MARCHIARO GIANCARLO - giancarlo.marchiaro@crf.

it

PS.50036
FCA Italy Class: CMD
ZINC ELECTROPLATED COATINGS
FCA US Doc. Type: PS
TRESS KIM - [email protected]

Page: 1/20

Date: 12-DEC-2015
Co-Author
Author
FCA ITALY -- GROUP MATERIALS LABS (CRF) - SURFACE TREATMENTS & AN ...

HARMONIZED DOCUMENT

Change level Date Description of change

Initial release. This document supersedes FCA Italy Procurement
FCA US -- ORGANIC MATERIALS - 5840

- 12-DEC-2015 Specification 9.57405 and FCA US Process Standard PS-79, PS-

4220<S>, PS-Plating, PS-1207, PS-8814, and PS-10509
Co-Author Department
Author Department

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 FCA Italy S.p.A. and FCA US LLC..
IN CASE OF DISPUTE, THE ONLY VALID REFERENCE IS THE ENGLISH EDITION
 FCA Italy S.p.A. Page 2/20
FCA US LLC PS.50036
Change Level: -

ZINC ELECTRODEPOSITED COATINGS

TABLE OF CONTENTS

1 GENERAL ................................................................................................................................................. 3
1.1 Purpose .................................................................................................................................................. 3
1.2 Coverage of this Standard (Applicability) and Limitations on Usage ..................................................... 3
2 REFERENCES .......................................................................................................................................... 5
3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS ..................................................................... 6
4 PROCESS AND PROCESS CONTROL REQUIREMENTS .................................................................... 6
4.1 Condition of the part prior to processing ................................................................................................ 6
4.2 Procedure ............................................................................................................................................... 6
4.2.1 Pretreatment ....................................................................................................................................... 6
4.2.2 Plating process .................................................................................................................................... 7
4.2.3 Hydrogen Embrittlement Relief ........................................................................................................... 7
4.2.4 Passivation .......................................................................................................................................... 7
4.2.5 Post Treatment.................................................................................................................................... 8
4.3 Process control ...................................................................................................................................... 8
4.4 Inspection requirements ......................................................................................................................... 8
4.4.1 Significant Surfaces ............................................................................................................................ 8
4.4.2 Workmanship ...................................................................................................................................... 8
4.4.3 Thickness ............................................................................................................................................ 9
4.4.4 Topcoats and/or Sealers ................................................................................................................... 11
4.4.5 Bolt friction coefficient ....................................................................................................................... 11
4.4.6 Adhesion ........................................................................................................................................... 11
4.4.6.1 Heat/Quench (Heat/Shock) Method ............................................................................................... 11
4.4.6.2 Bend Method (to be adopted only on parts made of thin sheet or tape) ....................................... 12
4.4.7 Hydrogen Embrittlement Test ........................................................................................................... 12
4.4.8 Accelerated Corrosion Resistance .................................................................................................... 12
4.4.9 Dry to Touch ...................................................................................................................................... 13
4.4.10 Condensing Humidity (for topcoats and sealers) ............................................................................ 13
4.4.11 Galvanic Compatibility..................................................................................................................... 13
4.4.12 Tapping Screw Test Protocol .......................................................................................................... 14
4.4.13 Washer Assembly Breakaway Torque ............................................................................................ 14
4.4.14 Fastener Head Fill (For topcoats only)............................................................................................ 14
4.4.15 UV Resistance ................................................................................................................................ 14
4.4.16 Chromium presence ........................................................................................................................ 14
4.5 Re-process ........................................................................................................................................... 14
4.6 Part Maintenance Requirements ......................................................................................................... 14
5 SPECIAL REQUIREMENTS ................................................................................................................... 16
6 QUALITY ................................................................................................................................................. 16
7 TEST EQUIPMENT ................................................................................................................................. 16
7.1 Test Facilities ....................................................................................................................................... 17
7.1.1 Production Laboratory ....................................................................................................................... 17
7.1.2 Quality Laboratory ............................................................................................................................. 17
7.2 Test Equipment .................................................................................................................................... 17
8 APPROVED SOURCE LIST ................................................................................................................... 18
9 DRAWING CALLOUT CROSS-REFERENCE ........................................................................................ 20

COPYRIGHT FCA Italy S.p.A. and FCA US LLC

 FCA Italy S.p.A. Page 3/20
FCA US LLC PS.50036
Change Level: -

1 GENERAL
This standard defines harmonized requirements for all zinc or zinc iron (containing <2% of iron in the
deposit) electroplated components for use by FCA Italy S.p.A. and FCA US LLC.

This document supersedes Fiat Group Procurement Specification 9.57405 and FCA US Process
Standard PS-79, PS-4220<S>, PS-Plating, PS-1207, PS-8814, and PS-10509. Please refer to PS-9295
for duplex coatings.

