DAIMLERCHRYSLER CORPORATION No: PS-8955

Process Standard Date Published: 2003-12-10

Category Code: H-1 Change: Q
EASL Req. Yes
Restricted: No

ZINC ALLOY ELECTRODEPOSITED COATINGS

1.0 GENERAL

1.1 Purpose

This standard specifies the plating and performance requirements for various zinc-cobalt, zinc-nickel and
zinc-iron alloy electrodeposits and their associated chromate coatings, used for enhanced corrosion
resistance on ferrous parts.

1.2 Part Drawings

Specific requirements shown on the part drawing shall take precedence over related requirements
specified in this standard, or may be in addition to the requirements of this standard.

Because this standard covers more than one zinc alloy, the chemical symbol of the alloying element must
be added as a suffix after the process standard number to designate the specific alloy desired. For
example, PS-8955 Ni for zinc-nickel, PS-8955 Co for zinc-cobalt, and PS-8955 Fe for zinc-iron alloy.
If a suffix is not specified, any of the alloys covered by this standard may be used at the discretion of the
vendor.

A. The desired deposit thickness must be specified after the process standard number using a code
designation. For example, the designation PS-8955 Ni Code 30 means a zinc-nickel alloy deposit with a
thickness of 8 micrometers or 0.00030 inch.

B. Parts with a hardness of Rockwell HRC 32 or greater require a mandatory bake for hydrogen
embrittlement relief according to Process Standard PS-9500 (Hydrogen Embrittlement Relief).

C. The symbol <D> has been substituted for the diamond symbol in this standard to identify critical but
non-regulatory items that require continuous Statistical Process Control (SPC). Refer to PS-7300.

D. The notation <D> QAR per PS-7300" shall appear in the Part Drawing Standards Block.

2.0 PROCESS

2.1 Electroplating Process

Both acid and alkaline zinc alloy plating processes are covered by this process standard.

2.2 Finish Requirements on Significant Surfaces

The requirements of this Standard apply to the significant surfaces of a part. Unless otherwise specified
on the part drawing, significant surfaces for plating thickness and corrosion resistance determination are
all surfaces that can be touched by a 19 mm (0.75 in) diameter sphere. The threads of threaded fasteners
are not classified as significant surfaces. However, the entire head area of screws and bolts, and the
unthreaded shanks of bolts are significant surfaces.

2.3 Workmanship

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The plating shall be smooth, adherent, and free of blisters, pits, nodules, and other functional defects.
Coverage shall be complete and uniform in appearance on significant surfaces, with respect to the
electroplated deposit. Iridescence in the chromate finish is expected and acceptable.

2.4 Alloy Composition

The amount of alloying element present in the zinc alloy electrodeposits covered by this standard is
different for each alloy. The concentration limits for the various alloys are listed in Table 1.

NOTE: Zinc-nickel alloy deposits may be obtained from alkaline or mildly acidic plating solutions. The
acidic plating processes generally produce higher nickel content alloys than the alkaline systems, however
alkaline systems are available which offer the same alloy content as acid systems. The corrosion
resistance of zinc-nickel alloys is a function of both the alloys nickel content as well as the particular
chromate conversion coating employed. In general, zinc-nickel alloy deposits containing a higher percent
nickel within limits provide better corrosion protection than alloys with less nickel. However, the quality of
the chromate is crucial. Accurate control of the alloy composition within the limits given in Table 1 is
essential for optimum corrosion protection.

TABLE 1: ALLOYING COMPOSITIONS AND PERMISSIBLE CONCENTRATION RANGE

WT.% RANGE OF ALLOYING NOMINAL WT.% RANGE OF

DEPOSIT ALLOY
ELEMENT ALLOYING ELEMENT

Zinc-cobalt 0.4 to 1.0% Co 0.6% Co

Alkaline zinc-nickel 5.0 to 16.0% Ni 8.0% Ni
Acid zinc-nickel 9.0 to 16.0% Ni 12.0% Ni
Zinc-iron 0.3 to 0.8% Fe 0.5% Fe

2.5 Plating Requirements

2.5.1 Plate Thickness on Significant Surfaces

The plate thickness on significant surfaces (Section 2.2) must meet the minimum thicknesses as specified
by the Code designation (refer to Section 2.5.2).

