Engineering Material Specification: Printed Copies Are Uncontrolled

ENGINEERING MATERIAL SPECIFICATION
CORROSION PROTECTIVE COATING, ZINC NICKEL ALLOY, WSS-M21P44-A1

TRIVALENT PASSIVATE, SILVER

TRIVALENT PASSIVATE WITH ORGANIC SEAL, SILVER

TRIVALENT PASSIVATE WITH CATHODIC ELECTROCOAT,
BLACK

TRIVALENT PASSIVATE WITH WATERBORNE TOP COAT,
BLACK
1. SCOPE
The materials defined by these specifications are corrosion protective coatings applied sequentially per
supplier specifications over steel. They consist of an alkaline zinc nickel alloy electrodeposit and a
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trivalent chromium passivate/adhesion promoter. A2, A3 and A4 are followed respectively by an
organic seal, a cathodic electrocoat, or a waterborne top coat. When used with an integrally cured
torque modified post dip, these processes provide consistent torque-tension control.
All processes are free of hexavalent chromium, lead and cadmium.
2. APPLICATION
These specifications were released for materials used as corrosion protective coatings over steel
fasteners and small parts. The processes may induce hydrogen embrittlement and therefore these
coatings must be hydrogen embrittlement relieved when applied to high hardness parts in accordance
with WSS-M99A3-A.
The cure temperature of the organic seal used for A2 is 80 to 120 °C.
The cure temperature of the cathodic system for A3 is 175 to 200 °C.
The cure temperature of the waterborne system for A4 is 190 to 205 °C.
These coatings shall not be specified if this temperature adversely affects the component being coated.
2.1 SERVICE TEMPERATURE
The maximum continuous service temperature for A and A2 is 310 °C.
The maximum continuous service temperature for A3 and A4 is 260 °C.
Date Action Revisions

2004 09 14 Revised Para 3.5.1 revised D. Drobnich
Para 1, 3.3.1, 3.3.2, 3.3.4, 3.4.1, 3.4.3, 3.5.1, 3.5.2, 3.5.3, 3.5.4,
2004 09 08 Revised
3.5.5, 3.7.1, 3.12, Table 1 and Table 1 (C) revised D. Drobnich
2004 09 02 Activated D. Drobnich
Printed copies are uncontrolled
Copyright Ford Motor Company
Provided by IHS under license with FORD
Copyright © 2004, Ford Global Technologies, LLC
Licensee=Magna International Inc/5926707100, User=Kollmann, Drew
Page 1 of 6
No reproduction or networking permitted without license from IHS Not for Resale, 09/05/2006 08:07:56 MDT
WSS-M21P44-A1/A4
3. REQUIREMENTS
3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS
Material suppliers and part producers must conform to the Company's Quality System
Requirements for Production Materials (WSS-M99P1111-A).
Part producers must use approved materials specified on the Company’s Approved Source List.
3.2 APPROVED APPLICATOR QUALITY REQUIREMENTS
Applicators must follow coating manufacturer procedures and recommendations for chemical
usage, equipment, analysis and processing.
3.3 APPEARANCE
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3.3.1 The ZnNi coating will have a metallic silver appearance prior to passivate/adhesion
promoter application.
3.3.2 The passivate/adhesion promoter will have an appearance of slight iridescence and
color variation consistent with interference films (e.g. yellow, orange, green, blue,
purple variegation).
3.3.3 The organic seal used for A2 will be a translucent film free from discontinuities.
3.3.4 The cathodic coating used for A3 and the waterborne coating used for A4 will be a
semi-gloss black finish free from discontinuities. The gloss level for A3 shall be 25 to
55° of gloss when measured using a 60° meter.
3.4 COATING COMPOSITION
3.4.1 The alkaline ZnNi electrodeposit shall have a nickel content of 12 to 15% as
measured by calibrated X-ray fluorescence spectrometers in accordance with the
supplier's requirements. In some instances a 'strike' layer may be applied to the
substrate prior to ZnNi electrodeposition. In such cases the presence of a strike layer
must be noted so that appropriate methods for measuring composition and thickness
of the ZnNi may be employed.
3.4.2 The alkaline ZnNi electrodeposit shall have a phase composition which includes
substantial metallurgical gamma phase ZnNi as defined by standard reference phase
diagrams such as ASM Handbook, Volume 3, 10th edition. Presence of substantial
gamma phase ZnNi may be demonstrated by comparing x-ray diffraction patterns to
reference materials such as ICDD PDF 06-0653. Crystallographic preferred
orientations, such as 330 and/or 600 Miller index hkl for gamma phase ZnNi, should
be present in accordance with the chemical supplier’s requirements; and subject to
periodic verification using x-ray diffraction or an alternative, preapproved, standard
crystallographic determination method.
3.4.3 The passivate/adhesion promoter shall have a composition in accordance with the
chemical suppliers requirements. For A3 and A4, the passivate/adhesion promoter
must be cobalt and carboxylic acid free.
3.4.4 The organic seal of A2, the cathodic coating of A3, and the waterborne coating of A4
shall have a composition in accordance with the chemical suppliers requirements.

