PS-8955,ChangeAD,2015-08-24

CopyrightFCAUSLLC

FCAUSLLC

ProcessStandard

CategoryCode:H-1

EASLRequirement:Yes

Restricted:No

DocumentNumber:PS-8955

DatePublished:2015-08-24

ChangeLevel:AD

Contact:KimTressA.

Phone:2485122442

DepartmentNumber:5840

DocumentOwnerGroup:CoC/OrganicMaterialsEngineering

AuthorTressKimA-kim.tress@

rsossononesJhCjhf-..cagropcm

ZINCALLOYELECTRODEPOSITEDCOATINGS

CARRYOVERONLY

NOTE:Thisstandardisbeingphasedoutandshallbeusedoncarryoverparts/programsonly.Ifthereisanewdocumenttoreferto,thatdocumentnumberisPS.50031

DONOTUSETHISSTANDARDONNEWPARTS/PROGRAMSoraddthisstandardasachangeto

anymodel.ThisstandardmayberetainedonCATIA/NXmodelsrevisions,ifitwasincludedatthe

AuthorDepartmentFCAUS--ORGANICMATERIALS-5840

SupervisordepartmentFCAUS--ORGANICMATERIALS-5840

beginningoftheprogram.Contacttheoriginatingdepartmentidentifiedwiththisstandardfortheproperreplacementstandard.

ChryslerGroupLLCDocumentNumber:PS-8955ProcessStandardDatePublished:2012-11-27CategoryCode:H-1ChangeLevel:AB

EASLRequirement:Yes

Restricted:No

ZINCALLOYELECTRODEPOSITEDCOATINGS

1.0GENERAL

1.1Purpose

Thisstandardspecifiestheplatingandperformancerequirementsforvariouszinc-cobalt,zinc-nickelandzinc-ironalloyelectrodepositsandtheirassociatedpassivatecoatingsandtopcoats,usedforenhancedcorrosionresistanceonferrousparts.

1.2RequirementsonPartDrawings***

Specificrequirementsshownonthepartdrawingshalltakeprecedenceoverrelatedrequirementsspecifiedinthisstandard,ormaybeinadditiontotherequirementsofthisstandard.

Becausethisstandardcoversmorethanonezincalloy,thechemicalsymbolofthealloyingelementmustbeaddedasasuffixaftertheprocessstandardnumbertodesignatethespecificalloydesired.Table1liststheallowablealloysandtheproperdesignation.

TABLE1:DESIGNATIONSFORDRAWINGS***

ALLOYDESIGNATION

DESCRIPTION

NI

Deposit:Zinc-NickelAlloy

NI-HA

Deposit:Zinc-NickelHigh-Alloy

FE

Deposit:Zinc-IronAlloy

CO1

Deposit:Zinc-CobaltAlloy

THICKNESSDESIGNATION

DESCRIPTION

Code20

Thickness:5micrometers(0.00020inch)

Code30

Thickness:8micrometers(0.00030inch)

PASSIVATEDESIGNATION

DESCRIPTION

Clear

Passivate:Clear,blue-bright,orcolorless

Black

Passivate:Black

Plain

Nopassivates,topcoat,orsealers

NOTE1:PS-8955COalloyisusedfor“CARRY-OVERONLY.”This

applicationisbeingphasedoutbytheendofDecember2012.PS-8955NICode20shallbethereplacement.

A.Thedesireddepositthicknessmustbespecifiedaftertheprocessstandardnumberusinga“Code”

designation.Forexample,thedesignation“PS-8955NICode30”meansazinc-nickelalloydepositwithathicknessof8micrometers(0.00030inch)minimumonsignificantsurfaces.

B.ThedefaultalloyfortheplateddepositisPS-8955NIunlessotherwisenotedonthedrawing.

C.ThedefaultthicknessfortheplateddepositisCode30unlessotherwisenotedonthedrawing.

D.Thedefaultcolorforthechromiteorpassivateisclearunlessotherwisenotedonthedrawing.Forexample,thedesignation“PS-8955NICode30Black”requiresablackfinalappearance.

