelectionofSamplingPlansforInspectionofElectrodepositedMetallicandInorganicCoatings

ASTMB762

StandardTestMethodofVariablesSamplingofMetallicandInorganicCoatings

ASTMD2247

StandardPracticeforTestingWaterResistanceofCoatingsin100%RelativeHumidity

CEP-11916

EASLApprovalReviewProcessElectroplatedAndInorganicCoatings

PS-8955

ZincAlloyElectrodepositedCoatings

PS-12182

CoatingSystem-Black,GalvanicProtectionBased

LP-461H-118

GalvanicCorrosionTestForFasteners

SAE/USCAR-1

SpecificationForTestingAutomotiveLightBulbSockets

SAEJ2334

LaboratoryCyclicCorrosionTest

SAEJ2527

PerformanceBasedStandardforAcceleratedExposureofAutomotiveExteriorMaterialsUsingaControlledIrradianceXenon-ArcApparatus

ISO/TS16949

QualityManagementSystems-ParticularRequirementsforthe

ApplicationofISO9001:2008forAutomotiveProductionAndRelevantServicePartOrganizations

ISO/IEC17025

GeneralRequirementsfortheCompetenceofTestingandCalibrationlaboratories

3DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS

AIAG:AutomotiveIndustryActionGroup

ASTM:AmericanSocietyforTestingandMaterials

BIW:BodyInWhite

C:Celsius

F:Fahrenheit

HRc:RockwellHardness,usingScaleC

mm:Millimeters

N:Newton

SAE:SocietyofAutomotiveEngineers

4PROCESSANDPROCESSCONTROLREQUIREMENTS

Approvaloftheplatingprocess,andanyproposedchangesshallbeobtainedfromtheFCAMaterialsEngineeringDepartment.

4.1Conditionofthepartpriortoprocessing

Allforming,heattreating,andstakingoperationsshallbecompletedpriortocoating.AnydeviationmustbereviewedandapprovedbyFCAMaterialsEngineeringGroups.

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4.2Procedure

4.2.1Cleaning

Thepreplateprocessforcomponentsprocessedperthisstandardisnotdefined.Anyprocessthatcanbedemonstratedtoprovidepartsconformingtothefullrequirementsofthisstandardisallowed.Itisthesupplier’sresponsibilitytousetheappropriatemeansnecessarytoensureacceptableplatecoverage,adhesion,andfullcompliancetothestandard.

Whenprocessingpartshavingatensilestrengthof1040N/mm2orgreater,orHRc32orgreater,theprocessrestrictionstoreducetheriskofhydrogenembrittlementmustbefollowedinaccordancewithPS.50023<S>HydrogenEmbrittlementRelief.

4.2.2Plating

Thezincnickelplatingmaybeperformedinarackorbarrelapplicationprovidedthefinishedpartsmeetalltherequirementsofthisstandard,andtheprocessdoesnothaveanynegativeeffectonthepart.

4.2.3Passivates

HEXAVALENTSYSTEMSARENOLONGERALLOWED.ALLPASSIVATESSHALLBETRIVALENTCHROMIUMORCHROMIUMFREEONLY.

Atrivalentchromiumorchromium-freetypepassivateisconsideredanintegralpartofthisprocessstandardandsignificantlyenhancetheoverallcorrosionresistanceofthedeposit.Thepassivatemustbeformulatedforzincnickel.Slightcoloriridescenceandcolorvariationsareacceptable.

Partsrequiringablackpassivatesshallprovideauniform,decorativeblackappearancethatisUVstable.Thepartsshallbefreefrombarespotsandnotchiporflakeduringnormalhandling.

4.2.4Topcoatsand/orSealers

Theuseofatopcoatorsealerisrecommendedonpartsotherthansurfacesthatwillbewelded,orcomponentsrequiringelectricalconductivity.Thetopcoatorsealermustbedry-to-the-touchandpassallfluidcompatibilityrequirementsforeachapplication.Thetopcoatorsealermustnotinterferewiththeassemblyorperformanceofthepart.Topcoatsareappliedafterhydrogenembrittlementreliefisperformed,whennecessary.

NOTE:Onfastenersandotherthreadedparts,theuseoflubricantorlubricatedsealerforloweringthefrictioncoefficientmustbepre-approved.