1.1 Purpose

This coating system is used for enhanced corrosion resistance on ferrous parts, including cast iron,
carbon steel, alloy steel, and fasteners. This standard specifies the plating classification, test methods
and performance requirements for zinc or zinc iron electrodeposits (containing <2% of iron in the deposit)
and the associated passivation coatings and sealers.

1.2 Coverage of this Standard (Applicability) and Limitations on Usage

To comply with the provisions of European Community Directive 2000/53/EC and amendments dated
June 27, 2002, coatings with passivation containing hexavalent chromium salts mentioned in these
Specifications MUST NOT BE USED after July 1, 2006.

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
available designations.

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.

1.2.1 Range of Application

2
These coatings may be used on assorted parts with a tensile strength less than 1500 N/mm or hardness
less than HRc <39. It is not recommended for parts which reach a continuous operating temperature
above 250 °C, or which corrosion products may interfere with normal operation. This coating shall not be
2
used on steel components with tensile strength greater than 1200 N/mm or hardness greater than HRc
32 where failure or premature deterioration affects safety.

Provided that all cosmetic, functional, and performance requirements are met, zinc with alloying element
content less than 2% may be used, e.g. zinc-iron alloy.

1.2.2 Designations for Drawings

Examples of designation for drawings : DOC NO C8 SC2 ST or DOC NO C8 Black LUB DEIDR.

COPYRIGHT FCA Italy S.p.A. and FCA US LLC

 FCA Italy S.p.A. Page 4/20
FCA US LLC PS.50036
Change Level: -

Additional information for these designations can be found in section 4.

Table 1 - Designations for Drawings

Thickness Code (1) Description
C8 Thickness: 8 micrometers (0.00030 inch) minimum
C12 Thickness: 12 micrometers (0.00050 inch) minimum
Passivate (2) Description
No passivates or permanent topcoat.
Plain
Recommended when subsequent processing to a treatment not
compatible with the presence of passivation (e.g. brazing, phosphating)
Clear, blue-bright or colorless hexavalent chromium-free passivation.
SC1
Recommended for use when medium-corrosion resistance is needed and
in zones not directly exposed to weather or high visibility applications.
Thick-layer hexavalent chromium-free iridescent passivation.

SC2 Recommended for use when good corrosion resistance is needed and in
zones having minimal exposure to weather and appearance requirements
(e.g. interior).
Hexavalent chromium-free black passivation followed with a black sealer
Black
or lubricated sealer.
Post Treatment (2) Description
Sealer or topcoat for enhancing corrosion resistance applied over SC2 or
ST
Black passivate on components.
Water-based, lubricant or lubricated sealer applied over SC2 or Black
passivate for enhancing corrosion resistance AND maintaining a
coefficient of friction of 0.10 to 0.16. Typical coating thickness of lubricant
LUB
is below 2 microns. Different friction coefficient values within the
dispersion range of 0.12 to 0.18 may be specified.
Example: (Cf = 0.12 to 0.18).
Color (3) Description
When special coloring is required for identification purposes, the required
color shall be specified. Colors other than black may be specified. The
e.g. Red, Green,
corrosion resistance shall meet the performance required for the relevant
Yellow, or Blue
type.
Example: (DOC NO C8 SC2 LUB Yellow)
Hydrogen
Description
Embrittlement Relief
Process restrictions and thermal treatment to reduce the risk of hydrogen
embrittlement, including conformance testing in accordance with
PS.50023<S> must be followed. Even when not specified, this is a
DEIDR
mandatory requirement for parts with tensile strengths greater than 1040
2
N/mm , hardness greater than HRc 32, or surface hardened parts.
Example: (DOC NO C8 SC2 LUB DEIDR)
NOTE (1): When necessary, a maximum thickness may be specified. Thickness greater than or equal to 12 microns are not
to be specified for fasteners. Other thicknesses may be specified, contact Materials Engineering for
performance requirements.
NOTE (2): In order to comply with the Directive 2000/53/CE all the passivation and sealing treatments used must be free of
hexavalent chromium, cadmium, lead and mercury.
NOTE (3): When special coloring is required for identification purposes, the required color shall be indicated at the end of the
designation
COPYRIGHT FCA Italy S.p.A. and FCA US LLC
 FCA Italy S.p.A. Page 5/20
FCA US LLC PS.50036
Change Level: -

