AMS 2402H

AEROSPACE
MATERIAL Issued DEC 1942
400 Commonwealth Drive, Warrendale, PA 15096-0001
SPECIFICATION Revised APR 2001

Superseding AMS 2402G

Plating, Zinc

1. SCOPE:

1.1 Purpose:

This specification covers the engineering requirements for electrodeposition of zinc and the
properties of the deposit.

1.2 Application:

This process has been used typically to provide corrosion resistance to metal parts, but usage is not
limited to such applications.

1.3 Safety-Hazardous Materials:

While the materials, methods, applications, and processes described or referenced in this
specification may involve the use of hazardous materials, this specification does not address the
hazards which may be involved in such use. It is the sole responsibility of the user to ensure
familiarity with the safe and proper use of any hazardous materials and to take necessary
precautionary measures to ensure the health and safety of all personnel involved.

2. APPLICABLE DOCUMENTS:

The issue of the following documents in effect on the date of the purchase order forms a part of this
specification to the extent specified herein. The supplier may work to a subsequent revision of a
document unless a specific document issue is specified. When the referenced document has been
cancelled and no superseding document has been specified, the last published issue of that document
shall apply.

SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely
voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.”
SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.
Copyright 2001 Society of Automotive Engineers, Inc.
All rights reserved. Printed in U.S.A.
QUESTIONS REGARDING THIS DOCUMENT: (724) 772-7161 FAX: (724) 776-0243
TO PLACE A DOCUMENT ORDER: (724) 776-4970 FAX: (724) 776-0790
SAE WEB ADDRESS: http://www.sae.org
 AMS 2402H SAE AMS 2402H

2.1 SAE Publications:

Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.

AMS 2759/9 Hydrogen Embrittlement Relief (Baking) of Steel Parts

2.2 ASTM Publications:

Available from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.

ASTM B 117 Operating Salt Spray (Fog) Testing Apparatus

ASTM B 253 Preparation of Aluminum Alloys for Electroplating
ASTM B 487 Measurement of Metal and Oxide Coating Thicknesses by Microscopical Examination
of a Cross Section
ASTM B 499 Measurement of Coating Thicknesses by the Magnetic Method; Nonmagnetic
Coatings on Magnetic Basis Metals
ASTM B 504 Measurement of Thickness of Metallic Coatings by the Coulometric Method
ASTM B 555 Measurement of Electrodeposited Metallic Coating Thicknesses by the Dropping Test
ASTM B 567 Measurement of Coating Thickness by the Beta Backscatter Method
ASTM B 568 Measurement of Coating Thickness by X-Ray Spectrometry
ASTM B 571 Adhesion of Metallic Coatings
ASTM E 376 Measuring Coating Thickness by Magnetic-Field or Eddy-Current (Electromagnetic)
Test Methods
ASTM F 519 Mechanical Hydrogen Embrittlement Evaluation of Plating Processes and Service
Environments

3. TECHNICAL REQUIREMENTS:

3.1 Preparation:

3.1.1 Parts shall be within drawing dimension limits before plating, except as specified in 3.1.2.1.

3.1.1.1 Parts having part numbers with the prefix MA, AN, MS, or AS or parts where the drawing
specifies dimensions apply after plating shall be made to such dimensions that parts will be
within drawing limits after plating. Undercutting before plating shall not be permitted unless
specifically authorized by specifications referenced or the applicable drawing.

3.1.2 Steel parts having hardness higher than 40 HRC and which have been ground after heat treatment
shall be cleaned to remove surface contamination and suitably stress-relieved before preparation
for plating. Temperatures to which parts are heated shall be such that maximum stress relief is
obtained without reducing hardness of parts below drawing limits but, unless otherwise specified,
not less than 275 °F (135 °C) for not less than five hours for parts with hardness of 55 HRC or over,
or not less than 375 °F (191 °C) for not less than four hours for other parts.

3.1.3 Any specified residual compressive stress-inducing operations, such as shot peening, shall follow
stress relieving but precede plating.

-2-
 AMS 2402H SAE AMS 2402H

3.1.4 Parts shall have clean surfaces, free of waterbreak, prior to immersion in the plating solution.

3.1.5 Electrical contact points shall be as follows: for parts which are to be plated all over, location shall
be acceptable to purchaser; for parts which are not to be plated all over, location shall be in areas
on which plating is optional.