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WSS-M21P44-A1/A4
3.5 COATING THICKNESS
3.5.1 The ZnNi electrodeposit will have an optimum thickness of 8 + 4/- 2 microns
measured on flat surfaces. Documentation demonstrating throwing power, measured
in accordance with supplier’s instructions, in excess of 70% will assure adequate
thickness in recessed areas including threads.
3.5.2 The passivate/adhesion promoter thickness is not subject to measurement but will be
less than one micron and greater than 50 nm based upon SEM examinations using
cryofractured samples and/or calibrated depth profiling using scanning Auger or x-ray
photoelectron spectroscopies.
3.5.3 The organic seal thickness for A2 is typically between 0.5 and 5 microns. The
minimum thickness shall be sufficient to meet the corrosion requirements of the
substrate material. A typical film that exhibits the appropriate corrosion resistance for
A2 is 1 to 2 microns in thickness.
3.5.4 A specific cathodic coating thickness for A3 is not specified. The minimum thickness
shall be sufficient to meet the corrosion requirements of the substrate material. A
typical film that exhibits the appropriate corrosion resistance for A3 is 12.7 to 20.0
microns in thickness.
3.5.5 A specific waterborne coating thickness for A4 is not specified. The minimum
thickness shall be sufficient to meet the corrosion requirements of the substrate
material. A typical film that exhibits the appropriate corrosion resistance for A4 would
be no less than 10.0 microns in thickness.
3.5.6 Excessive coating thickness on threaded components may cause assembly concerns.
The general requirements of the Ford Worldwide Fastener Standards, Finish
Specification WX100, and Section 5 apply to these coatings.
3.6 THREAD ACCEPTANCE REQUIREMENTS

(WA900, WE900, WX100)
For thread acceptance requirements see Ford Worldwide Fastener Standards WA900, WE900
and WX100.
3.7 CURING AND TRANSPORTATION
3.7.1 The ZnNi electrodeposit with passivate/adhesion promoter will be cured and
packaged in accordance with supplier’s requirements prior to transportation to a
subsequent coating applicator.
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3.7.2 The organic seal coating for A2 shall be cured 15 minutes at a metal temperature of
80 to 120 °C.
3.7.3 The cathodic electrocoat for A3 shall be cured 20 minutes at a metal temperature of
175 to 200 °C.
3.7.4 The waterborne coating for A4 shall be cured 15 to 20 minutes at a metal temperature
of 190 to 205 °C.
3.7.5 These coatings shall not be used on materials that are adversely affected by these
metal temperatures.

Page 3 of 6
WSS-M21P44-A1/A4
3.8 CLEANING
Prior to coating, the substrate shall be free of oil, dirt, and similar foreign materials. If a cleaning
process is necessary, it shall have no detrimental effect on the substrate, including freedom
from embrittlement.
3.9 ADHESION
The coating shall withstand normal handling, storage, and installation without flaking or peeling
or other loss of adhesion.
3.10 TORQUE TENSION

(WZ101)
Applicators preparing the final layer of parts in accordance with A2, A3 or A4 must have torque
tension measurement equipment in accordance with WZ 101.
The coatings shall meet the torque and friction coefficient specified in Table 1.
3.11 RESISTANCE PROPERTIES
3.11.1 Corrosion resistance

(SAE/USCAR-1, ASTM B 117, ASTM D 610, WX100)
Fasteners shall be tested and evaluated in accordance with SAE/USCAR-1, and shall
pass the number of hours specified in Table 1 and the “General Requirements” of
WX100.
Parts other than fasteners shall be tested in accordance with ASTM B 117. Parts
shall show no single ferrous corrosion spot larger than 1.5 mm in diameter, and shall
not exhibit ferrous corrosion overall exceeding 0.1%, per ASTM D 610, grade 8, after
the number of test hours specified in Table 1.
3.11.2 Water Resistance

(FLTM Bl 104-01)
Shall not blister or show any signs of red rust when subjected to immersion in water
for 240 hours.
3.11.3 Gasoline Resistance
Shall not blister or show any signs of softening or dulling when subjected to
immersion in current factory fill gasoline for 24 hours at 23 +/- 2 °C.
3.11.4 Hot Oil Resistance
immersion in engine oil (SAE 10W30 per WSE-M2C903-A2 or equivalent) for 24
hours at 66 +/- 3 °C.
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WSS-M21P44-A1/A4
3.11.5 Ethylene Glycol Resistance
immersion in a 50% solution of water and long life coolant concentrate (WSE-
M97B44-B or equivalent) for 24 hours at 23 +/-2 °C.
3.11.6 Brake Fluid Resistance
immersion in currently approved brake fluid for 24 hours at 23 +/-2 °C.
3.11.7 Power Steering/Transmission Fluid
immersion in current factory fill power steering and transmission fluid for 24 hours at
66 +/-3 °C.
3.12 ELECTRICAL CONDUCTIVITY
Coating system A exhibits electrical continuity to the substrate but not sufficient enough to be
considered acceptable for general for electrical grounding applications. Coating systems A2,
A3 and A4 are not recommended for electrical grounding applications.
3.13 FORMABILITY
For A and A2, parts such as brackets, stampings, tubing, etc. that will be post formed following
processing shall follow coating manufacturers approved procedures; such as, ISO 8401-1986
(E) - cylindrical mandrel bending ensuring bendability, must be used and results recorded.
3.14 ULTRAVIOLET EXPOSURE

