MIL-DTL-5002E
3.5.1 Electrodeposition restrictions. Unless otherwise specified in the applicable plating
specification, electrodeposited coatings shall not be used on steel parts having a surface hardness
of Rockwell C49 (240 ksi) or greater unless approval is obtained from the cognizant engineering
organization.
3.5.2 Thermal spraying. Assemblies that will trap plating solutions and assemblies or parts
that are of extreme size and weight for conventionally available plating or coating equipment
shall be thermal sprayed. The material for coating shall be applied directly to the surface of the
part after surface preparation. Unless otherwise specified in the contract or order, the coating
thickness shall be not less than 0.004 inch and shall not be greater than 0.006 inch. Powders
used for plasma spray coatings shall conform to A-A-59315.
3.5.2.1 For corrosion control (see 3.9). When metallic materials such as zinc or aluminum
are thermal sprayed for corrosion control of parts, no undercoating of another metal such as
molybdenum shall be permitted on the substrate.
3.5.2.2 For functional purposes (see 3.10). When non-metallic coatings, such as zirconia,
alumina, metallic-ceramics, carbides, silicides, titanates, and cermets, are thermal sprayed for
functional use on parts, an undercoat of another material or mixtures of materials in various
proportions to produce coatings shall be allowed as a substrate where required to control the
matching of the coefficients of thermal expansion between the base metal and the coating.
3.5.2.3 Thermal spraying restrictions. When coatings are applied thermally, in no case
shall the part be raised to a temperature that would adversely affect its mechanical, corrosion or
stress corrosion resistant properties. If a part is shot-peened prior to the coating application, all
thermal treatments performed after shot peening shall conform to the requirements of
SAE AMS2430.
3.5.3. Hot-dip coating restrictions. When approved by the cognizant engineering
organization, coatings may be applied by the hot-dip method.
3.5.4 Brush plating restrictions. Brush plating shall be used only for touch-up. Brush
plated chrome coatings have substantially lower hardness values than conventionally plated
chrome coatings, resulting in a lower abrasion resistance. Brush plating may be approved by the
cognizant engineering organization when conventional plating methods are inappropriate. When
approved by the cognizant engineering organization, brush plating shall be in accordance with
MIL-STD-865.
3.6 Metallic coatings.
3.6.1 Cadmium coatings. Electrodeposited cadmium shall be in accordance with
SAE AMS-QQ-P-416 or MIL-STD-870. Other cadmium coatings shall be in accordance with
SAE AMS-C-8837 or SAE AMS-C-81562. Cadmium coatings may be applied by thermal spray
using materials in A-A-59315. Unless otherwise specified in the contract or order, cadmium
coatings shall be Class 1 thickness (0.0005 inch). Parts with threads shall be plated to Class 2
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