These tests are performed on the process to ensure the system is capable of meeting the coating requirements by class. These tests shall be performed on SC25, Type 0 coupons at a frequency established in subsection based on the class.

Galling Test

The producer shall perform the galling test in accordance with the procedures established in Appendix X1. The producer shall prepare the finishing lot galling report and shall demonstrate that loaded specimens will pass 608 days of evaluation with the torque ration of less than 2.5.

Chemical Composition

The nickel-cobalt alloy composition shall be measured quarterly or more frequently as specified using Test Method E2465 or other elemental analysis methods that can be demonstrated to meet precision and bias requirements of better than 1% mass weight.

Hydrogen Embrittlement Test

The producer shall perform quarterly, or more frequently, the procedure outlined in Test Method F519 by processing a set of four standard 1a specimens. They shall pass Test Method F519 criteria of no failure after 200 hours at 75% UTS.

Corrosion Testing

Electrochemical Corrosion Rate – The nickel-cobalt alloy coated article shall have a corrosion rate of less than 0.8636 µm/y when tested under Test Method G59. Corrosion rate shall be calculated in accordance with Practice G102. The test solution shall be prepared by dissolving 5 6 1 parts by mass of sodium chloride in 95 parts of water conforming to Type IV water in Specification D1193 (except that for this practice, limits for chlorides and sodium may be ignored). Careful attention should be given to the chemical content of the salt.
The salt used shall be sodium chloride with not more than 0.3 % by mass of total impurities. Halides (bromide, fluoride, and iodide) other than chloride shall constitute less than 0.1 % by mass of the salt content. Copper content shall be less than 0.3 ppm by mass. Sodium chloride that has had anti-caking agents added shall not be used because such agents may act as corrosion inhibitors. The level of pH shall be equal to 6.5 to 7.2, temperature 25 6 3° C, with atmospheric pressure and static conditions. The frequency of this shall be quarterly unless the purchaser specifies an increased frequency.

Environmental Testing
CASS Test

The producer shall evaluate the process corrosion protection by performing Test Method B368 on test coupons quarterly or more frequently as required. Panels processed to SC25 shall not show any red rust before 120 hours of exposure

Salt Spray (Fog) Test

The producer shall evaluate the process corrosion protection of the nickel-cobalt alloy by Practice B117 quarterly or more frequently as specified. Panels processed to SC25 shall pass with no red rust before 500 hours of exposure to salt spray (fog) as outlined in Practice B117.

Modified Salt Spray (Fog) Test

The producer shall evaluate the process corrosion protection of the nickel-cobalt alloy by Test Method G85 (A2 cyclic acidified salt fog testing) quarterly or more frequently as specified. Coupons processed to SC25 shall pass with no red rust before 200 hours of exposure to the Test Method G85 testing.

Third Party Reports

If a third party is used to perform these qualification tests, the test report shall include: Testing laboratory name, name and signature of person responsible for the test, location, list of equipment, current calibration certificates, and required permits for operating equipment (x-ray).

Frequency of Qualification Tests

The maintenance of a process requires frequent testing to ensure the quality is maintained and to instruct the operators in good practice to ensure good workmanship at all times. Table 1 shall be used to establish the maximum frequency for qualification testing of the process by class.