(ASTM D 4587-01, ASTM G 154-00a)
A and A2 coating systems are recommended for applications using ASTM D4587-01.
A3 and A4 coating systems are recommended for applications using ASTM G154-00a.
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WSS-M21P44-A1/A4
TABLE 1 – GUIDANCE TO PROPERTIES OF WSS-M21P44-A/A4 COATING SYSTEMS
Specification Color Typical WZ 101 WZ 101 N.S.S. N.S.S. Min. Examples of Part
Thickness Torque NM Friction Hours Hours Cycles Applications
µm (a) Coefficient Ferrous Zinc APGE to
µ Corrosion Oxidation Red Rust
(b) (c)
Parts for interior and
exterior use especially
where good corrosion
WSS-M21P44-A Silver 6 to 12 NA NA 480 hours NA 15/30 protection and electrical
conductivity are required,
brackets, clips, stampings
and tubing.
Mean: Mean: exterior use where very
44-49 .14 +/- .01 good corrosion protection
WSS-M21P44-A2 Silver 7 to 14 960 hours 360 hours 20/40 is required, externally
3 Sigma: 3 Sigma: threaded fasteners M4.2
38-55 .14 +/- .03 and larger, brackets, clips,
stampings and tubing.
Mean: Mean: exterior use where
44-49 .14 +/- .01 excellent corrosion
WSS-M21P44-A3 Black 18 to 30 960 hours 480 hours 30/60 protection is required,
3 Sigma: 3 Sigma: externally threaded
38-55 .14 +/- .03 fasteners M4.2 and larger,
brackets and stampings.
Mean: Mean: exterior use where
44-49 .14 +/- .01 excellent corrosion
WSS-M21P44-A4 protection is required,
Black 16 to 25 840 hours 480 hours 30/60
3 Sigma: 3 Sigma: externally threaded
38-55 .14 +/- .03 fasteners M8 and larger,
brackets, clips and
stampings.
(a) Based on WZ101 test program ‘B’ for M10x1.5 PC 8.8 surrogate bolt. Torque values taken @ 25.3 kN
tension.
(b) It is a characteristic of ZnNi that it will produce thin and adherent layers of zinc oxide corrosion products,
often referred to as gray veil, as it slowly sacrifices itself. Visible and voluminous zinc oxidation is
characterized as corrosion products, induced by a neutral salt spray cabinet, which are clearly visible
when wet and have affected surface topography on non-post formed surfaces and fasteners in
accordance with SAE/USCAR-1 section 5.
(c) Based upon Fasteners installed into test panels and testing in accordance with FLTM BI 123-02. Test
results are for comparative purposes only and do not necessarily correlate to actual APG performance.
The number left of the slant line indicates the APGE performance when tested against cathodic
electrocoated cold rolled steel panels. The number right of the slant line indicates the APGE
performance when tested against primed, painted and clearcoated 6111-T4 aluminum panels.

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ENGINEERING MATERIAL SPECIFICATION

CORROSION PROTECTIVE COATING, ZINC NICKEL ALLOY, WSS-M21P44-A1

CORROSION PROTECTIVE COATING, ZINC NICKEL ALLOY, WSS-M21P44-A2

CORROSION PROTECTIVE COATING, ZINC NICKEL ALLOY, WSS-M21P44-A3

CORROSION PROTECTIVE COATING, ZINC NICKEL ALLOY, WSS-M21P44-A4

All processes are free of hexavalent chromium, lead and cadmium.

2.1 SERVICE TEMPERATURE

The maximum continuous service temperature for A and A2 is 310 °C.

The maximum continuous service temperature for A3 and A4 is 260 °C.

Date Action Revisions

3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS

3.2 APPROVED APPLICATOR QUALITY REQUIREMENTS

3.4 COATING COMPOSITION

Printed copies are uncontrolled

3.5 COATING THICKNESS

3.6 THREAD ACCEPTANCE REQUIREMENTS

3.7 CURING AND TRANSPORTATION

Printed copies are uncontrolled

3.10 TORQUE TENSION

3.11 RESISTANCE PROPERTIES

3.11.1 Corrosion resistance

3.11.2 Water Resistance

3.11.3 Gasoline Resistance

3.11.4 Hot Oil Resistance

Printed copies are uncontrolled

3.11.5 Ethylene Glycol Resistance

3.11.6 Brake Fluid Resistance

3.11.7 Power Steering/Transmission Fluid

3.12 ELECTRICAL CONDUCTIVITY

3.14 ULTRAVIOLET EXPOSURE

Printed copies are uncontrolled

TABLE 1 – GUIDANCE TO PROPERTIES OF WSS-M21P44-A/A4 COATING SYSTEMS

Printed copies are uncontrolled

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