PS-8955,ChangeAB,2012-11-27,Page1

CopyrightChryslerGroupLLC

(08-06-2007)

CopyrightChryslerGroupLLC

(08-06-2007)

E.Theuseoftopcoatsorsealersisrecommendedtoenhancecorrosionresistanceexceptwhenthepropertiesorperformanceofthepartwillbenegativelyaffected,suchastorqueorelectrical

conductivity.

F.Partsrequiringextrahighcorrosionresistancemustbespecifiedaftertheprocessstandardnumberusing“NI-HA”designation.

G.PartswithhardnessofRockwellHRC32orgreaterrequireamandatorybakeforhydrogen

embrittlementreliefaccordingtoProcessStandardPS-9500<S>(HydrogenEmbrittlementRelief).

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

2.0PROCESS

2.1ElectroplatingProcess

Bothacidandalkalinezincalloyplatingprocessesarecoveredbythisprocessstandardforthe“NI”

designation.Onlyalkalinezincnickelalloyplatingprocessesareacceptableforthe“NI-HA”designation.

2.2SolutionControl

TheplatingconditionsandprocesscontrolrangesshallbemonitoredandrecordedasdescribedbytheAIAGCQI-11:SpecialProcess:PlatingSystemAssessment,ProcessTableA:ZincandZincAlloy

Plating.AdditionalrequirementsspecifiedinthisstandardoronthepartdrawingshalltakeprecedenceovertheCQI-11controls.Rinseoverflows,bathdumpschedules,chemicalconcentrations,operating

parameters,andmaintenanceshallbecontrolledaccordingtothechemicalsupplier'srecommendations.

Approvaloftheplatingprocess,andanyproposedchangesshallbeobtainedfromtheChryslerOrganicMaterialsEngineeringDepartment.

2.3HydrogenEmbrittlementRelief

Highstrength/highhardnesssteelpartswithaRockwellHardnessofHRC32orgreaterMUSTBE

PROPERLYBAKEDaccordingtothescheduleandprocedurespecifiedinProcessStandardPS-

9500<S>,“HydrogenEmbrittlementRelief”,withinonehourafterplatingandatspecifiedtemperature

withintwohoursafterplating.Thebakeoperationmaybedoneaftertrivalentchromiteorpassivatepostdip,provideditcanbeshownthatthereisnodetrimentaleffectonthecorrosionresistance.

2.4FinishRequirementsonSignificantSurfaces

TherequirementsofthisStandardapplytothesignificantsurfacesofapart.Unlessotherwisespecifiedonthepartdrawing,significantsurfacesforplatingthicknessandcorrosionresistancedeterminationareallsurfacesthatcanbetouchedbya19mm(0.75in)diametersphere.Thethreadsofthreaded

fastenersarenotclassifiedassignificantsurfaces.However,theentireheadareaofscrewsandbolts,andtheunthreadedshanksofboltsaresignificantsurfaces.

2.5Workmanship

Theplatingshallbesmooth,adherent,andfreeofblisters,pits,nodules,andotherfunctionaldefects.

Coverageshallbecompleteanduniforminappearanceonsignificantsurfaces,withrespecttothe

electroplateddeposit.Inthezincnickeldeposit,thepresenceofmicrocracksreachingthebasemetalisallowedprovidedthattheydonotcompromisetheresistancetocorrosion.Passivates,topcoatsand/orsealersshallcompletelycovertheplatedsurfaces,beadherentanddry-to-touchbutnotpowdery.

PS-8955,ChangeAB,2012-11-27,Page2

CopyrightChryslerGroupLLC

(08-06-2007)

Iridescenceinthefinishisexpectedandacceptable.

3.0PERFORMANCEREQUIREMENTS

3.1AlloyComposition

Theamountofalloyingelementpresentinthezincalloyelectrodepositscoveredbythisstandardisdifferentforeachalloy.TheconcentrationlimitsforthevariousalloysarelistedinTABLE2.