2 REFERENCES

Table 2 - References
Document Number Document Title
Service Classes Assignment of Three Service Classes to Motor Vehicle
00160
Components
9.01102 Supply Quality
9.01103 Product Quality and Conformity Certificate
9.01107 Use Provisions for the I.M.D.S. System
Quality of Supplies Forbidden/Limited Substances or Substances to be
9.01108
Monitored (Annex CK)
7.G0114 Measurement of Friction Coefficient of Bolts. PGE
CS-9003 Regulated Substances and Recyclability
CS-9800 General Information
CS-9801 Quality Requirements
PS-8814 Sealant for Zinc Plated, Passivated Fasteners
PS-10509 Torque Modified Sealant for Zinc Plated, Passivated Fasteners
PS.20001 “TORX” 6-Lobe Internal Recess – Inspection Practice
PS.50023<S> Hydrogen Embrittlement Relief
PS-79 Zinc Plating – Electro-Deposited (see PS-PLATING)
PS-1207 Chromite Type Conversion Coatings For Zinc And Zinc Alloy Coated Parts
AIAG CQI-11 Special Process: Plating System Assessment
ASTM B-117 Standard Practice for Operating Salt Spray (Fog) Apparatus
Standard Test Method for Measurement of Metal and Oxide Coating
ASTM B-487
Thickness by Microscopical Examination of Cross Section
Standard Test Method for Measurement of Coating Thickness by Magnetic
ASTM B-499
Method: Nonmagnetic Coatings on Magnetic Basis Metals
Standard Test Method for Measurement of Thickness of Metallic Coatings
ASTM B-504
by the Coulometric Method
Standard Test Method for Measurement of Coating Thickness by X-Ray
ASTM B-568
Spectrometry
ASTM B-571 Standard Practice for Qualitative Adhesion Testing of Metallic Coatings
Standard Test Method for Attribute Sampling of Metallic and Inorganic
ASTM B-602
Coatings
Standard Guide for Selection of Sampling Plans for Inspection of
ASTM B-697
Electrodeposited Metallic and Inorganic Coatings
Standard Test Method of Variables Sampling of Metallic and Inorganic
ASTM B-762
Coatings
Metallic and Other Inorganic Coatings – Chromate Conversion Coatings on
ISO 3613 Zinc, cadmium, Aluminium-Zinc Alloys, and Zinc-Aluminium Alloys – Test
Methods
SAE/USCAR-1
SAE J2334
SAE J2527

COPYRIGHT FCA Italy S.p.A. and FCA US LLC

 FCA Italy S.p.A. Page 6/20
FCA US LLC PS.50036
Change Level: -

3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS
AIAG : Automotive Industry Action Group.

ASTM : American Society for Testing and Materials.

BIW: Body In White.

C: Celsius (temperature).

F: Fahrenheit (temperature).

HRc: Rockwell Hardness, using Scale C.

mm: Millimeters.

N: Newton.

SAE: Society of Automotive Engineers.

Shift: 8-hours of production.

4 PROCESS AND PROCESS CONTROL REQUIREMENTS

2
High-strength steels having a tensile strength of 1040 to 1500 N/mm , or hardness of HRc 32 to 49, shall
not be specified to thickness greater than 8 micrometers. These parts require a mandatory bake
operation to relieve hydrogen embrittlement in accordance with PS.50023<S>.
2
High-strength steels having a tensile strength greater than 1500 N/mm , or hardness greater than HRc 49
shall not be electroplated.

Approval of the plating process, and any proposed changes shall be obtained from the FCA Materials
Engineering Department.
2
For all machine threaded fasteners or parts with a tensile strength of 1040 to 1500 N/mm , or hardness of
HRc 32 to 49, parts plated in NAFTA MUST be coated by an applicator included in the Engineered
Approved Source List (EASL) located at the end of this standard.

4.1 Condition of the part prior to processing

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.

4.2 Procedure

4.2.1 Pretreatment

The preplate process for components processed per this standard is not defined. Any process that can
be demonstrated to provide parts conforming to the full requirements of this standard is allowed. It is the

COPYRIGHT FCA Italy S.p.A. and FCA US LLC

 FCA Italy S.p.A. Page 7/20
FCA US LLC PS.50036
Change Level: -

supplier’s responsibility to use the appropriate means necessary to ensure acceptable plate coverage,
adhesion, and full compliance to the standard.
2
When processing parts having a tensile strength of 1040 N/mm , or HRc 32 or greater, or have been
surface hardened, the process restrictions to reduce the risk of hydrogen embrittlement must be followed
in accordance with PS.50023<S> Hydrogen Embrittlement Relief.

4.2.2 Plating process

Both acid and alkaline zinc plating processes are covered by this process standard. Parts may be
processed in a barrel or rack plating line. The appropriate system must be chosen to meet the functional
and performance requirements. Zinc-iron systems containing less than 2% iron in the deposit may be
used.

4.2.3 Hydrogen Embrittlement Relief

2
High strength/high hardness steel parts with a tensile strength of 1040 N/mm (HRC 32) or greater, or
parts that have been surface hardened 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 relief temperature within 2 hours after exiting the electroplating bath. The bake
operation may be done after trivalent chromium or chromium-free passivate post dip, provided it shall be
shown that there is no detrimental effect on the corrosion resistance or performance. Any torque
modifying topcoats must be applied after hydrogen embrittlement relief is performed.

Only applicators listed in Table 7 are approved in NAFTA for processing parts requiring hydrogen
embrittlement relief. Other applicators shall not be used.

