SECTION 3

Corrosion Protection
• Corrosion Types
Topics
• Plating Options
• Galvanizing
• Coating Options
• Other Materials
• Compliance
 Types of Corrosion
• Environmental
• Galvanic (dissimilar metals)

Electron Flow Oxidation

Buildup

Anode Anode

Time
Electrolyte
Electrolyte

Cathode Cathode
 Galvanic Corrosion
The electrons are flowing
Electron Flow
through the battery from the +
(anode) to the – (cathode).
Wire
Cathode Anode
Salt Bridge
To satisfy the potential difference between the
anode and cathode, electrons travel along the
wire to the cathode. This in turn leaves the
anode to react with the environment due to this
loss of electrons.

Battery
 Galvanic Series
Galvanic Series of Metals: The table
indicates the “groups” of various metals and
alloys. All metals have electrical potentials.
The galvanic series of metals chart is based
on the potentials of different base metals and
alloys when exposed to sea water. Those in
similar groups represent low potential
difference or more compatible material.
 Corrosion Protection Options

Add the platings, coatings, galvanizing, and nickel based alloys

Think about adding a barrier/sacrificial slide after this

Bob had cathodic barrier slide in there
 Measuring Corrosion Resistance
• ASTM B117 dictates the procedures, apparatus, and conditions to create a
controlled environment for corrosion resistance
• This creates an “apples to apples” comparison
• No direct real world translation
B633 is meant for plate
material (coupons)

• ASTM B633
• Paragraph 1.5 from B633:

• ASTM F1941
 Plating Standards
• ASTM F1941
– Inch Standard since 1998
• ISO 4042
– Metric standard
• ASTM B633 Not the best bet for fasteners but still
on many prints
 ASTM F1941
• Fastener specific corrosion requirements
• Clear distinction between white and red
rust
• 2015 revision features new baking
guidance for hydrogen embrittlement
• Defines significant surfaces
 Electro-Zinc Plating
• Clean the parts
– Generally alkaline based solutions that the parts sit in for varying amounts of
time
– After soaking they get a “scrub” in those same solutions
– Hydrochloric acid pickling for 5-10 minutes (commonly a 35% concentration)
• Rinse
• Zinc Electroplate
• Chromate
• Inspection
Electroplating Process

Barrel Plating Rack Plating

 Effects of Electroplating

• Buildup heavier at sharp corners

• Thickness is greater at extreme ends
• Buildup is least in recessed areas
• Pitch diameter changes by 4X thickness
Restricted Substance Directives
RoHS – Restrictions of Hazardous Substances (EU and China)
WEEE – Waste of Electrical and Electronic Equipment
CPSIA – Consumer Product Safety Information Act
ELV - End of Life Vehicle
GADSL – Global Automotive Declarable Substances
REACH – Registration, Evaluation, Authorization and restriction
of Chemicals
 RoHS-EU
European Union Directive 2002/95/EC, effective July 1, 2006, restricts the
use of six hazardous substances in electrical and electronic equipment.

Table 1 Compliance Matrix for Plain Carbon, Alloy and Stainless Steel Fasteners
Substance Reference Maximum Limit (in wt%) Fastener Material
Pb ANNEX (6) 0.35% < .35% (steels)
< 0.4% (aluminum alloys)
< 4.0% (copper alloys)
Φ
Cd TAC 0.01% Free from Cd
Φ
Hg TAC 0.1% Free from Hg
Φ
Cr+6 TAC 0.1% Free from Cr+6¥
PBB TACΦ 0.1% Free from PBB
Φ
PBDE TAC 0.1% Free from PBDE
Φ
The Directive itself does not define composition limit requirements, therefore, it is necessary to follow current
Technical Adaptation Committee (TAC) maximum concentration values or exemptions.
¥
Alloy and stainless steels contain metallic chromium alloying elements (valence state 0). Be advised that welding on
an alloy or stainless steel can cause the benign chromium in these steels to enter a hazardous Cr+6 state.
Hexavalent Chromium +6
(Cr )
Passivate film forms
“barrier” protection for
“sacrificial” zinc layer

If layer is broken, Cr+6

forms new passivate film
with water and zinc

Passivate film is
regenerated: self-healing
 Advantages of Hex Chrome
Prevents Oxide Formation
Provides Colors
Slows Corrosion
Provides Adhesion for Organics (Paint)
Thin
Conductive
Flexible
Resilient (self-healing)
 Drawbacks to Plating
• Most cost effective platings are generally decorative
• Restrictions on use of some of the more effective platings
• Internal Hydrogen Embrittlement (IHE)
• Brittle fracture that occurs when hydrogen is trapped during the
plating process
• Delayed failure
• Requires susceptible material, tensile stress, a hydrogen source, and
time to occur
 Hydrogen Embrittlement
F
Close up of
Micro crack H
Micro crack H
H

