8 STD - PS-50031 - Rev. B - 2021-06 - ZINC NICKEL ALLOY
8 STD - PS-50031 - Rev. B - 2021-06 - ZINC NICKEL ALLOY
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PS.50031
ZINC NICKEL ALLOY Process Standard
ELECTRODEPOSITED COATINGS
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TRESS KIM - [email protected]
Date: 24-JUN-2021
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GLOBALLY HARMONIZED DOCUMENT
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Co-Author
Author
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Change level Date Description of change
rn ) Initial release. Harmonized version of 9.57409, PS-8955, and PS-
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- 22-JUN-2015
12182.
Clarification of requirements throughout
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B 24-JUN-2021
Section 4.4.3 Updated
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Section 9 Updated
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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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PS.50031
Change Level: B
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TABLE OF CONTENTS
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1 GENERAL ................................................................................................................................................. 4
1.1 Purpose .................................................................................................................................................. 4
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1.2 Coverage of this Standard ..................................................................................................................... 4
2 REFERENCES .......................................................................................................................................... 6
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3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS ..................................................................... 7
4 PROCESS AND PROCESS CONTROL REQUIREMENTS .................................................................... 7
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4.1 Condition of the part prior to processing ................................................................................................ 7
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4.2 Procedure ............................................................................................................................................... 8
4.2.1 Cleaning .............................................................................................................................................. 8
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4.2.2 Plating ................................................................................................................................................. 8
4.2.3 Passivates ........................................................................................................................................... 8
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4.2.4 Topcoats and/or Sealers ..................................................................................................................... 8
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4.2.5 Hydrogen Embrittlement Relief ........................................................................................................... 8
4.3 Process control ...................................................................................................................................... 9
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7.1 Test Facilities ....................................................................................................................................... 21
7.2 Test Equipment .................................................................................................................................... 21
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8 SAFETY PRECAUTIONS ....................................................................................................................... 22
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9 APPROVED SOURCE LIST ................................................................................................................... 22
10 DRAWING CALLOUT CROSS-REFERENCE ...................................................................................... 26
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PS.50031
Change Level: B
1 GENERAL
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This standard defines harmonized requirements for zinc nickel electroplated components for use by FCA
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Italy and FCA US.
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This document supersedes FCA Italy Procurement Specification 9.57409 and FCA US Process
Standards PS-8955 Ni.
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1.1 Purpose
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This standard specifies the plating and performance requirements for zinc-nickel alloy electrodeposits and
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their associated passivate coatings and topcoats. This coating system is used for enhanced corrosion
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resistance on ferrous parts, including fasteners.
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1.2 Coverage of this Standard
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Specific requirements shown on the part drawing shall take precedence over related requirements
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specified in this standard, or may be in addition to the requirements of this standard.
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Alkaline zinc nickel processes shall be used unless otherwise noted. When a specific substrate cannot
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be effectively plated in alkaline zinc nickel, such as AVP steels, high Carbon content steels and cast iron
components, or when a brighter appearance is required, the supplier must obtain approval from Materials
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Because this standard covers more than one finish, the abbreviated description must be added as a suffix
after the process standard number to designate the specific system. Table 1 provides a list of the
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available designations.
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coefficient control.
Lubricated sealer or topcoat for enhancing corrosion resistance and for
LUB (3)
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NOTE (4): If there is no designation specified or drawing notes provided, the default requirements are:
Thickness for the plated deposit is 8 micrometers minimum
Color for the passivate is clear
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Sealer or topcoat shall be applied for parts other than machine-threaded fasteners and conditions described in
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Section 1.2 B
NOTE (5): This designation shall not be used for fasteners and threaded elements, including brackets with weld studs or weld
nuts.
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A. For example, the designation “PS.50031 C8 Black LUB Cf = 0.12 to 0.18” requires a black final
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appearance with a lubricating sealer that provides a coefficient of friction of 0.12 to 0.18, as per
section 4.4.5. If there is nothing noted on the drawing, the default thickness for the plated deposit is 8
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micrometers minimum and the default color for the passivate is clear.
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B. The use of topcoats or sealers is recommended to enhance corrosion resistance except when the
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properties or performance of the part will be negatively affected, such as torque or electrical
conductivity, parts that will be subsequently welded, parts that must subsequently be painted by
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cataphoresis (ecoat), or small blocks reinforcements and bushings intended for rubber-metal
connection.
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C. When specifying this coating for components to be processed through the Body In White (BIW), the
“Plain” designation shall be used, unless otherwise noted on the drawing. This designation is only
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recommended for components that will be subsequently painted or subject to further processing
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D. Plated parts with tensile strength of 1040 or greater, or hardness of Rockwell HRC 32 or greater, and
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all property class 9.8 and 10.9 bolts require conformance to the requirements of Process Standard
PS.50023<S> Hydrogen Embrittlement Relief.
