MARCHIARO GIANCARLO - giancarlo.marchiaro@crf.

it

Doc. No. PS-8956

CONDUCTIVE PLATED COATINGS
FOR ELECTRICAL CONNECTORS FCA Italy Class: N/A
AND CORROSION PROTECTION
TRESS KIM - kim.tress@fcagroup.com

FCA US Doc. Type: PS

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Date: 16-MAY-2019

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HARMONIZED “CLUSTER” DOCUMENT

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Co-Author
Author

This is a document used by FCA

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for joint products and processes
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FCA ITALY -- GROUP MATERIALS LABS (CRF) - SURFACE TREATMENTS & AN ...

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Changes
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Change Publication Review Description of change

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level Date Date

This is a selected FCA Italy S.p.A or FCA US LLC document
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W 16-MAY-2019 16-MAY-2019 that will be used as it is for the joint products

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FCA US -- ORGANIC MATERIALS - 5840

Considerations:
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1. This is selected specification that will be used by FCA.

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2. In case of minor changes, this specification will keep the original document number and
will be updated with a new change level (Revision)
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3. Just when major updates are required the responsible (FCA Italy or FCA US Author), will
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have to rewrite it following the requirements, templates and guidelines that prevail at that
time. A new code (nomenclature) will be assigned and this document replaced by the
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new one.
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Co-Author Department
Author Department

NOTE: The original document has a watermark indicating that this is a selected specification used by FCA as a common
specification. Technical information corresponds to the last revision published either in ADRESS or beSTandard databases

ANY PRINTED COPY IS TO BE DEEMED AS UNCHECKED; THEREFORE THE UPDATED COPY MUST BE CHECKED IN THE APPROPRIATE WEB SITE

CONFIDENTIAL
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT FROM THE DEVELOPER AND
COPYRIGHT OWNER. IN CASE OF DISPUTE, THE ONLY VALID REFERENCE IS THE ENGLISH EDITION.
 PS-8956
TIN ZINC PLATING
CONDUCTIVE COATING FOR ELECTRICAL Process Specification
CONNECTORS AND CORROSION
PROTECTION Page: 1/21

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Date: 16-MAY-2019

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Change level Date Description of change
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W 16-MAY-2019 Format change, update references to harmonized standards

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Convert thickness code from English units to Metric units.

New sections 4.6.4, 4.6.8, 4.7.4, 4.8-4.8.9, 4.9, 5.1-5.8, 7-7.2,
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Update 9
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This norm will become a Cluster

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ANY PRINTED COPY IS TO BE DEEMED AS UNCHECKED; THEREFORE THE UPDATED COPY MUST BE CHECKED IN THE APPROPRIATE WEB SITE

CONFIDENTIAL
THIS DOCUMENT MUST NOT BE REPRODUCED OR CIRCULATED TO THIRD PARTIES WITHOUT PRIOR WRITTEN CONSENT BY THE RELEVANT FCA COMPANY.
IN CASE OF DISPUTE, THE ONLY VALID REFERENCE IS THE ENGLISH EDITION
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TIN ZINC PLATING

48
CONDUCTIVE COATING FOR ELECTRICAL CONNECTORS AND
CORROSION PROTECTION

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TABLE OF CONTENTS

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1 GENERAL ................................................................................................................................................. 4

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1.1 Purpose .................................................................................................................................................. 4

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1.2 Coverage of this Standard (Applicability) and Limitations on Usage ..................................................... 4
1.3 Requirements on Part Drawings ............................................................................................................ 4

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2 REFERENCES .......................................................................................................................................... 5
3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS ..................................................................... 5

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4 PROCESS REQUIREMENTS................................................................................................................... 6
4.1 Process Controls .................................................................................................................................... 6
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4.2 Hardened Parts or Spring Steel Substrates ........................................................................................... 6
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4.3 Method of Application............................................................................................................................. 6
4.4 Condition of the part prior to processing ................................................................................................ 6
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4.5 Pretreatment Process – Applicable for Electroplating or Mechanical Plating ........................................ 6
4.5.1 Alkaline Cleaning ................................................................................................................................ 6
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4.5.2 Rust and Scale Removal .................................................................................................................... 6

4.5.3 Acid Cleaning and Pickling ................................................................................................................ 6
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4.6 Mechanical Plating Process ................................................................................................................... 7

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4.6.1 Media Size .......................................................................................................................................... 7

4.6.2 Surface Conditioner ............................................................................................................................ 7
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4.6.3 Accelerator / Promotor ........................................................................................................................ 7

4.6.4 Coating Deposition .............................................................................................................................. 8
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4.6.5 Mechanical Plate Water Polish ........................................................................................................... 8

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4.6.6 Passivation .......................................................................................................................................... 8

4.6.7 Sealant ................................................................................................................................................ 8
4.6.8 Dry ....................................................................................................................................................... 8
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4.7 Electrolytic Plating Process .................................................................................................................... 8

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4.7.1 Electroplated Thicknesses .................................................................................................................. 8

4.7.2 Plate Thickness on Significant Surfaces ............................................................................................. 9
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4.7.3 Passivation .......................................................................................................................................... 9

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4.7.5 Drying ................................................................................................................................................ 10

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4.8 Inspection requirements ....................................................................................................................... 10

4.8.1 Workmanship .................................................................................................................................... 12
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4.8.2 Finish Requirements on Significant Surfaces ................................................................................... 12

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4.8.3 Alloy Composition ............................................................................................................................. 12

