Gold coatings are often specified for the contacts of separable electrical connectors and other devices. Electrodeposits are the form of gold that is most used on contacts, although it is also employed as inlay or clad metal and as weldments on the contact surface. The intrinsic nobility of gold enables it to resist the formation of insulating oxide films that could interfere with reliable contact operation.

Palladium coatings are sometimes specified as alternatives to gold on electrical contacts and similar electrical component surfaces, both as electrodeposits and as inlay or clad metal. This test method is particularly suitable for determining porosity in palladium coatings, since the reactive atmosphere that is used does not attack the palladium if the specified test conditions are followed. In contrast, palladium coatings are attacked by nitric acid (HNO₃) and other strong oxidizing agents, so that Test Method B 735 cannot be used for determining the porosity in such coatings.

In order for these coatings to function as intended, porosity, cracks, and other defects in the coating that expose base-metal substrates and underplates must be minimal or absent, except in those cases where it is feasible to use the contacts in structures that shield the surface from the environment or where corrosion inhibiting surface treatments for the deposit are employed. The level of porosity in the coating that may be tolerable depends on the severity of the environment to the underplate or substrate, design factors for the contact device like the force with which it is mated, circuit parameters, and the reliability of contact operation that it is necessary to maintain. Also, when present, the location of pores on the surface is important. If the pores are few in number and are outside of the zone of contact of the mating surfaces, their presence can often be tolerated.

Methods for determining pores on a contact surface are most suitable if they enable their precise location and numbers to be determined. Contact surfaces are often curved or irregular in shape, and testing methods should be suitable for them. In addition, the severity of porosity-determining tests may vary from procedures capable of detecting all porosity to procedures that detect only highly porous conditions.

The present test method is capable of detecting virtually all porosity or other defects that could participate in corrosion reactions with the substrate or underplate. The test is rapid, simple, and inexpensive. In addition, it can be used on contacts having complex geometry such as pin-socket contacts (although with deep recesses it is preferred that the contact structures be opened to permit reaction of the sulfur dioxide with the interior significant surfaces).

The relationship of porosity levels revealed by particular tests to contact behavior must be made by the user of these tests through practical experience or by judgment. Thus, absence of porosity in the coating may be a requirement for some applications, while a few pores in the contact zone may be acceptable for others.

This test is considered destructive in that it reveals the presence of porosity by contaminating the surface with corrosion products and by undercutting the coating at pore sites or at the boundaries of the unplated areas. Any parts exposed to this test shall not be placed in service.

This test is intended to be used for quantitative descriptions of porosity (such as number of pores per unit area or per contact) only on coatings that have a pore density sufficiently low that the corrosion sites are well separated and can be readily resolved. As a general guideline this can be achieved for pore densities up to about 100/cm². Above this value the tests are useful for the qualitative detection and comparisons of porosity.

For these purposes, the measurement area, or significant surface, shall be defined as those portions of the surface that are essential to the serviceability or function of the part, such as its contact properties, or which can be the source of corrosion products or tarnish films that interfere with the function of the part. The significant surfaces shall be indicated on the drawings of the parts, or by the provision of suitably marked samples.

1.1 This test method covers equipment and methods for determining the porosity of gold and palladium coatings, particularly electrodeposits and clad metals used on electrical contacts.

1.2 This test method is designed to show whether the porosity level is less or greater than some value which by experience is considered by the user to be acceptable for the intended application.

1.3 A variety of other porosity testing methods are described in the literature. ^, Other porosity test methods are B 735, B 741, B 798, and B 809. An ASTM Guide to the selection of porosity tests for electrodeposits and related metallic coatings is available as Guide B 765.

1.4 The values stated in SI units are to be regarded as standard. The values given in parentheses are for information only.

1.5 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to become familiar with all hazards including those identified in the appropriate Material Safety Data Sheet (MSDS) for this product/material as provided by the manufacturer, to establish appropriate safety and health practices, and determine the applicability of regulatory limitations prior to use. For specific hazards, see Section 6.