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E. Zinc nickel alloy coating shall not be used for steel parts with tensile stress (R) > 1500 N/mm 2
regardless of part classification, nor for steel parts with R ≥ 1220 N/mm 2 for which functional class 1
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F. Cast iron components, such as brake calipers, may be plated in either acid zinc nickel systems or in a
duplex (acid zinc and subsequent alkaline zinc nickel) system.
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Specific requirements shown on the part drawing shall take precedence over related requirements
defined in this standard, or may be in addition to the requirements of this standard.
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PS.50031
Change Level: B
2 REFERENCES
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Table 2 - References
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downloadable
Shield/Designator for suppliers
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Document Number (if applicable) Document Title from
beSTandard
<S,D,E,A>
(Y/N)
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SERVICE CLASSES – ASSIGNMENT OF THREE SERVICE N
00160
CLASSES TO MOTOR VEHICLE COMPONENTS
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9.01102 SUPPLY QUALITY – FCA AUTOMOBILES S.P.A. Y
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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7.G0114 FASTENER FRICTION TEST Y
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METALLIC AND OTHER INORGANIC COATINGS – CHROMATE
ISO 3613 CONVERSION COATINGS ON ZINC, CADMIUM, ALUMINIUM-ZINC N
ALLOYS AND ZINC-ALUMINIUM ALLOYS – TEST METHODS
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CORROSION TESTS IN ARTIFICIAL ATMOSPHERES — SALT N
ISO 9227
SPRAY TESTS
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RECYCLABILITY
CS-9800 GENERAL INFORMATION Y
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PF-8500
CONTINUING CONFORMANCE TESTING
INSPECTION OF THREADED FASTENERS FOR NORMAL AND
PF.90348 S SPECIAL USE AND SURFACE DISCONTINUITIES ON THREADED Y
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FASTENERS
PS.20001 "TORX®" 6-LOBE INTERNAL RECESS – INSPECTION PRACTICE Y
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APPARATUS
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Table 2 - References
downloadable
Shield/Designator for suppliers
(if applicable) Document Title from
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Document Number
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<S,D,E,A>
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(Y/N)
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INORGANIC COATINGS
LP-461H-118 GALVANIC CORROSION TEST FOR FASTENERS Y
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SPECIFICATION FOR TESTING AUTOMOTIVE LIGHT BULB N/A
SAE/USCAR-1
SOCKETS
N/A
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SAE J2334 LABORATORY CYCLIC CORROSION TEST
PERFORMANCE BASED STANDARD FOR ACCELERATED
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SAE J2527 EXPOSURE OF AUTOMOTIVE EXTERIOR MATERIALS USING A N/A
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CONTROLLED IRRADIANCE XENON-ARC APPARATUS
QUALITY MANAGEMENT SYSTEMS - PARTICULAR
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REQUIREMENTS FOR THE APPLICATION OF ISO 9001:2008 FOR N/A
ISO/TS 16949
AUTOMOTIVE PRODUCTION AND RELEVANT SERVICE PART
ORGANIZATIONS
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GENERAL REQUIREMENTS FOR THE COMPETENCE OF N/A
ISO/IEC 17025
TESTING AND CALIBRATION LABORATORIES
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3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS
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F: Fahrenheit
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N: Newton
SAE: Society of Automotive Engineers
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Approval of the plating process, and any proposed changes shall be obtained from the FCA Materials
Engineering Department.
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The cleaners, plating brighteners, passivations, and sealers or topcoats shall be supplied from a single
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All forming, heat treating, and staking operations shall be completed prior to coating. Any deviation must
be reviewed and approved by FCA Materials Engineering Groups.
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PS.50031
Change Level: B
4.2 Procedure
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4.2.1 Cleaning
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The preplate process for components processed per this standard is not defined. Any process that can
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be demonstrated to provide parts conforming to the full requirements of this standard is allowed, including
combinations of mechanical and chemical processes. It is the supplier’s responsibility to use the
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appropriate means necessary to ensure acceptable plate coverage, adhesion, and full compliance to the
standard.
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When processing parts having a tensile strength of 1040 N/mm 2 or greater, or HRc 32 or greater, the
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process restrictions to reduce the risk of hydrogen embrittlement must be followed in accordance with
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PS.50023<S> Hydrogen Embrittlement Relief.
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4.2.2 Plating
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The zinc nickel plating may be performed in a rack or barrel application provided the finished parts meet
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all the requirements of this standard, and the process does not have any negative effect on the part.
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4.2.3 Passivates
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A trivalent chromium or chromium-free type passivate is considered an integral part of this process
standard and significantly enhance the overall corrosion resistance of the deposit. The passivate must be
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formulated for zinc nickel. Slight color iridescence and color variations are acceptable.
