DAIMLERCHRYSLER CORPORATION PROCESS STANDARD NO: PS-80

Vehicle Engineering
Approved Source List Required: Yes Change: Z
Volume: H Section: 2 Page: 640

ZINC PHOSPHATE COATING - CORROSION RESISTANT ON IRON AND STEEL

1.0 GENERAL

1.1 Purpose of the Standard

This standard outlines the procedure for producing and the requirements of a dark gray to black
phosphate coating on iron and steel parts (including spring steel parts) using materials specified in
Material Standard MS-3327. The zinc phosphate coating is subsequently coated with an approved
companion rust inhibiting compound found in MS-4325.

1.2 Purpose of the Process

This process provides to the part a dark gray to black corrosion resistant coating. This process should
not be designated for parts that are to receive a subsequent paint coating.

1.3 Coverage of this Standard

This standard covers the process and performance requirements for a heavy zinc phosphate coating.
There are three versions of this process which may be listed as:

PS-80 The treated metal parts are subsequently coated with a rust inhibiting
compound (oil).
PS-80-Stained Black No special treatment is necessary for this requirement. The dark gray to
black color is satisfactory.
PS-80-Unoiled These parts shall not be coated with the rust inhibiting compound. This
applies to parts where an oiled surface would be objectionable; such as
assemblies containing rubber.

2.0 PROCESS

Parts shall be treated after all machining, welding, stamping, perforating, and heat treating operations
have been completed.

2.1 General Process Requirements

2.1.1 Racking

The parts shall be racked in such a manner to prevent any metal to metal contact between adjacent parts.

2.1.2 Solution Carryover

Solution carryover must be minimized by proper racking of parts and adequate drain time between
stages.

2.1.3 Operation

PS-80, Change Z, Page 1

Rinse overflows, bath dump schedules, chemical concentrations and operating parameters, and
maintenance shall be controlled according to the chemical surface treatment supplier’s recommendations.

2.1.4 Processing Water

Unless otherwise specified, make-up water and rinses shall contain less the 300 ppm of dissolved solids
with a maximum hardness of 250 mg/l CaO.

2.1.5 Handling

The parts should not be handled after processing and prior to the rust preventive. CLEAN LINT-FREE
GLOVES MUST BE WORN WHEN AN EMERGENCY WARRANTS HANDLING OF THE PARTS AT
THIS POINT IN THE PROCESS.

2.2 Phosphate Coat

2.2.1 Clean

Clean and prepare for phosphate treatment. Spring steel parts shall not be cleaned by acid pickling.

2.2.2 Phosphate Coat

Treat parts by immersion in an approved phosphate processing solution prepared and maintained with
MS-3327 for a period of 5 to 20 minutes, or within the parameters specified by the supplier.

2.2.3 Rinse

Rinse in cold water for 0.5 to 1 minute.

2.2.4 Seal

Rinse in hot dilute chromic acid sealing rinse for 0.5 to 1 minute.

2.2.5 Drain

Allow excess solution to drain from parts. Drying of the parts is preferred.

2.2.6 Unload Parts

Unload parts from processing racks or barrels.

NOTE: The parts shall not be coated with rust preventive while on the racks or in barrels used for
phosphating unless provisions are made for removing all rust preventive before reloading with additional
parts to be phosphated.

2.2.7 Relieve Hydrogen Embrittlement

Phosphated hardened steel parts with a Rockwell hardness of HRC 38 or higher must be hydrogen
relieved according to the requirements of PS-9500, Hydrogen Embrittlement Relief, Section 2.2.2. If the
baking option is used, it shall be done before the parts are coated with rust preventive oil.

2.2.8 Apply Rust Preventive

Coat parts with rust preventive, MS-4325, by dipping or flow coating.

PS-80, Change Z, Page 2

2.2.9 Drain

Drain to remove excess rust preventive. Rotate parts as required to prevent heavy coating in pocket
areas or ends of parts. Centrifugal driers may be used.

2.2.10 Dry

Dry before packing. Force drying at 121 degrees C (250 degrees F) is recommended. The protective
coating shall be sufficiently dry so that it will not be objectionable for handling.

3.0 FUNCTIONAL REQUIREMENTS AND TESTING

3.1 Testing Equipment and Materials Required

An in-house laboratory facility is necessary for phosphate material evaluation and solution control.
Required capabilities include titration for total acidity, free acidity, accelerator, total alkalinity, as well as
pH, and coating weight determination per DaimlerChrysler Laboratory Procedure LP-461J-96.

3.2 Testing Required

The testing outlined below is intended for use as well as verification of the process only. Suppliers
seeking materials approval must meet the requirements of the appropriate material standard(s).

3.2.1 Solution Control

The baths shall be controlled in accordance with the chemical supplier’s recommendations. The
temperatures, pressures, titrations, and process times shall be monitored and recorded as called out in
PF-7051.

3.2.2 Phosphate Coating Weight

Surfaces coated in accordance with this standard shall have a coating weight of no less than 10.9 g/sq m
(1000 mg/sq ft). The coating weight shall be determined per DaimlerChrysler Laboratory Procedure LP-
461J-96 at the frequency specified in PF-7051.

