AMS2451™ REV.

D
AEROSPACE
MATERIAL SPECIFICATION Issued 1998-07
Revised 2019-05

Superseding AMS2451C

Plating, Brush
General Requirements

RATIONALE

AMS2451D results from a Five-Year Review and update of this specification with changes to ordering information, operator
training (3.2), preparation (3.3), thickness (3.5.1.1), slash specification requirements (3.5.2), adhesion to specimens
(3.5.2.1), quality (3.6), and preproduction tests (4.2.3).

NOTICE

ORDERING INFORMATION: The following information shall be provided to the plating processor by the purchaser.

1. Purchase order shall specify not less than the following:

• AMS2451 slash specification number and revision letter.

• Plating thickness desired (see 3.5.1.1).

• Basis metal to be plated.

• Tensile strength or hardness of the basis metal.

• Pre-plate stress relief to be performed by plating processor (time and temperature) if different from 3.3.1.

• Special features, geometry or processing present on parts that requires special attention by the plating processor.

• Hydrogen embrittlement relief, when specified in the slash specification, to be performed by plating processor
(parameters or reference document) if different from 3.4.3.1.

• Provisions peculiar to parts or assemblies to be repaired or overhauled.

• Optional: Periodic testing frequency (4.2.2) and sample quantity (4.3.2) if different from 4.2.2 and 4.3.2.

• Quantity of pieces to be plated.

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

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1. SCOPE

1.1 Purpose

This specification and its supplementary slash specifications establish the requirements for electrodeposition of metals by
brush plating.

1.2 Application

This process has been used typically to improve surface properties such as corrosion resistance, wear resistance, and
brazeability or to repair damaged, worn, or mismachined parts, but usage is not limited to such applications. This process
is particularly useful for plating localized areas on-site, especially on large parts or assemblies, and for minimizing masking.

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.

2.1 SAE Publications

Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA
and Canada) or +1 724-776-4970 (outside USA), www.sae.org.
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AMS2759 Heat Treatment of Steel Parts, General Requirements

AMS2759/9 Hydrogen Embrittlement Relief (Baking) of Steel Parts

ARP1917 Clarification of Terms Used in Aerospace Metals Specifications

AS2390 Chemical Process Test Specimen Material

2.2 ASTM Publications

Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959,
Tel: 610-832-9585, www.astm.org.

ASTM B117 Operating Salt Spray (Fog) Apparatus

ASTM B253 Preparation of Aluminum Alloys for Electroplating

ASTM B374 Terminology Relating to Electroplating

ASTM B487 Measurements of Metal and Oxide Coating Thickness by Microscopical Examination of a Cross Section

ASTM B499 Measurement of Coating Thicknesses by the Magnetic Method: Nonmagnetic Coatings on Magnetic Basis
Metals

ASTM B504 Measurement of Thickness of Metallic Coatings by the Coulometric Method

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ASTM B530 Measurement of Coating Thicknesses by the Magnetic Method: Electrodeposited Nickel Coatings on
Magnetic and Nonmagnetic Substrates

ASTM B567 Measurement of Coating Thickness by the Beta Backscatter Method

ASTM B568 Measurement of Coating Thickness by X-Ray Spectrometry

ASTM B571 Qualitative Adhesion Testing of Metallic Coatings

ASTM E140 Hardness Conversion Tables for Metals Relationship Among Brinell Hardness, Vickers Hardness, Rockwell
Hardness, Superficial Hardness, Knoop Hardness, Scleroscope Hardness, and Leeb Hardness

ASTM E376 Measuring Coating Thickness by Magnetic-Field or Eddy Current (Electromagnetic) Testing Methods

ASTM E384 Microindentation Hardness of Materials

ASTM F519 Mechanical Hydrogen Embrittlement Evaluation of Plating/Coating Processes and Service Environments

2.3 U.S. Government Publications

Copies of these documents are available online at http://quicksearch.dla.mil.

