MARCHIARO GIANCARLO - giancarlo.marchiaro@crf.

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PS.50036

ZINC ELECTROPLATED COATINGS

Process Standard
TRESS KIM - [email protected]

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Date: 27-NOV-2018

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GLOBALLY HARMONIZED DOCUMENT
Co-Author

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Author

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FCA ITALY -- GROUP MATERIALS LABS (CRF) - SURFACE TREATMENTS & AN ...

Change level Date Description of change

Initial release. This document supersedes FCA Italy Procurement
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- 12-DEC-2015 Specification 9.57405 and FCA US Process Standard PS.50036,

PS.50023, PS-Plating, PS-1207, PS-8814, and PS-10509
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Add C4 thickness option,

Add default callouts,
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New section: fastener gaging requirements

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Quality requirements clarified

Update Corrosion Resistance table
Update Approved Source List
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FCA US -- ORGANIC MATERIALS - 5840

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For Information, please contact the following references:

01

Region Surname Name Phone number / Department

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e-mail address
Group Materials Labs (CRF)
03

EMEA
390110033033
Giancarlo Marchiaro - Surface Treatments & Anti-
[email protected]
Corrosion
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248-512-442
NAFTA Kim Tress Organic Materials
[email protected]
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Frederico De Almeida 55 3121233806 Vehicle Concept &

LATAM
Mendes [email protected] Integration
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86 212-351-6807 Vehicle Concept &

APAC China Henry Yang Jinkui
[email protected] Integration
91 203-018-4520 Vehicle Concept &
Co-Author Department

APAC India Avinash Thopte

[email protected] Integration
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 THE RELEVANT FCA COMPANY.
IN CASE OF DISPUTE, THE ONLY VALID REFERENCE IS THE ENGLISH EDITION
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PS.50036
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ZINC ELECTRODEPOSITED COATINGS

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TABLE OF CONTENTS

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

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

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1.2 Coverage of this Standard (Applicability) and Limitations on Usage ..................................................... 4

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1.2.1 Range of Application ........................................................................................................................... 4
1.2.2 Designations for Drawings .................................................................................................................. 4

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2 REFERENCES .......................................................................................................................................... 6
3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS ..................................................................... 7

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4 PROCESS AND PROCESS CONTROL REQUIREMENTS*** ................................................................ 7
4.1 Condition of the part prior to processing ................................................................................................ 7

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4.2 Procedure ............................................................................................................................................... 7
4.2.1 Pretreatment ....................................................................................................................................... 7
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4.2.2 Plating process .................................................................................................................................... 8
4.2.3 Hydrogen Embrittlement Relief ........................................................................................................... 8
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4.2.4 Passivation .......................................................................................................................................... 8

4.2.5 Post Treatment.................................................................................................................................... 8
4.3 Process control ...................................................................................................................................... 9
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4.4 Inspection requirements ......................................................................................................................... 9

4.4.1 Significant Surfaces*** ........................................................................................................................ 9
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4.4.2 Workmanship ...................................................................................................................................... 9

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4.4.3 Thickness*** ...................................................................................................................................... 10

4.4.4 Topcoats and/or Sealers ................................................................................................................... 12
4.4.5 Fastener friction coefficient ............................................................................................................... 12
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4.4.6 Adhesion*** ....................................................................................................................................... 12

4.4.6.1 Heat/Quench (Heat/Shock) Method***........................................................................................... 12
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4.4.6.2 Bend Method (to be adopted only on parts made of thin sheet or tape) ....................................... 13
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4.4.7 Hydrogen Embrittlement Test*** ....................................................................................................... 13

4.4.8 Accelerated Corrosion Resistance*** ............................................................................................... 13
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4.4.9 Dry to Touch ...................................................................................................................................... 14

4.4.10 Condensing Humidity (for topcoats and sealers)*** ........................................................................ 14
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4.4.11 Galvanic Compatibility..................................................................................................................... 14

4.4.12 Tapping Screw Test Protocol .......................................................................................................... 14
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4.4.13 Washer Assembly Breakaway Torque ............................................................................................ 15

4.4.14 Fastener Head Fill (For topcoats only)............................................................................................ 15
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4.4.15 UV Resistance*** ............................................................................................................................ 15

4.4.16 Chromium presence ........................................................................................................................ 15
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4.4.17 Material Gaging for Parts with Threads*** ...................................................................................... 15

4.5 Re-process*** ....................................................................................................................................... 15
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4.6 Part Maintenance Requirements*** ..................................................................................................... 16