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Parts requiring a black passivates shall provide a uniform, decorative black appearance that is UV stable.
The parts shall be free from bare spots and not chip or flake during normal handling.
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The use of a topcoat or sealer is recommended on parts other than surfaces that will be welded, or
components requiring electrical conductivity. The topcoat or sealer must be dry-to-the-touch and pass all
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fluid compatibility requirements for each application. The topcoat or sealer must not interfere with the
assembly or performance of the part. Topcoats are applied after hydrogen embrittlement relief is
performed, when necessary.
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NOTE: On fasteners and other threaded parts, the use of lubricant or lubricated sealer for lowering the friction coefficient must be
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pre-approved. A list of pre-qualified materials can be found in Section 8 Approved Source List.
High strength/high hardness steel parts with a tensile strength of 1040 N/mm 2 or greater, or HRC 32 or
greater, MUST BE PROPERLY BAKED according to the schedule and procedure specified in Process
Standard PS.50023<S>, “Hydrogen Embrittlement Relief”, within one hour after plating and at specified
temperature within two hours after plating. The parts must reach the relief temperature within 2 hours
after exiting the electroplating bath. The bake operation may be done after trivalent chromite or passivate
post dip, provided it has been shown that there is no detrimental effect on the corrosion resistance or
performance.
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PS.50031
Change Level: B
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1040 to 1220 N/mm 2 (32 to 36 HRc) 200 +/- 10 C for 4 hours minimum
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1220 to 1500 N/mm 2 (37 to 49 HRc) 200 +/- 10 C for 8 hours minimum
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4.3 Process control
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Process control analysis and procedures necessary to ensure optimum electroplating process
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performance are required of all applicators electroplating to the requirements of this standard. The
applicator is responsible to perform all necessary and prudent process control and is responsible for
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maintaining all records relevant to the plating process. FCA SQ will verify compliance within the scope of
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the PPAP/PSO. These records include:
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A. Solution Control Requirements – The control requirements shall be followed with minimum
frequencies to meet the requirements identified in AIAG’s CQI-11 Version 2 Process Table A unless
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otherwise specified by Supplier Quality. If parts are coated having a tensile strength of 1040 N/mm 2
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(HRc 32) or greater, the minimum frequencies to meet the requirements identified in AIAG’s CQI-11
Version 2 Process Table I are also required, unless otherwise specified by Supplier Quality.
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Process Control targets and ranges shall be established by the processor and material supplier(s) and
documented on the Control Plan. Any changes must be documented.
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The requirements of this standard apply to the significant surfaces of a part. Unless otherwise specified
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on the part drawing, significant surfaces for plating thickness and corrosion resistance determination are
all surfaces that can be touched by a 20 mm (or 0.75 in) diameter sphere. For tubular-shaped parts or
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similar geometry with deep recesses, the significant surface shall extend into the depth a distance of 1.5
times the opening dimension unless otherwise specified.
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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. The recessed area
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used for the internal drive feature (e.g. Torx® head) does not need to meet minimum thickness but shall
meet all other characteristics including appearance and corrosion resistance.
4.4.2 Workmanship
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. The presence of micro cracks reaching the base metal is allowed provided that
they do not compromise the resistance to corrosion. Passivates, topcoats and/or sealers shall completely
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PS.50031
Change Level: B
cover the plated surfaces, be adherent and dry-to-touch but not powdery. Iridescence in the finish is
expected and acceptable for clear finishes, but should be minimal for black finishes.
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4.4.3 Alloy Composition
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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 4. The
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determination of the Nickel percentage in the deposited alloy shall be carried out by one of the following
methods:
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A. Preferred Method: X-ray fluorescence (non-destructive method)
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B. Alternate Method: Acid dissolution of coating and subsequent chemical analysis (destructive method)
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Table 4 - Alloy Composition
Deposit Alloy
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Acid zinc-nickel (1) 9.0 to 16.0% 12.0%
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substrate cannot be effectively plated in alkaline zinc nickel, such as cast iron components, or when a
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brighter appearance is required, the supplier must obtain approval from Materials Engineering.
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The plate thickness on all Significant Surfaces defined by Section 4.4.1 must meet the minimum
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For all components plated to this standard, the supplier shall analyze parts plated in a production intent
process taken from the highest and lowest current density locations on the plating rack for Coating Build
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Capability. For barrel or bulk plating processes, a minimum of 5 pieces shall be measured from a single
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load. The selected parts shall be checked for thickness at all identified significant surfaces, or as required
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by Supplier Quality. Each measurement must be less than 10 cm apart and appropriately distributed
based on the part size and configuration such that each significant surface is inspected.
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The Coating Build Capability study will verify the effectiveness of the proposed rack design to meet the
required thickness. Additionally, the coating thickness analysis will provide data to determine the coating
thickness distribution across the entire part, verify conformance to all significant surfaces requirements
and assist in selecting P-Points by FCA Supplier Quality for routine coating thickness control.