4.2.5HydrogenEmbrittlementRelief

Highstrength/highhardnesssteelpartswithatensilestrengthof1040N/mm2orgreater,orHRC32orgreater,MUSTBEPROPERLYBAKEDaccordingtothescheduleandprocedurespecifiedinProcessStandardPS.50023<S>,“HydrogenEmbrittlementRelief”,withinonehourafterplatingandatspecifiedtemperaturewithintwohoursafterplating.Thepartsmustreachtherelieftemperaturewithin2hoursafterexitingtheelectroplatingbath.Thebakeoperationmaybedoneaftertrivalentchromiteorpassivatepostdip,providedithasbeenshownthatthereisnodetrimentaleffectonthecorrosionresistanceorperformance.

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Table3-HydrogenReliefRequirements

TensileStress/Hardness

HydrogenRelief

1040to1220N/mm2(32to36HRc)

200+/-10Cfor4hoursminimum

1220to1500N/mm2(37to49HRc)

200+/-10Cfor8hoursminimum

4.3Processcontrol

Processcontrolanalysisandproceduresnecessarytoensureoptimumelectroplatingprocessperformancearerequiredofallapplicatorselectroplatingtotherequirementsofthisstandard.Theapplicatorisresponsibletoperformallnecessaryandprudentprocesscontrolandisresponsibleformaintainingallrecordsrelevanttotheplatingprocess.FCASQwillverifycompliancewithinthescopeofthePPAP/PSO.Theserecordsinclude:

A.SolutionControlRequirements–ThecontrolrequirementsshallbefollowedwithminimumfrequenciestomeettherequirementsidentifiedinAIAG’sCQI-11Version2ProcessTableAunlessotherwisespecifiedbySupplierQuality.Ifpartsarecoatedhavingatensilestrengthof1040N/mm2(HRc32)orgreater,theminimumfrequenciestomeettherequirementsidentifiedinAIAG’sCQI-11Version2ProcessTableIarealsorequired,unlessotherwisespecifiedbySupplierQuality.

B.ProcessMaintenanceSpecifications–ThemaintenancerequirementsandminimumanalyticalfrequenciesshallbefollowedtomeettherequirementsidentifiedbySupplierQuality.

ProcessControltargetsandrangesshallbeestablishedbytheprocessorandmaterialsupplier(s)anddocumentedontheControlPlan.Anychangesmustbedocumented.

4.4Inspectionrequirements

4.4.1FinishRequirementsonSignificantSurfaces

Therequirementsofthisstandardapplytothesignificantsurfacesofapart.Unlessotherwisespecifiedonthepartdrawing,significantsurfacesforplatingthicknessandcorrosionresistancedeterminationareallsurfacesthatcanbetouchedbya20mm(or0.75in)diametersphere.Thethreadsofthreadedfastenersarenotclassifiedassignificantsurfaces.However,theentireheadareaofscrewsandbolts,andtheunthreadedshanksofboltsaresignificantsurfaces.

4.4.2Workmanship

Theplatingshallbesmooth,adherent,andfreeofblisters,pits,nodules,andotherfunctionaldefects.Coverageshallbecompleteanduniforminappearanceonsignificantsurfaces,withrespecttotheelectroplateddeposit.Thepresenceofmicrocracksreachingthebasemetalisallowedprovidedthattheydonotcompromisetheresistancetocorrosion.Passivates,topcoatsand/orsealersshallcompletelycovertheplatedsurfaces,beadherentanddry-to-touchbutnotpowdery.Iridescenceinthefinishisexpectedandacceptableforclearfinishes,butshouldbeminimalforblackfinishes.

4.4.3AlloyComposition

Theamountofalloyingelementpresentinthezincalloyelectrodepositscoveredbythisstandardisdifferentforeachalloy.TheconcentrationlimitsforthevariousalloysarelistedinTABLE4.ThedeterminationoftheNickelpercentageinthedepositedalloyshallbecarriedoutbyoneofthefollowingmethods:

A.PreferredMethod:X-rayfluorescence(non-destructivemethod)

B.AlternateMethod:Aciddissolutionofcoatingandsubsequentchemicalanalysis(destructivemethod)

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Table4-AlloyComposition

DepositAlloy

Weight%RangeofNickel

NominalWeight%ofNickel

Acidzinc-nickel

9.0to16.0%

12.0%

Alkalinezinc-nickel

12to17%

14%

4.4.4PlateThickness

MeasurementLocations

TheplatethicknessonallSignificantSurfacesdefinedbySection4.4.1mustmeettheminimumthicknessasspecifiedinTable5.ThicknesschecksforContinualConformanceshallbemeasuredatcheckpoints(P-Points)indicatedonthedrawingofthepartasaconvenienceonly.Allotherlocations,ifinspected,mustmeetminimumrequirements.