5 SPECIAL REQUIREMENTS ................................................................................................................... 17
5.1 Process Validation ............................................................................................................................... 17
5.2 Supplier Approval*** ............................................................................................................................. 18
5.3 Supplier Product Inspection*** ............................................................................................................. 18
5.4 Material Quality*** ................................................................................................................................ 18
5.5 Field Performance***............................................................................................................................ 18
5.6 Forever Requirements*** ..................................................................................................................... 18
5.7 Non-Conforming Material*** ................................................................................................................. 19
6 QUALITY ................................................................................................................................................. 19
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PS.50036
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7 TEST EQUIPMENT ................................................................................................................................. 19

7.1 Test Facilities ....................................................................................................................................... 19
7.1.1 Production Laboratory ....................................................................................................................... 19

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7.1.2 Quality Laboratory ............................................................................................................................. 19
7.2 Test Equipment .................................................................................................................................... 20

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8 APPROVED SOURCE LIST ................................................................................................................... 20
9 DRAWING CALLOUT CROSS-REFERENCE ........................................................................................ 22

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PS.50036
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1 GENERAL

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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.

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This document supersedes FCA Italy Procurement Specification 9.57405 and FCA US Process Standard

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PS.50036, PS.50023, PS-Plating, PS-1207, PS-8814, and PS-10509.

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Please refer to PS-9295 for duplex coatings.

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1.1 Purpose

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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

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and performance requirements for zinc or zinc iron electrodeposits (containing <2% of iron in the deposit)
and the associated passivation coatings and sealers.
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1.2 Coverage of this Standard (Applicability) and Limitations on Usage
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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
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Specifications MUST NOT BE USED after July 1, 2006.

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Because this standard covers more than one finish, the abbreviated description must be added as a suffix
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after the process standard number to designate the specific system. Table 1 provides a list of the
available designations.
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Specific requirements shown on the part drawing shall take precedence over related requirements
specified in this standard, or may be in addition to the requirements of this standard.
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1.2.1 Range of Application

These coatings may be used on assorted parts with a tensile strength less than 1500 N/mm2 or hardness
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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
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used on steel components with tensile strength greater than 1200 N/mm2 or hardness greater than HRc
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32 where failure or premature deterioration affects safety.

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

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1.2.2 Designations for Drawings

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Examples of designation for drawings PS.50036 C8 SC2 ST or PS.50036 C8 Black LUB DEIDR.
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PS.50036
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Additional information for these designations can be found in section 4.

Table 1 - Designations for Drawings (4)***

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Thickness Code (1) Description

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C4 Thickness: 4 micrometers (0.00015 inch) minimum
C8 Thickness: 8 micrometers (0.00030 inch) minimum
C12 Thickness: 12 micrometers (0.00050 inch) minimum

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Passivate (2) Description

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No passivates or permanent topcoat. A temporary rust preventative may

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be applied to protect parts from corrosion during transit. The rust
preventative must not interfere with the subsequent processing.
Plain

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Recommended when subsequent processing to a treatment not

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compatible with the presence of passivation (e.g. brazing, phosphating)

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Clear, blue-bright or colorless hexavalent chromium-free passivation.
SC1
Recommended for use when medium-corrosion resistance is needed and
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in zones not directly exposed to weather or high visibility applications.
Thick-layer hexavalent chromium-free iridescent passivation providing
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enhanced corrosion protection.

SC2
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Recommended for use when good corrosion resistance is needed and in

zones having minimal exposure to weather and appearance requirements
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(e.g. interior).
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Hexavalent chromium-free black passivation followed with a black sealer

Black
or lubricated sealer.
Post Treatment (2) Description
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Sealer or topcoat for enhancing corrosion resistance applied over SC2 or

ST
Black passivate on components.
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Water-based, lubricant or lubricated sealer applied over SC2 or Black

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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.
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Different friction coefficient values within the dispersion range of 0.12 to

0.18 may be specified. Example: (COF = 0.12 to 0.18).
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Color (3) Description

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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
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Yellow, or Blue
type.
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Example: (PS.500036 C8 SC2 LUB Yellow)

Hydrogen
Description
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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.
DEIDR Even when not specified, this is a mandatory requirement for parts with
tensile strengths greater than 1040 N/mm 2, hardness greater than HRc
32, or surface hardened parts.
Example: (PS.500036 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
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PS.50036
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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.