The following ASTM Standard Methods are recommended for determining the coating thickness:

- ASTM B 487 Microscopic Cross Section

- ASTM B 568 X-Ray Method
- ASTM B 499 Magnetic Method
- ASTM B 504 Coulometric Method

Except for the microscopic method, it is essential to calibrate the test instrument with an alloy of the same
composition as that being measured.

2.5.2 Minimum Deposit Thickness

The minimum coating thicknesses are specified by the Code number suffix after the process standard
number as follows:

Code 0: Not recommended, use PS-79 or PS-4220 if color identification of parts is required; see
PS-Plating.
Code 20: 5 micrometers (0.00020 in)

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 Code 30: 8 micrometers (0.00030 in)

Deposit thicknesses greater than Code 30 are generally not recommended. If it is determined that
thicknesses less than Code 20 or greater than Code 30 are necessary for a particular application, drawing
notes shall be used to designate the required thickness. If no Code is specified on the drawing, the
default is Code 30.

To insure compliance with the minimum thickness requirements of this standard, the plating thicknesses
shall be measured on a regular and frequent basis using acceptable sampling plans, such as
recommended in ASTM B 697, B 602, and B 762 or equivalents. Control charts and records documenting
compliance with the minimum thickness requirements of this standard shall be prepared and maintained.

2.6 Chromate Type Conversion Coatings

A chromate type passivate is considered an integral part of the electrodeposited zinc alloys of this process
standard. Chromated coatings significantly enhance the overall corrosion resistance of the deposit. The
zinc alloy electrodeposits covered by this process standard require a hexavalent or trivalent chromate
conversion coating that is formulated for the particular alloy.

NOTE: Parts submitted prior to JANUARY 1, 2007 may utilize either a hexavalent or trivalent chromate.
Parts supplied beginning JANUARY 1, 2007 shall use a trivalent chromate system only. Hexavalent
chromates will no longer be allowed at that time . No topcoats are allowed on fasteners and other
threaded parts unless approved by Fastener Engineering. Slight color iridescence and color variations are
acceptable.

The effectiveness of the chromate coating is measured by the number of hours of salt spray exposure
before the development of voluminous white corrosion products. A faint white film or blush does not
constitute a failure. Table 2 summarizes the required minimum hours of salt spray exposure before the
formation of white corrosion products for the alloys and chromate coatings covered by this standard, as
well as the minimum number of hours to red rust.

2.7 Performance Requirements

2.7.1 Adhesion

The deposit shall not peel from itself or from the substrate when tested in accordance with ASTM B 571
(Standard Test Methods for Adhesion of Metallic Coatings).

The hardened, aged chromate coating shall be tightly adherent to the zinc alloy substrate and shall not be
removed by ordinary handling.

2.7.2 Hydrogen Embrittlement Relief

High strength/high hardness steel parts with a Rockwell Hardness of HRC 32 or greater MUST BE
PROPERLY BAKED according to the schedule and procedure specified in Process Standard PS-9500,
Hydrogen Embrittlement Relief, within one hour after plating. The bake operation shall be used prior to
hexavalent chromate post dip and may be done after trivalent chromate post dip, provided it can be shown
that there is no detrimental effect on the corrosion resistance.

2.7.3 Hydrogen Embrittlement Test

The hydrogen embrittlement test is to be performed according to Process Standard PS-9500.

2.7.4 Accelerated Corrosion Resistance

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NOTE: The salt spray test is only used to test the integrity of the alloy deposit and the effectiveness of the
chromate coating. The hours to white or red rust SHALL NOT be construed as having any correlation to
the actual service life of the part!

Sample parts shall be dried and aged for 24 hours prior to exposing them to salt spray. The test shall be
conducted in accordance with ASTM B 117 for the times shown in Table 2.

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.

The objective of the Hours to White Rust requirement in Table 2 is less than 5% white corrosion products
after testing for the number of hours listed. However, chromate 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.

On parts with a surface area greater than 155 sq cm (24 sq in), the appearance of six or more red rust
spots per 1000 sq cm (1 sq ft.) of significant surface, that are visible to the unaided eye at normal reading
distance or any rust spot originating from an area larger than 1.6 mm (1/16 in) in diameter is considered a
failure.