The supplier is responsible for using auxiliary anodes, current robbers or shields when coating parts to
this standard to meet the plating thickness requirements for all significant surfaces. All testing to verify
rack design including electrical current robbers or shields must be documented as well as all racking and
other improvements.
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PS.50031
Change Level: B
Coating Build Capability testing must be completed for each part supplied to FCA as part of the test
requirements for PPAP/PSO and also Forever Requirements notifications identifying process changes.
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B. P-Point Selection
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Thickness checks for Continual Conformance shall be measured at checkpoints (P-Points) indicated on
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the drawing of the part as a convenience only. All other locations, if inspected, must meet minimum
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requirements.
To select potential P-Points, the supplier provides the supporting Coating Build Capability report and
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proposes P-Points to FCA Supplier Quality. The proposed P-Points are to be 1 to 5 well-spaced and
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typically symmetrical points exhibiting low thickness but conforming to Significant Surface requirements.
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FCA Supplier Quality approves the proposed P-Points or identifies other preferred locations. For parts
with restrictive dimensional tolerances or performance requirements, P-Points for thickness in the high
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current density may also be required.
If part geometry is such that it is impractical to achieve minimum thickness on the entire part, a proposal
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must be made by the supplier to FCA Materials Engineering for a deviation to be considered.
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The following ASTM Standard Methods are recommended for determining the coating thickness for
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qualification:
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The following ASTM Standard Method is allowed for determining the coating thickness for quality
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management:
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Except for the microscopic method, it is essential to calibrate the test instrument with an alloy of the same
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To insure compliance with the thickness requirements of this standard, the plating thicknesses and alloy
shall be measured on a regular and frequent basis using acceptable sampling plans, such as
recommended in ASTM B697, B602, and B762 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 minimum coating thicknesses on significant surfaces are specified by the Code number suffix after
the process standard number as follows:
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Deposit thicknesses greater than 8 microns are generally not recommended. If it is determined that other
thicknesses are necessary for a particular application, drawing notes shall be used to designate the
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required thickness. If no “Code” is specified on the drawing, the default is 8 microns minimum.
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In the event of a discrepancy for thickness determination, the microscopic cross section shall be used.
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4.4.4.3 Maximum Deposit 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 cannot be defined. The maximum thickness must not interfere with the assembly or
performance of the part. Refer to Section 4.17 for gaging requirements of components with threads.
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When necessary, a maximum thickness may be defined on the print.
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4.4.4.4 Thickness on Fasteners
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With regard to coating thickness of bolts, if not otherwise specified by the Purchaser, holes, hollows,
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threads, and sharp edges are not considered to be significant surfaces. However, the entire head area of
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screws and bolts, and the unthreaded shanks of bolts are significant surfaces. The recessed area used
for the internal drive feature does not need to meet minimum thickness but shall meet all other
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characteristics including appearance and corrosion resistance. Refer to Section 4.17 for gaging
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Considering the variability of the electrolytic coating thickness on screws and nuts, the measurement is
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In case of screws, this point lies approximately at the center of the head surface, the center of the stem
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end, and the center of the unthreaded portion of the shaft. (see Figure 1).
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In case of cylindrical screws with countersunk hexagonal head and of screws with cross cut, the
measuring point lies on the flat surface of the head, between edge and countersunk hexagon, between
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edge and cross cut or on the side of the hexagon (see Figure 1). Countersunk and cut surfaces are
excluded from the measuring points.
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In case of nuts, thickness is measured on a side of the hexagon and/or on a support plane (see Figure 2).
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If not otherwise indicated on drawing, the friction coefficients must range within the dispersion limits Cf =
0.12 to 0.30, indicated in Procurement Specification 9.52605/01.
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For fasteners requiring LUB Type, the coefficient of friction shall be 0.10 to 0.16 unless otherwise
indicated on the drawing.
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Different values must be specified on drawing.
E.g.: PS.50031 C8 Clear LUB (Cf = 0.12 to 0.18).
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The method of the correct application of the friction conditioners must be carried out measuring the
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friction coefficient as indicated in the Standard 7.G0114. Other test method must be agreed upon
beforehand and approved by Materials Engineering Department of FCA.
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Materials applied to machine threaded fasteners that modify the frictional properties require pre-approval
by FCA Materials Engineering. A list of prequalified materials is available in Section 8 Approved Source
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List.
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4.5 Adhesion
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A. The deposit shall not peel from itself or from the substrate when tested in accordance with one of the
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method described below. Parts shall not exhibit chipping or flaking during normal handling. The
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hardened, aged passivate and topcoat and sealer shall be tightly adherent to the zinc nickel substrate
and shall not be removed by ordinary handling.