MIL-STD-865 Selective, Brush Plating, Electro-deposition

3. TECHNICAL REQUIREMENTS

3.1 Slash Specification

The requirements for a specific brush plating shall consist of all requirements specified herein in addition to requirements
specified in the applicable slash specification. In case of conflict between requirements of this basic specification and the
applicable slash specification, requirements of the slash specification shall govern.

3.2 Operator Training

3.2.1 Operators performing work under this standard shall be certified as qualified operators by the Quality Control
Department of the plating facility or by the solution manufacturer/supplier. Operator training shall include plating of
simulated parts and specimens, and approval shall be based on evaluation of the operator’s familiarity with the
brush plating equipment/solutions, and the specification requirements. Certification shall be conferred on trained

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operators, who have successfully demonstrated knowledge of the process and their ability to produce satisfactory
plating per this standard through written and practical examination.

3.2.2 Parts and test specimens shall be plated by trained operators who have been approved and certified initially and
then annually thereafter for plating on the basis material with the equipment and processing materials to be used
(see 8.3).

3.3 Preparation

3.3.1 All steel parts having a hardness of 40 HRC and above and that are machined, ground, cold formed or cold
straightened after heat treatment shall be cleaned to remove surface contamination and thermally stress relieved
before plating. (Residual tensile stresses have been found to be damaging during electroplating.) Furnaces used
for stress relief shall be controlled per AMS2750; the minimum requirements shall be Class 5 and Type D
Instrumentation. Temperatures to which parts are heated shall be such that stress relief is obtained while still
maintaining hardness of parts within drawing limits. Unless otherwise specified, the following treatment
temperatures and times shall be used:

3.3.1.1 For parts, excluding nitrided parts, having a hardness of 55 HRC and above, and for carburized and induction
hardened parts, stress relieve at 275 °F ± 25 °F (135 °C ± 14 °C) for 5 to 10 hours.

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3.3.1.2 For parts having a hardness less than 55 HRC, and for nitrided parts, stress relieve at 375 °F ± 25 °F (191 °C ±
14 °C) for a minimum of 4 hours. Higher temperatures shall be used only when specified or approved by the
cognizant engineering organization.

3.3.1.3 For peened parts: If stress relief temperatures above 375 °F (191 °C) are elected, the stress relieve shall be
performed prior to peening or the cognizant engineering organization shall be consulted and shall approve the
stress relief temperature.

3.3.1.4 Assemblies shall be treated in a manner acceptable to the cognizant engineering organization.

3.3.2 The plating shall be applied over a surface free from water breaks. The cleaning procedure shall not produce pitting
or intergranular attack of the basis metal and shall preserve dimensional requirements.

3.3.3 For parts that are to be plated all over, electrical contact locations shall be acceptable to purchaser. For parts that
are not to be plated all over, locations shall be in areas on which plating is not required.

3.4 Procedure

3.4.1 The equipment, materials, and procedures used to process specimens and parts shall conform to a schedule of
control factors (see 4.4.3) and to the recommendations of the manufacturer of the selective plating equipment and
processing materials.

3.4.1.1 Aluminum alloys may be zincate or stannate treated in accordance with ASTM B253 or other method acceptable
to the cognizant engineering organization prior to plating.

3.4.2 After plating, parts shall be rinsed with water, to remove residual plating solution, and immediately dried.

3.4.3 Post Treatment

3.4.3.1 Hydrogen Embrittlement Relief

3.4.3.1.1 Treatment of steel parts shall be in accordance with AMS2759/9 except baking of parts plated in accordance
with AMS2451/4, AMS2451/9, and AMS2451/10 is not required when compliance with 3.5.2.6 is achieved
without baking.