H
H

F
With
StartsDUCTILE fastener
with a micro as (EVERYTHING
crack a tensile load “F”
HASisCRACKS
applied–(such
theseascracks
whenmay tightened),
the sharpfrom
initiate point of the crack expands/grows
manufacturing, and becomes
fatigued, overload, blunt (rounded)
or other various reasons notwhich
stops
With the
related tocrack
HE). propagation.
susceptible material
Note theand Hydrogen
“H” is
appropriate
hydrogen also attracted
amount
present of by the
inhydrogen, area of
the crack
the material high to
continues
stress, whichconcentrates
grow .Stress is the crackat(note theand
the tip rounded
hydrogensurface of the
migrates crack
to the distributes
stress the
concentration
point (note
hydrogen the hydrogen now concentrated at the tip). The crack continues to grow
concentration).
through the now embrittled material
 Hydrogen Embrittlement
Hydrogen
The final
second escapes
first fingerprint
fingerprint
fingerprint after
we a failure
identify
would
is the beisso
transition we
the
the zone
have
betweento look
presence of afor
the other
brittle
ductile
brittle signs.
fracture.
failure.
and ductile These
This signs
means
fractures.
are
This the
Trapped
the metal
zone“fingerprints”
hydrogen
tried to
helps hang ofon
differentiatea hydrogen
concentratesasthe longat
twothetypes of
as
embrittlement
micro cracks
possible
fractures. and The near
evenfailure.
the Inoforder
edge
stretched
presence ofbefore
multiple to fastener,
the itfracture
just
identify
we expect
couldn’t
types them
withtaketo we
see
it
a clear anyhave
evidenceto use
longer.
transition of aappears
powerful
brittleness
Itconfirms like
that
tool
there called
around
small wasthat
cratersaa localized
scanning
area.
or dimples electron
under
brittle area theonSEM,
the this Microvoid
microscope
We can
type and(SEM).
identify
of failure
fastener that SEMas
is aknown
brittle
brittle photo
fracture
microvoid
zone shown
ended.by on Coalescence
the right
spotting
coalescence.
For ajagged
instance if thelooking surface
brittle zone wasthatcarried
some say
across theresembles
entire fastener rock candy
we would under the
probably Intergranular
microscope.
have The material
a heat treating problem scienceinstead worldof Cracking
calls this intergranular
hydrogen embrittlement cracking.
 Hydrogen Embrittlement
• Hydrogen embrittlement Triggers
needs the following
conditions to create a
concern: Source of Tensile
1) A susceptible Hydrogen Stress
material
2) Hydrogen Source
HE
3) Tensile Stress
4) Time - Given time,
three conditions
must be met in
sufficient overlapping
quantities for HE
Susceptible
failure to occur.
Material

Root Cause
 IHE Examples
Example1 2– –
Example
Standard
Standard A574/12.9
SAE J429 Grade
Source of (HRC 33-39)
8 (HRC 39-44) with
Tensile
Hydrogen “typical”
“typical” electro
electro zinc
zinc
Stress
Result
Result – HEHE
– NO Concern

So, we use a bake to try to

“eliminate” the hydrogen

Susceptible 4 hours is not

Material sufficient, so we need
to go longer -----
 RoHS Compliance Options
Plain Finish without coating
Stainless Steel
Other Options:
Zinc with non-hexavalent chromate passivate
protective coatings - trivalent chromium
conversion coatings (Cr3 or Cr III), sealers, etc.
Chromium Free Dip Spin Coating: Geomet,
Magni, etc.
ArmorGalv – Thermal Diffusion Coating
Paint (lead free)
300 Series Stainless-Inch
300 Series Stainless-Metric
The most common callouts for Fastenal would be for A2 or A4

A2 is like calling for 18-8

A4 is like calling for 316

Property class 70 is the default (cold worked condition) with

fasteners
 Other Stainless Options
• Strain hardened versions
• Super Alloys
• Inconel
• Monel
• Hastelloy

All of these options are available as customs, they have applications in highly
corrosive environments but you will pay a premium for them
 Other Coatings

•Hot Dip Galvanized – ASTM F2329, ASTM A153

•Mechanical Galvanized – ASTM B695
•Geomet – ASTM F1136
 Hot Dip Galvanizing
Fasteners coated with zinc by a hot
dipping process are considered
galvanized. The advantage of the hot dip
galvanizing is the added corrosion due to
the thickness.
Coating Thickness: hot dip fasteners will
range from 1.7 – 3.4 mils (43-86 microns).