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NOTE (3): When special coloring is required for identification purposes, the required color shall be indicated at the end of the
designation.
NOTE (4): If a designation is not specified, the default thickess shall be C8 (8 microns minimum), with passivation SC2 (thick

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layer passivation). Refer to section 4.2.5 for the use of topcoats or sealers.

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2 REFERENCES

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Table 2 - References
Document Number Document Title

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Service Classes Assignment of Three Service Classes to Motor Vehicle
00160

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Components
9.01102 Supply Quality

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9.01103 Product Quality and Conformity Certificate
7.G0114 Measurement of Friction Coefficient of Bolts. PGE
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CEP.00036 EASL Approval Review Process, Electroplated and Inorganic Coatings
CS-9003 Regulated Substances and Recyclability
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CS-9800 General Information

PS-8814 Sealant for Zinc Plated, Passivated Fasteners
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PS-10509 Torque Modified Sealant for Zinc Plated, Passivated Fasteners

PS.20001 “TORX” 6-Lobe Internal Recess – Inspection Practice
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PS.50023<S> Hydrogen Embrittlement Relief

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PS.50036 ZINC Electrodeposited Coatings

PS-1207 Chromite Type Conversion Coatings For Zinc And Zinc Alloy Coated Parts
AIAG CQI-11 Special Process: Plating System Assessment
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ASTM B-117 Standard Practice for Operating Salt Spray (Fog) Apparatus
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Standard Test Method for Measurement of Metal and Oxide Coating

ASTM B-487
Thickness by Microscopical Examination of Cross Section
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Standard Test Method for Measurement of Coating Thickness by Magnetic

ASTM B-499
Method: Nonmagnetic Coatings on Magnetic Basis Metals
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Standard Test Method for Measurement of Thickness of Metallic Coatings

ASTM B-504
by the Coulometric Method
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Standard Test Method for Measurement of Coating Thickness by X-Ray

ASTM B-568
Spectrometry
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ASTM B-571 Standard Practice for Qualitative Adhesion Testing of Metallic Coatings
Standard Test Method for Attribute Sampling of Metallic and Inorganic
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ASTM B-602
Coatings
Standard Guide for Selection of Sampling Plans for Inspection of
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ASTM B-697
Electrodeposited Metallic and Inorganic Coatings
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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 Salt Spray Testing and Evaluation of Fastener Finishes
SAE J2334 Laboratory Cyclic Corrosion Test
Performance Based Standard For Accelerated Exposure of Automotive
SAE J2527
Exterior Materials Using a Controlled Irradiance Xenon-Arc Apparatus
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PS.50036
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3 DEFINITIONS/ABBREVIATIONS/ACRONYMS/SYMBOLS

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AIAG : Automotive Industry Action Group.
ASTM : American Society for Testing and Materials.

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BIW: Body In White.
C: Celsius (temperature).

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F: Fahrenheit (temperature).

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HRc: Rockwell Hardness, using Scale C.
mm: Millimeters.

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N: Newton.
SAE: Society of Automotive Engineers.

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Shift: 8-hours of production.

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4 PROCESS AND PROCESS CONTROL REQUIREMENTS***
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High-strength steels having a tensile strength of 1040 to 1500 N/mm2, or hardness of HRc 32 to 49, shall
not be specified to thickness greater than 8 micrometers. These parts require a mandatory bake
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operation to relieve hydrogen embrittlement in accordance with PS.50023<S>.

High-strength steels having a tensile strength greater than 1500 N/mm 2, or hardness greater than HRc 49
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shall not be electroplated.

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

For all machine threaded fasteners, or parts with a tensile strength of 1040 to 1500 N/mm 2, or hardness
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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. For other regions, the local FCA
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Materials or FCA Supplier Quality Engineer shall provide approval.

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4.1 Condition of the part prior to processing

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

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4.2 Procedure
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4.2.1 Pretreatment
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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
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supplier’s responsibility to use the appropriate means necessary to ensure acceptable plate coverage,
adhesion, and full compliance to the standard.

When processing parts having a tensile strength of 1040 N/mm 2, 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.
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PS.50036
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4.2.2 Plating process

Both acid and alkaline zinc plating processes are covered by this process standard. Parts may be

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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

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used.

4.2.3 Hydrogen Embrittlement Relief

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High strength/high hardness steel parts with a tensile strength of 1040 N/mm 2 (HRC 32) or greater, or

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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 2 hours

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after exiting the electroplating bath. The bake operation may be done after trivalent chromium or

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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

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embrittlement relief is performed.

