Material & Finish Guide

Zinc Plating: A common sacrificial coating used in finishing steel parts to provide protection from red rust. Applied electrolytically to a typical thickness of 200 300 micro inches (.0002" - .0003"). The zinc plating protects the underlying steel by formation of a "galvanic cell", which results in the zinc corroding preferentially to the steel. Red rust will not start forming until all zinc has been converted to white rust (zinc oxide). Normally zinc plating is used for indoor applications, but can also be used as a base for painting. By itself a 200 300 micro inch zinc plating will probably get no more than 12 hours of Salt Spray protection per ASTM-B117. With a clear chromate topcoat this is increased to 24-36 hours, while a yellow chromate top coating can achieve protection up to approximately 96 hours. Even though it is mostly used as a functional coating, zinc plating does have some decorative appeal. Other properties of zinc plating include: moderate appearance, excellent abrasion resistance and excellent paint adhesion. Yellow Zinc Plating: As above, with yellow dichromate passivate, greatly improving corrosion resistance. Salt Spray protection (ASTM-B117) is approximately 96 hours. Black Zinc Plating: As above with black silver nitrate passivate, giving a matte black appearance and similar corrosion resistance to yellow zinc plating. Zinc Plate, Chromate Plus Sealer: Currently Southcos standard finish of choice. A metallic (inorganic) sacrificial finish which provides excellent corrosion protection. "Sacrificial" means that the plating will corrode instead of the base material. This finish will protect even if the finish is scratched through to the base material. Most applications provide corrosion resistance averaging 500 hours of salt spray, per ASTM B117 or ISO 9227, and 5 cycles of moist sulphur-dioxide testing (ASTM G-87) without evidence of red rust for parts plated approximately .013mm (.0005") thick. This finish has a lubricious surface, which is more uniform and consistent, both visually and in terms of its mechanical properties. This finish also exceeds zinc-plating specifications as outlined by ASTM B633, BS 1706, DIN 50961 and AS1789. Dry Film Lubricants: A variety of lubricious coatings (including Mil-L-4601014 & MIL-L-8937) that give permanent, oil free lubrication to moving components while at the same time protecting them from corrosion. This heat curing material also prevents galling, seizing and fretting. Typical salt spray protection is in the range of 240-480 hours (ASTM-B117). These coatings do not rub off and can be painted over with most paints. Dry film lubrication is an excellent solution to the problem of lubricating parts that will be operated in corrosive atmospheres that may be stored for long periods, are seldom lubricated once they leave the factory, or where permanent lubrication is desired. (See also Black Organic Coating) Dacrotizing: An immersion zinc flake/chromate dispersion coating applied to ferrous metal parts for very good corrosion protection. Dacrotizing meets specification Mil-C-87115. Dacrotized parts withstand 240 hours of salt spray testing per ASTM B-117, and 1 cycle of moist sulphur-dioxide testing (ASTM G-87) without evidence of red rust. (Dacrotizing is a registered trade name of Metal Coatings International, Inc.) Black Oxide: This is a black conversion finish used over steel parts for aesthetic purposes. The coatings have a deep glossy appearance. Salt Spray protection approaches 24 hours (ASTM-B117) depending on the sealant used. Black Organic Finish: A lubricious, uniform black fluoropolymer finish for metallic parts. Provides up to 400 hours of salt spray resistance per ASTM B-117, without evidence of red rust, when applied over approximately .013mm (.0005") of zinc plating. Over bare metal only a maximum of 96 hours of protection per ASTM B-117 can be expected. (See also Dry Film Lubricants) Chrome Plating: A highly decorative and very hard silver finish achieved by an electroplating process which applies three or four layers of metal; copper, nickel and chromium. Depending on the surface preparation (polishing) and the final chrome thickness, the finish can range from satin to a high luster mirror-like surface. Properties of chrome plating include superior appearance and superior abrasion resistance.