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4.8.4 Hydrogen Embrittlement Relief for Electrolytic and Mechanical Plated Parts .................................. 12
4.8.5 Hydrogen Embrittlement Test for Electrolytic and Mechanical Plated Parts .................................... 13
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4.8.6 Adhesion, General ............................................................................................................................ 13

4.8.7 Dimensional Tolerance ..................................................................................................................... 14
4.8.8 Material Gaging for Parts with Threads ............................................................................................ 14
4.8.9 Friction coefficient of Fasteners ........................................................................................................ 14
4.8.10 Accelerated Corrosion Resistance .................................................................................................. 14
4.8.11 Evaluation of Topcoats ................................................................................................................... 15
4.9 Re-process ........................................................................................................................................... 15
5 SPECIAL REQUIREMENTS ................................................................................................................... 16
5.1 Process Validation ............................................................................................................................... 16
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5.2 Supplier Approval ................................................................................................................................. 16

5.3 Supplier Conformance ......................................................................................................................... 16

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5.4 Supplier Product Inspection ................................................................................................................. 16

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5.5 Material Quality .................................................................................................................................... 17
5.6 Field Performance ................................................................................................................................ 17

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5.7 Forever Requirements (FR) ................................................................................................................. 17

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5.8 Non-Conforming Material ..................................................................................................................... 17
6 QUALITY ................................................................................................................................................. 17
7 TEST EQUIPMENT ................................................................................................................................. 18

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7.1 Test Facilities ....................................................................................................................................... 18

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7.2 Test Equipment .................................................................................................................................... 18

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8 SAFETY PRECAUTIONS ....................................................................................................................... 18
9 APPROVED SOURCE LIST ................................................................................................................... 19

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1 GENERAL

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This standard describes tin-zinc alloy coatings that are commonly applied to ferrous substrates for

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electrical grounding and corrosion resistance.

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1.1 Purpose

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This standard specifies the process and performance requirements for electrodeposited and mechanically
plated tin-zinc coatings, and their associated chromite coatings, for use primarily on fasteners used for

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electrical grounding and other electrically conductive components (e.g., lamp sockets), when these

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automotive elements are used in corrosive environments. These coatings may also be used for corrosion
protection of non-electrical components.

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These coatings can also be used for galvanic protection between aluminum and steel.

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This coating may be used for all FCA global regions.
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1.2 Coverage of this Standard (Applicability) and Limitations on Usage
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Coatings may be applied by either electrolytic or mechanical deposition. Electroplated deposits may be
applied in rack or barrel applications.
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The following table summarizes the permissible alloy compositions covered by this process standard.
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Table 1 - Deposit Requirements

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Type of Deposit Percent Tin Percent Zinc

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PS-8956E, Electroplated Alloy 70 +/- 10 30 +/- 10

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PS-8956M, Mechanically Plated Alloy 30 +/- 5 70 +/- 5

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PS-8956L, Mechanically Plated Alloy, 2.5 micrometers (0.0001 in) 8.0 micrometers (0.0003 in)
Layered Deposit tin top layer zinc bottom layer
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This alloy should not be used in applications exceeding 177 C (350 F) for long-term exposure.
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Processing to a temperature of 192°C (380 °F) is allowed for a period not to exceed 1 hour.
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1.3 Requirements on Part Drawings

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A. When this process standard is specified, an E or M or L suffix shall be added to the process standard
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number to indicate the method of coating application:

E for Electroplate
M for Mechanical plate
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L is for a Layered deposit

If a suffix is not added, electroplated method of application (PS-8956 E) is preferred.

B. The desired deposit thickness must be specified after the process standard number using a ”thickness
code” designation, e.g., PS-8956E C8 means an electroplated deposit with a thickness of 8
micrometers (0.0003 inch).
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C. 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.

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2 REFERENCES

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Table 2 - References
downloadable

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Shield/Designat for suppliers
Document Number or (if applicable) Document Title from
beSTandard
<S,D,E,A>

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(Y/N)

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CEP.00036 EASL Approval Review Process Electroplated And Inorganic Coatings Y
CS-9003 Regulated Substances and Recyclability Y

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CS-9800 General Information Y
LP-461H-118 Galvanic Corrosion Test for Fasteners Y

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PF-8500 Requirements for Verification, Validation and Continuing Conformance Y
Testing
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PF.90012 Standard for Automotive Electrical Connection Systems Y
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PS.50023 <S> Hydrogen Embrittlement Relief Y
SP.10033 ISO Metric Screw Threads Medium Fit General Specification Y
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7.G0114
9.01102
Fastener Friction Test
Supply Quality
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Y
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9.01103 Product Quality and Conformity Certificate Y

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9.52605/01 Normal and Special Service Threaded Fasteners Y

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ASTM B117 Practice for Operating Salt Spray (Fog) Apparatus N

ASTM B487 Test Method for Measurement of Metal and Oxide Coating Thickness by N
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Microscopical Examination of Cross Section

ASTM B499 Test Method for Measurement of Coating Thicknesses by the Magnetic N
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Method: Nonmagnetic Coatings on Magnetic Basis Metals

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ASTM B568 Standard Test Method for Measurement of Coating Thickness by X-Ray N
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Spectrometry
ASTM B571 Practice for Qualitative Adhesion Testing of Metallic Coatings N
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ASTM B697 Standard Guide for Selection of Sampling Plans for Inspection of N
Electrodeposited Metallic and Inorganic Coatings
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ASTM B762 Test Method of Variables Sampling of Metallic and Inorganic Coatings N
AIAG CQI-11 Special Process: Plating System Assessment N
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ASTM G-85 Standard Practice for Modified Salt Spray (Fog) Testing N
IATF 16949 Automotive Quality Management System N
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ISO-IEC 17025 General requirements for the competence of testing and calibration N
laboratories
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3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS
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°C: Degrees Celsius (temperature)

°F: Degrees Fahrenheit (temperature)
AIAG: Automotive Industry Action Group
ASTM: American Society for Testing and Materials
mm: millimeters
sq cm: square centimeters
sq in: square inches
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4 PROCESS REQUIREMENTS

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4.1 Process Controls

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The pretreatment and process controls shall be in compliance with relevant Process Tables found in the

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AIAG CQI-11: Special Process: Plating System Assessment. Additional requirements specified in this
standard or on the part drawing shall take precedence over the CQI-11 controls.

