Final report


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Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
0.0 
0.0 
0.0 
Dura-White 5Sn/12.4Cu* 
Ŷ 
Ɣ 
Ÿ 
Ɣ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ɣ 
Ŷ 
Ÿ 
Ÿ 
318.3 
375.6 
743.1 
Dura-White 7.7Sn/12.7Cu* 
Ŷ 
Ɣ 
Ÿ 
Ɣ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ɣ 
Ŷ 
Ÿ 
Ÿ 
318.3 
375.6 
743.1 
Dura-White 
10.2Sn/11.2Cu* 
Ŷ 
Ɣ 
Ÿ 
Ɣ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ɣ 
Ŷ 
Ÿ 
Ÿ 
318.3 
375.6 
743.1 
Key:  
Level of Impact – 
Ŷ
:  Significant; 
Ɣ0DUJLQDO
Ÿ
:  Minimal 
M = million; CPS = copper-plated steel; RM = Royal Mint; SS = stainless steel; NPS = nickel-plated steel; MPS = Multi-Ply-plated steel; RCM = Royal 
Canadian Mint; Sn = tin; Cu = copper 
* Dura-White-Plated Zinc 
** Est = most probable; † = apparent seamless option; additional verification advised; ‡ = apparent EMS match with existing circulating coin; additional 
verification advised 
220  

Table 4-11. 
Impact to Stakeholders:  Change Both Coin Dimensions and Material Composition of US Coins 
Material 
D
enomin
a
ti
o
n
Ven
d
in
g
 M
a
ch
in

Own
ers 
a
n
d
 Op
era
to
rs
Laundr
om
at O
w
ne
rs
 and 
Op
era
to
rs
P
a

P
h
on
e Own
ers a
n
d
Op
era
to
rs
M
u
n
ici
p
a
l P
a
rk
in
g
 Offi
ci
a
ls
Am
u
sem
en
t M
a
ch
in
e Own
ers 
a
n
d
 Op
era
to
rs
Ga
m
in
g
 M
a
ch
in
e Own
ers 
a
n
d
 Op
era
to
rs
Tra
n
sit Officia
ls
Ca
r Wa
sh
 Own
ers a
n
d
Op
era
to
rs
M
erch
a
n
ts
Manuf
ac
tu
re
rs
 of
Co
m
m
erci
a
l Co
in
-H
a
n
d
li
n
g
Equip
m
en
t
Ven
d
in
g
 M
a
ch
in
e a
n

Oth
er 
Co
in
-Accep
to

Manuf
ac
tur
er
s
Dep
o
sito
ry
 In
stit
u
tion
s
Co
in 
a
n
d
 Cu
rren
cy
 Han
d
lers/
A
rmor
ed
-C
ar
 O
p
er
a
to
rs
B
lind and 
V
is
u
all
y
-I
mp
air
ed
Public 
Estimated Total Cost 
Impact in Fall 2014 
Accounting for Net 
Effective Conversion 
Cost Associated with a 
20% Corporate Tax 
($M) 
Low 
Est** 
High 
5052-H32 Aluminum 
One-
cent 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
82.5 
120.6 
180.3 
CPS – Jarden 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ɣ 
33.5 
70.6 
127.9 
CPS – RM 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ɣ 
33.5 
70.6 
127.9 
302HQ SS 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ɣ 
33.5 
70.6 
127.9 
Surface-Modified Zinc 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
33.5 
70.6 
127.9 
NPS – RM 