Table 3 - Hydrogen Relief Requirements

Tensile Stress / Hardness Hydrogen Relief
2
1040 to 1220 N/mm (32 to 36 HRc) 200 +/- 10 degrees C for 4 hours minimum
2
1220 to 1500 N/mm (37 to 49 HRc) 200 +/- 10 degrees C for 8 hours minimum

4.2.4 Passivation

In order to comply with the Directive 2000/53/CE all the passivation treatments used must be free of
hexavalent chromium, cadmium, lead and mercury.

The passivation process will significantly enhance the overall corrosion resistance of the deposit. The
passivate must be formulated for zinc or zinc iron deposits. Slight color iridescence and color variations
are acceptable for clear and blue-bright designations.

Parts requiring a black passivate shall provide a uniform, decorative black appearance that is UV stable.

Iridescence is not allowed for parts requiring a black finish. The parts shall be free from bare spots and
not chip or flake during normal handling.

COPYRIGHT FCA Italy S.p.A. and FCA US LLC

 FCA Italy S.p.A. Page 8/20
FCA US LLC PS.50036
Change Level: -

4.2.5 Post Treatment

The use of topcoats or sealers is recommended to enhance corrosion resistance except when the
properties or performance of the part will be negatively affected, such as torque or electrical conductivity,
on parts that must subsequently be painted, on small blocks reinforcements and bushings intended for
rubber-metal connection.

Topcoats shall be applied over the thick-layer hexavalent chromium-free iridescent passivation. For non-
threaded parts, any of the post treatments that achieve the cosmetic, performance and functional
requirements may be used.

The application of the passivation and lubricant must be applied within the times recommended by the
chemical supplier.

4.3 Process control

Process control analysis and procedures necessary to ensure optimum electroplating process
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
maintaining all records relevant to the plating process. FCA Supplier Quality will verify compliance within
the scope of the PPAP/PSO. These records include :

A. Solution Control Requirements – The control requirements shall be followed with minimum
frequencies to meet the requirements identified in the AIAG’s CQI-11 Process Table A : Zinc & Zinc
Alloy Plating unless otherwise specified by FCA Supplier Quality.
2
If parts are coated having a tensile strength of 1040 N/mm (HRc 32) or greater, the minimum frequencies
to meet the requirements identified in AIAG’s CQI-11 Process Table I: Hydrogen Embrittlement Relief
Bake Process are also required.

B. Process Maintenance Specifications – The maintenance requirements and minimum analytical

frequencies shall be followed to meet the requirements identified on Table 9, unless otherwise
specified by Supplier Quality.

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 and approved by FCA Materials
Engineering and/or FCA US Supplier Quality.

4.4 Inspection requirements

4.4.1 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 20 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.

4.4.2 Workmanship

The plating shall be smooth, adherent, and free of blisters, pits, nodules, roughness, cracks and other
functional defects. Coverage shall be complete and uniform in appearance with respect to the
COPYRIGHT FCA Italy S.p.A. and FCA US LLC
 FCA Italy S.p.A. Page 9/20
FCA US LLC PS.50036
Change Level: -

electroplated deposit. Passivates, topcoats and/or sealers shall completely cover the plated surfaces, be
adherent and dry-to-touch but not powdery. Iridescence in the finish is expected and acceptable for parts
with the clear or blue-bright designation.

4.4.3 Thickness

The plate thickness on all significant surfaces must meet the minimum thickness as specified by the
thickness designation. Unless otherwise specified on the part drawing, significant surfaces are all
surfaces that can be touched by a 20 mm (0.75 in) diameter sphere.

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

- ASTM B487 Microscopic Cross Section.

- ASTM B568 X-Ray Method.

- ASTM B499 Magnetic Method.

- ASTM B504 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.

To insure compliance with the 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 B697, B602, and B762 or equivalents. Control charts and records documenting compliance with
the minimum thickness requirements of this standard shall be prepared and maintained.

A. Minimum Deposit Thickness

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

Table 4 - Coating Thickness

Description Code Thickness Requirement

C8 8 micrometers (0.00030 inch) minimum
C12 12 micrometers (0.00050 inch) minimum

Thickness greater than or equal to 12 microns are not to be specified for fasteners. If it is determined that
other thicknesses are necessary for a particular application, drawing notes shall be used to designate the
required thickness. If no thickness is specified on the drawing, the default is 8 microns minimum. Unless
otherwise specified on drawing, contact Materials Engineering for corrosion performance requirements.

B. Maximum Deposit Thickness

Because of various factors such as the part configuration and type of plating process used, the maximum
thickness values cannot be defined. The maximum thickness must not interfere with the assembly or
performance of the part. When necessary, a maximum thickness may be defined on the print.