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4.2 Hardened Parts or Spring Steel Substrates

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For all machine threaded fasteners or parts with a tensile strength of 1040 to 1500 N/mm 2, or hardness of
HRc 32 to 49, parts electroplated in NAFTA shall be coated by an applicator included in the Engineered

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Approved Source List (EASL) located at the end of this standard.

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Parts susceptible to hydrogen embrittlement, as defined in PS.50023<S>, may be either electroplated or
mechanically plated. Process controls and testing as defined by PS.50023<S> apply for both mechanical
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and electroplated systems. For susceptible parts, mechanical plating is preferred to avoid the possibility
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of hydrogen embrittlement whenever practical (as determined by part size, shape, etc.).
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4.3 Method of Application RM

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This standard covers both electroplating and mechanical plating in barrel and rack applications.
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4.4 Condition of the part prior to processing

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All forming, heat treating, and staking operations shall be completed prior to coating. Any deviation must
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be reviewed and approved by FCA Materials Engineering Groups.

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4.5 Pretreatment Process – Applicable for Electroplating or Mechanical Plating

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Approval of the plating process, and any proposed changes shall be obtained from the FCA Materials
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Engineering Department.
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4.5.1 Alkaline Cleaning

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Light soils may be removed by soaking parts in a heated alkaline cleaner. Electrocleaning, with the parts
made anodic (positive polarity), may also be used. Parts subject to hydrogen embrittlement shall not be
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cleaned cathodically (negative).

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4.5.2 Rust and Scale Removal

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The preferred procedures for the removal of heat treat scale or rust on high strength/high hardness parts
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are tumbling, vibratory finishing or blasting with a fine abrasive. Alkaline rust removers and descalers
may also be used.

4.5.3 Acid Cleaning and Pickling

Acid Cleaning is the least desirable of the available cleaning methods for hardened steel parts because it
can contribute to hydrogen embrittlement. Consequently, if fasteners, spring steel or hardened steel
parts with high hardness as defined in PS.50023<S> are acid cleaned, it is required that an inhibited,
dilute acid based acid be used and the parts limited to a maximum of 10 minutes’ exposure. Controls
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shall be implemented and records shall be kept on the type and strength of inhibitor. Steps shall also be
taken to remove the parts from the acid bath during plant shutdown due to mechanical or power failure in

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less than the 10-minute maximum acid exposure time. Hardened steel parts exceeding this acid

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exposure limit shall be quarantined and tested per PS.50023<S>.

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4.6 Mechanical Plating Process

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The operation of the alloy tin-zinc mechanical plating bath shall be carried out in accordance with the
instructions of the proprietary chemical supplier of the plating process, and shall produce the alloy

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composition listed in Table 1. Table 3 defines common thickness callouts for mechanically plated

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deposits. Other callouts may be used, but shall be defined on the part print.

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Table 3 - Minimum Mechanically Plated Thicknesses (PS-8956 M)

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Thickness Code Thickness Comments

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Code 8 8 micrometers
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(0.00030 inch)
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Code 10 (1) 10 micrometers Default thickness unless otherwise
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specified
(0.00040 inch)
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NOTE 1: Mechanically plated coatings are applied to Code 10 (10 micrometers, 0.0004 in) thickness unless otherwise specified
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and shall consist of a uniform mixture of about 70 percent zinc and 30 percent tin. Alternatively, 8 micrometers (0.0003
in) of mechanically deposited zinc, can be subsequently plated with 2.5 micrometers (0.0001 in) of mechanically
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deposited tin.
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The following ASTM Standard Methods are recommended for determining the coating thickness:
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ASTM B 487 Microscopic Cross Section

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ASTM B 499 Magnetic Method

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In the event of a discrepancy for thickness determination, the microscopic cross section shall be used.
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4.6.1 Media Size

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The selection of impact media has an important effect on the quality of the plating obtained. On some
part types, such as cross-recess head screws, or parts with integrated washers, media may become
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lodged. The plater must carefully select a media mix that will apply the desired coating and will not lodge
in the recess, threaded area or under free spinning washers.
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4.6.2 Surface Conditioner

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A proprietary surface conditioner such as a copper strike shall be used to ensure a clean, receptive
surface and seal pores. This conditioner shall be applied without the use of electric current. There are no
thickness requirements for this step.
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4.6.3 Accelerator / Promotor

The use of a flash coat is recommended for controlled deposition rate and bonding of the zinc deposit.
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4.6.4 Coating Deposition

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The coating is applied by building of fine, powdered metal particles through mechanical impact with inert
media to the surface without the use of electrical current. This step is executed in an aqueous solution

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containing proprietary accelerators / coating promoters.

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4.6.5 Mechanical Plate Water Polish

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Mechanically plated parts must be suitably burnished by “water polishing” to consolidate the coating and

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minimize loose surface particles prior to conversion coating.