3.4.3.2 Assemblies shall be treated in a manner acceptable to the cognizant engineering organization.

3.5 Properties

3.5.1 The following requirements apply to all slash specifications.

3.5.1.1 Thickness

Plating thickness shall be as specified on the drawing/purchase order determined in accordance with any of the following
methods as applicable: ASTM E376, ASTM B487, ASTM B499, ASTM B504, ASTM B530, ASTM B567, ASTM B568,
measuring equipment such as micrometers, bore gauges and calipers or other method acceptable to the cognizant
engineering organization. For surfaces where the plating thickness is unable to be measured, thickness measurement is
not required to be determined as long as the thickness is controlled by ampere hours. Unless otherwise specified, plating
thickness shall be uniform within ±20%, except within 1/8 inch (3.2 mm) of exterior edges and corners where thicker plating
(buildup) is permissible. Unless otherwise specified, surfaces such as holes, recesses, threads and other areas where a
controlled deposit cannot be obtained under normal plating conditions, may be under the specified limit provided they show
visual plating coverage.

3.5.1.1.1 Where “nickel flash” is specified, plate thickness shall be approximately 0.0001 inch (1.27 µm).

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3.5.1.2 Adhesion to Parts

There shall be no visual evidence of plating separation from the underlying substrate when the following test is performed.
Tape, 1 inch (25 mm) wide or wider, having adhesive strength of not less than 60 ounces per inch (0.66 N/mm) of width,
shall be firmly applied to the plated area. It shall then be pulled manually from the plated area at approximately 90 degrees
to the plated surface in one sharp movement. When both unplated and plated areas can be covered by the tape, it shall be
pulled from the unplated area toward the plated area.

3.5.1.2.1 When plating is to be subsequently machined, this test may be omitted if acceptable to the cognizant
engineering organization.

3.5.2 The following requirements only apply when specified in a slash specification. These requirements shall not be
applicable for touch-up applications of less than 30% surface area repairs and when used for braze preparation.

3.5.2.1 Adhesion to Specimens

Adhesion shall meet the requirements of ASTM B571 by the Bend Test method. There shall be no evidence of separation
of plating from the basis metal when examined at 4X to 10X magnification; cracks which do not result in flaking or peeling
of the plate are acceptable.

3.5.2.2 Hardness
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Hardness values shall be as specified and shall be determined in accordance with ASTM E384.

3.5.2.3 Stress

The residual surface stress in the deposit shall be as specified in a slash specification and shall be determined by X-ray
diffraction or another method which is acceptable to the cognizant engineering organization.

3.5.2.4 Heat Resistance

3.5.2.4.1 Plated ferrous and corrosion resistant parts or specimens shall withstand without blistering, cracking, or
debonding, being heated in air to 700 °F ± 15 °F (371 °C ± 8 °C) and held at temperature for not less than
23 hours, followed by heating in air to 1000 °F ± 15 °F (538 °C ± 8 °C) and holding at temperature for not less
than 60 minutes, then air cooling to room temperature.

3.5.2.4.2 Plated aluminum and aluminum alloy, and copper and copper alloy parts or specimens, shall pass the heat-
quench test of ASTM B571.

3.5.2.5 Corrosion Resistance

Representative specimens shall be plated, and post-plating treated shall be as specified in a slash specification. There shall
be no visual evidence of corrosion of the basis metal on plated surfaces after continuous exposure to salt spray in
accordance with ASTM B117, for 48 hours, -0, +1 hour, unless another period is specified. Where plating is used only to
aid brazing or where used only for dimensional restoration, corrosion testing may be waived if acceptable to the cognizant
engineering organization.

3.5.2.6 Hydrogen Embrittlement

The plating process shall not cause hydrogen embrittlement in steel parts 36 HRC and over determined in accordance
with 4.3.3.3.

3.6 Quality

Visually, without the use of magnification, the plating shall be continuous and free from plating defects such as frosty areas,
pin holes, blisters, porosity, nodules, and pits; slight staining or discoloration is permissible. Parts shall be free from evidence
of arcing and of overheating.