3.2 Procedure:

3.2.1 Except as noted, the zinc shall be deposited directly on the metal part from a suitable zinc plating
solution.

3.2.1.1 Nickel or cobalt alloys and corrosion resistant steels may be given a nickel or other suitable metal
strike prior to zinc plating. A zincate immersion coating in accordance with ASTM B 253 may be
used on aluminum alloys.

3.2.2 After rinsing in water and without allowing the parts to dry, plated parts shall unless otherwise
specified be chemically treated by a process which has been demonstrated to prevent the
formation of white corrosion products. When plated parts require post thermal treatment as in 3.3,
surface reactivation and the supplementary treatment shall follow hydrogen embrittlement relief.

3.3 Hydrogen Embrittlement Relief:

Treatment of steel parts shall be in accordance with AMS 2759/9.

3.4 Properties:

The plating shall conform to the following:

3.4.1 Thickness: Shall be as specified on the drawing, determined on representative parts or, when
permitted by purchaser, on test specimens (See 4.3.3) in accordance with ASTM B 487, ASTM B
499, ASTM B 504, ASTM B 567, ASTM B 568, or ASTM E 376, the drop test of ASTM B 555, or
other method acceptable to purchaser. When thickness is determined by the drop test method,
plating shall not be perforated in less time than specified in Table 1.

3.4.1.1 Plate thickness may be specified by AMS 2402 and a suffix number normally designating the
minimum thickness in ten-thousandths of an inch (µm); except as indicated in Table 1, the
maximum plate thickness shall be 0.0002 inch (5 µm) greater than the minimum. Thus
AMS 2402-2 designates a thickness of 0.0002 to 0.0004 inch (5 to 10 µm) and AMS 2402-6
designates a thickness of 0.0006 to 0.0008 inch (15 to 20 µm).

3.4.1.1.1 Plate thickness, when specified by AMS 2402 and a suffix number, shall be as specified in
Table 1 for the specified suffix number and type of part or surface.

3.4.1.2 Where “zinc strike” is specified, plate thickness shall be approximately 0.0001 inch (2.5 µm).

-3-
 AMS 2402H SAE AMS 2402H

TABLE 1A - Plate Thickness, Salt Spray Corrosion Resistance, and Perforation Time Requirements, Inch/Pound Units

Nuts, Nuts,
Nuts, Washers, & Washers, &
Washers, & Unthreaded Unthreaded
Unthreaded Surfaces of Surfaces of
Surfaces of Bolts, Screws, Bolts, Screws,
Bolts, Screws, Studs, & Other Studs, & Other
External External Studs, & Other Parts Externally Parts Externally Other Other
AMS 2402 External Threads Threads Parts Externally Threaded Threaded Other Parts Parts
Thickness Threads Salt Spray Perforation Threaded Salt Spray Perforation Parts Salt Spray Perforation
Designation Thickness Resistance Time Thickness Resistance Time Thickness Resistance Time
Specified Inch hours, min seconds, min Inch hours, min seconds, min Inch hours, min seconds, min
2402 0.0001 to 100 10 0.0002 to 150 20 0.0005 to 200 51
0.0004 0.0005 0.0007
2402-1 0.0001 to 100 10 0.0002 to 150 20 0.0001 to 100 10
0.0003 0.0004 0.0003
2402-2 0.0001 to 100 10 0.0002 to 150 20 0.0002 to 150 20
0.0004 0.0004 0.0004
2402-3 0.0002 to 150 20 0.0003 to 168 30 0.0003 to 168 30
0.0005 0.0005 0.0005
2402-4 0.0003 to 168 30 0.0004 to 185 41 0.0004 to 185 41
0.0006 0.0006 0.0006
2402-5 0.0004 to 185 41 0.0005 to 200 51 0.0005 to 200 51
0.0007 0.0007 0.0007

Note 1: For thickness designations AMS 2402-X, where X is greater than five, plate thickness in
ten-thousandths of an inch shall be X to X+2 except on external threads where the plate thickness
shall be X-1 to X+2; such parts shall withstand salt spray for not less than 250 hours and plating
shall not be perforated in less than 10X seconds in thickness determinations by drop test.

NOTE 2: Perforation times specified above are for the drop test solution of 3.4.1 at 70°F;
equivalent perforation times at other temperatures are as shown in Table 2B.