NOTE:Zinc-nickelalloydepositsmaybeobtainedfromalkalineormildlyacidicplatingsolutions.The

corrosionresistanceofzinc-nickelalloysisafunctionofboththealloynickelcontentaswellastheparticularchromiteconversioncoatingemployed.Ingeneral,zinc-nickelalloydeposits

containingahigherpercentnickelwithinlimitsprovidebettercorrosionprotectionthanalloyswithlessnickel.However,thequalityofthepassivateiscrucial.Accuratecontrolofthealloy

compositionwithinthelimitsgiveninTABLE2isessentialforoptimumcorrosionprotection.

TABLE2:ALLOYINGCOMPOSITIONSANDPERMISSIBLECONCENTRATIONRANGE

DEPOSITALLOY

WT.%RANGEOFALLOYING

ELEMENT

NOMINALWT.%RANGEOFALLOYINGELEMENT

Alkalinezinc-nickel

5.0to16.0%Ni

8.0%Ni

Acidzinc-nickel

9.0to16.0%Ni

12.0%Ni

Alkalinezinc-nickelhighalloy

12to17%Ni

14%Ni

Zinc-iron

0.3to0.8%Fe

0.5%Fe

Zinc-cobalt

CARRY-OVERONLY

0.4to1.0%Co

0.6%Co

3.2PlateThicknessonSignificantSurfaces

Theplatethicknessonsignificantsurfacesmustmeettheminimumthicknessesasspecifiedbythe

“Code”designation.Unlessotherwisespecifiedonthepartdrawing,significantsurfacesareallsurfacesthatcanbetouchedbya19mm(0.75in)diametersphere.Thethreadsofthreadedfastenersarenot

classifiedassignificantsurfaces.However,theentireheadareaofscrewsandbolts,andtheunthreadedshanksofboltsaresignificantsurfaces.

ThefollowingASTMStandardMethodsarerecommendedfordeterminingthecoatingthickness:

-ASTMB487MicroscopicCrossSection

-ASTMB568X-RayMethod

-ASTMB499MagneticMethod

-ASTMB504CoulometricMethod

Exceptforthemicroscopicmethod,itisessentialtocalibratethetestinstrumentwithanalloyofthesamecompositionasthatbeingmeasured.

Toinsurecompliancewiththethicknessrequirementsofthisstandard,theplatingthicknessesshallbemeasuredonaregularandfrequentbasisusingacceptablesamplingplans,suchasrecommendedinASTMB697,B602,andB762orequivalents.Controlchartsandrecordsdocumentingcompliancewiththeminimumthicknessrequirementsofthisstandardshallbepreparedandmaintained.

PS-8955,ChangeAB,2012-11-27,Page3

CopyrightChryslerGroupLLC

(08-06-2007)

3.2.1MinimumDepositThickness

TheminimumcoatingthicknessesonsignificantsurfacesarespecifiedbytheCodenumbersuffixaftertheprocessstandardnumberasfollows:

Code0:Notrecommended,usePS-79orPS-4220<S>

Ifcoloridentificationofpartsisrequired;seePS-PLATING.

Code20:5micrometers(0.00020inch)minimum

Code30:8micrometers(0.00030inch)minimum

DepositthicknessesgreaterthanCode30aregenerallynotrecommended.Ifitisdeterminedthat

thicknesseslessthanCode20orgreaterthanCode30arenecessaryforaparticularapplication,drawingnotesshallbeusedtodesignatetherequiredthickness.Ifno“Code”isspecifiedonthedrawing,the

defaultis“Code30”.

3.2.2MaximumDepositThickness

Becauseofvariousfactorssuchasthepartconfigurationandtypeofplatingprocessused,themaximumthicknessvaluescannotbedefined.Themaximumthicknessmustnotinterferewiththeassemblyor

performanceofthepart.Whennecessary,amaximumthicknessmaybedefinedontheprint.

3.3Passivates

Atrivalentchromitetypepassivateisconsideredanintegralpartoftheelectrodepositedzincalloysofthisprocessstandard.Chromitecoatingssignificantlyenhancetheoverallcorrosionresistanceofthedeposit.Thezincalloyelectrodepositscoveredbythisprocessstandardrequireatrivalentchromiteconversion

coatingthatisformulatedfortheparticularalloy.Slightcoloriridescenceandcolorvariationsareacceptable.