cent 
Ŷ 
Ÿ 
Ŷ 
Ŷ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ɣ 
Ɣ 
826.0 
1048.5 
1590.6 
Unplated 31157 
Ŷ 
Ÿ 
Ŷ 
Ŷ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ɣ 
Ɣ 
826.0 
1048.5 
1590.6 
MPS – RCM 
Ŷ 
Ÿ 
Ŷ 
Ŷ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ɣ 
Ɣ 
826.0 
1048.5 
1590.6 
Dura-White-Plated Zinc 
Ŷ 
Ÿ 
Ŷ 
Ŷ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ɣ 
Ɣ 
826.0 
1048.5 
1590.6 
669z 
Ŷ 
Ÿ 
Ŷ 
Ŷ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ɣ 
Ɣ 
826.0 
1048.5 
1590.6 
G6 Mod 
Ŷ 
Ÿ 
Ŷ 
Ŷ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ɣ 
Ɣ 
826.0 
1048.5 
1590.6 
302HQ SS 
Ŷ 
Ÿ 
Ŷ 
Ŷ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ɣ 
Ɣ 
826.0 
1048.5 
1590.6 
Surface-Modified Zinc 
Ŷ 
Ÿ 
Ŷ 
Ŷ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ɣ 
Ɣ 
826.0 
1048.5 
1590.6 
302HQ Stainless Steel 
10­
cent 
Ŷ 
Ÿ 
Ŷ 
Ŷ 
Ÿ 
Ÿ 
Ŷ 
Ÿ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ɣ 
826.0 
1048.5 
1590.6 
NPS – RM 
25­
cent 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ɣ 
1078.6 
1445.1 
2090.1 
MPS – RCM 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ɣ 
1078.6 
1445.1 
2090.1 
302HQ Stainless Steel 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ɣ 
1078.6 
1445.1 
2090.1 
669z-Clad C110 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ɣ 
1078.6 
1445.1 
2090.1 
Dura-White 5Sn/12.4Cu* 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ɣ 
1078.6 
1445.1 
2090.1 
Dura-White 
7.7Sn/12.7Cu* 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ɣ 
1078.6 
1445.1 
2090.1 
Dura-White 
10.2Sn/11.2Cu* 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ŷ 
Ŷ 
Ŷ 
Ŷ 
Ɣ 
Ɣ 
1078.6 
1445.1 
2090.1 
Key:  
Level of Impact – 
Ŷ
:  Significant; 
Ɣ0DUJLQDO
Ÿ
:  Minimal 
M = million; CPS = copper-plated steel; RM = Royal Mint; SS = stainless steel; NPS = nickel-plated steel; MPS = Multi-Ply-plated steel; RCM = Royal 
Canadian Mint; Sn = tin; Cu = copper 
* Dura-White-Plated Zinc 
** Est = most probable 
221  

4.7  
OTHER FACTORS THAT COULD ALTER THE CONVERSION COSTS TO 
STAKEHOLDERS 
The impact of changes to circulating coins to all stakeholder groups discussed above was based 
on several assumptions including the following. 
x  100% of impacted coin-processing equipment will be upgraded. 
x  Equipment upgrades will be a focused activity rather than one completed when other 
opportunities (such as routine maintenance) present themselves. 
Given coin-acceptance equipment manufacturers’ experience related to the multi-year lag that 
vending and other equipment owners and operators had with upgrading their machines to accept 
the recently released and redesigned US $5 note from the Bureau of Engraving and Printing 
(BEP), a percentage of the current owners and operators will either refuse to upgrade their 
equipment to accept coins of new metallic construction or they will take advantage of other 
maintenance needs to complete equipment upgrades.  These operating strategies would 
significantly reduce the conversion cost estimates defined above.  However, it is difficult to 
predetermine the size of this impact.  This thought is echoed by a report from HM Treasury when 
discussing the impact of recent changes to the materials of construction for the United 
Kingdom’s 5-pence and 10-pence coins [4].  This reference expects that a significant number of 
machine owners will wait for up to 18 months or more to upgrade their equipment.  Given that 
on average each year one-third of coin validators within the vending industry receives attention 
from a service technician, it is conceivable, that as many as 66% of the US coin acceptors could 
be upgraded without the attendant cost of a separate service fee. 
4.8  
VALIDATION OF NONSENSE PIECES 
A fundamental element in the approach to defining alternative coinage materials centers around 
two competing financial aspects of the decision:  selecting materials and manufacturing 
processes that either: 
x  Reduce costs to the United States Mint 
x  Minimize the impact (including conversion costs) to stakeholders, who are dependent 
upon coins to conduct commerce. 
Striking the most favorable balance between these foci must be defined before final material 
selections can be made.  In the present study, alternative material candidates were selected that 
represent one or the other of these foci.  No metallic materials were found that can 
simultaneously accomplish both of these foci. 
Coins that would seamlessly (or nearly seamless) circulate with incumbent coins would satisfy a 
focus on minimizing the impact to stakeholders.  Other non-financially based factors must also 
be included when considering alternative material candidates for circulating coins, including an 
evaluation of the uniqueness of the characteristics and/or properties of alternative material 
candidates relative to other coins and common slugs available throughout the world. 
To that end, nonsense pieces were tested to evaluate the consistency of their characteristics and 
properties with incumbent US circulating coins as determined by measuring the response of 
these nonsense pieces in existing automated coin-processing equipment.  These drop tests were 
designed to provide confirmation of the intended characteristics and properties of proposed 
222  