COPYRIGHT FCA Italy S.p.A. and FCA US LLC

 FCA Italy S.p.A. Page 10/20
FCA US LLC PS.50036
Change Level: -

C. Coating Build Capability (Part / Rack Mapping)

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
Capability. For barrel or bulk plating processes, a minimum of 5 pieces shall be measured from a single
load. The selected parts shall be checked for thickness at all identified significant surfaces, or as required
by Supplier Quality.

To complete the Coating Build Capability study, the selected part is divided into a grid of square and/or
rectangular sections. Measurement of thickness is made at the center of each grid location. 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.

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
defined in Section 4.4.1 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.

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.

D. Zones for the measurement of the coating thickness of fasteners.

With regard to coating thickness of bolts, if not otherwise specified by the Purchaser, holes, hollows,
threads, and sharp edges are not considered to be significant surfaces. However, the entire head area of
screws and bolts, and the unthreaded shanks of bolts are significant surfaces.

Considering the variability of the electrolytic coating thickness on screws and nuts, the same is measured
on a point significant from the point of view of the corrosion protection rating.

For screws, this point lies approximately at the center of the head surface, the center of the stem end,
and the center of the unthreaded portion of the shaft. (see Figure 1).

For 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 edge and
cross cut or on the side of the hexagon (see Figure 1). Countersunk and cut surfaces are excluded from
the measuring points.

COPYRIGHT FCA Italy S.p.A. and FCA US LLC

 FCA Italy S.p.A. Page 11/20
FCA US LLC PS.50036
Change Level: -

For nuts, thickness is measured on a side of the hexagon and on a support plane (sees Figure 2).

Figure 1 - Measurement locations for bolts or screws

Fig 2 - Measurement locations for nuts

4.4.4 Topcoats and/or Sealers

The use of a topcoat or sealer is recommended on parts other than fasteners, surfaces that will be
welded, or components requiring electrical conductivity. The topcoat or sealer must be dry-to-the-touch
and pass all fluid compatibility requirements for each application. The topcoat or sealer must not
interfere with the assembly or performance of the part. For parts other than fasteners, topcoats do not
require FCA approval. On fasteners and other threaded parts, the use of lubricant or lubricated sealer
for lowering the friction coefficient must be pre-approved.

4.4.5 Bolt friction coefficient

When lubrication is required on fasteners, the bolt frictions coefficients must range between Cf = 0.10 to
0.16, unless otherwise indicated on drawing. If no lubrication is specified, the bolt friction coefficient must
range between Cf = 0.12 to 0.30.

Different values must be specified on drawing. Example : DOC No. C8 SC2 LUB (Cf = 0.12 to 0.18).

The inspection for the correct application of the friction modifiers must be carried out measuring the
friction coefficient as indicated in the Experimentation Standard 7.G0114. Other test methods must be
agreed upon beforehand and approved by FCA Materials Engineering Department.

4.4.6 Adhesion

The deposit shall not peel from itself or from the substrate when tested in accordance with one of the
method described below. Parts shall not exhibit chipping or flaking during normal handling. The
hardened, aged passivate and topcoat and sealer shall be tightly adherent to the zinc or zinc iron
substrate and shall not be removed by ordinary handling.

4.4.6.1 Heat/Quench (Heat/Shock) Method

A. Place the coated part to be tested into a constant temperature chamber for 1 hour at 290 to 310
ºC.
COPYRIGHT FCA Italy S.p.A. and FCA US LLC
 FCA Italy S.p.A. Page 12/20
FCA US LLC PS.50036
Change Level: -

B. Carefully remove the part and immediately immerse in water at room temperature (21 to 25 °C).

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

D. At the end of the test inspect the coating, ensuring there is no sign of swellings, blisters, flaking,
detachment from base metal, etc.

4.4.6.2 Bend Method (to be adopted only on parts made of thin sheet or tape)

A. 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.

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.

4.4.7 Hydrogen Embrittlement Test

The hydrogen embrittlement test is to be performed according to Process Standard PS.50023<S>. This
2
is required for all parts having tensile strength of 1040 N/mm or greater, or hardness of HRc 32 or
greater, or have been surface hardened.

4.4.8 Accelerated Corrosion Resistance

Sample parts shall be dried and aged for a minimum of 24 hours after applying the passivation and/or
lubricant or sealer, prior to exposing them to the test.

Heat soak the parts to be tested in constant temperature ventilated chamber for 1 hour  5 minutes at 150
 5 °C, then condition the parts for minimum 1 hour but no more than 24 hours at room temperature,
followed by testing in accordance with ASTM B117 for the times shown in TABLE 5.

After exposure, White Corrosion 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.

After exposure, Red Rust requirements are met if there is no evidence of base metal corrosion.

The corrosion testing of fasteners must follow the procedure as outlined in SAE/USCAR-1, “Salt Spray
Testing and Evaluation of Fastener Finishes”. 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 (zinc) and red
(base metal) corrosion for the minimum times listed in TABLE 5.

