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PEM® REF/ SURFACE FINISHING SHEET METAL ASSEMBLIES

SUBJECT: SURFACE FINISHING SHEET METAL ASSEMBLIES WITH

SELF-CLINCHING FASTENERS

Introduction
Steel and aluminum panels in assemblies often will undergo surface finishing for reasons ranging
from cosmetics to performance, while stainless steel panels may require passivation. For any
assembly subject to surface finishing and requiring self-clinching hardware, a central question will
arise: How and when should a metal panel be surface finished without degrading the installed
performance of the self-clinching fasteners? A basic understanding about self-clinching fastener
technology and the issues associated with surface finishing can help guide the way toward best
practices.

In the discussion following, we will use the terms “assembly/assemblies” to mean panels and/or
chassis with self-clinching fasteners already installed (unless noted otherwise.)

Basics of Self-clinching

Figure 1
Self-clinching fasteners provide permanent and reusable
load-bearing threads in thin metal sheets and historically
have been specified in sheet metal too thin to allow for
secure fastening by any other method. Upon installation
(usually during the fabrication process), they become
integral parts of an assembly, will not loosen or fall out
(even when the mating thread is removed), and never
have to be restrained from rotation with a tool. Clinching
of these fasteners is enabled by a non-round displacer
feature, which embeds into the host panel and displaces
panel material into the fastener’s undercut. (See Figure 1.)

This results in the fastener’s permanent attachment in a panel with the capability to withstand
rotation (because of the non-round displacer) and axial force (because of the displaced panel
material in the undercut). Panels must always be sufficiently ductile to cold flow without
fracturing and fasteners must always be sufficiently harder than the panel to prevent fastener
deformation, even as the panel is deformed during the installation process.

Although it is always preferable to avoid surface finishing an assembly after self-clinching

fasteners have been installed, sometimes this approach may be necessary.

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Reasons why Assemblies may need to be Surface Finished

The first reasons involve the cosmetics / performance of the final assembly. These
include:

• Concern for scratching or otherwise damaging a finished panel during installation handling.

•A
 desire to achieve the same color and texture on both the panel and the fasteners. When zinc
plated (with clear chromate) fasteners are installed into a panel that has been zinc plated and
clear chromated there is often a slight color variation because it is likely that both were not
plated in the same process.

•A
 chieving surface properties on the fastener that are not present with the standard fastener
finish. These may include low light reflectance, color fastness and “non-stick” properties for
clean room applications.

A second group of reasons for needing to finish an assembly involves surface treatments on the
panel that are detrimental to the self-clinching process if performed before fastener installation.
These are less common and include:

•H
 ard-coat anodizing of aluminum panels and nitriding of steel panels. These panel treatments
increase the hardness and decrease the ductility of a panel’s surface - making the panel surface
more resistant to the cold flow required during installation of a self-clinching fastener.

•P
 owder coating a panel too, becomes an issue because the typical coating thickness prevents
full installation of the displacer feature on the fastener. In essence the fastener will “clinch” in to
the coating and not into the metal.

•T
 hin brittle platings such as hardened electroless nickel will also prove problematic. These
platings can crack and/or flake off from the severe deformation they must undergo during
fastener installation.

•T
 hick hot dip galvanizing will likely exhibit some of both the hard panel and brittle plating issues
discussed here.

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Hazards of Surface Finishing Assemblies

Now let’s examine the potential hazards involved in finishing a panel or chassis that
already has fasteners installed.

Since most surface finishing processes are wet processes, we will focus our discussion in this area.

There are three primary types of these hazards:

• The first hazard: Fastener damage from an incompatible finishing process.

An extreme example is installing a steel fastener into an aluminum panel and then anodizing the
assembly. The anodizing solution will almost totally destroy the steel fastener.

Sometimes the incompatibility will be less obvious. A frequently reported issue involves zinc
plating a steel panel with steel fasteners installed. Since both are steel a typical presumption is
that a plating process appropriate for the panel is also appropriate for the fasteners. This may not
be the case. Steel panels are typically low carbon steel in a slightly work hardened condition –
generically cold rolled steel. Because self-clinching fasteners must be harder (typically by about
20 points on the HRB or HRC scale) than the host panel, most steel fasteners are heat treated.

Important to note here is that fasteners can be produced using either heading/forming or
machining processes.

Fasteners produced by heading or forming are low carbon steel that have been neutral hardened
(aka through hardened) and generally are not difficult to electroplate.