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Only applicators listed in Table 6 are approved in NAFTA for processing parts requiring hydrogen
embrittlement relief. Other applicators shall not be used.
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4.2.4 Passivation
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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.
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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.
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Parts requiring a black passivate shall provide a uniform, decorative black appearance that is UV stable.
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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.
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4.2.5 Post Treatment

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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,
on parts that must subsequently be painted, on small blocks reinforcements and bushings intended for
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rubber-metal connection.
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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
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requirements may be used.

The application of the passivation and lubricant must be applied within the times recommended by the
chemical supplier.
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PS.50036
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4.3 Process control

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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

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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

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the scope of the PPAP/PPA. These records include :

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A. Solution Control Requirements – Unless otherwise specified by FCA Supplier Quality Control, the

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control requirements shall be followed with minimum frequencies to meet the requirements identified
in the AIAG’s CQI-11 Process Table: Zinc & Zinc Alloy Plating.

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If parts are coated having a tensile strength of 1040 N/mm 2 (HRc 32) or greater, the pyrometry
requirements (e.g. oven controls for hydrogen embrittlement relief) identified in AIAG’s CQI-11 are

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also required.
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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.
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Process Control targets and ranges shall be established by the processor and material supplier(s) and
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documented on the Control Plan. Any changes must be documented and approved by FCA Materials
Engineering and/or FCA Supplier Quality.
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4.4 Inspection requirements

4.4.1 Significant Surfaces***

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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
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all surfaces that can be touched by a 20 mm (0.75 in) diameter sphere. For tubular-shaped parts or
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.
01
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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
03

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.
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4.4.2 Workmanship
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The plating shall be smooth, adherent, and free of blisters, pits, nodules, roughness, cracks and other
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functional defects. Coverage shall be complete and uniform in appearance with respect to the
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.
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PS.50036
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4.4.3 Thickness***

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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

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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 :

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- ASTM B487 Microscopic Cross Section.

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- ASTM B568 X-Ray Method.
- ASTM B499 Magnetic Method.

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- ASTM B504 Coulometric Method.

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Except for the microscopic method, it is essential to calibrate the test instrument with an alloy of the same
composition as that being measured.
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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
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ASTM B697, B602, and B762 or equivalents. Control charts and records documenting compliance with
the thickness requirements of this standard shall be prepared and maintained.
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In the event of a discrepancy for thickness determination, the microscopic cross section shall be used.
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A. Minimum Deposit Thickness

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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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Table 3 - Coating Thickness

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Description Code Thickness Requirement

C4 4 micrometers (0.000150 inch) minimum
01

C8 8 micrometers (0.00030 inch) minimum

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C12 12 micrometers (0.00050 inch) minimum

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Thickness greater than or equal to 12 microns are not to be specified for fasteners. If it is determined that
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other thicknesses are necessary for a particular application, drawing notes shall be used to designate the
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required thickness. If no thickness is specified on the drawing, the default is 8 microns minimum. Unless
otherwise specified on drawing, contact FCA Materials Engineering for corrosion performance
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requirements not defined by Table 4.

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.

C. Coating Build Capability (Part / Rack Mapping)

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PS.50036
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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
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
by Supplier Quality.

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To complete the Coating Build Capability study, each selected part is measured in numerous locations

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reflecting all significant surfaces defined in section 4.4.1 or drawing requirements. Each measurement
must be less than 10 cm apart and appropriately distributed based on the part size and configuration such

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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

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required thickness. Additionally, the coating thickness analysis will provide data to determine the coating

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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.

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The supplier is responsible for using auxiliary anodes, current robbers or shields when coating parts to
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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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Coating Build Capability testing must be completed for each part supplied to FCA as part of the test
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requirements for PPAP/PPA and also Forever Requirements notifications identifying process changes.
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D. Zones for the measurement of the coating thickness of fasteners.

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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
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screws and bolts, and the unthreaded shanks of bolts are significant surfaces.
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Considering the variability of the electrolytic coating thickness on screws and nuts, the same is measured
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on a point significant from the point of view of the corrosion protection rating.
01

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).
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For cylindrical screws with countersunk hexagonal head and of screws with cross cut, the measuring
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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
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the measuring points.