ToselectpotentialP-Points,thesuppliershallidentifythe10pointsoflowestoverallthicknessconformingtoSignificantSurfacerequirementsonpartstakenfromthelowestcurrentdensitylocationontheplatingbarorrack.Fromthisdata,thesupplierprovidesthesupportingCoatingBuildCapabilityreportandproposesP-PointstoFCASupplierQuality.TheproposedP-Pointsaretobe1to5well-spacedandtypicallysymmetricalpointsexhibitinglowthicknessbutconformingtoSignificantSurfacerequirements.FCASupplierQualityapprovestheproposedP-Pointsoridentifiesotherpreferredlocations.

Ifpartgeometryissuchthatitisimpracticaltoachieveminimumthicknessontheentirepart,aproposalmustbemadebythesuppliertoMaterialsEngineeringforadeviationtobeconsidered.

MethodofMeasurement

ThefollowingASTMStandardMethodsarerecommendedfordeterminingthecoatingthicknessforqualification:

-ASTMB487MicroscopicCrossSection

-ASTMB568X-RayMethod

ThefollowingASTMStandardMethodisallowedfordeterminingthecoatingthicknessforqualitymanagement:

-ASTMB499MagneticMethod

Exceptforthemicroscopicmethod,itisessentialtocalibratethetestinstrumentwithanalloyofthesamecompositionasthatbeingmeasured.

Toinsurecompliancewiththethicknessrequirementsofthisstandard,theplatingthicknessesandalloyshallbemeasuredonaregularandfrequentbasisusingacceptablesamplingplans,suchasrecommendedinASTMB697,B602,andB762orequivalents.Controlchartsandrecordsdocumentingcompliancewiththeminimumthicknessrequirementsofthisstandardshallbepreparedandmaintained.

TheminimumcoatingthicknessesonsignificantsurfacesarespecifiedbytheCodenumbersuffixaftertheprocessstandardnumberasfollows:

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Table5-CoatingThickness

DescriptionCode

ThicknessRequirement

8

8micrometers(0.00030inch)minimum

12

12micrometers(0.00050inch)minimum

Depositthicknessesgreaterthan8micronsaregenerallynotrecommended.Ifitisdeterminedthatotherthicknessesarenecessaryforaparticularapplication,drawingnotesshallbeusedtodesignatetherequiredthickness.Ifno“Code”isspecifiedonthedrawing,thedefaultis8micronsminimum.

MaximumDepositThickness

Becauseofvariousfactorssuchasthepartconfigurationandtypeofplatingprocessused,themaximumthicknessvaluescannotbedefined.Themaximumthicknessmustnotinterferewiththeassemblyorperformanceofthepart.Whennecessary,amaximumthicknessmaybedefinedontheprint.

ThicknessonFasteners

Withregardtocoatingthicknessofbolts,ifnototherwisespecifiedbythePurchaser,holes,hollows,threads,andsharpedgesarenotconsideredtobesignificantsurfaces.However,theentireheadareaofscrewsandbolts,andtheunthreadedshanksofboltsaresignificantsurfaces.

Consideringthevariabilityoftheelectrolyticcoatingthicknessonscrewsandnuts,themeasurementismadeonapointsignificantfortheanticorrosiveprotectionrating.

Incaseofscrews,thispointliesapproximatelyatthecenteroftheheadsurface,thecenterofthestemend,andthecenteroftheunthreadedportionoftheshaft.(seeFigure1).

Incaseofcylindricalscrewswithcountersunkhexagonalheadandofscrewswithcrosscut,themeasuringpointliesontheflatsurfaceofthehead,betweenedgeandcountersunkhexagon,betweenedgeandcrosscutoronthesideofthehexagon(seeFigure1).Countersunkandcutsurfacesareexcludedfromthemeasuringpoints.

Incaseofnuts,thicknessismeasuredonasideofthehexagonand/oronasupportplane(seeFigure2).

Figure1-Measurementlocationsforboltsorscrews

Figure2-Measurementlocationsfornuts

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4.4.5Frictioncoefficient

Ifnototherwiseindicatedondrawing,thefrictioncoefficientsmustrangewithinthedispersionlimitsCf=0.12to0.30,indicatedinProcurementSpecification9.52605/01.

ForfastenersrequiringLUBType,thecoefficientoffrictionshallbe0.10to0.16unlessotherwiseindicatedonthedrawing.

Differentvaluesmustbespecifiedondrawing.

E.g.:DOCNOCode8ClearLUB(Cf=0.12to0.18).