On parts smaller than 155 sq cm (24 sq in), the appearance of more than one rust spot on any significant
surface or any rust spot originating from a spot larger than 1.6 mm (1/16 in) in diameter is a failure.

On threaded fasteners, the formation of corrosion products in the threaded areas DOES NOT constitute a
failure. However, the head and unthreaded shank of a screw or bolt is considered a significant surface
and must withstand the formation of white and red rust for the minimum times listed in Table 2.

TABLE 2: MINIMUM SALT SPRAY TEST REQUIREMENTS

UNTIL JANUARY 1 2007
with hexavalent chromates
HOURS TO WHITE HOURS TO RED
THICKNESS HEXVALENT RUST RUST
ALLOY
(micrometers) CHROMATE
RACK BARREL RACK BARREL
Alkaline zinc-nickel C- Yellow 300 240 1000 720
20 5
Black 240 140 1000 720
Alkaline zinc-nickel C- Yellow 300 240 1000+ 1000
30 8
Black 240 140 1000+ 1000
Acid zinc-nickel C-20 Yellow 400 300 1000+ 720
5
Black 240 140 1000 720
Acid zinc-nickel C-30 Yellow 400 300 1000+ 1000+
8
Black 240 140 1000 1000
Zinc-cobalt C-20 5 Yellow 200 140 400 300
Zinc-cobalt C-30 Yellow 200 140 480 400
8
Black 200 140 400 300
Zinc-iron C-20 5 Black 240 140 720 300
Zinc-iron C-30 8 Black 240 140 1000 400

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Copyright DaimlerChrysler Corporation

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 ***TABLE 3: MINIMUM SALT SPRAY TEST REQUIREMENTS
JANUARY 1 2007
with trivalent chromates and a sealer or topcoat
HOURS TO WHITE HOURS TO RED
THICKNESS TRIVALENT RUST RUST
ALLOY
(micrometers) CHROMATE
RACK BARREL RACK BARREL
CLEAR 240 120 840 720
Zinc-nickel C-20 5

CLEAR 240 120

Zinc-nickel C-30 8 960 840
BLACK 192 96

Zinc-cobalt C-20 5 CLEAR 144 96 384 300

CLEAR 144 96 480 400

Zinc-cobalt C-30 8
BLACK 96 72

Zinc-iron C-20 5 CLEAR 192 96 480 300

CLEAR 192 96 720 400
Zinc-iron C-30 8
BLACK 144 72

NOTE: The salt spray test is to be used for process control and process capability only and not required
for lot control. Salt spray corrosion testing does not need to be completed prior to shipment of parts. The
corrosion testing of fasteners must follow the procedure as outlined in SAE/USCAR-1, Salt Spray Testing
and Evaluation of Fastener Finishes.

***TABLE 4: MINIMUM SALT SPRAY TEST REQUIREMENTS

JANUARY 1 2007
with trivalent chromates without a sealer or topcoat
HOURS TO WHITE HOURS TO RED
THICKNESS TRIVALENT RUST RUST
ALLOY
(micrometers) CHROMATE
RACK BARREL RACK BARREL
CLEAR 192 96 790 670
Zinc-nickel C-20 5

CLEAR 192 96
Zinc-nickel C-30 8 900 790
BLACK 144 72

Zinc-cobalt C-20 5 CLEAR 120 72 330 250

CLEAR 120 72 430 350

Zinc-cobalt C-30 8
BLACK 96 48

Zinc-iron C-20 5 CLEAR 144 72 430 250

CLEAR 144 120 670 350
Zinc-iron C-30 8
BLACK 120 96

3.0 QUALITY

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Refer to CS-9801 for general quality requirements.

4.0 GENERAL INFORMATION

Three asterisks *** after the section/paragraph header denotes multiple technical changes to the
section/paragraph. A triple asterisk before and after a string of text (***text***) identifies a single change.

Certain important information relative to this standard has been included in separate standards. To assure
the processes submitted meet all of DaimlerChrysler requirements, it is mandatory that the requirements
in the following standards be met.