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For nuts, thickness is measured on a side of the hexagon and on a support plane (sees Figure 2).
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Figure 1 - Measurement Locations for Bolts or Screws

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Fig 2 - Measurement Locations for Nuts

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4.4.4 Topcoats and/or Sealers

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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

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and pass all fluid compatibility requirements for each application. The topcoat or sealer must not interfere

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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

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lowering the friction coefficient must be pre-approved by FCA Materials Engineering.
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4.4.5 Fastener friction coefficient

When lubrication is required on fasteners, the bolt frictions coefficients must range between Cf = 0.10 to
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0.16, unless otherwise indicated on drawing. If no lubrication is specified, the bolt friction coefficient must
range between CoF = 0.12 to 0.30 (total friction).
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Different values must be specified on drawing. Example : PS.50036 No. C8 SC2 LUB (Cf = 0.12 to
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0.18).
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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
EL 00

agreed upon beforehand and approved by FCA Materials Engineering Department.

NI 2:

4.4.6 Adhesion***
DA 9 0

The deposit shall not peel from itself or from the substrate when tested in accordance with one of the
01

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
,2

substrate and shall not be removed by ordinary handling.

03

Adhesion shall be verified on every lot that is strip and replated.

ay

4.4.6.1 Heat/Quench (Heat/Shock) Method***

M

A. Place the coated part to be tested into a constant temperature chamber for 1 hour at 190 to 210
ºC.
on

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.
 Page 13/22
PS.50036
Change Level: A

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

LO
angle, first on one side and then on the other, until it breaks.

BE
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.

A
om R
4.4.7 Hydrogen Embrittlement Test***

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

up id
greater, or have been surface hardened. The Tier 1 supplier is responsible to ensure that parts pass the

ro er
hydrogen embrittlement test prior to shipment to FCA.

ag us
4.4.8 Accelerated Corrosion Resistance***
fc 1) -
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.
O@C+

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,
EL UT

followed by testing in accordance with ASTM B117 for the times shown in Table 4.
AB (

After exposure, White Corrosion requirements are met if less than 3% of the surface exhibits aesthetic
.R PM

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.
EL 00

After exposure, Red Rust requirements are met if there is no evidence of base metal corrosion.
NI 2:

The corrosion testing of fasteners must follow the procedure as outlined in SAE/USCAR-1, “Salt Spray
DA 9 0

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 entire head (including socket
01

recesses for internal drives) and unthreaded shank of a screw or bolt are considered a significant
surfaces and must withstand the formation of white (zinc) and red (base metal) corrosion for the minimum
,2

times listed in Table 5.

03

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

Table 4 - Minimum Salt Spray Test Requirements

M

All Lubricants, Topcoats or Sealers Must be Pre-Approved For Use on Machine Threaded
Fasteners ***
on

Barrel Process Rack Process

Description Hours to Hours to Red Hours to Hours to Red
White Rust Rust White Rust Rust
C4, SC1 16 24 NA NA
C8, Plain NA 48 NA 56
C8, SC1 24 72 24 120
C8, SC2 96 168 96 192
 Page 14/22
PS.50036
Change Level: A

Table 4 - Minimum Salt Spray Test Requirements

All Lubricants, Topcoats or Sealers Must be Pre-Approved For Use on Machine Threaded
Fasteners ***

LO
Barrel Process Rack Process

BE
Description Hours to Hours to Red Hours to Hours to Red
White Rust Rust White Rust Rust

A
C8, (SC2 or Black) ST 120 408 120 456

om R
C8, (SC2 or Black) LUB 120 408 120 456

.c : D
C12, Plain NA 72 NA 96

up id
C12, SC1 24 168 24 192

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C12, SC2 96 240 96 288
C12, (SC2 or Black) ST 120 504 120 552

ag us
C12, (SC2 or Black) LUB 120 504 120 552
fc 1) -
The salt spray test is only used to test the integrity of the alloy deposit and the effectiveness of the
O@C+

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
EL UT

shipment of parts after PPAP approval is granted.

AB (

If the test is performed in the FCA US production plant, a 10% reduction in the general performance
.R PM

requirements of the parts is allowed for barrel processed parts.

4.4.9 Dry to Touch

EL 00

No visual stain shall be observed on Whatman Paper (Whatman Filter Paper #41) after being squeezed
NI 2:

in the palm of the hand for 5 to 10 seconds.

DA 9 0

4.4.10 Condensing Humidity (for topcoats and sealers)***

01

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
,2

from scribe, blistering, whitening, discoloration, loss of gloss, or corrosion on significant surfaces away
from scribed lines is allowed.
03

4.4.11 Galvanic Compatibility

ay

Galvanic compatibility testing to Aluminum (AA 6061) and Stainless Steel (AISI 304) is performed based
M

on the FCA US LP-461H-118 procedure. SAE J2334 is used as the corrosion test method. For galvanic
on

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 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.
 Page 15/22
PS.50036
Change Level: A

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

LO
one half of the fastener thread size, not to exceed 6 Newton-meters.