However, steel fasteners produced by a machining process are typically low carbon free
machining (re-sulfurized and re-phosphorized) leaded steel which has been carburized (or case
hardened). Typically, this will cause high carbon and numerous inclusions on the fastener surface.
As a result these fasteners may experience degradation during a pre-treatment that is designed
solely for cold rolled steel. The fasteners may also be susceptible to hydrogen embrittlement
from exposure to atomic hydrogen during acid cleaning or electroplating. Another example
of an incompatible process is a panel treatment such as nitriding whose temperatures may be
detrimental to the fasteners.

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• The second hazard: Unique to wet processing it involves trapped caustic solutions.

Figure 2

The fastener-to-panel connection is all metal and

may not always be liquid tight. Although this
joint may be water tight in the classic sense of
preventing liquid from passing through, there are
almost always crevices, particularly on the shank
side of the fastener which can trap processing
solutions. A typical example is a self-clinching
standoff. (Note the crevice beyond the fastener
head as shown in Figure 2)

When processing solutions become trapped, troubles follow. If the solution is caustic, the solution
will continue to attack the surrounding metal which can degrade the strength of the clinch
connection and/or cause a cosmetic problem on the surface of the panel and/or the fastener.
Even if effective rinsing renders any trapped solutions non-caustic, their entrapment under the
finish can flash to steam -- causing the plating to bubble if the assembly is subsequently heated
above the boiling point of the trapped liquid.

• The third hazard: Tight threads from excessive plating build up in the threads.

This plating buildup effect will cause “tight” or non-gageable threads. Most self-clinching fastener
manufacturers produce threads in their steel parts with the appropriate allowance to accept the
plating thickness that is provided as standard. Common plating thickness is a minimum of .0002
inch (5 microns) which allows for a maximum plating thickness of .0004 inch (10 microns). But
this value should always be confirmed with the fastener manufacturer and never assumed. Even
if the allowance is known, plating an assembly can still present pitfalls. If the fasteners were
previously plated, the plating must be completely stripped from the threads in order for the
original allowance to be available for the re-plating. It is also important to note that stainless
steel and aluminum fasteners typically have no thread allowance for any type of additive plating
or coating.

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Table I
Commonly Cited Reasons For
Alternative Techniques Allowing
Surface Finishing a Panel Only
For Panel Finishing
After Self Clinching Fasteners
Before Fastener Installation
Have Been Installed
Mitigate potential for panel damage by breaking sharp edges on
all contact tooling (installation punches and anvils) and covering or
To avoid damaging panel finish during
radiusing all corners and edges of fastener feed tooling. Develop
fastener installation
procedures for operating handling of panels.
Choose a more damage resistant panel finish
To achieve same appearance on panel Ask the surface finisher who plates the panel to match the fastener.
and fasteners. Concern over variations Purchase unplated fasteners and have them plated by the panel surface
in hue between zinc plated panels and finisher.
zinc plated fasteners is common. Ask the fastener manufacturer to match the plating on the panel.
To achieve a special purpose finish
Ask the fastener manufacturer to supply the special purpose finish.
on the fastener. An example is a
very specific color definition associated Purchase unplated fasteners and have the special-purpose finish applied
with a product brand. by the panel surface finisher.
Mask the mounting hole ID and an annular ring around it on the side
Surface finish will make the outer surface from which the fastener will be installed.
of the panel too hard and/or too brittle If high hardness is the only issue, check with fastener manufacturer
for self-clinching. Examples include about purchasing a higher hardness fastener.
hard coat anodizing of aluminum panels Consider alternate means of fastener captivation, such as broaching
or nitriding or other surface hardening instead of self-clinching.
of steel panels. If fastener is a nut which does not need to be flush on the shank side, a
blind threaded insert can be used.
Additive coating is too thick to allow full Mask the mounting hole ID and an annular ring around it on the side
installation of the displacer component of from which the fastener will be installed.
The self-clinching fastener. Examples Purchase a special self-clinching fastener with an intentionally oversized
include powder coating or very thick paint. displacer height.
Mask the mounting hole ID and an annular ring around it on the side
Additive plating or coating is too brittle to from which the fastener will be installed.
deform without fracturing during fastener
Thermally treat the coating to increase ductility.
installation. Hardened electroless nickel
plating is one example. Choose a more ductile coating with similar corrosion resistance and
appearance.

Table 1 – outlines alternative techniques to installing fasteners before finishing.

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Guidance for Mitigating the Hazards

When valid reasons to surface finish an assembly and none of the avoidance techniques
(see Table I) are feasible there are ways to plate an assembly successfully with self-
clinching hardware already installed. While some issues may arise, the following guidelines can
help optimize outcomes.