ThemethodofthecorrectapplicationofthefrictionconditionersmustbecarriedoutmeasuringthefrictioncoefficientasindicatedintheStandard7.G0114.OthertestmethodmustbeagreeduponbeforehandandapprovedbyMaterialsEngineeringDepartmentofFCA.

4.5Adhesion

A.Thedepositshallnotpeelfromitselforfromthesubstratewhentestedinaccordancewithoneofthemethoddescribedbelow.Partsshallnotexhibitchippingorflakingduringnormalhandling.Thehardened,agedpassivateandtopcoatandsealershallbetightlyadherenttothezincnickelsubstrateandshallnotberemovedbyordinaryhandling.

4.5.1Heatshockmethod

A.Placethecoatedparttobetestedintoaconstanttemperaturechamberfor1hourat290°Cto310oC.

B.Carefullyremovethepartandimmediatelyimmerseinwateratroomtemperature.

C.Aftercooling,takethepartoutanddryitwithaflowofcompressedair.

D.Attheendofthetestinspectthecoating,ensuringthereisnosignofdetachmentfrombasemetal,swellings,blisters,flaking,etc.

4.5.2BendMethod(tobeadoptedonlyonpartsmadeofthinsheetortape)

A.Thetestconsistsinbendingthepartorsampletobetested,manuallyorwithpliers,atanacuteangle,firstononesideandthenontheother,untilitbreaks.

B.Inspecttheareaalongthebreak,confirmingthecoatingdoesnotliftordetachfromthebasemetalandthatthereisnosignofflaking.

4.6HydrogenEmbrittlementTest

ThehydrogenembrittlementtestistobeperformedaccordingtoProcessStandardPS.50023<S>.Thistestisrequiredforallpartshavingtensilestrengthof1040N/mm2orgreater,orHRc32orgreater,includingpropertyclass9.8and10.9fasteners.

4.7AcceleratedCorrosionResistance

Heatsoakthepartstobetestedinconstanttemperatureventilatedchamberfor55to65minutesat145°Cto155°C,followedbytestinginaccordancewithASTMB117forthetimesshowninTABLE6.

Samplepartsshallbedriedandagedforaminimumof24hourspriortoexposingthemtothetest.

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TABLE6summarizestherequiredminimumhoursofsaltsprayexposurebeforetheformationofwhitecorrosionproductsforthealloysandchromitecoatingscoveredbythisstandard,aswellastheminimumnumberofhourstoredrust.

SaltspraycorrosiontestrequirementsDONOTapplytodeeprecesses,suchassmallblindholesandtheinterioroftubing.

ThecorrosiontestingoffastenersmustfollowtheprocedureasoutlinedinSAE/USCAR-1,“SaltSprayTestingandEvaluationofFastenerFinishes”.Onthreadedfasteners,theformationofcorrosionproductsinthethreadedareasDOESNOTconstituteafailure.However,theheadandunthreadedshankofascreworboltisconsideredasignificantsurfaceandmustwithstandtheformationofwhite(zinc)andred(basemetal)corrosionfortheminimumtimeslistedinTABLE6.Afterexposure,WhiteRustrequirementsaremetiflessthan3%ofthesurfaceexhibitsaestheticalterationsincludingblackspotsorwhitehaze/blush.Partswithablackfinishmayberinsedwithwarmwatertodeterminewhetherthepassivationlayerisundamagedandmaintainstheoriginalcolor.

Afterexposure,RedRustrequirementsaremetifthereisnoevidenceofbasemetalcorrosion.

Table6-MinimumSaltSprayTestRequirements

NoTopcoatorSealersareAllowedonFastenersUnlessApprovedByFastenerEngineering

Description

(AlkalineorAcidic

systems)

BarrelProcess

RackProcess

Hoursto

WhiteRust

HourstoRed

Rust

Hoursto

WhiteRust

HourstoRed

Rust

8microns,Plain

NA

500

NA

500

8microns,Clear

120

840

144

864

8microns,Clear,ST

216

1000

240

1100

8microns,Black,ST

216

1000

240

1100

8microns,Clear,LUB

216

1000

240

1100

8microns,Black,LUB

216

1000

240

1100

8microns,Black,TAP

240

1000

240

1000

12microns,Clear

120

1000

144

1100

12microns,Clear,ST

216

1200

240

1500

12microns,Black,ST

216

1200

240

1500

12microns,Clear,LUB

216

1200

240

1500

12microns,Black,LUB

216

1200

240

1500

Thesaltspraytestisonlyusedto