consolidating zinc w/ chromate plating specifications pcn … · 2020. 6. 19. · revision revision...

Consolidating Zinc w/ Chromate Plating Specifications

PCN 10202

Test Report

Revision Revision Date Created By Comments

A 04/15/2019 AC Initial

Summary The following series of tests were performed with the intent to show that our new zinc w/ chromate coating would perform equally or better than our legacy zinc w/ chromate coating for the purpose of replacement. Tests were performed using testing coupons plated with our legacy coating (Pavco TruBlue 2000 (an RoHS compliant trivalent chromium based chemical conversion with the addition of Pavco blue dye #10)), and our new coating (TriPass ELV 7500 (an RoHS compliant trivalent chromium based chemical conversion coating) with HydroKlad SI (an RoHS compliant clear, inorganic seal used as an extended protection adhesive.)) A total of 12 test coupons were tested, with 6 having the legacy coating and 6 having the new coating. Testing was done as a comparison of coatings and not to show pass/fail characteristics. Abrasion Resistance Test (reference RTE 18-29) An abrasion resistance test was performed under the guidelines of ASTM B-201. A gritless, soft art gum erasure was used to attempt to remove the chromate coating. Samples were rubbed with approximately 10 psi of pressure for 10 strokes approximately 50 mm. (2 in.) long. The results are:

Plating Legacy Legacy Legacy Legacy Legacy Legacy

Sample # 1 2 3 4 5 6

Results Chromate not removed.

Chromate not removed.





Plating New New New New New New

Sample # 7 8 9 10 11 12

Results Chromate not removed.






Conclusion: Test coupons plated with the new coating performed equally as compared to test coupons plated with our legacy coating. Temperature Cycling Test (reference RTE 18-29) A temperature cycling test was performed following the procedure of EIA-364-32, Condition I. Samples were positioned on a wire rack so that air flow was uninterrupted. Samples were cycled from -55°C +0°/-3° C to 125° C +3°/-0° C five times. The results are:


Sample # 1 2 3 4 5 6

Results No damage to chromate coating.

No damage to chromate coating.






Sample # 7 8 9 10 11 12

Results No damage to chromate coating.






Conclusion: Test coupons plated with the new coating performed equally as compared to test coupons plated with our legacy coating.

Humidity Test (reference RTE 18-29) A humidity test was performed as outlined by EIA-364-31, Method IV. Samples were suspended from racks in the environmental chamber so that the samples did not come into contact with each other. The observations are:


Sample # 1 2 3 4 5 6

Observations White rust and pitting observed.

White rust and pitting observed.






Sample # 7 8 9 10 11 12

Observations White rust and pitting observed. Red rust observed around edges.

White rust and pitting observed. Red rust observed around edges.





Sample #1, White Rust and Pitted

Sample #2, White Rust and Pitted

Sample #2

Sample #7, Red and White Rust and Pitted

Sample #8, Red and White Rust and Pitted

Sample #7 Conclusion: Per EIA-364-31, locations where pooling can happen are exempt from scrutiny. The red rust in this case can be ignored as it occurred in an exempt area. Test coupons plated with the new coating are considered to have performed equally as compared to test coupons plated with our legacy coating. Salt Spray (Corrosion Resistance) Test (reference RTE 18-29)

A corrosion resistance test was performed as outlined by EIA/ECA-364-26, Condition B. Prior to testing, test coupons underwent a humidity test as outlined above. Samples were suspended in salt spray chamber using glass rods, positioned so that samples did not touch each other or sides of chamber. After 48 hours of exposure, samples were removed from the chamber and all salt deposits were removed with warm tap water. Samples were then placed in an air circulating oven set at 38° C for 12 hours to dry. The observations are:


Sample # A (1) 2 3 4 B (5) C (6)

Observations Chromate removed, white rust, red rust, and pitting.

Chromate removed, white rust, and pitting.

Chromate removed, white rust, and pitting.

Chromate removed, white rust, red rust, and pitting.




Sample # 7 8 9 10 11 12

Observations Chromate removed, white rust, red rust, and pitting.






Sample #3, Best Case Surface

Sample C, Worst Case Surface

Sample #9, Best Case Surface

Sample #7, Worst Case Surface Conclusion: Test coupons plated with the new coating performed visually better as compared to test coupons plated with our legacy coating. Fluid Immersion Test (Hydraulic Fluid) (reference RTE 18-29) A fluid immersion test was performed as outlined by EIA-364-10, Test Fluid A. Test coupons were placed in Teflon wrack and immersed in fluid to a depth of about 1 in. This test consisted of 7 cycles of immersion, drain time, oven cure time, and cool time. A digital hot plate was used to warm the test fluid to 85°C and a Fluke thermometer was used to maintain and verify this temperature. A Blue M Oven was used for the oven cure time portion of the test and was maintained at 100°C and verified using a PPE thermometer. The results are:

Plating Legacy Legacy Legacy

Sample 2 3 4

Results No defective effects seen

No defective effects seen


Plating New New New

Sample 7 8 9




Conclusion: Test coupons plated with the new coating performed equally as compared to test coupons plated with our legacy coating. Fluid Immersion Test (Lubricating Oil)) (reference RTE 18-29) A fluid immersion test was performed as outlined by EIA-364-10, Test Fluid D. Test coupons were placed in Teflon wrack and immersed in fluid to a depth of about 1 in. This test consisted of 7 cycles of immersion, drain time, oven cure time, and cool time. A digital hot plate was used to warm the test fluid to 120°C and a Fluke thermometer was used to maintain and verify this temperature. A Blue M Oven was used for the oven cure time portion of the test and was maintained at 125°C and verified using a PPE thermometer. The results are:

Plating Legacy Legacy Legacy

Sample A (1) B (5) C (6)




Plating New New New

Sample 10 11 12




Conclusion: Test coupons plated with the new coating performed equally as compared to test coupons plated with our legacy coating. Overall Conclusion Referencing the tests performed above, the overall conclusion is the new zinc w/ chromate coating (TriPass ELV 7500 w/ HydroKlad SI) performs equally or better than our legacy zinc w/ chromate coating (Pavco TruBlue 2000) and is a suitable replacement.

consolidating zinc w/ chromate plating specifications pcn … · 2020. 6. 19. · revision revision...

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