TABLE 1B - Equivalent Perforation Time

Perforation Time Seconds Seconds
Seconds at Temperature Shown at Temperature Shown
at 70 °F 75 °F 80 °F
10 10 10
20 20 19
30 30 29
41 39 37
51 49 47

-4-
 AMS 2402H SAE AMS 2402H

TABLE 1C - Plate Thickness, Salt Spray Corrosion Resistance, and Perforation Time Requirements, SI Units

Nuts, Nuts, Nuts,

Washers, & Washers, & Washers, &
Unthreaded Unthreaded Unthreaded
Surfaces of Surfaces of Surfaces of
Bolts, Screws, Bolts, Screws, Bolts, Screws,
External External Studs, and Other Studs, and Other Studs, and Other Other Other
AMS 2402 External Threads Threads Parts Externally Parts Externally Parts Externally Other Parts Parts
Thickness Threads Salt Spray Perforation Threaded Threaded Salt Spray Threaded Perforation Parts Salt Spray Perforation
Designation Thickness Resistance Time Thickness Resistance Time Thickness Resistance Time
Specified µm hours, min seconds, min µm hours, min seconds, min µm hours, min seconds, min
2402 3 100 10 5 150 20 8 200 51
10 13 13
2402-1 3 100 10 5 150 20 3 100 10
8 10 8
2402-2 3 100 10 5 150 20 5 150 20
10 10 10
2402-3 5 150 20 8 168 30 8 168 30
13 13 13
2402-4 8 168 30 10 185 41 10 185 41
15 15 15
2402-5 10 185 41 13 200 51 13 200 51
18 18 18

Note 1: For thickness designation AMS 2402-X where X is greater than five, plate thickness in
micrometers shall be 2.5X to 2.5 (X+2) except for external threads where the plate thickness
shall be 2.5 (X-1) to 2.5 (X+2); such parts shall withstand salt spray for not less than 250 hours
and plating shall not be perforated in less than 10X seconds in thickness determinations by drop test.

Note 2: Perforation times specified above are for the drop test solution of 3.4.1
at 70 °F (21 °C); equivalent perforation times at other temperatures are as
shown in Table 2D.

TABLE 1D - Equivalent Perforation Time

Seconds Seconds
Perforation Time, Seconds at Temperature Shown at Temperature Shown
at 21 °C 24 °C 16 °C
10 10 10
20 20 19
30 30 29
41 39 37
51 49 47

-5-
 AMS 2402H SAE AMS 2402H

3.4.1.3 The plate shall be substantially uniform in thickness on significant surfaces except that slight
build-up on exterior corners or edges will be permitted provided finished drawing dimensions are
met.

3.4.1.4 No requirements are established for minimum plate thickness for surfaces of holes, recesses,
internal threads except as specified in Table 2, contact areas of parts plated all over, and other
areas where a controlled deposit cannot be obtained under normal plating conditions, but such
areas shall not be masked to prevent plating. However, such surfaces shall show visual
evidence of coverage. Except as specified in Table 2 for externally threaded sections, the
resulting thickness shall be considered only when such surfaces of parts can be touched by a
sphere 0.75 inch (19.0 mm) in diameter.

3.4.1.4.1 If internal surfaces as defined in 3.4.1.4 are required to be plated to a specified thickness,
notes on the drawing will so specify.

3.4.2 Adhesion: Plating shall be firmly adhered to the basis metal and shall be tested using one of the
following methods:

3.4.2.1 The plating shall be scraped through to the basis metal with a sharp knife or awl to expose the
basis metal and examined at approximately 5X magnification for evidence of flaking off or
separation.

3.4.2.2 The basis metal shall be plastically bent or deformed as required to cause it to crack and
examined at approximately 5X magnification for evidence of flaking or separation of the plating.

3.4.2.3 Test adhesion using the burnishing test, draw test, or heat quench test of ASTM B 571.

3.4.2.4 Adhesion testing is not required for parts that are post treated by heating to at least 375 °F (191
°C), quenched, and examined for blisters or other signs of lack of adhesion.

3.4.3 Corrosion Resistance: Except as specified in 3.4.3.2, ferrous metal parts or representative
specimens as in 4.3.3 shall show no visual evidence of corrosion of the basis metal after being
subjected for a time not less than specified in Table 2 to continuous salt spray corrosion test
conducted in accordance with ASTM B 117. Intentionally unplated areas may be masked during
testing. Where the drawing specifies a specific plating thickness, the most stringent test
requirement for the minimum specified thickness shall apply.

3.4.3.1 In addition to the requirements of 3.4.3, plated parts which have received a supplementary
chemical treatment as in 3.2.2 shall not show evidence of white corrosion product, determined by
exposure for 96 hours to corrosion test in accordance with ASTM B 117.