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A. Place the coated part to be tested into a constant temperature chamber for 1 hour at 290°C to 310ºC.
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B. Carefully remove the part and immediately immerse in water at room temperature (20 to 23°C).
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C. After cooling, take the part out and dry it with a flow of compressed air.
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D. At the end of the test inspect the coating, ensuring there is no sign of detachment from base metal,
swellings, blisters, flaking, etc. Eventual damages of sealer or topcoat DO NOT constitute a failure.
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4.5.2 Bend Method (to be adopted only on parts made of thin sheet or tape)
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A. The test consists in bending the part or sample to be tested, manually or with pliers, at an acute
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angle, first on one side and then on the other, until it breaks.
B. 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.
The hydrogen embrittlement test is to be performed according to Process Standard PS.50023<S>. This
test is required for all parts having tensile strength of 1040 N/mm 2 or greater, or HRc 32 or greater,
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PS.50031
Change Level: B
including property class 9.8 and 10.9 fasteners. The Tier 1 supplier is responsible to ensure that parts
pass the hydrogen embrittlement test prior to shipment to FCA.
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4.7 Accelerated Corrosion Resistance
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Heat soak the parts to be tested in constant temperature ventilated chamber for 55 to 65 minutes at
145°C to 155°C, followed by testing in accordance with ASTM B117 for the times shown in TABLE 6.
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Sample parts shall be dried and aged for a minimum of 24 hours prior to exposing them to the test.
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When used for process control, it is allowed to carry out the neutral salt spray test according to ISO 9227.
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TABLE 6 summarizes the required minimum hours of salt spray exposure before the formation of white
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corrosion products for the alloys and chromite coatings covered by this standard, as well as the minimum
number of hours to red rust.
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Salt spray corrosion test requirements DO NOT apply to deep recesses, such as small blind holes and
the interior of tubing. rn )
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The corrosion testing of fasteners must follow the procedure as outlined in SAE/USCAR-1, “Salt Spray
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Testing and Evaluation of Fastener Finishes”. On threaded fasteners, the formation of corrosion products
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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 (zinc) and red
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(base metal) corrosion for the minimum times listed in TABLE 6. After exposure, White Rust
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requirements are met if less than 3% of the surface exhibits aesthetic alterations including black spots or
white haze/blush. Parts with a black finish may be rinsed with warm water to determine whether the
passivation layer is undamaged and maintains the original color.
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After exposure, Red Rust requirements are met if there is no evidence of base metal corrosion.
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(Alkaline or Acidic
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Hours to Hours to Red Hours to Hours to Red
systems) White Rust Rust (1) White Rust Rust (1)
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C12 microns, Clear, ST 216 1200 240 1500
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C12 microns, Black, ST 216 1200 240 1500
C12 microns, Clear, LUB 216 1200 240 1500
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C12 microns, Black, LUB 216 1200 240 1500
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Note (1): For substrates other than ferrous metals, the Hours to Red Rust shall be used to indicate
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corrosion resistance performance for base metal corrosion.
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The salt spray test is only used to test the integrity of the alloy deposit and the effectiveness of the
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passivate coating. The hours to white or red rust SHALL NOT be construed as having any correlation to
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the actual service life of the part. Salt spray corrosion testing does not need to be completed prior to
shipment of parts once PPAP is approved.
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For barrel processed components, if the test is performed in the FCA production plant, a 15% reduction in
the general performance requirements of the parts is allowed.
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No visual stain shall be observed on Whatman Filter Paper #41 after being squeezed in the palm of the
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Condensing humidity is performed per ASTM D2247 for 96 hours. There shall be a single line scribed
though the coating to the plating layer prior to humidity exposure. No loss of adhesion in excess of 1 mm
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from scribe is allowed. No blistering, whitening, loss of gloss or corrosion on significant surfaces away
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from scribed lines is allowed. Adhesion is tested per ASTM D3359 Method B within 10 minutes after
humidity exposure is completed.
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Perform as required based on part application. Galvanic compatibility testing to Aluminum (A96061) and
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Stainless Steel (S30400) is performed based on the LP-461H-118 procedure. SAE J2334 is used as the
corrosion test method. For galvanic testing to aluminum, there shall be no pitting, exfoliation or localized
corrosion of the test panel in the vicinity of the coated fastener. For galvanic testing to stainless steel, the
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Tapping screw test protocol validates the “Torque to Tap – Torque to Strip” capability of the coating. The
procedure is supplied and results evaluated by FCA Fastener Engineering. Self-tapping screws shall only
be coated with materials approved in Table 8.
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PS.50031
Change Level: B
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The torque required to break the washer free from a screw or nut assembly shall be equal to or less than
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one half of the fastener thread size, not to exceed 6 Newton-meters
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4.13 Recess Fill (For topcoats and sealer)
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A recess penetration gage shall enter into the recess or fastener head at the minimum penetration
requirements with no more than 4.5 kg (10 pounds) axial load. Refer to PS.20001 for details for Torx®
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head requirements.