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Parts shall be separated from the media through a separator prior to passivation. Additional rinsing may

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be required to insure complete removal. The parts shall be completely dried if passivation is not
immediately applied.

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4.6.6 Passivation ag +
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Clear or colored trivalent chromite systems are required. This should be done immediately after plating
and while the parts are still wet. Topcoats or sealers are not allowed on fasteners or other threaded parts
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unless approved by Fastener Engineering. Slight color variations and iridescence are permitted for
colorless coatings. RM
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4.6.7 Sealant
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Mechanically plated fasteners shall additionally be coated with an approved, proprietary sealant after
passivating or “chromiting”. Approved sealants, listed in Table 11, shall be maintained and applied
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according to the recommendations of the sealant supplier. The sealer shall not interfere with any
performance requirements of the component. The sealant shall be dry to the touch, and not leave a
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sticky or tacky residue.

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4.6.8 Dry
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Parts shall be completely dried prior to packaging.

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4.7 Electrolytic Plating Process

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The operation of the alloy tin-zinc electroplating bath shall be carried out in accordance with the
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instructions of the proprietary chemical supplier of the plating process, and shall produce the alloy
composition listed in Table 1. Table 4 defines common thickness callouts for electrolytically plated
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deposits. Other callouts may be used, but shall be defined on the part print.
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4.7.1 Electroplated Thicknesses

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The minimum electroplated thickness is specified by the Code Number suffix appearing after the process
standard number as follows:
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Table 4 - Minimum Electroplated Thicknesses (PS-8956 E)

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Thickness Code (1) Thickness

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Code 5 5 micrometers (0.00020 inch)

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Code 8 8 micrometers (0.00030 inch)
Code 10 10 micrometers (0.00040 inch)

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Code 13 (2) 13 micrometers (0.00050 inch)

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NOTE 1: Prior to this revision, thickness codes were expressed in English units (e.g. C30 = 0.00030 inch, equivalent to C8 = 8

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microns.)

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NOTE 2: Deposit thicknesses greater than Code 13 are generally not recommended. If it is determined that electroplated
thicknesses less than Code 5 or greater than Code 13 are necessary for a particular application, drawing notes shall be used to

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designate the required thickness.
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Because of various factors such as the part configuration and type of plating process used, the maximum
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thickness values shall be defined at PPAP. The maximum thickness must not interfere with the assembly
or performance of the part. Refer to section 4.8.8 for gaging requirements of components with threads.
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When necessary, the maximum thickness may be defined on the print.

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4.7.2 Plate Thickness on Significant Surfaces

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To insure compliance with the minimum thickness requirements of this standard, the plating thicknesses
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shall be measured on a regular and frequent basis using acceptable sampling plans, such as
recommended in ASTM B 697 and B 762 or equivalents. Control charts and records documenting
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compliance with the minimum thickness requirements of this standard shall be prepared and maintained.
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The plate thickness on significant surfaces must meet the minimum thickness as specified by the “Code”
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designation (refer to Table 3 above).

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The following ASTM Standard Methods are recommended for determining the coating thickness:
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ASTM B 487 Microscopic Cross Section

ASTM B 568 X-Ray Method
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ASTM B 499 Magnetic Method

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Except for the microscopic method, it is essential to calibrate the test instrument with an alloy or mixture
of the same composition as that being measured.
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In the event of a discrepancy for thickness determination, the microscopic cross section shall be used
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4.7.3 Passivation
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A trivalent chromium type coating is considered an integral part of the electrodeposited tin-zinc alloy of
this process standard. These coatings significantly enhance the overall corrosion resistance of the
deposit. The tin-zinc alloy electrodeposit, covered by this process standard, requires a trivalent chromite
conversion coating that is formulated for the particular alloy.
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4.7.4 Sealant

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Sealants are NOT recommended for parts used for electrical grounding unless otherwise indicated, and
the coating does not interfere with the electrical grounding.

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When used for galvanic protection, electroplated parts may additionally be coated with an approved,
proprietary sealant after passivating. Approved sealants, listed in Table 11, shall be maintained and
applied according to the recommendations of the sealant supplier.

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The sealer shall not interfere with any performance requirements of the component. The sealant shall be

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dry to the touch, and not leave a sticky or tacky residue.

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NOTE: NO TOPCOATS ARE ALLOWED ON FASTENERS AND OTHER THREADED PARTS UNLESS APPROVED BY
FASTENER ENGINEERING.

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4.7.5 Drying
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Parts shall be completely dried before packaging.

4.8 Inspection requirements

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Parts shall be tested from each plating line to the frequencies identified in the table below.
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Validation tests are required for new applicator approval, new part approval, PPAP, equipment change,
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line program change, rack design change, or barrel change using a different perforation size, shape, or
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diameter.
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Table 5 - Product Inspection Requirements

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Minimum Quantity and/or

Test Description Requirement
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Frequency (1, 2)
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Appearance Validation, Re-process and Every lot

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Continual Conformance
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Coating Thickness Validation Barrel: 25 pieces

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Rack: 6 pieces representing

Low, Medium, and High Current
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density parts
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Re-process and Continual Every barrel load or rack load

Conformance
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Alloy Validation Barrel: 25 pieces

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Rack: 6 pieces representing

Low, Medium, and High Current
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density parts
Re-process and Continual Every barrel load or rack load
Conformance
Adhesion Validation, Re-process and Minimum one piece per shift
Continual Conformance
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Table 5 - Product Inspection Requirements

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Minimum Quantity and/or
Test Description Requirement
Frequency (1, 2)

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Salt Spray Resistance for white Validation Quantity: Fasteners and small

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and red (base metal) corrosion parts (e.g. springs, washers,
clips) :

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10 pieces representing a
minimum total surface area of

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0.3 dm2 (0.03 ft2)

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Rack parts and other barrel
plated brackets and stampings :

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3 pieces representing a
minimum total surface area of

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1.0 dm2 (0.1 ft2)
Salt spray testing for white and
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Re-process and Continual Frequency: Once per month for
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red (base metal) corrosion Conformance each passivate and sealer
combination used
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RM Fasteners and small parts (e.g.