• Anodizing or Conversion Coating Aluminum Panel Assemblies

For non-heat treatable aluminum alloy panels such as 5052, aluminum fasteners, (which are
always made from a heat treatable aluminum alloy) can be used. In these cases, the entire
assembly can be anodized or given a conversion coating.

Typically there are no major issues with assemblies processed in this manner as long as rinsing
is adequate to eliminate potentially trapped caustic solutions. It should be noted that when
aluminum assemblies are clear anodized, the fasteners may have a slightly different appearance
(usually darker) after anodizing due to the alloying elements present in the fasteners. Common
alloys for aluminum fasteners are 2024 in the T4 condition and 7075 in the T6 condition.
Although marginal on strength for clinching, 6061-T6 is used for some aluminum fastener
components not containing the clinch feature.

Panels made from heat treatable aluminum alloys in the hardened condition are typically too
hard for aluminum fasteners which have a maximum panel hardness limit of HRB 50. As a result
300 Series stainless fasteners are often specified. When this is the case, the assembly cannot be
anodized, but a conversion coating can be applied. Experience has shown that the conversion
coating process may need to be adjusted slightly to keep the stainless fasteners from darkening.
Darkening of the 300 series fasteners is most common with machined fasteners using type 303
(UNS S30300) which has high sulfur content for improved machinability. The high sulfur content
reduces corrosion resistance and makes this alloy more susceptible to darkening. The adjustment
will involve making the acid etch step (prior to the actual chromate conversion step) less
aggressive.

• Electroplating Steel Panel Assemblies.

The most common practice with steel panels is to use steel fasteners and the most common
surface finish on steel panels is zinc electroplating. However, these recommendations are also
applicable to electroplating with other increasingly popular metals or alloys such as zinc-nickel or
tin-zinc. The lowest risk procedure will be to plate the panel first and then install plated fasteners.

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When this can not be done, the second lowest risk procedure is to purchase unplated
steel fasteners, install them and then plate the assembly. This eliminates the need to
strip the zinc plating from the fasteners which could potentially damage the surface of
the fastener. Unfortunately unplated fasteners are typically not stocked and therefore their use
requires appropriate planning, but does have the benefit of not needing to strip the fasteners.

When plated fasteners are used, extreme care must be used in stripping the plating from them.
Case hardened fasteners are particularly susceptible to acid damage during stripping because
of the high carbon content of their surface. A contributing factor is that many inhibitors used
in acids are much less effective in preventing attack of high carbon steels than they are in
preventing attack of low carbon steels, such as the typical cold rolled steel panel. Through- or
neutral-hardened fasteners are only slightly more susceptible to acid attack than cold rolled steel
and, generally are not damaged by acid during stripping and re-plating an assembly.

All case hardened parts and high hardness through hardened parts are susceptible to hydrogen
embrittlement and should be appropriately baked after plating, unless it can be established
with certainty that a particular plating process is not embrittling to a particular fastener.
Fasteners used in tension, such as a self-clinching stud in a critical application, should always
be appropriately baked for hydrogen relief if the hardness is at or above the value at which the
applicable plating standard requires baking. (The fastener manufacturer can be consulted for
fastener hardness values to determine the need for baking and the appropriate baking process
parameters.)

Although less common, 300 series stainless steels are sometimes used in steel panels. Because
the process needed to electroplate 300 series stainless steel is so different from the process
for plating a carbon steel panel, attempts to plate an assembly of a steel panel with 300 series
stainless steel fasteners are rarely - if ever - successful. (The most common problem is poor
plating adhesion on the fasteners.)

Adequate rinsing is the best way to manage the hazard of trapped solutions. In some cases a
neutralizing soak is the most effective way to ensure that any retained solution is not caustic.
Many assemblies are rack plated and the orientation of the fastener is important. Shank down is
the preferred orientation and shank up is the worst orientation. Some fasteners with complicated
geometry are made from alloy steel powdered metal and are particular susceptible to retained
solutions because of the porosity of the base metal. A porosity sealant is typically used and
alleviates this problem, but may not totally eliminate it.

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• Passivating Stainless Steel Panel Assemblies.

