At the completion of validation testing, the test results were documented in a JTR. The JTR will documents the data and results of the testing and is available as a reference for future pollution prevention and other DoD, NASA and commercial users.

In summary, the JTR indicates that zinc-nickel plating applied from either a Dipsol of America alkaline or Boeing process and IVD-AL are acceptable coatings to replace cadmium on component parts made of low strength steel (less than 200 ksi), stainless steel, aluminum, and copper alloys. These three candidate coatings passed the critical tests of adhesion to substrate, corrosion resistance, and paint adhesion. Tin-zinc plating coupons showed red rust in the scribed corrosion test and developed resistance values greater than cadmium in the galvanic corrosion test. For this reason it cannot be recommended for use on component parts. IVD-AL and Boeing zinc-nickel coatings passed the lubricity tests. The tin-zinc and alkaline zinc-nickel coatings on the fasteners were too thick rendering the test results for these coatings invalid. The run-on/break-away characteristics of the candidate coatings differ from that of cadmium. Further testing may be required to determine acceptability of these coatings on threaded components. Additional evaluation with the participation of a fastener manufacturer is needed to fully validate these coatings for acceptability on standard fasteners. For high strength steel applications (greater than 200-ksi-strength level) tin-zinc, IVD-AL, and Boeing zinc-nickel are candidate coatings. These three coatings passed the sustained tensile load test in the as-coated condition and had equivalent performance to cadmium in the rotating beam fatigue test. The alkaline zinc-nickel plating failed sustained tensile load and showed decreased fatigue life relative to cadmium plating. The potential use of alkaline zinc-nickel plating on system critical components should be carefully reviewed. All of the candidate coatings showed acceptable processing characteristics, fluid resistance, and repairability. Zinc-nickel brush plating is recommended for use as a repair method on cadmium and all of the candidate coatings tested here.

To view the Joint Test Report for Validation of Alternatives to Electrodeposited Cadmium for Corrosion Protection and Threaded Part Lubricity Applications, dated December 9, 2002, please click below, for the section you wish to review.

• Main Document
• Appendix A - Boeing-Philadelphia Test Report
• Appendix B - Boeing-St. Louis Test Report
• Appendix C - Plating Specifications
  • Cadmium-Boeing
  • Low-Hydrogen-Embrittlement-Cadmium_BAC5718
  • Tin-Zinc-Boeing
  • Titanium-Cadmium-BAC5804
  • Zinc-Nickel-Boeing_BAC5637

This site last updated February 28, 2008.