alternative material candidates.  To validate the performance of each alternative material 
candidate, CTC procured samples (either in planchet, blank or strip form), produced blanks (as 
needed) and worked with the United States Mint to produce test pieces using nonsense dies. 
Two sets of tests were completed.  Nonsense pieces of alternative material candidates were 
struck at the United States Mint during an initial striking trial.  Samples of these nonsense pieces 
were tested by SCAN COIN.  This information was useful in eliminating some of the early 
alternative material candidates.  After further development on selected alternative material 
candidates, a second striking trial was completed at the United States Mint in Philadelphia.  The 
resulting nonsense pieces were then tested by three coin processing manufacturers:  SCAN 
COIN, MEI and Coinco.
107 
Each of these manufacturers relies upon different proprietary coin 
recognition technology and strategies.  Therefore, limiting this initial evaluation to these 
manufacturers was expected to provide broad initial feedback on the suitability of the alternative 
material nonsense pieces to meet the objectives of Public Law 111-302. 
4.8.1  Round One Testing 
Round One alternative material nonsense pieces (one-cent, 5-cent and quarter dollar) were struck 
at the United States Mint in Philadelphia on December 13–15, 2011.  Samples of these nonsense 
pieces, along with randomly selected circulated coins, were tested in a SCAN COIN SC4000 
machine.  Testing was completed on December 19, 2011.  The EMS and coin dimensions were 
evaluated for each of the 15 alternative material nonsense piece designs.  Except for one of the 
aluminized steel one-cent coin alternative material nonsense pieces (which had 10 total 
specimens), each alternative material-denomination combination included 40 specimens.  The 
circulated coin lots included 100 coins for each denomination tested.  These confirmation tests 
were led by SCAN COIN, Ashburn, Virginia and were supervised by CTC.  The nonsense pieces 
were kept at room temperature (approximately 21 °C [70 °F]) for over one hour before the start 
of testing.  Each set of nonsense pieces was passed through the SC4000 machine once and then 
each set of nonsense pieces was passed through the machine a second time in the same sequence 
as that used in the first pass through the machine.  Each pass through the coin sorter/counter for 
any given set of nonsense pieces (or circulating coins) took approximately 30 seconds. 
The following measurements were made for each nonsense piece and circulated coin: 
x  Diameter 
x  Thickness (an average of several readings) 
x  Inner electrical conductivity at low frequency 
x  Inner electrical conductivity at high frequency 
x  Inner magnetic permeability 
x  Outer electrical conductivity at low frequency 
x  Outer electrical conductivity at high frequency 
x  Outer magnetic permeability. 
107 
SCAN COIN, which has an American-based sales office, manufacturers high-speed coin sorting and counting 
equipment.  MEI and Coinco, which are American owned, manufacture coin acceptors for vending machines and 
other devices.  The project team recognizes that other coin-processing equipment manufacturers are resident in the 
US; CTC recommends that the United States Mint include comments from and have future alternative material 
nonsense pieces evaluated by additional automated coin-acceptance and coin-handling equipment manufacturers if 
the project is extended to include additional production development phases. 
223  