Chromium-freepassivatesmaybeusedifallperformancerequirementsaremet.

3.4Topcoatsand/orSealers

Theuseofatopcoatorsealerisrecommendedonpartsotherthanfasteners,surfacesthatwillbe

welded,orcomponentsrequiringelectricalconductivity.Thetopcoatorsealermustbedry-to-the-touchandpassallfluidcompatibilityrequirementsforeachapplication.Thetopcoatorsealermustnotinterferewiththeassemblyorperformanceofthepart.

NOTE:NotopcoatsorsealersareallowedonfastenersandotherthreadedpartsunlessapprovedbyFastenerEngineering.

3.5Adhesion

ThedepositshallnotpeelfromitselforfromthesubstratewhentestedinaccordancewithASTMB571(StandardTestMethodsforAdhesionofMetallicCoatings).

Thehardened,agedchromitecoatingandtopcoatandsealershallbetightlyadherenttothezincalloysubstrateandshallnotberemovedbyordinaryhandling.

3.6HydrogenEmbrittlementTest

ThehydrogenembrittlementtestistobeperformedaccordingtoProcessStandardPS-9500<S>.

PS-8955,ChangeAB,2012-11-27,Page4

CopyrightChryslerGroupLLC

(08-06-2007)

3.7AcceleratedCorrosionResistance***

ThetestshallbeconductedinaccordancewithASTMB117forthetimesshowninTABLES3and4.TherequirementsofTABLE3representgeneralperformancerequirementsforallnon-threadedfastener

components.TABLE4shallapplytofasteners,threadedpartsorothercomponentswheretheuseofatopcoatorsealermayhaveanadverseeffectontheperformance.TABLE5representsthegeneral

performancerequirementsforpartswithoutanyformofchromite,passivationortopcoats.

Samplepartsshallbedriedandagedforaminimumof24hourspriortoexposingthemtosaltspray.

TABLES3,4,and5summarizetherequiredminimumhoursofsaltsprayexposurebeforetheformationofwhitecorrosionproductsforthealloysandchromitecoatingscoveredbythisstandard,aswellastheminimumnumberofhourstoredrust.

Afaintwhitefilmor“blush”doesnotconstituteafailure.Awhite“powdery”filmthatdoesnotincrease

withtimeisalsonotafailure.Chromitecoatingsareinherentlyfragilefilmsandsomedamageatsharpedges,corners,etc.istobeexpected.SmallamountsofwhitecorrosionproductsatsuchdamagesitesDONOTconstituteafailure.

SaltspraycorrosiontestrequirementsDONOTapplytodeeprecesses,suchassmallblindholesandtheinterioroftubing.

Onpartswithasurfaceareagreaterthan155sqcm(24sqin),theappearanceofsixormoreredrust

spotsper1000sqcm(1sqft.)ofsignificantsurface,thatarevisibletotheunaidedeyeatnormalreadingdistanceoranyrustspotoriginatingfromanarealargerthan1.6mm(1/16in)indiameterisconsideredafailure.

Onpartssmallerthan155sqcm(24sqin),theappearanceofmorethanonerustspotonanysignificantsurfaceoranyrustspotoriginatingfromaspotlargerthan1.6mm(1/16in)indiameterisafailure.

ThecorrosiontestingoffastenersmustfollowtheprocedureasoutlinedinSAE/USCAR-1,“SaltSpray

TestingandEvaluationofFastenerFinishes”.Onthreadedfasteners,theformationofcorrosionproductsinthethreadedareasDOESNOTconstituteafailure.However,theheadandunthreadedshankofa

screworboltisconsideredasignificantsurfaceandmustwithstandtheformationofwhiteandredrustfortheminimumtimeslistedinTABLE4.