3.4.3.2 Salt spray corrosion tests shall not apply to plated parts made of austenitic corrosion-resistant
steels, to parts made of any corrosion-resistant steel or alloy when not plated all over, and to
parts made of any steel when thickness is specified as “flash”.

-6-
 AMS 2402H SAE AMS 2402H

3.4.4 Hydrogen Embrittlement: When parts with hardness of 36 HRC or higher are plated, the process
used shall not cause hydrogen embrittlement when tested in accordance with requirements of
ASTM F 519.

3.5 Quality:

Plated zinc, as received by purchaser, shall be continuous, adherent to basis metal, uniform in
appearance, and not coarsely crystalline and shall be essentially free from pin holes, porosity,
blisters, nodules, pits, and other imperfections detrimental to performance of the plated zinc. Slight
staining or discoloration is permissible. There shall be no evidence of double plating or spotting-in
after plating.

4. QUALITY ASSURANCE PROVISIONS:

4.1 Responsibility for Inspection:

The processor shall supply all test specimens for processor’s tests and shall be responsible for
performance of all required tests. When parts are to be tested, such parts shall be supplied by
purchaser. Purchaser reserves the right to sample and to perform any confirmatory testing deemed
necessary to ensure that processing conforms to the requirements of this specification.

4.2 Classification of Tests:

4.2.1 Acceptance Tests: Thickness (3.4.1), adhesion (3.4.2), and quality (3.5) are acceptance tests and
shall be performed to represent each lot.

4.2.2 Periodic Tests: Corrosion-resistance (3.4.3), hydrogen embrittlement, when parts 36 HRC or
higher are plated, (3.4.4) and tests of cleaning and plating solutions to ensure that the deposited
metal will conform to specified requirements (See 8.5) are periodic tests and shall be performed at
a frequency selected by the processor unless frequency of testing is specified by purchaser.

4.2.3 Preproduction Tests: All technical requirements are preproduction tests and shall be performed
prior to or on the first-article shipment of plated parts to a purchaser, when a change in material,
and/or processing requires approval by the cognizant engineering organization (See 4.4.2), and
when purchaser deems confirmatory testing to be required.

4.3 Sampling and Testing:

Shall be not less than the following; a lot shall be all parts of the same part number, plated to the
same range of plate thickness in the same set of solutions, in each consecutive 24 hours of
operation, and presented for processor’s inspection at one time.

4.3.1 For Acceptance Tests: Test samples shall be selected randomly from all parts in the lot. Unless
purchaser supplies a sampling, plan, the minimum number of samples shall be as shown in Table
2.

-7-
 AMS 2402H SAE AMS 2402H

TABLE 2 - Sampling for Acceptance Tests

Number of Thickness and
Parts in Lot Quality Adhesion
Up to 6 All 3
7 to 15 7 4
16 to 40 10 4
41 to 110 15 5
111 to 300 25 6
301 to 500 35 7
501 to 700 50 8
701 to 1200 75 10
Over 1200 125 15

4.3.2 For Periodic Tests and Preproduction Tests: Sample quantity shall be at the discretion of the
processor unless otherwise specified by purchaser.

4.3.3 Nondestructive testing shall be performed wherever practical. Except as noted, actual parts shall
be selected as samples for tests.

4.3.3.1 When plated parts are of such configuration or size as to be not readily adaptable to the specified
tests or when nondestructive testing is not practical on actual parts, or it is not economically
acceptable to perform destructive tests on actual parts, separate test specimens of the same
generic class of alloy as the parts represented, cleaned, plated, and post-treated with the
represented parts may be used.

4.3.3.2 Test specimens for corrosion testing, when required, shall be fabricated from low carbon steel,
approximately 0.032 x 1 x 4 inches (0.8 x 25 x 102 mm) or bars approximated, 0.5 inch (13 mm)
in diameter and 4 inches (102 mm) long.

4.3.3.3 Hydrogen embrittlement test specimens shall conform to ASTM F 519 Type 1 using notched
round bars stressed in tension under constant load. For test purposes, plating thickness shall be
0.0005 to 0.0007 inch (13 to 18 µm), measured on the smooth section of the specimen, but with
visual evidence of plating in the root of the notch.

4.4 Approval:

4.4.1 The process and control factors, a preproduction sample plated part, or both, whichever is
specified, shall be approved by the cognizant engineering organization before production parts are
supplied.