The nonsense pieces tested in the Round One confirmation tests included the following: 
x  One-cent nonsense pieces 
ƒ
Copper-plated steel 
ƒ
Aluminum alloy 5052-H32 
ƒ
Aluminized steel from Atlas 
ƒ
Aluminized steel from Ryerson  
x  5-cent nonsense pieces  
ƒ
Dura-White-plated zinc (tin-plated zinc) 
ƒ
Multi-Ply-plated steel – lot# 11-137 (copper/nickel-plated steel) 
ƒ
Multi-Ply-plated steel – lot# 11-170 (copper/nickel-plated steel) 
ƒ
G6 mod (copper-based alloy) 
ƒ
669z (copper-based alloy) 
ƒ
430 stainless steel 
ƒ
302HQ stainless steel 
ƒ
302 stainless steel with altered annealing heat treatment 
ƒ
Nickel-plated 31157 (copper-based alloy)  
x  Quarter dollar nonsense pieces  
ƒ
Multi-Ply-plated steel 
ƒ
669z-clad C110 (copper-based alloy clad on commercially pure copper alloy C110). 
The electrical conductivity and magnetic permeability measurements are ratios of the measured 
value to a reference value used by SCAN COIN.  Given the electronic sensors used by SCAN 
COIN, all individual parameters represent values that give relative magnitudes of local property 
rather than actual measured property values.  For any given coin/nonsense piece, however, these 
reading are relatively as consistent as are the actual material properties and material distribution 
within each coin/nonsense piece.  The resulting values for the US circulating coins were found to 
be consistent with readings that SCAN COIN has observed previously for US circulating coins. 
This was an indication that the SC4000 used for these tests was properly calibrated. 
Some EMS properties for the 430 stainless steel 5-cent nonsense pieces were beyond the 
acceptable limits set at the factory for the SC4000 machine used for these tests.  As a result, the 
machine would not permit these nonsense pieces to pass completely through the machine to 
obtain the above-mentioned properties.  Should 430 stainless steel nonsense pieces be of interest 
for future tests, these software-defined property limits could be modified to allow 430 stainless 
steel nonsense pieces to be evaluated with an SC4000. 
None of the one-cent nonsense pieces from Round One tests were found to have a similar 
electromagnetic signature to either pre-1982 or post-1982 one-cent US circulating coins.  Three 
of the 5-cent nonsense pieces (G6 mod, 669z and 31157 [either unplated or nickel-plated]) were 
found to be indistinguishable from the incumbent cupronickel US 5-cent coins.  Likewise, the 
669z-clad C110 quarter dollar nonsense pieces closely matched the electromagnetic signature of 
the incumbent cupronickel-clad C110 US quarter dollar coin.  All other alternative material 
nonsense pieces that were tested had a significantly different EMS than that of the corresponding 
incumbent US circulating coins. 
224  