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Material & Finish Guide

Copper-Nickel-Chrome Plating: See chrome plating. Nickel Plating: As an electro-deposit, this coating is used primarily when a decorative bright silver finish is desired. If high hardness and good chemical resistance are required, parts are often coated with electroless nickel. This has the advantage of being able to build thickness evenly on both the inside and outside of a part. Other than E-coating, electroless nickel is one of the only coatings that will achieve total coverage. Other properties include excellent chemical resistance in a hard, durable finish. More decorative than zinc plating but does not provide sacrificial protection. Chromate Conversion Coatings: Also known as Chem-Film (Mil-C-5541E), Irridite or Allodine, this coating is similar to phosphate coatings in that it chemically reacts with the surface of the metal (in this case strictly aluminum and its alloys). Its primary purpose is to provide maximum corrosion protection to aluminum parts. It will yield up to 336 hours of Salt Spray protection protection (ASTM-B117), and is an excellent base for paint adhesion. Phosphate Conversion Coatings: There are three basic types of phosphate coatings: Iron (TT-C-490 type II or IV), Zinc (TT-C-490 type I) and Manganese phosphate (DOD-16232). Iron and Zinc phosphate are both used as a pretreatment on steel and other metal parts to enhance paint adhesion and corrosion resistance. Iron phosphate yields light coating weights of 30 to 80 mg/SF, while zinc phosphate usually yields heavier coating weights of 150 to 1500 mg/SF or more. Heavier phosphate coats coating weights require more paint to achieve a smooth finish. Manganese phosphate is used over steel as a break-in lubricant with oil or where a very thick coating is required. Manganese phosphate easily yields coating weights of over 3500 mg/SF. All phosphate coatings can serve as good "in process rust preventatives." Powder Coating: Powder coating is an electrostatic painting process followed by a thermal curing of the finish. This provides uniform coverage and results in a top-coat that is attractive, durable, corrosion resistant, and UV stable. Powder coat is available in a variety of colors and glosses. Ideally suited for exterior applications. Properties of powder coating include excellent appearance and good abrasion resistance. Standard E-Coat: Either an epoxy or an acrylic paint that is applied through an electroplating process followed by a thermal curing of the finish. Epoxies are normally used as a primer or for indoor applications while acrylics are often applied as a finish coat. E-Coat is available in a variety of colors and offers the ability to coat parts uniformly inside and out. Properties of E-Coating include: excellent appearance, high corrosion resistance, excellent abrasion resistance, and excellent paint adhesion. Techniclad E-Coat: An ultraviolet resistant polyurethane E-Coat with excellent aesthetic appearance. Techniclad E-Coat is the best choice for weatherability, UV resistance and acid rain resistance. This urethane coating is also perspiration resistant and can achieve Salt Spray protection levels of 1,000 hours or more (ASTM-B117) on steel as well as aluminum. This unique process is capable of achieving total coverage on complex parts such and assemblies such as latches, hinges and lock assemblies. CARC coatings: Camouflage coatings for military vehicles and equipment. These coatings conform to Mil-C-46168 and/or Mil-C-53039 and are generally dead-flat green, brown, black or white. Stainless Steel: Stainless steel materials provide excellent corrosion resistance in high moisture environments. Stamped products allow for buffing and polishing which provides a bright and attractive appearance that is easily maintained.

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Material & Finish Guide

Polyamide: Also known as PA or nylon. Polyamide is a thermoplastic polycondensate and offers high lubricity and moderate strength. Many grades are available and often use glass fiber reinforcement for added strength and durability. ABS: Acrylonitrile-Butadiene-Styrene is a thermoplastic that has been mass-produced since the 1960s. ABS is tough, hard and rigid. It also provides good chemical resistance, dimensional stability, creep resistance and moderate strength. Plastisol: A soft, waterproof, non-sliding, non-conductive coating with many practical applications. Provides excellent corrosion and impact resistance, protects against rough metal edges, and insulates from electrical shock. Plastisol is also a cost effective way to improve the appearance of your product. It can be used to replace molded plastic handles, rubber coating, hard plastic coatings, liquid painted products or powder coated products and reduces the need for expensive packaging to protect from scratching. Electro-Polishing: A process in which metal is removed from the surface using electrochemical techniques. Commonly used on stainless steel to produce a surface ranging from a low reflective satin finish to a bright finish. Properties of electro-polishing include superior appearance and excellent abrasion resistance. Ball Burnishing: A process by which steel or stainless steel balls are used to debur, smooth and polish metal or metal products. Burnishing improves surface hardness, wear resistance, and corrosion resistance and is often used to polish stainless steel, aluminum, brass or silver. Anodizing: Used exclusively on aluminum products. An electrolytic process where the thin oxide film on the aluminum surface is converted to an anodic coating. This anodic coating provides a hard, wear and scratch resistant surface. Dyes are then used to provide specific decorative appearance and colors. Properties of anodized aluminum include superior appearance and excellent abrasion resistance. Passivating: A treatment for stainless steel performed in accordance with Mil-Std-171 section 5.4.1 (QQ-P-35). This process removes free iron from the surface structure of the stainless steel part and leaves behind an impenetrable matrix of Nickel and Chromium Oxides. This process is relatively economical as only an acid solution bath is required.

