Cadmium Plating Replacement

Zn-Ni Plating Technology for

Boeing Commercial Airplane

Louie Tran

Chemical Technology
SERDP/ESTCP WORKSHOP - ASETSDefense 2009
Sept 03, 2009
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Technical Requirements/Performance Summary–
Comparable to Cd/Cd-Ti
Engineering, Operations & Technology | Boeing Research & Technology Chemical Technology

9 Adhesion to Substrates (alloy steels 9 Lubricity on gear / spline

and others) 9 In-service Evaluation
9 Adhesion to Paint (primer and /or ‰ Torque-tension performance
topcoat)
9 Standard Parts
9 Corrosion Resistance
9 Large Axle Simulation
9 Type II coating
9 Plating Process performance
9 Type II coating + primer
9 On Threads
9 Touch-up and Repair
9 On Large Parts
9 Type II coating on fasteners
9 Microstructure
9 Bushing Installation / Removal Effect
‰ Maintenance Fluid Compatibility
‰ Electrical Resistance / Conductivity
‰ Runway Deicer Compatibility
9 Fatigue Allowables Evaluation
‰ Hydraulic Fitting Usability
9 Hydrogen Embrittlement
9 Complete
‰ In-work
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Plating Adhesion (low strength substrates) - Pass
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• Panels plated with

0.5 to 0.8 mils (low
alloy steel and other
substrates)
• Bend adhesion
tested per BSS7235
• Results - No flaking
of plating observed

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 Paint Adhesion Results – Pass
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BMS10-11 BMS10-20 BMS10-60

• Panels plated 0.5 – 0.8 mils and painted as noted

• Painted adhesion tested per BSS7225, Class IV, Wet and Dry
• Results - No paint flaking along scribed line (wet and dry)
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 Corrosion Resistance (Ty II) Results - Pass
(with Cr+6 and Cr+3 Seal)
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Hexavalent Chromate Trivalent Chromate

Panels plated 0.5 to 0.8 mils.

• Salt spray per ASTM B117.
• Results: No white rust (WR) after 96 hrs
salt spray.
Note: White streaks in Trivalent
chromate (right) was not corrosion

Panels plated 0.5 to 0.8 mils.

1 3 4 7 8 • Scribed through plating to expose metal
X X
in groove (panels 7X to 10X)
• Salt spray test per ASTM B117.

• Results: No red rust (RR) after 1500 hrs

2 5 6 9 10 salt spray, including Type I (Panels 1 &
X X
2 are without CC)

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 Corrosion Resistance (Stylus Zn-Ni Repair) - Pass
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Cd repaired with stylus Zn-Ni Zn-Ni repaired with stylus Zn-Ni

Goodrich data were removed

• Panels plated 0.5 to 0.8 mils Cd (left) and Zn-

Ni (right)
• Repaired (center of panels) 0.5 to 0.8 mils
brush Zn-Ni
• Salt spray per ASTM B117
• Results: No white corrosion after 96 hrs S/S
• SIFCO 4018/5970 qualified for BAC5664
Issue:
• Only one qualified solution
• Limited repair area (4 in2)
• Option (not preferred); stylus LHE Cd
In Work:
• Expand area
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• Qualify new solution
Bushing Installation/Removal
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• Lug specimens (fatigue test specimen)

• Test specimens selected based on
similar cycles-to-failure
Condition Lug Bushing
Finish Finish

Run-out Cycle- Cd-Ti Zn-Ni

to-failure

Load
Run-out Cycle- Alkaline Alkaline
to-failure Zn-Ni Zn-Ni Direction
fmax = 60ksi
R = 0.10
0.5M Cycle-to- Cd-Ti Cd Freq = 5 Hz
failure

0.5M Cycle-to- Alkaline Cd

failure Zn-Ni

• No damage to plating or exposed base

metal after bushing removal
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Electrical Resistance/Conductivity – Bonded Joint
(Bonding & Grounding)
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Test Configurations
1. Faying Bonded Joint
– Current path is Zn-Ni plated CRES to bare Al
– Compared acid and alkaline Zn-Ni process on CRES with Aluminum
2. Clearance Fit Structural Joint (BAC5117-18)
– Fasteners (conductive) intended to provide electrical current path through a non-conductive
joint (CFRP)
3. Interference Fit Structural Joint (BAC5117-19)
– Electrical path through fasteners with two metal surfaces

Test Conditions
• Test configurations/set up conditioned and measured
• Corrosion testing per modified ASTM B 117
• Humidity testing per modified MIL-STD-810F
• Thermal testing – cycles between -65F and 160F @ 95+5%
• Vibration tested
• DC electrical current measured