4.8.2  Round Two Testing 
A second round of coins was struck at the United States Mint in late March 2012.  These 
nonsense pieces were tested by three manufacturers:  two coin-acceptor and one coin-handling 
equipment manufacturers.  Although each of the manufacturers measures coin dimensions and 
EMS, the specific technology to do so differs from one to another:  the most significant 
difference being the EMS frequencies used to identify the metallic composition of the coins.  
These differences in sensor design (and in the software used to interpret the output signals) result 
in varying degrees of sensitivity to detect slight differences in material composition.  To 
maintain anonymity among the three manufacturers, summary observations are provided without 
reference to specific manufacturers.  Furthermore, each manufacturer indicated that details 
defined within their individual reports are proprietary.  Since all three manufacturers have fielded 
units throughout the world, they necessarily must be able to tune each unit to accept alternative 
coins as they are introduced into circulation throughout the world.  Consequently, each 
manufacturer used its own unique, preexisting product standard test methods to evaluate the 
alternative material nonsense pieces.  Each manufacturer requested some details on the 
alternative material candidates being tested; to avoid inappropriately disclosing proprietary 
information on the composition or suppliers of these materials, the descriptions provided by CTC 
to these manufacturers were kept simple (such as [but not limited to] “aluminum alloy,” “plated 
steel,” “stainless steel,” “copper alloy,” “plated zinc” or “plated copper,” as appropriate). 
In addition to the alternative material nonsense pieces, newly minted 2012 circulating coins, 
nonsense pieces made from the same materials as those used for circulating coins and randomly 
selected circulated coins of various mint dates were tested for each of the coin denominations 
evaluated.  The circulated coins, which were randomly selected from coins in public use, were 
used to form a baseline from which the nonsense pieces could be compared.  Nonsense pieces 
made from the same material as circulating coins, but with the nonsense image,
108 
were 
compared to the newly minted 2012 coins to determine if any detectable difference could be 
determined between the coins/nonsense pieces struck with the two different images. 
Since all three coin-processing manufacturers found no detectable difference among the newly 
minted 2012 coins, nonsense pieces struck on incumbent material and randomly selected 
circulated coins, CTC was confident that any detectable differences between the alternative 
material nonsense pieces and the circulated coins could be attributed to material differences and 
not the differences in the struck image between the nonsense pieces and circulating coins.  Note 
that all nonsense pieces made from alternative material candidates were struck with nonsense 
dies. 
The nonsense pieces tested for Round Two verification tests included the following: 
x  One-cent coins 
ƒ
Newly minted 2012 
ƒ
Circulated pre-1982 
ƒ
Circulated post-1982 
108 
These nonsense pieces had scrambled lettering throughout, an image of Martha Washington on the obverse and 
another image on the reverse.  The United States Mint has used similar images for previous experimental 
evaluations.  These images were designed to have features that mimic those of circulating coins to test the striking 
characteristics of the proposed alternative material candidates. 
225  

ƒ
Incumbent material with nonsense dies 
ƒ
Aluminum alloy 5052-H32 
ƒ
Copper-plated steel from JPZ 
ƒ
Copper-plated steel from RM 
ƒ
302HQ stainless steel  
x  5-cent coins  
ƒ
Newly minted 2012 
ƒ
Circulated 
ƒ
Incumbent material with nonsense dies 
ƒ
Nickel-plated steel 
ƒ
Unplated 31157 
ƒ
Multi-Ply-plated steel 
ƒ
Dura-White-plated zinc 
ƒ
669z 
ƒ
G6 mod 
ƒ
302HQ stainless steel  
x  Quarter dollar coins  
ƒ
Newly minted 2012 
ƒ
Circulated 
ƒ
Incumbent material with nonsense dies 
ƒ
Nickel-plated steel 
ƒ
Multi-Ply-plated steel 
ƒ
669z-clad C110 
ƒ
Dura-White-plated zinc  
  5-micron plating  
  8-micron plating  
  10-micron plating.  
4.8.2.1  One-Cent Nonsense Pieces 
All three coin-processing equipment manufacturers drew similar conclusions about the one-cent 
coin alternative material candidates.  Because of the differences in material construction, the pre­
1982 one-cent coins have a different signature than that of the post-1982 one-cent coins.  This 
situation is typically accommodated in active coin-processing software by allowing for two 
separate entries into the coin-property database; any coin that meets either of the two sets of 
characteristics and properties in these databases is accepted as a one-cent coin. 
Both the newly minted 2012 one-cent coins and the one-cent nonsense pieces of the incumbent 
post-1982 one-cent coin material provided signatures that were indistinguishable from the post­
1982 circulated one-cent coins.  In other words, those three sets of coins would validate as a one-
cent coin in all coin acceptors/sorters/counters used in the present evaluation. 
All other one-cent nonsense pieces that were tested had signatures that differed from either of the 
two US one-cent circulating coins (i.e., pre-1982 one-cent coins, which were made of a mono-
layer of a copper alloy and post-1982 one-cent coins made of copper-plated zinc).  The two 
copper-plated steel nonsense pieces had similar signatures to each other; however, a detailed 
assessment of the signals showed that these two nonsense pieces could be distinguished from 
each other by some, but not all, coin-handling equipment.  The copper-plated steel nonsense 
226  