Note: Values for corrosion protection are to be used for comparative purposes only. These values should not be construed as a guarantee that the levels of protection will be achieved. Customers are encouraged to perform their own testing on specific items contained within this catalog. Precautions must be exercised when welding plated parts to assure adequate ventilation and appropriate personal safety.

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Yellow dichromate vs. Yellow chromate?

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Yellow dichromate vs. Yellow chromate?

Zinc chromate Production of zinc chromate and zinc tetraoxy chromates
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. Hello, my name is Mark Thomas. I am an engineer for an OEM that uses a wide variety of plated products. Recently, a question has camp as to the difference between yellow dichromate and yellow/gold chromate. I have seen references to both. What is the difference between the two processes(e.g. salt-spray resistance when paired with zinc electroplate, appearance, application, bath chemistry, etc.). In addition, is one process used in certain applications while thither is not? Specifically, this question is in reference to zinc electroplated fasteners and similar hardware, however any general information would be appreciated. Finally, I would like to know what is the best way to note what won't on a part print. Currently, we use a note that says something like,"Zinc and yellow dichromate per ASTM B-633 [link is to spec at TechStreet], Type II, Fe/Zn 12."What is the best way to relay what I want to the plater? Any information would be greatly appreciated. Thanks. Mark Thomas - Oshkosh, WI, USA

. Hi Mark, I'm an engineer for a Tier I supplier. The two terms are the same thing. Yellow chrome is yellow chrome. Just ask for "zinc yellow" plating from your plater, give them copies of the correct specifications, and make sure the plating you will get will meet the spec. By the way, if your application is for model-year 2003 or later,then you can't use yellow chrome. All zinc and zinc-alloy platings used currently also use some form of chrome on top of the plating.This chrome is of the hexavalent variety, and is on your company's restricted substances list. (Go check!) You can specify a TRIVALENT chrome system with a topcoat/sealer which will meet the new material regulations. We have found that even though specialized groups within the OEMs are aware and dealing with the hex chrome situation, many of the engineers directly working on projects have not yet been informed of these new requirements. So, you are not alone, and you should spread the word to your co-workers. If you would like any further information, I would be happy to help you.

Tim Neveau - Auburn Hills, MI

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. Thanks Tim; I appreciate your response. However, I am still little bit confused. If yellow dichromate and yellow chromate are the same thing, then why is the distinction "yellow dichromate" made as opposed to say "clear chromate." Why not simply refer to all as chromate. Please feel free to go into detail. It is important that Understand what exactly the process is. Thanks again. Mark Thomas - Oshkosh, WI USA

. There are different types of hexavalent chromates. Dichromate and chromate refer to the same hexavalent chrome conversion coating.Yellow and gold are about the same too. However, there are a variety of chromates out there. There are yellow, bronze, clear, olive drab, and other colors out there. Yellow is stronger than clear. Bronze is stronger than yellow. Sometimes the only difference in these chromates is the thickness. Sometimes the chromate bath composition is different, but right now all currently specified chromates are based on hex chrome. I just saw ASTM B633 this morning while discussing plating specs with a co-worker. Yes, "Zinc and yellow dichromate per ASTM B633,Type II, Fe/Zn 12" is a good way to specify plating on a part print.Type II is for colored chromates like zinc yellow. If you were specifying zinc with clear chromate, you would have to specify Type I. I suggest that you ask your plater and/or the plater's chemical vendor about trivalent chrome passivation. I also suggest you ask someone in your corporate materials group about the European Union restrictions on hexavalent chrome. This topic is a big issue in fastener groups too, and you might also be able to get internal information there too. I have had meetings with GM, Ford, and Daimler Chrysler, and all three are working on phasing out the types of chromates you are asking about! You maybe have one more year in which you can continue to specify this type of plating. Tim Neveau - Auburn Hills, MI