COPYRIGHT FCA Italy S.p.A. and FCA US LLC

 FCA Italy S.p.A. Page 13/20
FCA US LLC PS.50036
Change Level: -

Salt spray corrosion test requirements do not apply to deep recesses, such as small blind holes and the
interior of tubing.

Table 5 - Minimum Salt Spray Test Requirements

All Lubricants, Topcoats or Sealers Must be Pre-Approved For Use on Machine Threaded
Fasteners
Barrel Process Rack Process
Description Hours to Hours to Red Hours to Hours to Red
White Rust Rust White Rust Rust
C8, Plain NA 48 NA 56
C8, SC1 24 72 24 120
C8, SC2 96 168 96 192
C8, (SC2 or Black) ST 120 408 120 456
C8, (SC2 or Black) LUB 120 408 120 456
C12, Plain NA 72 NA 96
C12, SC1 24 168 24 192
C12, SC2 96 240 96 240
C12, (SC2 or Black) ST 120 504 120 480
C12, (SC2 or Black) LUB 120 504 120 480

The salt spray test is only used to test the integrity of the alloy deposit and the effectiveness of the
passivate coating. The hours to white or red rust Shall Not be construed as having any correlation to the
actual service life of the part. Salt spray corrosion testing does not need to be completed prior to
shipment of parts after PPAP approval is granted.

If the test is performed in the FCA US production plant, a 10% reduction in the general performance
requirements of the parts is allowed for barrel processed parts.

4.4.9 Dry to Touch

No visual stain shall be observed on Whatman Paper (Whatman Filter Paper #41) after being squeezed
in the palm of the hand for 5 to 10 seconds.

4.4.10 Condensing Humidity (for topcoats and sealers)

Condensing humidity is performed per ASTM D2247. No loss of adhesion in excess of 1 mm from scribe,
blistering, whitening, discoloration, loss of gloss, or corrosion on significant surfaces away from scribed
lines is allowed.

4.4.11 Galvanic Compatibility

Galvanic compatibility testing to Aluminum (AA 6061) and Stainless Steel (AISI 304) is performed based
on the FCA US 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

COPYRIGHT FCA Italy S.p.A. and FCA US LLC

 FCA Italy S.p.A. Page 14/20
FCA US LLC PS.50036
Change Level: -

vicinity of the coated fastener. For galvanic testing to stainless steel, the coated fastener shall not exhibit
greater than 1% red corrosion.

4.4.12 Tapping Screw Test Protocol

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.

4.4.13 Washer Assembly Breakaway Torque

The torque required to break the washer free from a screw or nut assembly shall be equal to or less than
one half of the fastener thread size, not to exceed 6 Newton-meters.

4.4.14 Fastener Head Fill (For topcoats only)

A recess penetration gage shall enter into the recess at the minimum penetration requirements per
PS.20001 with no more than 10 pounds axial load.

4.4.15 UV Resistance

For black sealers and topcoats only : UV Resistance is performed by Xenon Arc exposure per SAE
J2527 for 2400 kJ using boro/boro filters. Tested parts shall exhibit no loss of adhesion, chalking,
cracking, blistering or significant color changes. Additionally, parts shall be reviewed by the FCA
Engineering or Product Design Office for appearance approval.

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
environment. 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 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.

4.4.16 Chromium presence

Confirm the absence of hexavalent chromium compounds in the coating composition by following the
procedures and using the equipment described in ISO 3613.

4.5 Re-process

Stripping and replating the parts is allowed, provided that the parts are only reprocessed once, and all
requirements are met. Surface hardened parts and/or high strength steel parts with a tensile strength of
2
1040 N/mm or greater, and/or HRC 32 or 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 4.2 within 2 hours after
stripping, prior to replating. If parts need to be reworked more than once, pre-approval from the part
manufacturer and FCA Materials Engineering is required.

4.6 Part Maintenance Requirements

Unless otherwise defined by FCA US Supplier Quality or Engineering, the minimum inspection frequency
described below must be followed.

COPYRIGHT FCA Italy S.p.A. and FCA US LLC

 FCA Italy S.p.A. Page 15/20
FCA US LLC PS.50036
Change Level: -

Table 6 - Product Inspection Requirements

Test Description Requirement Minimum Frequency

Validation, Re-process and

Appearance Every lot
Continual Conformance
Validation, Re-process and
Coating Thickness 5 pieces/shift per part number
Continual Conformance
Validation, Re-process and 5 pieces/shift taken from
Adhesion
Continual Conformance different barrels or racks
Fasteners and small parts (e.g.
springs, washers, clips) :
10 pieces/day representing a
minimum total surface area of
2 2
0.3 dm (0.03 ft )

Rack parts and other barrel

Validation, Re-process and
Salt Spray Resistance plated brackets and stampings :
Continual Conformance
3 pieces/day representing a
minimum total surface area of
2 2
1.0 dm (0.1 ft )