pieces had similar characteristics and/or properties to the greatest number of foreign coins or 
common slugs available throughout the world.  The stainless steel nonsense pieces had the 
smallest range of values for each of the measurements used to validate the one-cent nonsense 
pieces.
109 
In addition, the stainless steel one-cent nonsense pieces had the fewest number of 
coins with similar characteristics to other known coins throughout the world.  However, stainless 
steel is a commonly available material and can be easily frauded in automated coin-processing 
equipment through use of simple stainless steel disks.  Furthermore, the color and size of one-
cent stainless steel coins may result in confusion with the incumbent US dime coin. 
As a low-denomination coin, security is not a major concern for the US one-cent coin.  
Therefore, other factors should take precedence over fraud for this coin according to the three 
coin-processing equipment manufacturers.  Placing lower emphasis on coin security for this low-
denomination coin is also consistent with coin design strategies outlined in The WVA Coin 
Design Handbook [5]; it is also consistent with a previously stated position of the United States 
Mint [24]. 
Plated-steel coins were therefore the recommended material of choice by two of the coin-
processing equipment manufacturers.  The third manufacturer, however, noted that 
ferromagnetic-steel-based (plated or otherwise) coins could not be recognized by their US-based 
sensors.  Ferromagnetic-steel-based coins would create a significant validation and security issue 
for this manufacturer.  Therefore, they were not in favor of moving to any ferromagnetic-steel­
based materials for any coin denomination. 
The aluminum alloy 5052-H32 nonsense pieces caused operational problems for the two coin-
acceptance manufacturers.  While only a few aluminum one-cent nonsense pieces jammed one of 
the coin acceptors tested by one of the manufacturers, these aluminum nonsense pieces 
consistently jammed the other manufacturer’s devices.  Although no particular difficulties were 
reported during testing of the aluminum one-cent nonsense pieces in the coin-handling 
manufacturer’s tests, all three manufacturers warned against the use of aluminum in coinage.  
Specific problems beyond jamming of the mechanisms included concerns about the larger 
variability in electromagnetic properties of aluminum (relative to more traditional coinage 
materials including cupronickel) and a common problem of aluminum coins galling and cold 
welding in high-speed sorters/counters.  As reported by these manufacturers (and consistent with 
comments made by several stakeholders during one-on-one interviews), when coins cold weld, 
they often cause permanent damage to coin-processing machines.  Although cold welding is 
unlikely to occur in coin validators (since the coins do not rub across each other at high speeds 
and forces) and even though one-cent coins are rarely accepted by coin validators, insertion of 
one-cent coins is still attempted (and the coins promptly rejected and returned to the customer) 
for payment by unwitting customers.  Due to its low density and low resulting inertia, an 
aluminum coin put into a coin acceptor could stall in the coin chute and if followed by other 
aluminum coins, could jam the machine beyond the ability of the coin return mechanism to flush 
the obstruction from the system [27].  This would temporarily disable the machine until 
maintenance was performed.  According to one industry expert, the mean time between placing a 
maintenance call and the machine receiving the needed maintenance is four days.  The machine 
is essentially disabled during this time.  Furthermore, the owner of the machine must pay for a 
109 
Small ranges are desired for validation parameters to increase fraud prevention in circulating coins. 
227  