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springs, washers, clips) :

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10 pieces representing a
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minimum total surface area of
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0.3 dm2 (0.03 ft2)

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Rack parts and other barrel

plated brackets and stampings :
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3 pieces representing a
minimum total surface area of
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1.0 dm2 (0.1 ft2)

Validation, Re-process and
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Hydrogen Embrittlement Every lot

Continual Conformance
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Cyclic Corrosion Validation Initial Chemical and Applicator

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Approval
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Galvanic Compatibility (Sealers Validation Initial Chemical Approval

only)
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Handling Resistance Validation Initial Chemical and Applicator

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Approval
Washer Assembly Breakaway Validation Initial Chemical and Applicator
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Approval
Head/Recess Fill, Residual Validation, Re-process and Every lot
mechanical plating media Continual Conformance

Chemical Compatibility (Sealers Validation Initial Chemical Approval

only)
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Table 5 - Product Inspection Requirements

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Minimum Quantity and/or
Test Description Requirement
Frequency (1, 2)

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Torque/tension testing Validation Initial Chemical and Applicator

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(fasteners only) Approval
Validation

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Absence of hexavalent Initial Chemical and Applicator
chromium Approval

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NOTE 1: The number of pieces used for corrosion testing may be increased to meet the required surface area. The number of
pieces used for corrosion testing shall not be reduced without written approval by FCA Supplier Quality and Materials

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Engineering.

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NOTE 2: With written approval by FCA Supplier Quality and Materials Engineering, quantities and/or frequency may be adjusted
to insure production parts meet 100% compliance.

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4.8.1 Workmanship

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The plating shall be smooth and free from blisters, pits, nodules and other harmful defects. Coverage
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shall be uniform in appearance and complete. The finished parts shall have a uniform, silvery
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appearance with a matte to medium-bright luster. Mechanically deposited coatings are characteristically
not as smooth as electroplated coatings.
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4.8.2 Finish Requirements on Significant Surfaces RM

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The requirements of this standard apply to the significant surfaces of a part. Unless otherwise specified,
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significant surfaces for electroplating thickness and corrosion resistance are all surfaces that can be
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touched by a 19 mm (0.75 in) diameter sphere. Threads of electroplated threaded parts are not
considered significant surfaces for thickness measurements. The entire head of bolts and unthreaded
r.f 1:

shanks of bolts are significant surfaces.

to 0

On mechanically plated parts, significant surfaces are all surfaces that are readily accessible to the
vi 021

proper size impact media.

4.8.3 Alloy Composition

TE
,2
22

The parts must meet the alloy as defined in the table below.
US
ry

Table 6 - Deposit Requirements

ua

Type of Deposit Percent Tin Percent Zinc

br

CL

PS-8956E, Electroplated Alloy 70 +/- 10 30 +/- 10

Fe

PS-8956M, Mechanically Plated Alloy 30 +/- 5 70 +/- 5

PS-8956L, Mechanically Plated Alloy, 2.5 micrometers (0.0001 in) 8.0 micrometers (0.0003 in)
on

Layered Deposit tin top layer zinc bottom layer

4.8.4 Hydrogen Embrittlement Relief for Electrolytic and Mechanical Plated Parts

Hydrogen embrittlement relief is to be performed according to Process Standard PS.50023<S>. The Tier
1 supplier is responsible to ensure that parts pass the hydrogen embrittlement test prior to shipment to
FCA.
 Page: 13/21
PS-8956
Change Level: W

4.8.5 Hydrogen Embrittlement Test for Electrolytic and Mechanical Plated Parts

B
The hydrogen embrittlement test is to be performed according to Process Standard PS.50023<S>. This

48
test is required for all parts having tensile strength of 1040 N/mm2 or greater, or HRc 32 or greater,
including spring steel, property class 9.8 and 10.9 fasteners. The Tier 1 supplier is responsible to ensure

27
that parts pass the hydrogen embrittlement test prior to shipment to FCA.

F7
4.8.6 Adhesion, General

d:
The deposit shall not peel from itself or from the substrate when tested in accordance with one of the

om ri
method described below. Parts shall not exhibit chipping or flaking during normal handling. The

.c se
hardened, aged passivate and topcoat and sealer shall be tightly adherent to the tin-zinc substrate and
shall not be removed by ordinary handling.

up - u
Adhesion shall be verified on every lot that is stripped and replated.

ro 1)
4.8.6.1 Mechanical Plate Adhesion Tests ag +
fc TC
Mechanically plated parts shall show no evidence of loosely adherent or poorly consolidated plating when
inspected as follows:
@ (U

A. RM
Parts with smooth surfaces shall be subjected to a tape test. The adhesive side of a strip of
transparent tape (e.g. “3M Scotch” type 810) shall be pressed firmly against the smooth surfaces of a
ira M

part to pick up any loosely adherent metallic particles. The test tape is then applied to a clean, white
re P

paper for viewing. Evidence of loose particles adhering to the tape shall result in rejection of the entire
NO
er 08

lot of parts.
r.f 1:

B. Internal drive fasteners shall be subjected to a ”probe test”. The cavity of the drive recess shall be
probed with the end of a stiff wire (e.g., a paper clip) to loosen any poorly consolidated or poorly
to 0

bonded metal particles. Evidence of dislodged particles falling from the drive recess when the fastener
vi 021

is inverted over and tapped against a hard white surface shall result in rejection of the entire lot of
R

parts.
TE
,2

4.8.6.2 Electroplate Adhesion Test - Heat shock method

22

Place the coated part to be tested into a constant temperature chamber for 1 hour at 170°C to 180ºC.
US
ry

Carefully remove the part and immediately immerse in water at room temperature (20 to 23°C).
ua

After cooling, take the part out and dry it with a flow of compressed air.
br

CL

At the end of the test inspect the coating, ensuring there is no sign of detachment from base metal,
Fe

swellings, blisters, flaking, etc.

on

4.8.6.3 Electroplate Adhesion Test - Bend Method (to be adopted only on parts made of thin sheet
metal)

The test consists in bending the part or sample to be tested, manually or with pliers, at an acute angle,
first on one side and then on the other, until it breaks.

Inspect the area along the break, confirming the coating does not lift or detach from the base metal and
that there is no sign of flaking.
 Page: 14/21
PS-8956
Change Level: W

4.8.7 Dimensional Tolerance

B
Tolerances specified on drawings are for the final dimensions unless otherwise indicated. Allowance for

48
plating build-up may have to be made in the dimensions of threaded fasteners. Refer to the FCA or
SP.10033 for checking ISO metric screw threads.

27
F7
4.8.8 Material Gaging for Parts with Threads

Thread discontinuities (including nicks or gouges), contaminants and coating thickness shall not interfere

d:
with assembly of the proper GO thread plug gage with the application of a torque not more than 0.001

om ri
times the nominal diameter cubed, in N-m (145 times the nominal diameter cubed, in in-lbs., for inch

.c se
based fasteners). The manufacturer shall exercise due care during the manufacturing and handling of
parts to minimize the number and magnitude of thread discontinuities and coating build-up.

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4.8.9 Friction coefficient of Fasteners

ro 1)
If not otherwise indicated on drawing, the friction coefficients must range within the dispersion limits Cf =
ag +
0.12 to 0.30, indicated in Procurement Specification 9.52605/01.
fc TC
For fasteners requiring LUB Type, the coefficient of friction shall be 0.10 to 0.16 unless otherwise
@ (U

indicated on the drawing.

Different values must be specified on drawing.

RM
ira M

E.g.: PS-8955 C8 Clear LUB (Cf = 0.12 to 0.18).

re P

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The method of the correct application of the friction conditioners must be carried out measuring the
friction coefficient as indicated in the Standard 7.G0114. Other test method must be agreed upon
r.f 1:

beforehand and approved by Materials Engineering Department of FCA.

to 0

Materials applied to machine threaded fasteners that modify the frictional properties require pre-approval
vi 021

by FCA Materials Engineering. A list of prequalified materials is available in Section 8 Approved Source
R

List.
TE
,2

4.8.10 Accelerated Corrosion Resistance

22

Sample plated and chromited parts shall be dried and aged for 24 hours prior to exposing them to the salt
spray test. The test shall be conducted in accordance with ASTM B117 for the times shown in Table 7.
US
ry

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.
ua

The objective of the “Hours to White Corrosion” requirement (Table 7) is freedom from voluminous white
br

CL

corrosion products after testing for the number of hours listed. A light white film or “blush” does not
Fe

constitute a failure. Table 7 summarizes the required minimum hours of exposure to salt spray before the
formation of white corrosion products, as well as the minimum number of hours to red corrosion.
on

Also, chromite coatings are inherently fragile films 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.
 Page: 15/21
PS-8956
Change Level: W

B
Table 7 - Minimum Salt Spray Requirements

48
Minimum hours to
Method of Coating Thickness Code
White Corrosion Red Corrosion

27
Electroplated Code 5 120 300

F7
Electroplated Code 8 120 400

d:
Electroplated Code 10 120 500

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Electroplated Code 13 120 600

.c se
Mechanically Plated Code 8 120 200

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Mechanically Plated Code 10 120 250

ro 1)
On parts with a surface area greater than 155 sq cm (24 sq in), the appearance of one or more red rust
spots per each 155 sq cm (24 sq in) of significant surface (see SectioN 4.3), that are visible to the
ag +
unaided eye at normal reading distance or any rust spot originating from an area larger than 1.6 mm (1/16
fc TC
inch) 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 spot originating from a spot larger than 1.6 mm
@ (U

(1/16 inch) in diameter is a failure.

RM
ira M

On threaded fasteners, the formation of corrosion products in the threaded areas does not constitute a
re P

failure. However, the entire head and unthreaded shank of a screw or bolt; and the entire exterior surface
of a nut is considered a significant surface and must withstand the formation of white and red corrosion
NO
er 08

for the minimum times listed in Table 7. Edges on the bolt head and nut are considered significant
surfaces and shall be included in the evaluation.
r.f 1:
to 0

4.8.11 Evaluation of Topcoats

vi 021

For validation of topcoats to be considered in joints requiring electrical grounding, PF.90012 shall be
followed.
TE
,2

For galvanic protection of dissimilar metals, LP-461H-118 shall be followed, using ASTM G-85 Annex A2
22

for 60 cycles as the corrosion method for aluminum joints.