Parts shall be taken from

different barrels or racks from
each process line
Validation and Continual
Hydrogen Embrittlement Every lot
Conformance
Initial Chemical and Applicator
Cyclic Corrosion Validation
Approval
Galvanic Compatibility Validation Initial Chemical Approval
Initial Chemical and Applicator
Handling Resistance Validation
Approval
Initial Chemical and Applicator
Dry To Touch Validation
Approval
Initial Chemical and Applicator
Humidity + Adhesion Validation
Approval
Tapping Screw Test Validation Initial Chemical Approval
Validation and Continual
Washer Assembly Breakaway Every lot
Conformance
Validation and Continual
Head/Recess Fill Every lot
Conformance
Chemical Compatibility Validation Initial Chemical Approval
UV Resistance Validation Initial Chemical Approval
Initial Chemical Approval,
Torque/tension testing Validation
Applicator Approval, and PPAP
COPYRIGHT FCA Italy S.p.A. and FCA US LLC
 FCA Italy S.p.A. Page 16/20
FCA US LLC PS.50036
Change Level: -

Table 6 - Product Inspection Requirements

Test Description Requirement Minimum Frequency

Absence of hexavalent Initial Chemical and Applicator

Validation
chromium Approval

5 SPECIAL REQUIREMENTS
This section defines to part suppliers, Release Engineers, Supplier Quality, and others as necessary the
PPAP/PSO requirements for coatings processed per this standard. These tests, along with the use of
FCA approved substrates, will ensure that a plated part will meet the design intent of the application.

Testing defined in Table 5 attached to this document, must be completed and parts retained as part of
PPAP and Forever Requirement documentation. All testing must be performed by a certified laboratory.

Tested parts must be stored for a minimum of 12 months and provided to Supplier Quality upon request.

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

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

- New Part Supplier.

- New Part/Design.

- New Substrate or Significant Change to Existing Substrate.

- Change in Applicator Facility or Location.

- Change in Technology.

- New Supplier/Source.

Refer to CS-9003 for components produced for vehicles designed in NAFTA markets, or 9.01107 and
9.01108 (Annex CK) for components produced for vehicles designed in EMEA markets.

6 QUALITY
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 and CS-9801 must be met.

For components that will be part of a vehicle designed in EMEA and sold in all markets, the material
characteristics defined by 9.01102 and 9.01103 must be met.

7 TEST EQUIPMENT
All instruments must be certified and maintained in accordance with ISO TS 16949.

COPYRIGHT FCA Italy S.p.A. and FCA US LLC

 FCA Italy S.p.A. Page 17/20
FCA US LLC PS.50036
Change Level: -

The personnel shall be properly trained and qualified.

7.1 Test Facilities

7.1.1 Production Laboratory

There must be a structure with the necessary tools to perform primary controls for the proper analysis and
management of process baths.

- Control instruments for chemicals and waste water (titrator, centrifuges, Atomic Absorption unit,
colorimeter, etc.).

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

- pH meters.

- Hull cells and rectifier.

7.1.2 Quality Laboratory

There must be a structure within the production site equipped with the means to perform the required
inspections described within this standard.

- Visual aspect.

- Thickness.

- AAdhesion.

- CCorrosion resistance.

7.2 Test Equipment

The minimum test equipment must be:

- Optical microscope.

- Thickness tester.

- Oven.

- Salt Spray (Fog) Chamber.

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 US and/or ISO-IEC 17025 certified.

COPYRIGHT FCA Italy S.p.A. and FCA US LLC

 FCA Italy S.p.A. Page 18/20
FCA US LLC PS.50036
Change Level: -

8 APPROVED SOURCE LIST

For components produced in the NAFTA market, applicators listed in Table 7 MUST be used for
processing fasteners, and any parts that have been surface hardened, and with a tensile strength of 1040
2
N/mm or greater, and hardness of HRC 32 or greater.

Potential applicators seeking Engineering Approved Source List approval will be reviewed only after the
applicator has met a FCA Procurement and Supply business case per the requirements defined in CEP-
11916 (EASL Approval Review Process, Electroplated and Inorganic Coatings).

For overseas sourcing, the first-tier part supplier is responsible for all requirements of this standard
including selecting a capable, approved applicator and demonstrating the capability of the selected
applicator to FCA Materials Engineering and Supplier Quality.

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
EASL Update Audit Review within 90 days of notification by FCA US Materials Engineering.

An EASL approved applicator must resubmit for EASL approval if the coating process is changed.