TABLE3:MINIMUMSALTSPRAYTESTREQUIREMENTS

WITHTRIVALENTCHROMITESANDOPTIONALSEALERORTOPCOAT

NOTOPCOATORSEALERSAREALLOWEDONFASTENERSUNLESSAPPROVEDBY

FASTENERENGINEERING

ALLOY

THICKNESS

(micrometers)

TRIVALENT

CHROMITE

HOURSTOWHITE

RUST

with<3%whitecorrosion

HOURSTOREDRUST

RACK

BARREL

RACK

BARREL

ZINC-NICKELC-20

5

CLEAR

144

120

780

720

BLACK

ZINC-NICKELC-30

8

CLEAR

144

120

864

840

BLACK

ZINC-NICKELHIGH

ALLOYC-20

5

CLEAR

240

216

1000

720

BLACK

PS-8955,ChangeAB,2012-11-27,Page5

TABLE3:MINIMUMSALTSPRAYTESTREQUIREMENTS

WITHTRIVALENTCHROMITESANDOPTIONALSEALERORTOPCOAT

NOTOPCOATORSEALERSAREALLOWEDONFASTENERSUNLESSAPPROVEDBY

FASTENERENGINEERING

ALLOY

THICKNESS

(micrometers)

TRIVALENT

CHROMITE

HOURSTOWHITE

RUST

with<3%whitecorrosion

HOURSTOREDRUST

RACK

BARREL

RACK

BARREL

ZINC-NICKELHIGH

ALLOYC-30

8

CLEAR

240

216

1200

1000

BLACK

ZINC-NICKELHIGH

ALLOYC-50

13

CLEAR

168

120

1500

1200

BLACK

ZINC-IRONC-20

5

CLEAR

120

96

288

264

ZINC-IRONC-30

8

CLEAR

120

96

432

408

BLACK

ZINC-COBALTC-20

CARRY-OVERONLY

5

CLEAR

120

96

288

264

BLACK

ZINC-COBALTC-30

CARRY-OVERONLY

8

CLEAR

120

96

432

408

BLACK

TABLE4:MINIMUMSALTSPRAYTESTREQUIREMENTSFORTHREADEDFASTENERS

WITHTRIVALENTCHROMITESWITHOUTASEALERORTOPCOAT

NOTOPCOATORSEALERSAREALLOWEDONFASTENERSUNLESSAPPROVEDBY

FASTENERENGINEERING

ALLOY

THICKNESS

(micrometers)

TRIVALENT

CHROMITE

HOURSTOWHITE

RUST

With<3%white

corrosion

HOURSTOREDRUST

RACK

BARREL

RACK

BARREL

ZINC-NICKELC-20

5

CLEAR

72

72

696

672

BLACK

ZINC-NICKELC-30

8

CLEAR

72

72

792

768

BLACK

ZINC-NICKELHIGH

ALLOYC-20

5

CLEAR

168

120

1000

720

BLACK

ZINC-NICKELHIGH

ALLOYC-30

8

CLEAR

168

120

1200

1000

BLACK

ZINC-IRONC-20

5

CLEAR

72

72

264

240

PS-8955,ChangeAB,2012-11-27,Page6

CopyrightChryslerGroupLLC

(08-06-2007)

TABLE4:MINIMUMSALTSPRAYTESTREQUIREMENTSFORTHREADEDFASTENERS

WITHTRIVALENTCHROMITESWITHOUTASEALERORTOPCOAT

NOTOPCOATORSEALERSAREALLOWEDONFASTENERSUNLESSAPPROVEDBY

FASTENERENGINEERING

ALLOY

THICKNESS

(micrometers)

TRIVALENT

CHROMITE

HOURSTOWHITE

RUST

With<3%white

corrosion

HOURSTOREDRUST

RACK

BARREL

RACK

BARREL

ZINC-IRONC-30

8

CLEAR

72

72

384

360

BLACK

ZINC-COBALTC-20

CARRY-OVERONLY

5

CLEAR

72

72

264

240

BLACK

ZINC-COBALTC-30

CARRY-OVERONLY

8

CLEAR

72

72

384

360

BLACK

TABLE5:MINIMUMSALTSPRAYTESTREQUIREMENTSFORTHREADEDFASTENERS

WITHOUTPASSIVATEORTOPCOAT***

ALLOY

THICKNESS

(micrometers)

TRIVALENT

CHROMITE

HOURSTOWHITE

RUST

HOURSTOREDRUST

RACK

BARREL

RACK

BARREL

ZINC-NICKELC-30

8

None

NotApplicable

192

168

ZINC-NICKELHIGH

ALLOYC-30

8

None

NotApplicable

384

360

Thesaltspraytestisonlyusedtotesttheintegrityofthealloydepositandtheeffectivenessofthe

chromitecoating.ThehourstowhiteorredrustSHALLNOTbeconstruedashavinganycorrelationtotheactualservicelifeofthepart.Saltspraycorrosiontestingdoesnotneedtobecompletedpriortoshipmentofparts.