Requirement
• Meet a low electrical bond resistance measurement (milli-ohms)

Status:
• Testing completed. Initial data acceptable
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 Torque-Tension Characteristics
(Standard Parts)
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• Bolts - BMS10-85 (Al pigmented epoxy) coated in all cases

• Nuts - 3/8” plated to 0.3 to 0.6 mil Cd and/or Zn-Ni + DFL (Kalgard FA)
• Washers - 3/8” coated to 0.3 to 0.6 mil Cd, Zn-Ni or BMS10-85 or passivated
• Acceptability criterion – At 400 in-lb torque, target tension 30% to 60% of design limit (BAC5009)
• Result - Alkaline Zn-Ni plated nuts/washers performed comparable to Cd in torque-tension
relationship)
C H A R T 1 : U S B OLT , H R N U T , B P WA SH E R

T E NSI ON

18000
UT S = 20900
16000

14000
N6CD/ W6P K
12000
N6CD/ W6DP
10000 N6CD/ W6ZI NC

N6CS/ W6A P U
8000 45% of UT S
N6ZI NC/ W6P K
6000
N6ZI NC/ W6DP
30% of UT S
4000 T ar get I ns t al l at i on T or que = 400 i n-l b N6ZI NC/ W6ZI NC

2000

T ORQUE

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 Torque-Tension Characteristics
(Standard Parts)
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• Bolts - BMS10-85 (Al pigmented epoxy) coated in all cases

• Nuts - 3/8” plated to 0.3 to 0.6 mil Cd and/or Zn-Ni + DFL (Kaylube K130)
• Washers - 3/8” coated to 0.3 to 0.6 mil Cd, Zn-Ni or BMS10-85 or passivated
• Acceptability criterion – At 400 in-lb torque, target tension 30% to 60% of design limit (BAC5009)
• Result - Acid Zn-Ni plated nuts/washers performed comparable to Cd in torque-tension relationship)
CH AR T 2 : US B OLT , H R NU T , B P WA SHE R

T E NSI ON

14000
UT S = 20900

12000

10000 N6CD/ W6P K

N6CD/ W6DP
45% of UT S
8000 N6CD/ W6ZI NC

N6CS/ W6A P U

N6ZI NC/ W6P K

6000
30% of UT S N6ZI NC/ W6DP

N6ZI NC/ W6ZI NC

4000

T ar get I nst al l at i on

2000 T or que = 400 i n-l b

0
T s-50 i n-l bs T s-0100 i n- T s-0150 i n- T s-0200 i n- T s-0250 i n- T s-0300 i n- T s-0350 i n- T s-0400 i n- T s-0450 i n- T s-0500 i n- T ORQUE
l bs
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EOT_RT_Sub_Template.ppt | 10
 Trivalent Chrome Conversion Coating
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Hexavalent Chrome Conversion Coating (Ty II)

• Both Cd and Zn-Ni plating requires chromate solution Zn-Ni with Cr6+ CC
• Many solutions available with various appearance
• Hexavalent chrome - toxic substance under stringent
regulation (i.e. OSHA & REACH)
• Requirement
• Corrosion resistance
• Paint and dry film lubricant adhesion
• Compatible with maintenance fluids and other
Trivalent Chrome Conversion Coating (Type II)
• Approved chromate solutions for alkaline Zn-Ni plating
• Most are hexavalent chromate
• Presently one trivalent chromate solution
(EchoTri)
• Other trivalent chromate solutions are under
evaluation Zn-Ni with Cr3+ CC (EchoTri)
• MetalastTM TCP-HF (clear chromate)
• White corrosion between 72-96 hrs
• Can be adjusted to pass and
appears promising
• Dipsol IZ-264 in work
• Evaluated for Atotech and Dipsol
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 Fatigue Allowables for High Strength Steel
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Effect of Zn-Ni on fatigue life of high strength steels

• AISI 4340M notched specimens with baseline bare (uncoated) specimens
GROUP ID fmax = 150 ksi, R = -0.50 GROUP ID fmax = 60 ksi, R = 0.10

Bare Bare

Cd Cd

Cd-Ti Cd-Ti

Acid Zn-Ni Acid Zn-Ni

Alkaline Zn-Ni Alkaline Zn-Ni

10,000 100,000 1,000,000 10,000 100,000 1,000,000 10,000,000

Cycles Count Cycles Count
Lug Specimens Fracture
Round-Notched (Kt = 1.2) Fracture β test
βtest Runout / Suspended
Outlier