CS-9800 - Application of this standard, the subscription service, and approved sources
CS-9003 - Regulated substances and recyclability

Within Engineering Standards, the Regulatory (Government-mandated) requirements are designated by

<S>, <E> and <H> which correspond to Safety, Emission and Homologation Shields respectively. The
DCC-mandated requirements are designated by <D>, <A> and <T> and correspond to the Diamond,
Appearance and Traceability symbols respectively.

For specific information on this document, please refer to the contact person shown in the "Publication
Information" Section of this document. For general information on obtaining Engineering Standards and
Laboratory Procedures, see CS-9800 or contact the Engineering Standards Department at
engstds@dcx.com.

5.0 REFERENCES

CS-9003 CS-9800 CS-9801 PS-79 PS-809

PS-4220<S> PS-6239 PS-7300 PS-9003 PS-9500
PS-PLATING ASTM B117 ASTM B487 ASTM B499 ASTM B504
ASTM B568 ASTM B571 ASTM B602 ASTM B 697 ASTM B 762
DaimlerChrysler, Ford, and General Motors manual, Quality System Requirements QS-9000"

6.0 ENGINEERING APPROVED SOURCE LIST

Processes, covered by this standard, shall only be purchased from those sources listed in Table 5 below:

TABLE 5: ENGINEERING APPROVED SOURCE LIST

ZINC-IRON ZINC-COBALT ZINC-NICKEL
SUPPLIER BARRE BARRE
RACK RACK RACK BARREL
L L

Acadian Platers Ltd. X X

Rexdale, Ont. Canada
Ajax Metal Processing, Inc. X X X
Detroit, MI
API Industries X X
Elk Grove Village, IL

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Copyright DaimlerChrysler Corporation

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 TABLE 5: ENGINEERING APPROVED SOURCE LIST
ZINC-IRON ZINC-COBALT ZINC-NICKEL
SUPPLIER BARRE BARRE
RACK RACK RACK BARREL
L L

Atlas Plating Co. X

Cleveland, OH
Autotek Electroplating, Inc. X X
Rexdale, Ont. Canada
Barber Coleman/Robert Shah X
Rockford, IL
DeKalb Finishing Inc X
Auburn, IN
Cadillac Plating Co. X
Warren, MI
Coatings 85 Plnt B & C X X X
Mississauga, Ontario
Controlled Plating Tech X
Grand Rapids, MI
Elco Industries, Inc. X
Rockford, IL
Finishing Services X
Ypsilanti, MI
Gatto Industrial Platers X X
Chicago, IL
Greystone Induplate X X
North Providence, RI
Hohman Plating X
Dayton, OH
Howard Plating Industries X X
Madison Heights, MI
J D Plating Co. X X
Madison Heights, MI
K C Jones Plating Co. X
Hazel Park, MI
Marsh Plating Corp. X
Ypsilanti, MI
Modern Plating X X X
Freeport, IL
P & J Plating X X
Toledo, OH

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Copyright DaimlerChrysler Corporation

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 TABLE 5: ENGINEERING APPROVED SOURCE LIST
ZINC-IRON ZINC-COBALT ZINC-NICKEL
SUPPLIER BARRE BARRE
RACK RACK RACK BARREL
L L

Plating Technology, Inc. X X X X

Dayton, OH
Columbus, OH
Progressive Plating X
Indianapolis, IN
Rampart Industries X X X X
Detroit, MI
Reilly Plating Co. X X X
Melvindale, MI
Roy Metal Finishing X
Conetee, SC 29636
***South Holland X
Monee, IL
Superior Plating Co. X X
Minneapolis, MN
Whyco Chromium X X
Thomaston, CT
Wisconsin Plating X X
Racine, WI
Wolverine Plating Corp X
Roseville, MI

7.0 PUBLICATION INFORMATION

Contact/Phone No: R.J. Lash (248) 576-7461

Alternate Contact/Phone No:
Dept. Name & Dept. No./Tech Club/Organization: Body Materials Engineering, Dept 5820
Date Standard Originally (Initially) Issued: 2001-01-02
Date Published: 2003-12-10
Change Notice:
Description of Change: Editorial

#####

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Copyright DaimlerChrysler Corporation

(2002-05-06)