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4.14 UV Resistance
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For black sealers and topcoats only: UV Resistance is performed by Xenon Arc exposure per SAE J2527
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for 2400 kJ. Tested parts shall exhibit no loss of adhesion, chalking, cracking, blistering or significant
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color changes. Adhesion after UV Resistance is tested per section 4.9. Additionally, parts shall be
reviewed by the FCA Product Design Office for appearance approval.
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Coated parts subjected to UV Resistance testing must not include a non-permanent topcoat. To ensure
that this requirement is met, test parts must first be pre-conditioned through a simulated car wash
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environment.
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Preconditioning is achieved by immersing parts suspended on a nylon filament line into a 1 liter beaker of
0.5% Rally Car Wash solution at 60 °C for 60 seconds. Solution must be agitated using a magnetic stirrer
em 06
to create a slight vortex at the top of the solution. After immersion, parts are rinsed for 10 seconds in
deionized water and allowed to drip dry.
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.fo 1 0
Confirm the absence of hexavalent chromium compounds in the coating composition by following the
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4.16 Re-process
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Stripping and replating the parts is allowed, provided that the parts are only reworked once, and all
e
requirements are met. High strength steel parts with a tensile strength of 1040 N/mm 2 (HRC 32) or
n
greater must be stripped in an alkaline stripper. If an acidic stripper is used, the parts must be relieved of
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hydrogen as described by section 4.2 within 2 hours after stripping, prior to replating. Documentation
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
(NORTH AMERICA) Thread discontinuities (including nicks or gouges), contaminants and coating
thickness shall not interfere with assembly of the proper GO thread plug gage with the application of a
torque not more than 0.001 times the nominal diameter cubed, in N-m (145 times the nominal diameter
cubed, in in-lbs., for inch based fasteners). The manufacturer shall exercise due care during the
Page: 17/26
PS.50031
Change Level: B
manufacturing and handling of parts to minimize the number and magnitude of thread discontinuities and
coating build-up.
C
(EMEA) The thickness of the coating deposited on the threaded elements must not adversely affect
om 29
normal tightening and removal operations.
i.c 60
Thread discontinuities (including nicks or gouges), contaminants and coating thickness shall not interfere
with assembly of the proper GO thread plug gage with the application of a maximum torque specified in
at F5
PF.90348<S> - paragraph 7.1.11.
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Parts shall be tested from each plating line to the frequencies defined in Table 7.
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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
diameter.
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te +1
Table 7 - Product Inspection Requirements
Test Description Requirement Minimum Frequency (1)
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Continual Conformance
Validation, Re-process and
Alloy 5 pieces/shift
Continual Conformance
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Continual Conformance
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clips) :
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10 pieces representing a
minimum total surface area of
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3 pieces representing a
minimum total surface area of
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corrosion Conformance each passivate and topcoat ( or
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sealer) combination used
i.c 60
Fasteners and small parts (e.g.
at F5
springs, washers, clips) :
10 pieces representing a
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minimum total surface area of
0.3 dm2 (0.03 ft2)
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Rack parts and other barrel
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plated brackets and stampings :
3 pieces representing a
rn ) minimum total surface area of
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1.0 dm2 (0.1 ft2)
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Salt spray testing for red rust Re-process and Continual Frequency: Once every 8
(base metal corrosion) Conformance weeks
@ UT
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Conformance
Cyclic Corrosion Validation Initial Chemical and Applicator
on
Approval
Galvanic Compatibility Validation Initial Chemical Approval
Handling Resistance Validation Initial Chemical and Applicator
Approval
Dry To Touch Validation Initial Chemical and Applicator
Approval
Page: 19/26
PS.50031
Change Level: B
C
Approval
om 29
Tapping Screw Test Validation Initial Chemical Approval
i.c 60
Washer Assembly Breakaway Validation Initial Chemical and Applicator
Approval
at F5
Head/Recess Fill Validation Every lot
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Chemical Compatibility Validation Initial Chemical Approval
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UV Resistance Validation Initial Chemical Approval
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Torque/tension testing Validation Initial Chemical and Applicator
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Approval
Absence of hexavalent Validation Initial Chemical and Applicator
chromium rn ) Approval
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NOTE (1) With written approval by FCA Supplier Quality and Materials Engineering, quantities and/or
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5 SPECIAL REQUIREMENTS
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This section defines to part suppliers, Release Engineers, Supplier Quality, and others as necessary the
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PPAP/PSO requirements for coatings processed per this standard. These tests, along with the use of
FCA approved substrates, will ensure that the plated part will meet the design intent of the application.