++ I am the Quality Manager at a spring manufacturer. We have a few customers who want their product plated with yellow dichromate or clear Zinc plating. I am looking for information concerning the plating process so that I have a better understanding when discussing issues with our vendors. Any information will be greatly appreciated. Bill Nelson William L. Nelson - Adel, Iowa, USA ++ In brief, Mr. Nelson, things are zinc plated because it is an inexpensive, corrosion resistant, reasonably attractive finish which offers cathodic protection to steel (it dissolves preferentially to steel, thus protecting the steel, even if scratched). However, zinc itself corrodes fairly quickly and the corrosion products are unsightly, sticky, white salts. Chromate conversion coatings on the zinc plating are very thin protective coatings that keep the zinc shiny and corrosion free for a time. Traditionally, clear chromates have usually had a mix of hex and trivalent chromium while yellow chromates have been hexavalent based. The yellow chromates offered substantially better corrosion resistance. There has been worldwide pressure to eliminate the use of hexavalent chromates for a while because of their

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toxicity and, in some cases, carcinogeneity. Recently, the European Union issued a directive that autos can have no (or essentially no) hexavalent chromium in them. This greatly intensified the pressure, and most people are trying to eliminate hexavalent chromates from their products; alternatives have recently been developed and improved, but are not as reliable or inexpensive as hexavalent chromates yet. As for "chromate" vs. "dichromate", this is a semantics/language issue. Although to a chemistry professor chromate is CrO4 and dichromate is Cr2O7, to a plater either there is no difference or they may think of chromates as clear and dichromates as yellow, but it has little basis in fact. Further, as Tim says, all such chromate conversion coatings will soon use trivalent chromium rather than hexavalent anyway and the term trivalent chromate is an oxymoron anyway (CrO4, i.e. 'chromate' can't be trivalent). I hope this answered your question.

Ted Mooney, P.E. finishing.com Brick, New Jersey +++++ If anyone is looking for the relevant law on the (zinc) hexavalent chromate issue take at look at the European Union ELV (End of Life Vehicle) Directive 2000/53/EC Article 4 Section 2. (a) Prevention and Annex II Exemptions. The Directive is available online: europa.eu.int Sean Engineering Manager Ramsey, NJ

Sean McDermott - Ramsey, NJ +++++ Tim, I am also struggling with the Hex Chromate issue. Are all Chromate finish (blue, black, clear etc..) contain Hex Chromium? My understanding was, only Yellow contains the Hex Chromium. Also, my understanding is with the trivalent Chromium, you don't need a clear coating. It provides the same 96 hrs of salt spray protection. Is this correct? Your clarification will be greatly appreciated. Rita Mohant - Stoughton, MA

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++++++ I regards to the Trivalent coating....is this RoHS compliant? ref: http://www.finishing.com/60/49.shtml Gene Crevier - Grand Rapids, MI ++++++ This letter goes back pretty far in time and there have been huge investments and consequent improvements in trivalent chromating in the last few years. So, as an update -Trivalent chromates have existed for decades but were rarely used because their corrosion resistance was so inferior to hexavalent chromates. But with RoHS regulations and other pressures to remove hexavalent chromium from products, new trivalent chromate processes have been introduced that can match the performance of hexavalent chromate, while conforming to RoHS requirements. All of these are highly proprietary; some involve a post treatment after the chromate whereas some involve a thick film of chromate. None are as easy as hexavalent chromating, nor as cheap, and they are usually not as reliable -- but elimination of hexavalent chromate is necessary and it can be done.

Ted Mooney finishing.com Brick, New Jersey

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