Table 7 - Engineering Applicator Approved Source List – NAFTA

Materials covered by this standard shall only be purchased from those source(s) listed in this table
when processing fasteners or heat treated components.
Supplier Process type Process Description
Acadian Platers Ltd.
315 Rexdale Blvd Acid zinc Barrel
Rexdale, ON M9W 1R8
Acument Industries
2480 Owen Road Acid zinc Barrel
Ferndale, MI 48430
Ajax Metal Processing
4600 Bellevue Ave Acid and alkaline zinc Barrel
Detroit, MI 48209
AMAC Enterprises, Inc.,
5909 W 130th St Acid and alkaline zinc Barrel
Parma, OH 44130
Burbank Plating Services,
13561 Desmond St, Acid zinc Barrel and Rack
Pacoima, CA 91331
Cadon Plating Co.,
3715 Eleventh St Acid zinc Barrel
Wyandotte, MI 48192
Coatings 85 – Plant C
6975 Davand Acid zinc Rack and Barrel
Mississauga, ON L5T 1L5
COPYRIGHT FCA Italy S.p.A. and FCA US LLC
 FCA Italy S.p.A. Page 19/20
FCA US LLC PS.50036
Change Level: -

Table 7 - Engineering Applicator Approved Source List – NAFTA

Materials covered by this standard shall only be purchased from those source(s) listed in this table
when processing fasteners or heat treated components.
Supplier Process type Process Description
Elm Plating Company
1319 Elm Street Acid zinc Barrel
Jackson, MI 49203
Fintex, LLC
8900 Inkster Rd Acid and alkaline zinc Barrel
Romulus, MI 48174
J & M Plating,
4500 Kishwaukee St Acid zinc Barrel
Rockford, IL 61109
Master Mfg.,
4703 Ohara Dr Acid zinc Barrel
Evansville, IN 47711
Modern Plating
701 S Hancock Acid zinc Barrel
Freeport, IL 61032
Morgan Ohare, Inc.,
701 W. Factory Rd Acid Zinc Barrel
Addison, IL 60101
Paulo Products Co.,
1307 Rutledge Way Acid zinc Barrel
Murfreesboro, TN 37129
Protec Finishing Ltd.,
1820 Bonhill Rd Barrel
Acid Zinc
Mississauga, Ont., L5T 1C4
Canada
South Holland Metal Finish.
26100 S Whiting Way Acid Zinc Barrel
Monee, IL 60449
Superior Metal Finishing,
3510 E McNichols Acid zinc Barrel
Detroit, MI 48212
Torcad, Ltd., Toronto,
275 Norseman St Barrel
Acid zinc
Toronto, Ont M8Z 2R5
Canada
Varland Metal Service, Acid and alkaline zinc
Barrel
3231 Fredonia Ave
COPYRIGHT FCA Italy S.p.A. and FCA US LLC
 FCA Italy S.p.A. Page 20/20
FCA US LLC PS.50036
Change Level: -

Table 7 - Engineering Applicator Approved Source List – NAFTA

Materials covered by this standard shall only be purchased from those source(s) listed in this table
when processing fasteners or heat treated components.
Supplier Process type Process Description
Cincinnati, OH 45229
Wolverine Plating Corp
29456 Groesbeck Hwy Acid zinc Barrel
Roseville, MI 48066

9 DRAWING CALLOUT CROSS-REFERENCE

Table 8 - Drawing Callout Cross Reference

Equivalent Callout
Equivalent Callout
Drawing Callout Per FCA Italy Specification
Per FCA US Specification (2)
9.57405 (1), (2)
C8, Plain Fe/Zn 7 I PS-79 Code 30
C8, SC1 Fe/Zn 7 II PS-79 Code 30, PS-1207 SC1
C8, SC2 Fe/Zn 7 IV PS-79 Code 30, PS-1207 SC2
PS-79 Code 30, PS-1207, PS-
C8, SC2, ST Fe/Zn 7 IV S
8814
Fe/Zn 7 IV SB PS-79 Code 30, PS-1207, PS-
C8, SC2, LUB
Fe/Zn 7 IV LUB 10509
Fe/Zn 7 VII S
C8, Black, ST PS-79 Code 30, PS-1207 Black
Fe/Zn 7 VII ST
C12, Plain Fe/Zn 12 I PS-79 Code 50
C12, SC1 Fe/Zn 7 II PS-79 Code 50, PS-1207 SC1
C12, SC2 Fe/Zn 12 IV PS-79 Code 50, PS-1207 SC2
C12, SC2, ST Fe/Zn 12 IV S PS-79 Code 50, PS-1207, PS-
8814
C12, SC2, LUB N/A PS-79 Code 50, PS-1207, PS-
10509
Fe/Zn 12 VII S
C12, Black, ST PS-79 Code 50, PS-1207 Black
Fe/Zn 12 VII ST
NOTE 1: Parts formerly requiring 7 microns minimum shall be increased to 8 microns minimum.
NOTE 2: For specifications requiring PS-4220<S>, or any parts with a tensile strength greater than 1040 N/mm 2, Rockwell
hardness of HRC 32 or greater, or parts that have been surface hardened, DEIDR suffix shall be used,
requirements defined in PS.50023<S> must be followed, and an applicator included in Table 7 when processing
parts in NAFTA shall be used.

COPYRIGHT FCA Italy S.p.A. and FCA US LLC