BE
4.4.14 Fastener Head Fill (For topcoats only)

A
A recess penetration gage shall enter into the recess at the minimum penetration requirements per

om R
PS.20001 with no more than 10 pounds axial load.

.c : D
4.4.15 UV Resistance***

up id
For black sealers and topcoats only : UV Resistance is performed by Xenon Arc exposure per SAE

ro er
J2527 for 2400 kJ using boro/boro filters. Tested parts shall exhibit no loss of adhesion, chalking,
cracking, blistering or significant color changes. After Xenon Arc exposure, sealer/topcoat adhesion is

ag us
tested per section 4.4.6. Additionally, parts shall be reviewed by the FCA Engineering or Product Design
Office for appearance approval.
fc 1) -
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
O@C+

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
EL UT

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.
AB (
.R PM

4.4.16 Chromium presence

Confirm the absence of hexavalent chromium compounds in the coating composition by following the
EL 00

procedures and using the equipment described in ISO 3613.

NI 2:

4.4.17 Material Gaging for Parts with Threads***

DA 9 0

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
01

times the nominal diameter cubed, in N-m (145 times the nominal diameter cubed, in in-lbs., for inch
,2

based fasteners). The manufacturer shall exercise due care during the manufacturing and handling of
parts to minimize the number and magnitude of thread discontinuities and coating build-up. This test is
03

required when visual inspection identifies potential assembly issues due to thread damage or coating
issues.
ay
M

4.5 Re-process***
on

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
1040 N/mm2 or greater, and/or HRC 32 or greater must be stripped in an alkaline stripper. If an acidic
stripper is used on hardened or spring steel parts, the parts must be baked for relief of hydrogen for the
durations specified in PS.50023<S> 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.
 Page 16/22
PS.50036
Change Level: A

4.6 Part Maintenance Requirements***

Parts shall be tested from each plating line to the frequencies defined in Table 7.

LO
Validation tests are required for new applicator approval, new part approval, PPAP, equipment change,

BE
line program change, rack design change, or barrel change using a different perforation size, shape, or
diameter.

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

.c : D
Table 5 - Product Inspection Requirements***

up id
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Test Description Requirement Minimum Frequency

ag us
Validation, Re-process and
Appearance Every lot
Continual Conformance
fc 1) -
Validation, Re-process and
Coating Thickness 5 pieces/shift per part number
Continual Conformance
O@C+

Validation, Re-process and 5 pieces/shift taken from

Adhesion
Continual Conformance different barrels or racks
EL UT

Fasteners and small parts (e.g.

springs, washers, clips) :
AB (

10 pieces/day representing a
.R PM

minimum total surface area of

0.3 dm2 (0.03 ft2)
EL 00

Rack parts and other barrel

NI 2:

Salt Spray Resistance Validation, Re-process, and

plated brackets and stampings :
Continual Conformance
DA 9 0

3 pieces/day representing a
minimum total surface area of
01

1.0 dm2 (0.1 ft2)

,2

Parts shall be taken from

03

different barrels or racks from

each process line
ay

Validation and Continual

Hydrogen Embrittlement Every lot
Conformance
M

Initial Chemical and Applicator

Cyclic Corrosion Validation
Approval
on

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
 Page 17/22
PS.50036
Change Level: A

Table 5 - Product Inspection Requirements***

Test Description Requirement Minimum Frequency

LO
Tapping Screw Test Validation Initial Chemical Approval

BE
Validation and Continual
Washer Assembly Breakaway Every lot
Conformance

A
Validation and Continual
Head/Recess Fill Every lot
Conformance

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.c : D
Chemical Compatibility Validation Initial Chemical Approval
UV Resistance Validation Initial Chemical Approval

up id
Torque/tension testing Initial Chemical Approval,
Validation

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(fasteners only) Applicator Approval, and PPAP

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Absence of hexavalent Initial Chemical and Applicator
Validation
chromium Approval
fc 1) - Every lot when thread
Validation and Continual discontinuities or excessive
Material Gaging
Conformance coating accumulation is
O@C+

observed
EL UT

5 SPECIAL REQUIREMENTS
AB (
.R PM

Compliance with CS-9003 Restricted and Prohibited Substances is required for components produced in
all markets.
EL 00

5.1 Process Validation

NI 2:

This section defines to part suppliers, Release Engineers, Supplier Quality, and others as necessary the
DA 9 0

PPAP/PPA 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.
01

Testing defined in Table 5 attached to this document, must be completed and parts retained as part of
,2

PPAP and Forever Requirement documentation. All testing must be performed by a certified laboratory.
03

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

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

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

- 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.
 Page 18/22
PS.50036
Change Level: A

5.2 Supplier Approval***

LO
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

BE
these materials may be supplied to any FCA manufacturing plant, FCA assembly plant, or FCA tier one
supplier.