An important consideration in passivating stainless steel assemblies is choosing a

passivation process that is appropriate for both the panel alloy and the fastener alloy. The most
common stainless steel panel alloy is type 304, with type 316 also used, but less frequently.
Because of the required differential hardness, self-clinching fasteners used in type 304 or 316
panel will not be 300 series. When corrosion resistance is not a controlling requirement, fasteners
from type 410 or type 416 stainless steel offer a cost effective solution. When greater corrosion
resistance is needed a precipitation hardening grade such as 17-4 (UNS S17400) or A286 (UNS
S66286) will be used for the fastener. Regardless, if an assembly must be passivated the fastener
manufacturer should be consulted for the exact alloy of the fastener for proper guidance relative
to industry standards. As an example, SAE AMS 2700 can be used to find a passivation process
valid for both the panel alloy and the fastener alloy. Table 4 of AMS 2700 shows that method 1
(Nitric Acid) types 1, 2, or 3 are applicable to any combination of 304 or 316 panel and 410, 416,
17-4 or A286 fastener. Note that method 1 type 6 although applicable to and commonly used for
type 304, is not applicable to any of the above fastener alloys and therefore should not be used
for an assembly.

• Paint or Powder Coating Assemblies (Any Material).

With the possible exception of very thin paint, paint or powder coatings are too thick for the
standard thread allowance of self-clinching fasteners. Therefore threads should be masked
prior to painting or powder coating an assembly. In some cases fasteners can be ordered
with mask pre-applied from the manufacturer. For example PEM® Blu-Coat™ is available from
PennEngineering for this purpose. Other options include plugs and caps specifically designed for
this purpose to mask internal and external threads respectively. Both are commercially available
in a variety of sizes suited for thread masking. However, masking with caps and plugs can
create multiple crevices for entrapping solutions if they are applied before any wet process pre
treatment step. Ideally they should be applied after any wet processing. (A heavy layer of grease
applied to the threads can also serve as an effective mask, but the grease must be capable of
surviving the pretreatment or be applied after pretreatment.)

Trapped solutions from wet process pretreatment represent a real concern. Even if effectively
neutralized to be non-caustic, if they remain in a crevice or metal pore and the paint or powder
coating is applied over them, there is a risk of their flashing to steam during a subsequent heating
process, especially during the curing cycle for powder coating. Flashing to steam causes volume
expansion which can cause the coating to bubble and burst, leaving a blemished surface. The risk
can be mitigated by hot air drying between pretreatment and painting or powder coating.

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Another item to check is the effect of the paint or powder coating curing temperature
on the strength of the fastener. Generally this is not a problem with heat treated steel
fasteners as most can withstand at least 600°F with no permanent reduction in strength.
Type 410 and 416 stainless steel fasteners are most susceptible in this regard and could begin
to see a permanent reduction in strength if exposed to temperatures over 300°F (150°C). 300
series stainless steels and precipitation hardening stainless steels used for fasteners are even more
robust in this regard – typically not seeing any permanent strength reduction unless exposed
to over 900°F (482°C). If the curing cycle (time and temperature) is supplied to the fastener
manufacturer they should be able to comment on any strength reduction effect it will have on
their fastener.

• Nitriding Ferrous Panel Assemblies

Steel and stainless steel or any other ferrous metal panel can be nitrided. Although nitriding is
actually a form of case hardening it is sometimes used as a means of applying a durable black
surface finish.

Nitriding is a specialized form of heat treatment performed mostly by highly specialized

shops. When the need arises to nitride an assembly, the fastener manufacturer should first be
consulted for the fastener alloy and heat treatment. That information should then be provided
to the nitriding shop (along with the panel alloy to determine if there is a process that will be
compatible with both alloys).

If the alloys exhibit significantly different carbon content, the difference in critical temperatures
may be a problem. The effect of nitriding on corrosion resistance of some stainless steel fastener
materials also needs to be evaluated. Similarly, the effect of nitriding on the ductility of any
ferrous fastener material should always be evaluated, as it typically has a negative effect.

In conclusion
While finishing a panel before installing self-clinching fasteners will always be the preferred
process, these guidelines can help reduce inherent risks. There are many combinations of panel
material, fastener material, and surface finish – even more than outlined here. Ultimately, the best
practice is to consult the fastener manufacturer to ascertain the specific details on the fastener
material and seek expert advice about the particular combination of finish and fastener, based on
real-world experience. Surface finishers, too, can serve as key sources for technical information
and relevant guidance.

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Summary / Index of Panel and Fastener Combinations for Assembly Finishing

Fastener Material
Panel Material and Finish
400 Series
300 Series
Aluminum Steel & PH
Stainless Steel
Stainless Steel

Aluminum/Conversion Coated See page 6 See page 6

Aluminum/Anodized See page 6

Steel/Electroplated See page 6

Steel/Powder coated or painted See page 8 See page 8

Steel/Nitrided See page 9 See page 9

300 Series Stainless Steel/

See page 8
Passivated

Color Key: Can be plated as an assembly

with caution – see listed page

Not a compatible combination
for self-clinching

Not a compatible combination
for finishing as an assembly

Not a cost effective combination
- seldom if ever done

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