ENGINEERING MATERIAL SPECIFICATION

EMBRITTLEMENT AVOIDANCE WSS-M99A3-A

1. SCOPE

This specification outlines the conditions that enhance the embrittlement risk of steel components, steel
and aluminum fasteners, and cast iron. Mechanisms include hydrogen embrittlement, stress corrosion
cracking, intergranular corrosion, and liquid metal embrittlement. The specification identifies requirements
intended to minimize that risk.

2. APPLICATION

The requirements established by this specification apply to steel fasteners, aluminum fasteners, heat
treated cast iron or steel components, and cold worked cast iron or steel components.

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Hardness values in this specification are in the Vickers scale. All other readings are for reference only.
The specified hardness refers to the hardness on the part drawing or product standard and not the actual
part hardness. When hardness is not specified on the part drawing or product standard, parts shall be
tested for hardness and the measured hardness shall be used to determine conformance to this standard.

2.1 HYDROGEN EMBRITTLEMENT

The risk of hydrogen embrittlement exists for parts:

- with high tensile strength or hardness, including surface hardening,

- which have, or may absorb diffusible hydrogen, and
- are under tensile stress.

Hydrogen embrittlement can cause delayed brittle fracture under stress and most often occurs as a
result of hydrogen absorption during manufacturing processes such as acid cleaning, electroplating,
phosphate coating, and heat treatment. Hydrogen absorbed during these manufacturing processes
can be relieved by baking. Hydrogen absorption can also occur from exposure to corrosive
environments where the reduction reaction may produce atomic hydrogen.

The susceptibility to embrittlement increases with increasing stress and increasing material
strength, particularly for martensitic microstructures. Therefore, attention to the processes used for
cleaning, finishing, and heat treatment, as well as the review of the application environment for
hardened and cold worked steel components, are crucial in reducing the risk of embrittlement.

2.2 STRESS CORROSION CRACKING

Hardened steels are susceptible to brittle fracture when exposed to a corrosive environment under a
sufficient tensile stress. This failure mode is called stress corrosion cracking (SCC). The higher the
yield strength, the more susceptible the material is to SCC. Sensitivity varies with steel alloy, yield
strength, corrosive environment and the applied tensile stress and residual manufacturing stress.

Date Action Revisions Rev. 06

2022 04 07 Editorial See Summary of Revisions L. Sinclair, NA

2019 03 05 Editorial Rephrased the note in paragraph 3.5 A. Wedepohl, NA

1987 09 18 Released SM/ER 1209TC J.P.C. Lines EAO

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 ENGINEERING MATERIAL SPECIFICATION

WSS-M99A3-A

2.3 INTERGRANULAR CORROSION OF ALUMINUM FASTENERS

Threaded aluminum fasteners are susceptible to intergranular corrosion. Care should be taken in
designing bolted joints utilizing aluminum fasteners so that critical areas of the fastener are not
exposed to corrosive environments.

2.4 LIQUID METAL EMBRITTLEMENT

Normally ductile metals can experience cracking and brittle fracture when they come into contact
with liquid metals while subjected to a tensile stress. This failure mode is called liquid metal
embrittlement (LME). LME can occur when parts with metallic plating are exposed to temperatures
above their melting point during subsequent manufacturing processes or in use.

3. REQUIREMENTS

3.1 APPROVED SOURCES

This specification does not have approved sources.

3.2 CONTROL PLAN

Fasteners and components affected by this specification shall have a control plan that includes the
requirements of this specification. The control plan shall include verification test(s) to demonstrate
the effectiveness of the embrittlement relief procedures after electroplating. Verification procedures
are not required for acid cleaning, phosphating, or mechanical plating. In cases where the
electroplating process does not normally produce embrittlement, it may be necessary to establish
verification tests based on proven methodology.

3.3 RESTRICTIONS ON PART USAGE

Due to high tensile stresses involved in fastened joints, all fasteners or threaded components with a
maximum specified core or surface hardness greater than 390 HV (39 HRC) shall not be used in
critical applications where there is a potential for corrosion. Critical applications are determined as
those with an FMEA severity rating of 9 or 10 for fractures.

Fasteners and components used in non-critical applications where the maximum specified core or
surface hardness is greater than 390 HV (39 HRC) shall not be used where exposed to the potential
for corrosion without an appropriate FMEA. The FMEA shall include consideration of cracking
mechanisms, such as hydrogen embrittlement, stress corrosion cracking, etc. as possible causes of
fracture, as well as the need for corrosion protective finishes.

Carburization of through hardened components is not permitted unless specified on the Engineering
Drawing. Unintentional carburization sometimes occurs when hardened components are subjected
to a carbon rich atmosphere. In these cases, the surface hardness shall not be more than 30 HV
above the measured core hardness. For property class 10.9 fasteners, any increase in hardness at
the surface that indicates that the surface hardness exceeds 390 HV (39 HRC) is not acceptable.

3.4 ALUMINUM FASTENER USAGE

Externally threaded aluminum fasteners shall be free from intergranular corrosion in the under-
head, radius transition, shank and shank-to-thread transition areas and the entire threaded length.