A
om R
5.3 Supplier Product Inspection***

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

up id
or CAD model, (CATIA/NX).

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No change in material formulation, processing, or finishing from that originally agreed upon shall be made

ag us
by the supplier without prior approval by the FCA Organic Materials Engineering Department. To this
end, all approved materials will have a chemical analysis performed as part of the approval process. The
fc 1) -
supplier will be held accountable for maintaining compounding and processing procedures that will
produce stock matching the analysis data of the originally approved material. Random testing of parts
during the initial production sample submission and of subsequent production parts may be performed to
O@C+

insure compliance. Non-compliance could ultimately result in loss of current or future business on this
and other FCA Material Standards with the supplier being removed from the various Approved Source
EL UT

Lists.
AB (

5.4 Material Quality***

.R PM

The Material and processing supplier (primary source) is responsible for the quality of all materials
comprising the finished part whether they have been compounded internally or purchased from another
EL 00

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
NI 2:

another source approved by the FCA Engineering Office.

DA 9 0

Materials and parts supplied under the specified material standard must be evaluated against the DV
01

requirements of that standard on an annual basis (minimum test frequency). These annual audits must be
kept on file by the first tier supplier to FCA. More frequent audits of conformance to the designated
,2

standard may be required and will be at the discretion of FCA’s Supplier Development Department,
Materials Engineering, Appropriate Platform engineering group, or FCA first tier supplier.
03

5.5 Field Performance***

ay

All materials supplied must provide adequate field service as specified by the FCA Vehicle Engineering.
M

5.6 Forever Requirements***

on

The following situations require the submission and customer approval of a Forever Requirements (FR)
notice in the WebCN system before implementation:

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

2. Change of a sub-tier supplier provider of a sub-component or process;
3. Supplier-initiated internal change to a Manufacturing Location (i.e., proposal to move manufacture of a
part from location 12345A to location 12345B). Note that this usage of the FR system MUST be followed
by a Resource Notice.
 Page 19/22
PS.50036
Change Level: A

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

LO
be done via CN, Resource Notice, IAA, or other tool as appropriate.

BE
5.7 Non-Conforming Material***

A
Refer to PF-8500.

om R
.c : D
6 QUALITY

up id
For components that will be part of a vehicle designed in NAFTA and sold in all markets, conformance to

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the material characteristics described by CS-9800 must be met.

ag us
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.
fc 1) -
O@C+

7 TEST EQUIPMENT
EL UT

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

The personnel shall be properly trained and qualified.

AB (
.R PM

7.1 Test Facilities

7.1.1 Production Laboratory

EL 00
NI 2:

There must be a structure with the necessary tools to perform primary controls for the proper analysis and
management of process baths.
DA 9 0

- Control instruments for chemicals and waste water (titrator, centrifuges, Atomic Absorption unit,
01

colorimeter, etc.).
- Control instruments for qualitative and quantitative analysis of the baths (titrator, thermometer, etc.).
,2

- pH meters.
- Hull cells and rectifier.
03

7.1.2 Quality Laboratory

ay

There must be a structure within the production site equipped with the means to perform the required
M

inspections described within this standard.

on

- Visual aspect
- Thickness
- Adhesion
- Corrosion resistance
 Page 20/22
PS.50036
Change Level: A

7.2 Test Equipment

LO
The minimum test equipment must be:

BE
- Optical microscope
- Thickness tester

A
- Oven

om R
- Salt Spray (Fog) Chamber

.c : D
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.

up id
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8 APPROVED SOURCE LIST

ag us
For components produced in the NAFTA market, applicators listed in Table 6 MUST be used for
fc 1) -
processing fasteners, and any parts that have been surface hardened, and with a tensile strength of 1040
N/mm2 or greater, and hardness of HRC 32 or greater.
O@C+