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4. QUALITY ASSURANCE PROVISIONS

4.1 Responsibility for Inspection

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

4.2 Classification of Tests

4.2.1 Acceptance Tests

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Thickness (3.5.1.1), adhesion to parts (3.5.1.2), and quality (3.6) are acceptance tests and shall be performed on each lot.

4.2.2 Periodic Tests

When required by the applicable slash specification, adhesion to specimens (3.5.2.1), hardness (3.5.2.2), stress (3.5.2.3),
heat resistance (3.5.2.4) and corrosion resistance (3.5.2.5) are periodic tests and shall be performed at least quarterly
unless frequency of testing is specified by the cognizant engineering organization. When required by the applicable slash
specification, hydrogen embrittlement (3.5.2.6) is a periodic test and shall be performed at least once in each month that
steel parts 36 HRC and over are plated to the applicable slash specification unless frequency of testing is specified by the
cognizant engineering organization. Tests of preparatory and plating solutions are periodic tests and shall be performed at
a frequency established by the processor unless frequency of testing is specified by the cognizant engineering organization.

4.2.3 Preproduction Tests

All property verification tests (3.5) are preproduction tests and shall be performed for each schedule of control factors prior
to initial shipment of plated parts when specified by the purchaser and when the cognizant engineering organization requires
confirmatory testing.

4.3 Sampling for Testing

4.3.1 Acceptance Test

Test samples shall be randomly selected from all parts in the lot. A lot shall be all parts plated by the same schedule of
control factors, processed without a change of setup within a 7-day period by the same operator, and presented for
processor’s inspection at one time and presented for processor’s inspection at one time. Unless the cognizant engineering
organization provides a sampling plan, the minimum number of samples shall be as shown in Table 1.

Table 1 - Sampling for acceptance tests

Number of
Parts in Lot Quality Thickness Adhesion
1 to 6 All All All
7 to 15 All 7 All
16 to 40 All 8 16
41 to 100 All 10 20
101 to 300 All 12 24
301 to 500 All 14 28
Over 500 All 16 32

4.3.2 Periodic Tests

Sample quantity shall be selected at the discretion of the processor, unless otherwise specified.

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4.3.3 Sample Configuration

Nondestructive testing shall be performed wherever practical. Except as noted, actual parts shall be selected as samples
for tests. When representative specimens are used for acceptance testing, values so obtained shall be correlated with those
of parts since properties, such as thickness, may differ between parts and representative test specimens.

4.3.3.1 Representative test specimens may be used in lieu of parts under any one of the following circumstances: The
plated parts are of such configuration or size as to be not readily adaptable to specified tests, nondestructive
testing is not practical on actual parts, or it is not economically acceptable to perform destructive tests on actual
parts. Except as specified below, representative test specimens shall be made of the same generic class of alloy
as the parts, established in accordance with AS2390, distributed within the lot, cleaned, plated, and post treated
with the parts represented.

4.3.3.2 Corrosion Testing

When ferrous alloy parts are processed within the quarter yearly test period, representative test specimens shall be low
carbon or low alloy steel 0.025 inch (0.63 mm) minimum thickness and not less than 1 x 4 inches (25 x 102 mm) or bars
approximately 1 inch (25 mm) in diameter and 4 inches (102 mm) long having a surface roughness not to exceed
40 microinches (1 µm) AA. Representative test specimens for aluminum alloy parts (same specimen size as for steel) made
of either 2024-T3 or the same generic class of alloy as the parts processed within the test period when aluminum alloy parts
are plated. Representative test specimens made of the predominant generic class of alloy as the parts and plated within
the test period may be used when acceptable to the cognizant engineering organization. Alternative alloy or configuration
may be used when acceptable to the cognizant engineering organization. Plating thickness shall be 0.0003 to 0.0006 inch
(8 to 15 µm) unless otherwise specified or acceptable to the cognizant engineering organization.