4.0QUALITY

RefertoCS-9801forgeneralqualityrequirements.

5.0DEFINITIONS/ABBREVIATIONS/ACRONYMS

AIAG:AutomotiveIndustryActionGroup

ASTM:AmericanSocietyforTestingandMaterials

C:Celsius

F:Fahrenheit

mm:Millimeters

SAE:SocietyofAutomotiveEngineers

PS-8955,ChangeAB,2012-11-27,Page7

CopyrightChryslerGroupLLC

(08-06-2007)

6.0GENERALINFORMATION

Threeasterisks“***”afterthesection/paragraphheaderdenotessingleormultipletechnicalchangestothesection/paragraph.Specifictechnicalchangeswithinasection,subsection,table,orfiguremaybehighlightedinyellow.

Certainimportantinformationrelativetothisstandardhasbeenincludedinseparatestandards.To

assuretheprocessessubmittedmeetallofChryslerrequirements,itismandatorythattherequirementsinthefollowingstandardsbemet.

CS-9800-Applicationofthisstandard,thesubscriptionservice,andapprovedsourcesCS-9003-Regulatedsubstancesandrecyclability

WithinEngineeringStandards,theRegulatory(Government-mandated)requirementsaredesignatedby<S>and<E>whichcorrespondtoSafetyandEmissionShieldsrespectively.Whenapplicable,the

Chryslermandatedrequirementsaredesignatedby<D>whichcorrespondtotheDiamondsymbolandby<A>forAppearancerelatedobjectives,respectively.

Forspecificinformationonthisdocument,pleaserefertothecontactpersonshowninthe"PublicationInformation"Sectionofthisdocument.ForgeneralinformationonobtainingEngineeringStandardsandLaboratoryProcedures,seeCS-9800orcontacttheEngineeringStandardsDepartmentat

engstds@.

7.0REFERENCES

ChryslerStandards

ASTM

Standards

ISO

Standards

SAE

Standards

Federal

Standards

CS-9003

ASTMB117

SAE/USCAR-1

CS-9800

ASTMB487

CS-9801

ASTMB499

PS-79

ASTMB504

PS-4220<S>

ASTMB568

PS-9500<S>

ASTMB571

PS-PLATING

ASTMB602

ASTMB697

ASTMB762

QualityandReliabilityDocuments

OtherDocuments

AIAGCQI-11

-Availablefrom

PS-8955,ChangeAB,2012-11-27,Page8

CopyrightChryslerGroupLLC

(08-06-2007)

8.0ENGINEERINGAPPROVEDSOURCELIST

TABLE6:ENGINEERINGAPPROVEDSOURCELIST

Materialscoveredbythisstandardshallonlybepurchasedfromthosesource(s)listedinthistable.

SUPPLIER

ZINC-IRON

ZINC-NICKEL

ZINC-NICKEL

HIGHALLOY

RACK

BARREL

RACK

BARREL

RACK

BARREL

CANADA

AcadianPlatersLtd.

315RexdaleBlvd

Rexdale,ONM9W1R8

X

X

AutotekElectroplating,Inc.20Huddersfield

Rexdale,ONM9W5Z6

X

Coatings85–PlantB&C6975Davand

Mississauga,ONL5T1L5

X

X

MEXICO

NicroSAdeCV

Pirul#33ColBellaVistaTlalnepantla

X

X

TecniflexAnsorge

Calle9,No6and6ACol.AlceBlanco

CP53370,Naucalpan

X

X

USA

AjaxMetalProcessing4651BellevueAve

Detroit,MI48207

X

X

BFGElectroplating33ScottSt

Hamburg,NY14075

X

X

CadillacPlati