-8-
 AMS 2402H SAE AMS 2402H

4.4.2 The processor of plated parts shall make no significant change to materials, processes, or control
factors from those on which approval was based, unless the change is approved by the cognizant
engineering organization. A significant change is one which, in the judgment of the cognizant
engineering organization, could affect the properties or performance of the parts.

4.4.2.1 Control factors shall include, but not be limited to, the following:
Surface preparation and cleaning procedures
Surface activation procedures
Plating bath composition and composition control limits
Plating bath temperature limits and controls
Current/voltage limits and controls
Chemical post treatment
Method for testing plating thickness
Method for checking adhesion
Stripping procedure, if required
Periodic test plan.

4.5 Reports:

The processor of plated parts shall furnish with each shipment a report stating that the parts have
been processed and tested in accordance with specified requirements and that they conform to the
acceptance test requirements. This report shall include the purchase order number, lot number,
AMS 2402H, part number, and quantity.

4.6 Resampling and Retesting:

4.6.1 If the results of any acceptance test fail to meet specified test requirements, the parts in that lot
may be stripped by a method acceptable to purchaser that does not roughen, pit, or embrittle the
basis metal, pretreated, plated and post treated as defined herein, and tested. Alternatively, all
parts in the lot may be inspected for the nonconforming attribute, and the nonconforming parts may
be stripped by a method acceptable to purchaser that does not roughen, pit, or embrittle the basis
metal, pretreated, plated, post treated as defined herein, and tested.

4.6.2 If the results of any periodic test fail to meet specified requirements, the process is nonconforming.
No additional parts shall be plated until the process is corrected and new specimens are plated and
tested. Results of all tests shall be recorded and, when requested, reported. Purchaser shall be
notified of all parts plated since the last acceptable test.

5. PREPARATION FOR DELIVERY:

5.1 Plated parts shall be handled and packaged to ensure that the required physical characteristics and
properties of the plating are preserved.

-9-
 AMS 2402H SAE AMS 2402H

5.2 Packages of parts shall be prepared for shipment in accordance with commercial practice and in
compliance with applicable rules and regulations pertaining to the handling, packaging, and
transportation of the plated parts to ensure carrier acceptance and safe delivery.

6. ACKNOWLEDGMENT:

A processor shall mention this specification number and its revision letter in all quotations and when
acknowledging purchase orders.

7. REJECTIONS:

Parts on which the plating does not conform to this specification, or to modifications authorized by
purchaser, will be subject to rejection

8. NOTES:

8.1 A change bar ( l ) located in the left margin is for the convenience of the user in locating areas where
technical revisions, not editorial changes, have been made to the previous issue of this specification.
An (R) symbol to the left of the document title indicates a complete revision of the specification,
including technical revisions. Change bars and (R) are not used in original publications, nor in
specifications that contain editorial changes only.

8.2 Part manufacturing operations, such as heat treatment, forming, joining and media finishing, can
affect the condition of the substrate for plating, or, if performed after plating, could adversely affect
the plate. The sequencing of these types of operations should be specified by the cognizant
engineering organization and is not controlled by this specification.

8.3 The parts manufacturer should ensure that the surfaces of metal parts supplied to the processor are
free from blemishes, pits, tool marks, and other irregularities that will affect the quality of the finished
parts. Defects and variations in appearance that arise from surface conditions of the substrate, such
as porosity, scratches, or inclusions, that persist in the finished plate despite observance of industry
accepted plating practices would not be considered as cause for rejection.

8.4 Alkaline cleaning may be done with anodic current but should not be done with cathodic current or
periodic current reversal on ferrous metal parts.

8.5 ARP4992, Periodic Test Plan for Process Solutions, is recommended to satisfy the requirement for
control of processing solutions.

8.6 Key Words:

Corrosion resistance, electrodeposition

8.7 Dimensions and properties in inch/pound units and the Fahrenheit temperatures are primary;
dimensions and properties in SI units and the Celsius temperatures are shown as the approximate
equivalents of the primary units and are presented only for information.

- 10 -
 AMS 2402H SAE AMS 2402H

8.8 Purchase documents should specify not less than the following:

AMS 2402H
Plate thickness desired
Tensile strength or hardness of parts
Stress relief, if required
Quantity of pieces to be plated.

8.9 An acid dip may be used for surface activation or neutralization of residual alkaline cleaner.
However, the immersion time should be minimized to preclude pitting or embrittling effects.

PREPARED UNDER THE JURISDICTION OF AMS COMMITTEE “B”

- 11 -