3.2.3 Appearance and Workmanship

Oiled parts shall be dark gray to black, uniformly treated, and free from bare spots. The parts shall be
free from excessive rust preventive which might be objectionable for handling in assembly. Unoiled parts
shall be uniformly treated and free from bare spots.

3.2.4 Resistance to Salt Spray

Production parts sampled per PF-7051 shall be exposed to salt spray per ASTM B117 for 72 hours.

NOTE: Parts calling for PS-80 or PS-80-Stained Black shall not be cleaned or rinsed prior to salt spray
testing. Parts calling for PS-80-Unoiled shall be prepared for salt spray testing by coating with Rust
Preventive MS-4325 as described in Section 2.2.8.

After completion of the exposure period, the appearance of six or more rust spots per 9.3 sq. dm (1 sq. ft)
of significant surface which are visible to the unaided eye at normal reading distance, or any rust spots
originating from an area larger than 1.6 mm (1/16 in) in diameter, will be considered unsatisfactory and
sufficient cause for rejection.

PS-80, Change Z, Page 3

3.2.5 Tolerance

Dimensions specified on drawings are for the finished part. When final dimensions are critical, for
example on threaded parts, machining tolerances must be adjusted to compensate for coating build-up.

3.2.6 Torque-Tensile Testing

When used on bolts and nuts, the coating shall produce a satisfactory torque-tensile load ratio. That is,
for 8 mm x 1.25 bolts and nuts, the torque-tensile load ratio shall be between 1 to 670 and 1 to 830 (for
5/16-18 bolts and nuts this ratio shall be between 1 to 17 and 1 to 21). The torque is measured in
newton-meters (inch-pounds) and the tensile load in Newtons (pounds).

4.0 GENERAL INFORMATION

Three asterisks “***” after the paragraph header denotes multiple technical changes to the paragraph. A
triple asterisk before and after a string of text (***text***) identifies a single change.

Certain important information relative to this standard has been included in separate standards. To
assure the processes submitted meet all of DaimlerChrysler requirements, it is mandatory that the
requirements in the following standards be met.

CS-9800 - Application of this standard, the subscription service, and approved sources
CS-9801 - General quality requirements
CS-9003 - Regulated substances and recyclability

Within Engineering Standards, the designations <S>, <E>, <N>, <T>, or <H> will be substituted for the
Safety, Emission, Noise, Theft Prevention, or Homologation Shields respectively. The designation <D>
will be substituted for the Diamond symbol.

Processes shall only be purchased from those sources listed under Engineering Approved Source List.

5.0 REFERENCES

ASTM B117 CS-9003 CS-9800

CS-9803 LP-461J-96 MS-3327

MS-4325 PF-7051 PS-9500

6.0 ENGINEERING APPROVED SOURCE LIST

SUPPLIER SUPPLIER CODE

California Industrial Products, Inc.
850 Steam Plant Road, P.O. Box 189 23062
Gallatin, TN 37066-3319
Chemical Processing Inc.
5485 Concord Street 23356
Detroit, MI 48211
Chem-Plate Industries, Inc.
1990 E. Devon Avenue ---
Elk Grove, IL 60007

PS-80, Change Z, Page 4

 SUPPLIER SUPPLIER CODE
Commonwealth Industries Division
TRI MAS Corporation
23667
5900 Commonwealth Ave
Detroit, MI 48208
Crown City Plating Co.
4350 Temple City Blvd 19930
El Monte, CA 91371-1093
Curtis Metal Finishing Co.
6645 Sims Drive 40877
Sterling Heights, MI 48313
Fitzgerald Plating Co.
17450 Filer Ave. 38225
Detroit, MI 48212-1908
Hohman Plating and Mfg., Inc.
814 Hillrose Ave. 46420
Dayton, OH 45404-1199
Howard Plating Co.
32565 Dequindre 46512
Madison Heights, MI 48071-1583
Philadelphia Rustproofing Co.
2086 East Willard ---
Philadelphia, PA 19134
Reilly Plating Co.
17760 Clarann, P.O. Box 3213 79459
Melvindale, MI 48122-1300
API Industries, Inc.
1250 Morse Avenue 70647
Elk Grove Village, IL 60007
***Hi-Tech Coatings
24600 Industrial Hwy. ---
Warren, MI 48089 ***

7.0 BIBLIOGRAPHY

By entering the names of the approvers listed below, the writer is stating that the approver has reviewed
this Process Standard AS SUBMITTED and concurs with its contents.

Date Standard Originally (Initially) Issued: December 05, 1921

Department Name and Number: Body Materials Engineering, Dept. 5820
Current Contact/Phone No: Rodney Briggs, (248) 576-7448
Alternate Contact/Phone No: Joe Lesnek, (248) 576-6516

7.1 Revision (Technical, Editorial, or Source Change) Required Approvals

Date of Change: November 01, 2000

Model Year - Effectivity Code - Disposition Code:
Authority: Editorial
Change Level: Z
Owning Dept. Supervisor Approval: T. Bjelica
Owning Dept. Mgr. Approval:
Quality and Reliability Approval or Materials Engr. Mgr. Approval:

PS-80, Change Z, Page 5

Description of Change: Hi-Tech Coatings added to approved source list.

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PS-80, Change Z, Page 6