US
ry

4.9 Re-process
ua

Stripping and replating the parts is allowed, provided that the parts are only reworked once, and all
requirements are met. High strength steel parts with a tensile strength of 1040 N/mm 2 (HRC 32) or
br

CL

greater must be stripped in an alkaline stripper. If an acidic stripper is used, the parts must be relieved of
hydrogen as described by Section 4.6.5 within 2 hours after stripping, prior to replating. Documentation
Fe

shall be available that identifies the lot number and quantity of parts that have been re-processed and the
re-processing method that was used. If parts need to be reworked more than once, the part manufacturer
on

shall provide approval.

 Page: 16/21
PS-8956
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B
5 SPECIAL REQUIREMENTS

48
Refer to CS-9003 for components produced in all markets.

27
5.1 Process Validation

F7
This section defines to part suppliers, Release Engineers, Supplier Quality, and others as necessary the

d:
PPAP/PSO requirements for coatings processed per this standard. These tests, along with the use of
FCA approved substrates, will ensure that a decorative plated part will meet the design intent of the

om ri
application.

.c se
This standard also applies to PPAP/PSO and Forever Requirement testing driven by:

up - u
- Significant Process Changes (including changes in rack design and anode configuration)

ro 1)
- New Part Supplier
- New Part/Design ag +
- New Substrate or Significant Change to Existing Substrate
fc TC
- Change in Applicator Facility or Location
- Change in Technology
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- New Supplier/Source
RM
ira M

5.2 Supplier Approval

re P

Material approval by the FCA Materials Engineering Department and performance approval by the
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appropriate platform design/development department is required before material or parts made from
these materials may be supplied to any FCA manufacturing plant, FCA assembly plant, or FCA tier one
r.f 1:

supplier.
to 0

5.3 Supplier Conformance

vi 021

After approval, conformance testing must be performed periodically on production materials or parts. If
TE
,2

an approved supplier fails to meet these subsequent FCA tests and there is an indication from repeated
test failures that the functional qualities of the material/parts have deteriorated, then the supplier may be
22

removed from the Approved Source List.

US
ry

5.4 Supplier Product Inspection

ua

Production parts with approved Coatings shall be inspected with the frequency and to the degree required
to insure 100% compliance with the requirements for dimensions and materials stated on the part drawing
br

CL

or CAD model, (CATIA/NX).

Fe

No change in material formulation, processing, or finishing from that originally agreed upon shall be made
by the supplier without prior approval by the FCA Organic Materials Engineering Department. To this
on

end, all approved materials may have analysis performed as part of the approval process. The supplier
will be held accountable for maintaining compounding and processing procedures that will produce stock
matching the analysis data of the originally approved material. Random testing of parts during the initial
production sample submission and of subsequent production parts may be performed to insure
compliance. Non-compliance could ultimately result in loss of current or future business on this and other
FCA Material Standards with the supplier being removed from the various Approved Source Lists.
 Page: 17/21
PS-8956
Change Level: W

5.5 Material Quality

B
The Material and processing supplier (primary source) is responsible for the quality of all materials

48
comprising the finished part whether they have been compounded internally or purchased from another

27
material supplier (secondary source). A fabricating supplier (primary source) is responsible for the quality
of all components of a complete assembly whether they are manufactured internally or purchased from

F7
another source approved by the FCA Vehicle Engineering Office.

Materials and parts supplied under the specified material standard must be evaluated against the DV

d:
requirements of that standard on an annual basis (minimum test frequency). These annual audits must be

om ri
kept on file by the first tier supplier to FCA. More frequent audits of conformance to the designated

.c se
standard may be required and will be at the discretion of FCA’s Supplier Development Department,
Materials Engineering, Appropriate Platform engineering group, or FCA first tier supplier.

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5.6 Field Performance

ro 1)
All materials supplied must provide adequate field service as specified by the FCA Vehicle Engineering
ag +
fc TC
5.7 Forever Requirements (FR)
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RM
The following situations require the submission and customer approval of a Forever Requirements (FR)
notice in the WebCN system before implementation:
ira M

1. Supplier (or sub-tier supplier) change to the processing of a part or sub-component;

2. Change of a sub-tier supplier provider of a sub-component or process;
re P

3. Supplier-initiated internal change to a Manufacturing Location (i.e., proposal to move manufacture of a

NO
er 08

part from location 12345A to location 12345B). Note that this usage of the FR system MUST be followed
by a Resource Notice.
r.f 1:
to 0

FRs cannot be used for any other purpose. Changes to Fit, Form, Function, Appearance, Cost,
Customer-initiated resourcing, etc. of a part or sub-component of a part cannot be done via FR,
vi 021

regardless of whether the FCA drawing or design model is affected or not. These types of changes must
be done via CN, Resource Notice, IAA, or other tool as appropriate.
TE
,2

5.8 Non-Conforming Material

22

Refer to PF-8500.
US
ry
ua

6 QUALITY
br

CL

For components that will be part of a vehicle designed in NAFTA and sold in all markets, conformance to
the material characteristics described by CS-9800 must be met.
Fe

For components that will be part of a vehicle designed in EMEA and sold in all markets, the material
on

characteristics defined by 9.01102 and 9.01103 must be met.

 Page: 18/21
PS-8956
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B
7 TEST EQUIPMENT

48
7.1 Test Facilities

27
Production Laboratory:

F7
There must be a structure with the necessary tools to perform primary controls for the proper analysis and

d:
management of process baths.

om ri
- Control instruments for chemicals and waste water (titrator, centrifuges, etc.)