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This standard also applies to PPAP/PSO and Forever Requirement testing driven by:
at 20
- Significant Process Changes (including changes in rack design and anode configuration)
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- Change in Technology
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- New Supplier/Source
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Material approval by the FCA Materials Engineering Department and performance approval by the
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
supplier.
Page: 20/26
PS.50031
Change Level: B
C
Production parts with approved Coatings shall be inspected with the frequency and to the degree required
om 29
to insure 100% compliance with the requirements for dimensions and materials stated on the part drawing
or CAD model, (CATIA/NX).
i.c 60
No change in material formulation, processing, or finishing from that originally agreed upon shall be made
at F5
by the supplier without prior approval by the FCA Organic Materials Engineering Department. To this
end, all approved materials will have an infra-red spectra photometric analysis and a thermogravimetric
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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 infra-red spectra and
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thermogravimetric analysis data of the originally approved material. Random testing of parts during the
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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
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FCA Material Standards with the supplier being removed from the various Approved Source Lists.
comprising the finished part whether they have been compounded internally or purchased from another
@ UT
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
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Materials and parts supplied under the specified material standard must be evaluated against the DV
requirements of that standard on an annual basis (minimum test frequency). These annual audits must be
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kept on file by the first tier supplier to FCA. More frequent audits of conformance to the designated
standard may be required and will be at the discretion of FCA’s Supplier Development Department,
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Materials Engineering, Appropriate Platform engineering group, or FCA first tier supplier.
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All materials supplied must provide adequate field service as specified by the FCA Vehicle Engineering
at 20
The following situations require the submission and customer approval of a Forever Requirements (FR)
notice in the WebCN system before implementation:
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by a Resource Notice.
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,
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.
Page: 21/26
PS.50031
Change Level: B
C
Refer to PF-8500.
om 29
i.c 60
6 QUALITY
at F5
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.
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For components that will be part of a vehicle designed in EMEA and sold in all markets, the material
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characteristics defined by 9.01102 and 9.01103 must be met.
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7 TEST EQUIPMENT
Production Laboratory:
@ UT
There must be a structure with the necessary tools to perform primary controls for the proper analysis and
management of process baths.
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- Control instruments for chemicals and waste water (titrator, centrifuges, etc.)
- Control instruments for qualitative and quantitative analysis of the baths (titrator, thermometer, etc.)
- pH meters
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- Hull cells
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All instruments must be certified and maintained in accordance with ISO TS 16949.
.fo 1 0
Quality Laboratory:
at 20
There must be a structure within the production site equipped with the means to perform the required
inspections described within this standard.
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- Visual aspect
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- Thicknesses
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- Alloy
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- Adhesion
- Corrosion resistance
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All instruments must be certified and maintained in accordance with ISO TS16949.
The people shall be properly trained and qualified.
- Optical microscope
- X-Ray Fluorescence thickness tester
Page: 22/26
PS.50031
Change Level: B
- Oven
- Salt Spray Chamber
C
If the supplier is not able to perform one or more of the tests, they shall seek support from an accredited
om 29
third party lab approved by FCA and/or ISO-IEC 17025 certified.
i.c 60
at F5
8 SAFETY PRECAUTIONS
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Follow all appropriate safety practices.
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9 APPROVED SOURCE LIST
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For tapping screws produced in NAFTA market, materials covered by this standard shall only be
purchased from those sources listed in the Table 8 - Material Approved Source List For Tapping Screws.
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Generic or unapproved chemicals may not be substituted.
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Components meeting this requirement shall be purchased only from those sources listed in the Material
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Approved Source List in Table 9 of this standard. The use of other materials provided by the listed
@ UT
The Approved Applicators are identified in the Table 10. The Approved Applicator listed below are to be
ag AM
applied whenever the component will be produced in NAFTA and APAC markets.
Potential applicators seeking Approved Source List approval will be reviewed only after the applicator has
em 06
met a FCA Procurement and Supply business case per the requirements defined in CEP.00036 (EASL
Approval Review Process, Electroplated and Inorganic Coatings).
nt 8:
.fo 1 0
For overseas sourcing the first-tier part supplier is responsible for all requirements of this standard
including selecting a capable, FCA approved applicator and demonstrating the capability of the selected
applicator to FCA Materials Engineering and Supplier Quality.
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at 20
EASL Approved Applicators are subject to an EASL Update Audit Review every 3 years. To maintain
Approval Status, it is the Approved Applicator’s responsibility to meet all the requirements for the EASL
m 25,
An EASL approved applicator must resubmit for EASL approval if the coating process is changed.
n
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table.
Supplier Material Additional Information
PS.50031 C8 BLACK TAP
Coventec P7750B:
Black finish approved for tapping
Coventya Performa 285 + Finidip
screws and machine threaded
728 + Finigard 113
fasteners.