4.3.3.3 Hydrogen Embrittlement Test

Test shall be in accordance with the requirements of ASTM F519 Type 1a.1, or 1a.2 using round notched specimens or
Type 2a, unless a different specimen is specified by the cognizant engineering organization, stressed in tension under
constant load. For test purposes, the plating thickness shall be 0.0003 to 0.0006 inch (8 to 15 µm) on the smooth section
of the Type 1a.1 specimen and visual evidence of plating at the root of the notch.

4.4 Approval

4.4.1 The schedule of control factors shall be approved by the cognizant engineering organization before production parts
are supplied. The schedule of control factors shall contain a level of slash specification detail information sufficient
to ensure reproduction of preproduction characteristics in production parts. If supplier proprietary information is
involved, the supplier may certify that the information is proprietary and is available for review by the cognizant
engineering organization.

4.4.2 If the processor makes a significant change to any material, process, or control factor from that which was used for
process approval, all preproduction tests shall be performed, and the results submitted to the cognizant engineering
organization for process reapproval 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.

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4.4.3 The schedule of control factors shall be maintained and shall include not less than the following:

Basis metal and condition

Stress relief treatment prior to plating, if any
Surface preparation and cleaning
Preplate, if required
Equipment description
Anode design/designation
Plating solution composition or manufacturer’s designation
Voltage and current ranges
Relative motion between anode and workpiece during deposition
Restrictions on interrupted plating
Embrittlement relief time and temperature, if required
Test methods
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 AMS2451D and applicable slash number specification, and that they conform to the specified
requirements. This report shall include the purchase order number, lot number, part number, and quantity.

4.6 Resampling and Retesting

4.6.1 If any acceptance test fails to meet specified test requirements, the parts in that lot may be stripped, pretreated,
plated, and post treated as defined herein and retested. Alternatively, all parts in the lot may be inspected for the
nonconforming attribute, and the nonconforming parts may be stripped, pretreated, plated, and post treated as
defined herein and retested. After stripping and replating, parts shall meet the dimensions on the drawing.

4.6.1.1 When stripping is performed, the method shall be acceptable to the cognizant engineering organization and shall

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not roughen, pit, or embrittle the basis metal or adversely affect part dimensions.

4.6.2 If any periodic test fails to meet specified test 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
parts and the plating are preserved.

5.2 Packages of plated 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 parts to ensure
carrier acceptance and safe delivery.

6. ACKNOWLEDGMENT

Processor shall mention this specification number in all quotations and when acknowledging purchase orders.

7. REJECTIONS

Parts not conforming to this specification and the applicable slash specification, or to modifications authorized by the
cognizant engineering organization, will be subject to rejection.

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8. NOTES

8.1 Revision Indicator

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 document. An (R) symbol to the left of the document title
indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original
publications, nor in documents that contain editorial changes only.

8.2 Parts 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
operations should be specified by the cognizant engineering organization and is not controlled by this specification.

8.3 The plating company (facility) should have a program of training or instruction that includes study of
equipment/solutions, procedures and the practice of brush plating.

8.4 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 parts despite observance of industry accepted plating practices would not be considered
as cause for rejection.

8.5 For the desired plate, the applicable slash numbered specification should be specified on drawings or purchase
orders. The slash-numbered specification modifies, deletes, and adds to the requirements of this specification. Refer
to the SAE AMS Index for a list of these documents.

8.6 For applications where it would provide added assurance of durability of the part, the heat-quench test of ASTM B571,
Adhesion of Metallic Coatings, should be specified.
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8.7 Plating thickness should be controlled by ampere-hours.

8.8 Terms used in AMS are clarified in ARP1917. ASTM B374 should be utilized as a reference and referee document
when areas of design definition or technical interpretation arise.

8.9 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.

8.10 Plating meeting the requirements of this specification generally will meet the requirements of MIL-STD-865, but it is
incumbent upon the user to determine this.

8.11 Hardness conversion tables for metals are presented in ASTM E140.

PREPARED BY AMS COMMITTEE “B”

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