.c se
- Control instruments for qualitative and quantitative analysis of the baths (titrator, thermometer, etc.)
- pH meters

up - u
- Hull cells (for electroplated deposits)
- Sieves (for mechanically plated deposits)

ro 1)
All instruments must be certified and maintained in accordance with IATF 16949.
ag +
The personnel shall be properly trained and qualified.
fc TC
Quality Laboratory:
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RM
There must be a structure within the production site equipped with the means to perform the required
ira M

inspections described within this standard.

re P

- Visual aspect
NO
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- Thicknesses
- Alloy
r.f 1:

- Adhesion
to 0

- Corrosion resistance
vi 021

All instruments must be certified and maintained in accordance with IATF16949.

The people shall be properly trained and qualified.
TE
,2
22

7.2 Test Equipment

US

The minimum test equipment must be:

ry
ua

- Optical microscope
- X-Ray Fluorescence thickness tester (for electrolytic deposits) or magnetic thickness gage (for
br

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mechanically plated deposits)

- Oven
Fe

- Salt Spray Chamber

on

If the supplier is not able to perform one or more of the tests, they shall seek support from an accredited
third party lab approved by FCA and/or ISO-IEC 17025 certified.

8 SAFETY PRECAUTIONS
Follow all appropriate safety practices.
 Page: 19/21
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B
9 APPROVED SOURCE LIST

48
The Approved Source Lists in Table 8 below are to be applied whenever the component will be produced

27
in NAFTA market. For markets outside of North America, regional FCA Materials Engineering and/or
FCA Supplier Quality are responsible to ensure that the local applicators meet all related requirements

F7
and maintain a regional approval source list. Table 9, 10 and 11 are approved chemical suppliers that
shall be used globally.

d:
Potential applicators seeking Engineering Approved Source List approval will be reviewed only after the

om ri
applicator has met a FCA Procurement and Supply business case per the requirements defined in

.c se
CEP.00036 (EASL Approval Review Process, Electroplated and Inorganic Coatings).

up - u
EASL Approved Applicators are subject to an EASL Update Audit Review every 3 years. To maintain
EASL Approval Status, it is the Approved Applicator’s responsibility to meet all the requirements for the

ro 1)
EASL Update Audit Review within 90 days of notification by FCA Materials Engineering.
ag +
An EASL approved applicator must resubmit for EASL approval if the coating process is changed.
fc TC
Table 8 - Engineering Approved Source List – Applicators
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RM
Materials covered by this standard shall only be purchased from those source(s) listed in this
table
ira M

Supplier Additional Information

re P

NO
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Approved Mechanical Platers, PS-8956M

All Service Metal Treating --
r.f 1:

W. Trenton, NJ
to 0

Cadon Plating Co. --

vi 021

Wyandotte, MI
R

Acadian Group --
Coatings 85 Plant A, B & D
TE
,2

Mississauga, Ontario
22

Crest Products, Inc. Captive Shop

Lexington, KY
US
ry

Dynaburr Chicago Corp. --

Northlake, IL
ua

Fintex, LLC --
br

CL

Romulus, MI
Fe

Mechanical Galv-Plating --
Sidney, OH
Plateco --
on

Reedsburg, WI
Rotor Clip Co. Captive Shop
Somerset, NJ
Approved Electrolytic Platers, PS-8956E
Ajax Metal Processing Inc. --
Detroit, MI 48207
 Page: 20/21
PS-8956
Change Level: W

Table 8 - Engineering Approved Source List – Applicators

B
Materials covered by this standard shall only be purchased from those source(s) listed in this

48
table
AVK Industrial Products Captive Shop

27
Valencia, CA 91335
Burbank Plating --

F7
Pacoima, CA 91331
Finishing Services Inc. --

d:
Ypsilanti, MI

om ri
Modern Plating Corp --

.c se
Freeport, IL 61032
Plating Technology, Inc. --

up - u
Columbus, OH 43206
Roy Metal Finishing --

ro 1)
Conetee, SC 29636
Varland Metal Service, Inc.
ag + --
fc TC
Cincinnati, OH 45229
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RM
Table 9 - Engineering Approved Source List – Mechanical Plating Processes
ira M

Materials covered by this standard shall only be purchased from those source(s) listed in this table.
re P

Supplier Additional Information

NO
er 08

Atotech Atotech Italia S.r.l., Italy

r.f 1:

Rock Hill, SC Atotech (China) Chemicals Ltd, Shanghai, China

MacDermid Enthone, Italy
to 0

MacDermid Enthone Inc.

Waterbury, CT MacDermid Enthone, Jiangsu, China
vi 021

Mechanical Coatings Corp.

Sidney, OH
TE
,2

Plating Systems & Technologies

Jackson, MI
22

US
ry

Table 10 - Engineering Approved Source List – Electrolytic Plating Processes

ua

Materials covered by this standard shall only be purchased from those source(s) listed in this table.
Supplier Additional Information
br

CL

Columbia Chemical
Fe

Brunswick, OH
Dipsol of America Dipsol Chemicals
on

Livonia, MI
MacDermid Enthone Inc. MacDermid Enthone, Italy
Waterbury, CT MacDermid Enthone, Jiangsu, China
 Page: 21/21
PS-8956
Change Level: W

B
Table 11 - Engineering Approved Source List – Proprietary Sealants

48
Materials covered by this standard shall only be purchased from those source(s) listed in this
table.

27
Supplier Additional Information

F7
JS500
MacDermid Enthone Inc.
Ultraseal

d:
Waterbury, CT
TNT 18

om ri
Plating Systems & Technologies

.c se
Hyperseal
Jackson, MI

up - u
ro 1)
ag +
fc TC
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RM
ira M
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NO
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r.f 1:
to 0
vi 021

R
TE
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22

US
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ua
br

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on