• Acid Zn-Ni dropped from consideration due to fatigue debit

Effect of Zn-Ni on fatigue life of 15-5 PH CRES

• Coatings - bright Cd, LHE Cd, acid Zn-Ni, Atotech Zn-Ni and Dipsol Zn-Ni
• Testing in progress
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In-Process Hydrogen Detection Instrumentation
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Current Specification Testing Method

• BPPM is required for real-time, quick determination of low hydrogen
characteristic of the Cd-Ti plating solution
• BPPM or Lawrence gage for LHE Cd plating
• No such equivalent method for Zn-Ni plating.
• Requires notch tensile specimen

Test Method under development/evaluation for Zn-Ni

• Short Term
• BPPM
• Screening evaluation in progress
• Qualification to follow
• Long Term
• Notch Bend Test
• Boeing developed equipment and specimen configuration
• Correlation being established for bright Cd and LHE Cd
• Verification with Cd-Ti (Boeing Portland) - late 2009
• Evaluation with alkaline LHE Zn-Ni - 2009/2010

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 Alkaline Zn-Ni plating – Top View
Coating Microstructure
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• Both Cd-Ti and Zn-Ni

exhibit nodules/cracks
necessary for hydrogen
egress during HE relief
baking

Cd-Ti plating – Bend Fracture Alkaline Zn-Ni plating – Bend Fracture

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 Lubricity Characteristics
(Gears & Splines)
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Endurance Life Test - 767-400ER Leading Edge Gearbox
• A full Acceptance Test Procedure (ATP) performed
prior/after Life Endurance Test (one aircraft life = 49500
cycles)
• Conducted by Smith Aerospace (UK)
Results:
• Zn-Ni acted as good seal with no oil/water leak (water
ingress marginal and comparable to Cd)
• Zn-Ni performed comparable to Cd
In-Service Evaluation - 767-400ER Leading Edge Rotary
Actuator Gears
•Two Zn-Ni units installed on one wing. Cd-Ti units remain
on other wing for 2 - 3 yrs
•Four test units to be shipped to Boeing (M&PT) for
analysis at end of test

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 Maintenance Fluid Compatibility Results to-date
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• Weight loss (24 hour

immersion)
• Specimens plated with
Cd, Cd-Ti and Zn-Ni
• Testing 75% completed

• Hydrogen Re-
embrittlement
• Specimens plated with
LHE Cd, Cd-Ti and LHE
Zn-Ni
• Testing in progress

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Galvanic Compatibility with Aluminum - Pass
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Corrosion Potential
• Cd (-730 mV) and Zn-Ni (-770 mV) have similar corrosion potential
• Cd is compatible with Aluminum alloys
• Zn-Ni is compatible with Aluminum alloys

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 Galvanic Compatibility with CRES Result - Pass
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Potential Coupling
• Zn-Ni and Cd plated 4130 alloy steel with 15-5PH (CRES)
• All shows the same effect at 500 hrs salt spray

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Technical Summary
Engineering, Operations & Technology | Boeing Research & Technology Chemical Technology

• Modified Atotech Zn-Ni plating met key spec requirements

– Adhesion to Substrate (alloys steels and others)
– Adhesion to Paint (primer and topcoat)
– Bushing installation and removal effect
– Corrosion Resistance/Protection
– Fatigue Allowables for high strength steel
– Hydrogen Embrittlement
– Microstructure
– Torque-tension Characteristic
– Touch-up and Repair Application
• Modified Alkaline Zn Ni Process meets or exceeds performance of Cd-Ti
• Goodrich is qualified and on QPL
• Zn Ni Plating used successfully in service on low strength steel since 1992
• Fatigue allowables developed for high strength steel
• Hydrogen Embrittlement issue with high strength steel since 1992 has been
successfully resolved in 2005
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Benefits and Intellectual Property
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Benefits shared by all stakeholders

1. Reduces suppliers’ environmental and worker safety requirements during
manufacturing
2. Reduces airline customers’ environmental and worker safety requirements
during maintenance operations
3. Reduces impact of future regulatory requirement
4. Provides competitive advantage
5. Supports everyone’s environmental initiative

Intellectual Property
1. Boeing Alkaline Zn-Ni (BAC5637 and BAC5680) is a Boeing Intellectual
Property
2. Will be protected (Patent application submitted to the US Patent and
Trademark Office)
3. Licensing required for all users
4. Use on Boeing parts is ‘no-fee’ license
5. Use on non-Boeing hardware requires a license

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