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 ENGINEERING MATERIAL SPECIFICATION

WSS-M99A3-A

3.4.1 Grain Size

(ASTM E112, Comparison Procedure)

The average grain size for aluminum fasteners must be Grain Size No. 2.5 or finer (150
micrometers) in the longitudinal direction and Grain Size 4.0 or finer (90 micrometers) in the
transverse direction.

3.4.2 Laboratory Evaluation for Intergranular Corrosion

(FLTM AB 110-01)

All joints using externally threaded aluminum fasteners shall be tested per FLTM AB 110-01
during the Design Validation (DV) phase. No intergranular corrosion (No IGC) or cracking of
surface coatings is allowed.

3.4.3 Evaluation after Vehicle Corrosion Testing

(CETP 00.00-R-343, FLTM AB 110-01, ISO 6157-3)

All aluminum fasteners from vehicles completing the Total Vehicle Corrosion Test, CETP
00.00-R-343, shall be cross-sectioned after test completion and evaluated using the criteria in
FLTM AB 110-01. No intergranular corrosion (No IGC) or cracking of surface coatings is
allowed.

3.4.4 All aluminum fasteners shall be evaluated for surface discontinuities per ISO 6157-3. Only
allowable discontinuities may be present.

3.5 CLEANING PRIOR TO HEAT TREATMENT

All fasteners and components with a maximum specified core or surface hardness greater than 353
HV (35 HRC) must be cleaned prior to heat treatment to remove phosphorus-containing products or
any other detrimental contaminants from the surface. The formation of a white, phosphorus
enriched layer caused by penetration of phosphorus during the hardening process is not
permissible.

Note: Removal of phosphorus containing products from the surface is not necessary for
components that are only induction hardened due to the short time at temperature.

3.6 HEAT TREATMENT

All heat treatment operations, except embrittlement relief via baking (Section 3.8 Embrittlement
Relief), shall be completed prior to plating or phosphate coating.

3.7 CLEANING AFTER HEAT TREATMENT OR COLD WORKING

Acid cleaning of fasteners and components which have been heat treated to a specified core or
surface hardness greater than 353 HV (35 HRC) or have been highly stressed due to cold working,
enhances the susceptibility to hydrogen embrittlement, and shall be minimized. If such fasteners
and components are to be acid cleaned, an inhibited acid shall be used and a procedure shall be
established that limits exposure to the acid bath to a maximum of 10 minutes. Fasteners and
components that are acid cleaned and subsequently phosphate coated, mechanically plated, or
electroplated, shall follow the requirements in section 3.8 Embrittlement Relief Table 1 as
applicable. All other fasteners and components that are acid cleaned but not subsequently coated
or plated, shall not be used for 48 hours, or these parts shall be baked for a minimum of 1 hour at
110 °C minimum following cleaning.

Note: Inhibited acids have inhibitors added to the acid to reduce the corrosive attack on the steel
and absorption of hydrogen.
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 ENGINEERING MATERIAL SPECIFICATION

WSS-M99A3-A

3.8 EMBRITTLEMENT RELIEF

All references to temperature relate to part core temperature and not oven air temperature.
Statistical data of variations in temperature at the center of the oven and oven temperature shall be
established to develop the oven profile. The temperature of parts in a batch type oven shall be
monitored with a thermocouple placed in the middle of the load. For continuous bake ovens a
temperature trace through the oven must be run with a calibrated thermocouple in the lowest
temperature position according to the frequency listed in the control plan.

The part temperature should be reached within 1 hour after commencement of heating.

Longer times at heat than those given may be necessary if verification testing detailed in the Control
Plan indicates a failure risk.

Table 1: Hydrogen Relief Table

Process Specified Hardness Hydrogen Relief

(Surface and/or Core)
Acid Cleaning > 353 HV (35 HRC) Within four hours after acid
(for items not subsequently cleaning, bake parts at 110˚C
phosphated, mechanically minimum for 1 hour minimum, or
plated, or electroplated)) the parts shall not be used for 48
hours after acid cleaning.
Within four hours after coating,
bake parts at 110˚C minimum for 1
Phosphate Coating > 353 HV (35 HRC)
hour minimum or the parts shall not
be used for 48 hours after coating.
Within four hours after mechanical
plating, bake parts at 110˚C
Mechanical Plating > 353 HV (35 HRC) minimum for 1 hour minimum, or
the parts shall not be used for 48
hours after mechanical plating.

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 ENGINEERING MATERIAL SPECIFICATION

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Table 1: Hydrogen Relief Table (cont)

FASTENERS OR THREADED
COMPONENTS SHALL NOT BE
ELECTROPLATED

Non-Threaded Components:
> 390 HV (39 HRC)
Within 1 hour after electroplating
and before any supplementary
Electroplating chemical treatments, bake parts at
200˚C minimum for 8 hours
minimum.
Within 1 hour after electroplating
and before any supplementary
> 353 HV (35 HRC) chemical treatments, bake parts at
200˚C minimum for 4 hours
minimum.
Electroplating for parts Within 1 hour after electroplating,
tempered or stress relieved bake parts at 140˚C minimum for 8
below 230˚C or for tin or tin > 353 HV (35 HRC) hour minimum.
alloy platings to avoid liquid
metal embrittlement.