Offers cathodic (sacrificial) protection

 HDG Up Close

The end result is a metallurgical bond to the steel series of zinc-iron alloy layers topped by a free zinc layer.
 Global Processing of HDG
North America: Typical zinc bath is about 845° F
Thicker/Chunkier finish comes out dull gray
Rest of the World: 990°-1040° F
More uniform thickness, and less buildup in the threads,
typically comes out shinier

Can lead to torque/tension differences that could cause issues

if specs were based off one type
 Mechanical Galvanizing
• Tumbling parts with zinc powder, impact
media, and “promoter” to essentially beat
the zinc onto the part
• Processing takes a long time and is quite
manual so this does cost more than
HDG
• Internal threads don’t see as much
buildup
• Damage to threads can happen
• Thickness 5-70 microns
 Mechanical Galvanizing
• Specify by
– class (thickness)
– Type (color)
 Dip Spin Coatings
The dip-spin coatings describe the way they are applied
They were originally introduced to the automotive industry to replace cadmium
and as a means of achieving long-term exposure to environmental conditions.
•Dacromet
•Geomet
•Magni
•Doerken
Dip Spin (Zinc-Flake) Coatings
Zinc Flake coatings are made by a combination of zinc and
aluminum flakes with an inhibitor “binder” system.
 Application

1 2 3 4
Pretreatment Coating Curing
Cooling and
repeating and/or
Curing (baking)
Alkaline Cleaning adding topcoat if
Dip Spinning temperatures are
then Grit blasting necessary
Spraying dependant on
to ensure free of all
Dip Drain-Spin coating process
contaminants.
• Excellent Corrosion protection (1,000 hours to red rust) performs well in cyclical testing
• Excellent bi-metallic protection
• Self healing film (sacrificial)
• Chromium free
• Hydrogen embrittlement free
• Cleaned with alkaline or degreaser
• Mechanical blasting
• NO acids or electrolysis used in the processing
• Solvent resistant
• Not affected by oils or most liquids that are used in the
automotive industry
• Heat Resistant above many other coatings
• Cured around 600 degrees Fahrenheit
• Narrow torque/tension scatter
• Thinner than many dip spin offerings
• Water based binders
• Complies with ASTM F1136 Grade 5 and ISO 10683
 Other Coatings
Magni (Chrome free) ASTM F2833
Generally same benefits as Dacromet/Geomet, but thicker (12+
microns)
Coatings available to go over plating to greatly extend corrosion
resistance and improve torque/tension consistency
•Cures at lower temperature than Dac/Geo (450 F vs. 600 F)

Doerken Delta MKS (Chrome free)

Generally same benefits as Dacromet/Geomet, but thicker (12+
microns)
Coatings available to go over plating to greatly extend corrosion
resistance and improve torque/tension consistency
Cures at lower temperature than Dac/Geo (450 F vs. 600 F)
 Applicator Spec Sheets

If you work
with specific
Note: OEMs they
Performance will list the
Data Listed specs they are
approved for
 Drawbacks to Coatings
• Recess filling with socket head cap screws
• Buildup on threads can prevent gaging
• “nut fit” is the method to judge acceptability
• Nuts can present issues:
– All metal toplock nuts will scrape any plating or coating
– Nylon insert nuts cannot be coated as curing happens above the nylon’s upper limit
• Small parts under ¼” and fine threaded product can experience thread fill
• Nicking and chipping
• Flat washers tend to stick to one another and can require special handling or
sorting
 Coating Pricing/Cost
• There are minimum lot charges that apply to secondary processes
– Minimizing them as best we can by coating larger runs or mixing product
– Fastenal has the EcoGuard line done in large lots to minimize the piece price
• Typically more expensive than zinc, but cheaper than stainless

If I were selecting coatings (Personal Opinion)

1. Look to use EcoGuard if available off the shelf
2. Use the EcoGuard performance criteria as the secondary option but
only specify by the criteria not brand
3. Coat as much as I am comfortable committing to at a time
EcoGuard Performance Criteria

• Torque Coefficient or K Factor: .15 +/-.03

• Coating thickness average 6-12 microns
• Gaging is “nut fit”
 Wrap Up:

• Use ASTM F1941 instead of ASTM B633

• Compliance Directives dictate what we can use
• Coatings are the future of fastener corrosion protection
• Specify performance criteria rather than a brand
End of Section 3
Plating Options