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
EL UT

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

AB (

For overseas sourcing, the first-tier part supplier is responsible for all requirements of this standard
.R PM

including selecting a capable, approved applicator and demonstrating the capability of the selected
applicator to FCA Materials Engineering and Supplier Quality.
EL 00

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
NI 2:

EASL Update Audit Review within 90 days of notification by FCA US Materials Engineering.
DA 9 0

An EASL approved applicator must resubmit for EASL approval if the coating process is changed.
01

Table 6 - Engineering Applicator Approved Source List – NAFTA

,2

Materials covered by this standard shall only be purchased from those source(s) listed in this table
when processing fasteners or heat treated components.
03

Supplier Process type Process Description

Acadian Platers Ltd.
ay

315 Rexdale Blvd Acid zinc Barrel

Rexdale, ON M9W 1R8
M

Acument Industries
on

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.,
Acid and alkaline zinc Barrel
5909 W 130th St
 Page 21/22
PS.50036
Change Level: A

Table 6 - 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.

LO
Supplier Process type Process Description
Parma, OH 44130

BE
Burbank Plating Services,

A
13561 Desmond St, Acid zinc Barrel and Rack

om R
Pacoima, CA 91331

.c : D
Cadon Plating Co.,
3715 Eleventh St Acid zinc Barrel

up id
Wyandotte, MI 48192

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Coatings 85 – Plant C

ag us
6975 Davand Acid zinc Rack and Barrel
Mississauga, ON L5T 1L5 fc 1) -
Elm Plating Company
1319 Elm Street Acid zinc Barrel
O@C+

Jackson, MI 49203
EL UT

Fintex, LLC
8900 Inkster Rd Acid and alkaline zinc Barrel
AB (

Romulus, MI 48174
.R PM

J & M Plating,
4500 Kishwaukee St Acid zinc Barrel
EL 00

Rockford, IL 61109
NI 2:

Master Mfg.,
DA 9 0

4703 Ohara Dr Acid zinc Barrel

Evansville, IN 47711
01

Modern Plating
,2

701 S Hancock Acid zinc Barrel

Freeport, IL 61032
03

Morgan Ohare, Inc.,

Barrel
ay

701 W. Factory Rd Acid Zinc

Addison, IL 60101
M

Paulo Products Co.,

on

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.
Acid Zinc Barrel
26100 S Whiting Way
 Page 22/22
PS.50036
Change Level: A

Table 6 - 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.

LO
Supplier Process type Process Description
Monee, IL 60449

BE
Superior Metal Finishing,

A
3510 E McNichols Acid zinc Barrel

om R
Detroit, MI 48212

.c : D
Torcad, Ltd., Toronto,
275 Norseman St

up id
Acid zinc Barrel
Toronto, Ont M8Z 2R5

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Canada

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Varland Metal Service,
Acid and alkaline zinc
3231 Fredonia Ave Barrel
Cincinnati, OH 45229
fc 1) -
O@C+

9 DRAWING CALLOUT CROSS-REFERENCE

EL UT

Table 8 - Drawing Callout Cross Reference

AB (

Equivalent Callout Equivalent Callout

Drawing Callout
.R PM

Per FCA Italy Specification Per FCA US Specification

PS.50036
9.57405 (1), (2) PS.50036 or PS.50023 (2)***
C4, SC1 Code 15, PS-1207
EL 00

C8, Plain Fe/Zn 7 I Code 30

NI 2:

C8, SC1 Fe/Zn 7 II Code 30, PS-1207 SC1

DA 9 0

C8, SC2 Fe/Zn 7 IV Code 30, PS-1207 SC2

C8, SC2, ST Fe/Zn 7 IV S Code 30, PS-1207, PS-8814
01

Fe/Zn 7 IV SB
C8, SC2, LUB Code 30, PS-1207, PS-10509
,2

Fe/Zn 7 IV LUB
Fe/Zn 7 VII S
03

C8, Black, ST Code 30, PS-1207 Black

Fe/Zn 7 VII ST
ay

C12, Plain Fe/Zn 12 I Code 50

C12, SC1 Fe/Zn 12 II Code 50, PS-1207 SC1
M

C12, SC2 Fe/Zn 12 IV Code 50, PS-1207 SC2

on

C12, SC2, ST Fe/Zn 12 IV S Code 50, PS-1207, PS-8814

C12, SC2, LUB N/A Code 50, PS-1207, PS-10509
Fe/Zn 12 VII S
C12, Black, ST 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.50023, 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.