3.9 EXCEPTIONS

Exceptions to the embrittlement relief requirements may be made due to factors such as alloy
composition, coating thickness, coating type, design, or part size. Consideration should be given to
the application, tensile stress, and manufacturing processes. Investigations into the amount of
hydrogen absorption and effectiveness of the embrittlement relief for specific parts may result in
different recommended times and temperatures versus the ones listed above. In some cases
embrittlement relief may not be necessary.

Exceptions shall be authorized by the responsible Functional Chief Engineer and communicated to
the appropriate Materials/Fastener Engineering Activity.

For fasteners, exception approval shall be documented on Form e1217, Request for Part
Number or Drawing Change per FAP03-117. Exceptions agreed to for some Standard
Fasteners are shown in the General Requirements section of Ford Worldwide Fastener
Standard WX-100.

For components, exception approval shall be documented in RQT-002901-008060 (Legacy

SDS MA-0114), Embrittlement Avoidance.

3.10 CERTIFICATION

Compliance with this standard means that, if parts or fasteners meet the conditions to be potentially
susceptible to embrittlement as outlined in this standard, the actions required by this standard are in
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place. Compliance with the requirements of this specification for parts or fasteners with hardness of
353 HV (35 HRC) or greater, for heavily cold worked parts or fasteners, or for aluminum fasteners
shall be certified by completion of the certification form in Appendix 1. The completed form shall be
included in PPAP documentation for the part.

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 ENGINEERING MATERIAL SPECIFICATION

WSS-M99A3-A

4. GENERAL INFORMATION

The information given below is provided for clarification and assistance in meeting the requirements of
this specification. Contact gmfs@ford.com for questions concerning Engineering Material Specifications.

References:
ASTM B850 “Post-Coating Treatments of Steel for Reducing the Risk of Hydrogen
Embrittlement”

ISO 9588 Metallic and Other Inorganic Coatings - Post Coating Treatments of Iron or Steel
to Reduce the Risk of Hydrogen Embrittlement.

SAE/USCAR-5 “Avoidance of Hydrogen Embrittlement of Steel”

ASTM E112 “Standard Test Methods for Determining Average Grain Size”

ISO 6157-3 “Fasteners – Surface Discontinuities – Bolts, Screws, and Studs for Special
Requirements”

5. SUMMARY OF REVISIONS

2022 04 07 Editorial – Updated appendix A to be editable.

2019 03 05 Editorial – Re-phrased the note in 3.5.

2016 01 11 Added reference to aluminum fasteners and requirement of measuring hardness in

Application
Added Sections 2.3 and 2.4
Inserted Aluminum Fastener Usage as Section 3.3, renumbered following sections
Added Section 3.9
Added certification document as Appendix 1

2015 05 28 Added reference to cast iron

Align Embrittlement, De-Embrittlement, and Hydrogen Relief Nomenclature
Added Qualifying Note to Section 3.3
Updated Requirement Identification in Sec. 3.7

2012 03 20 Revised to include more distinction between parts and fasteners.

Added location of documented exceptions for components.

2008 02 06 Completely revised, reformatted and renumbered the document.

Application section specifically defines hydrogen embrittlement and stress corrosion
cracking.
The brittleness statement was moved to the control plan paragraph.
Carburization section was added into the restriction on part usage section.
The plating/coating method statement was moved to the hydrogen relief table.
The de-embrittlement section was aligned with SAE/USCAR 5 and the distinction
between core and surface hardness was removed. The temperature and times were
aligned with SAE/USCAR 5 and placed in tabular form.
The fastener exception sheet was updated from FAF-1217 to FAF03-117-01.

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 Appendix 1 – Embrittlement Avoidance Compliance Certification

Program Name/Code ______________________ Commodity Code (CPSC) ____________ Commodity Description _________________________________

Supplier Name _________________________________________________________ Supplier GSDB Code __________________

Is part
cleaned in Is part
Is part located Is part an Hardness Hardness acid and not Is coating compliant Additional comments
Ford or Supplier Part Number in a corrosive aluminum * (HV or * (HV or subsequently process to WSS- (Provide any control plan
and Description environment? fastener? HRC) HRC) coated? Surface Finish electroplating? M99A3-A? references here)
(Yes / No) (Yes / No) Surface Core (Yes / No) (Yes / No) (Yes / No)

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* For fasteners or components with a hardness of 353HV (35HRC) or greater, the supplier must ensure appropriate control plans and process controls are in place
to ensure compliance with the WSS-M99A3-A specification (as outlined in the Requirements - Section 3).

Supplier Certification Signature & Printed Name _____________________________________________________________

Supplier Certifier’s Position _____________________________________________________________

Certification Date _____________________________________________________________

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