Page: 23/26
PS.50031
Change Level: B
C
+ TriPass ELV + TnT12
fasteners.
om 29
MacDermid-Enthone
PS.50031 C8 BLACK TAP
i.c 60
ZinKlad 1000B (HG):
Enviralloy + TriPass 5100 Black finish approved for tapping
at F5
+ TriPass ELV + TnT15 screws and machine threaded
Black + TnT08 fasteners. Provides a higher gloss.
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.m se
Table 9 - Material Approved Source List –
Pre-Qualified Topcoats Specific For Machine Threaded Fasteners Other Than Tapping
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Screws
Materials covered by this standard shall only be purchased from those source(s) listed in this
rn ) table.
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Supplier Material Additional Information (1)
ex C
CoF=0.13
e
JS-600
MacDermid-Enthone
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TNT 08 CoF=0.12
Industrial Solutions
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TNT 12 CoF=0.15
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Note (1) Coefficient data is an average, and used for reference only. Refer to Section 4.4.5 for
testing requirements.
Page: 24/26
PS.50031
Change Level: B
C
Supplier Material Additional Information
om 29
CANADA
Acadian Platers Ltd. Alkaline Barrel
i.c 60
315 Rexdale Blvd
Rexdale, ON M9W 1R8
at F5
Coatings 85 – Plant B & C Alkaline Rack
6975 Davand Not approved for fasteners or parts
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Mississauga, ON L5T 1L5 that require hydrogen embrittlement
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relief.
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MEXICO
Nicro S A de C V Alkaline Rack and Barrel
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Pirul # 33 Col Bella Vista
Tlalnepantla
Tecniflex Ansorge rn ) Rack and Barrel
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Calle 9, No 6 and 6A
Col. Alce Blanco
ex C
CP 53370, Naucalpan
@ UT
USA
Ajax Metal Processing (1) Alkaline Barrel
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Detroit, MI 48207
BFG Electroplating Alkaline Rack and Barrel
33 Scott St Not approved for fasteners or parts
em 06
relief.
K C Jones Plating Co. Alkaline Rack
e
relief.
Marsh Plating Corp. Acid and Alkaline Rack and Barrel
on
C
Supplier Material Additional Information
om 29
relief.
Plating Technology, Inc. (1) Alkaline Barrel
i.c 60
1525 West River Rd
Dayton, OH 45418
at F5
Roy Metal Finishing Acid and Alkaline Rack and Barrel
120 McDougal Ct
er d:
Greenville, SC 29607
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South Holland (1) Alkaline Barrel
.m se
26100 S Whiting Way
Monee, IL 60449
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Twist Inc. Alkaline Rack and Barrel
1430 Lavelle Dr
Xenia, OH 45385 rn )
te +1
Varland Metal Service, Acid Barrel
3231 Fredonia Ave
ex C
Cincinnati, OH 45229
@ UT
relief.
APAC
Suzhou Penglei Autopart Co. Ltd Alkaline Barrel
em 06
7#No.518,Tangdong
nt 8:
Rd,Wuzhong Economic
Development Zone, Suzhou
.fo 1 0
China
Ningbo Chinaust Metal Surface Alkaline Rack and Barrel
tia 2
Kyungsangnam-do,
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Korea
NOTE (1): Applicator has demonstrated the criteria to meet the requirements and may bake parts
on
for 8 hours minimum that have tensile strengths between 1220 - 1500 N/mm2 and /or HRc 37 to
49 per PS.50023<S>
Page: 26/26
PS.50031
Change Level: B
C
om 29
Table 11 - Drawing Callout Cross-Reference
Equivalent Callout Equivalent Callout
i.c 60
Drawing Callout
per 9.57409 per PS-8955/PS-12182 (1)
at F5
PS-8955 NI C30 Plain or
PS.50031 C8 Plain Not Applicable
PS-8955 NI-HA C30 Plain
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PS-8955 NI C30 Clear or
PS.50031 C8 Clear Fe/ZnNi 7 IV
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PS-8955 NI-HA C30 Clear
.m se
PS-8955 NI C30 Clear or
PS.50031 C8 Clear LUB PS-8955 NI-HA C30 Clear with
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Fe/ZnNi 7 IV LUB
Sealer or Topcoat
PS.50031 C8 Clear LUB rn ) PS-8955 NI C30 Clear or
te +1
PS.50031 C8 Clear ST (Cf Fe/ZnNi 7 IV S PS-8955 NI-HA C30 Clear with
0.10 to 0.16) Sealer or Topcoat
ex C
PS-12182
PS.50031 C8 BLACK TAP Not Applicable PS-12182
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Sealer or Topcoat
.fo 1 0
Sealer or Topcoat
at 20
Note (1): Topcoats and sealers applied to machine threaded fasteners, including brackets with weld
studs or weld nuts shall obtain Materials Engineering Approval.
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