maintenance call, which averages $75 per visit.  Hence, the automated coin-acceptance and coin-
handling communities strongly recommend against minting aluminum circulating coins (one­
cent coins or otherwise). 
4.8.2.2  5-Cent Nonsense Pieces 
As with the one-cent nonsense pieces, newly minted 5-cent coins and nonsense pieces struck 
from incumbent 5-cent coin material were compared with a random sample of circulated 5-cent 
coins.  All three of these coins/nonsense pieces were found to be indistinguishable from each 
other.  Therefore, CTC concluded that any differences between the alternative material nonsense 
pieces and circulating coins, which form the baseline for the comparison, can be attributed solely 
to the materials of construction and the processing methods used to produce these nonsense 
pieces. 
For two of the three coin-processing equipment manufacturers, unplated 31157, 669z and G6 
mod monolithic nonsense pieces were indistinguishable from incumbent 5-cent coins.  The third 
manufacturer found unplated 31157 to be indistinguishable from incumbent 5-cent coins; 669z 
had a low acceptance rate (meaning that it had similar, but not acceptably consistent 
characteristics and properties to the incumbent 5-cent coin); G6 mod was consistently 
distinguishable from and outside the acceptance windows defined for incumbent 5-cent coins for 
this third manufacturer.  All three coin-processing equipment manufacturers noted that all other 
nonsense pieces had characteristics and/or properties that allowed ready discernment from 
incumbent 5-cent coins. 
The two plated-steel nonsense pieces had unique signatures and could be easily distinguished 
from each other by two of the three manufacturers.  However, for the third manufacturer, plated-
ferromagnetic-steel-based coins would not register with their coin-acceptance sensors.  
Ferromagnetic-steel-based coins would require both hardware and software upgrades for fielded 
coin acceptors produced by this manufacturer.  In general, the range in the signatures of the 
plated-steel nonsense pieces were wider than other nonsense pieces, meaning that these plated-
steel coins would require wider acceptance windows
110 
and would therefore be more susceptible 
to fraud. 
The Dura-White-plated zinc 5-cent nonsense pieces were noteworthy for two reasons. 
x  They had a very narrow band of properties in at least two of the three manufacturer’s 
products. 
x  They had the lowest number of potential signature matches by foreign coins and slugs. 
Dura-White-plated zinc construction appears to offer the most secure 5-cent coin of any 
materials tested, including the incumbent 5-cent coin material.  However, constructing coins of 
this material would require a substantial investment from the stakeholder communities to 
upgrade fielded coin-processing equipment to recognize this material construction. 
110 
The industry defines acceptance windows as the range in measured characteristics that have been determined to 
match a given coin.  When all measured values fall within each of the acceptance windows, then a coin is declared 
valid, its denomination accounted for and further actions taken within the coin-processing equipment. 
228  

4.8.2.3  Quarter Dollar Nonsense Pieces 
The quarter dollar nonsense pieces were used as a test platform for dime, quarter and half dollar 
coins, assuming that all three of these coins will continue to be constructed of like materials and 
will continue to have a weight that is proportional to the coin’s face value; this design philosophy 
is consistent with that of today for these three US circulating coins.  In other words, results from 
the quarter dollar material tests are assumed to be directly transferrable to the dime and half 
dollar coins. 
All three manufacturers were unable to distinguish between the newly minted 2012 quarter dollar 
coins, the circulated quarter dollar coins and the quarter dollar nonsense pieces made from 
cupronickel-clad C110 (the incumbent materials of construction for the quarter dollar coin).  
Therefore, CTC concluded that any differences between the measured properties for the 
alternative material nonsense pieces and the baseline circulated coins were strictly due to the 
materials of construction and production methods used to manufacture the nonsense pieces. 
The 669z-clad C110 nonsense pieces were found by all three coin-processing equipment 
manufacturers to be indistinguishable from the circulated quarter dollar coins.  Therefore, this 
coin construction shows promise to be seamless with the incumbent cupronickel-clad C110 
dime/quarter dollar/half dollar coin construction. 
All other quarter dollar nonsense pieces could be easily distinguished from incumbent US 
quarter dollar coins.  Therefore, if used in future quarter dollar coins, the materials and 
manufacturing methods used to produce these other quarter dollar nonsense pieces would require 
an upgrade to all fielded active coin-processing equipment produced by the three manufacturers 
who conducted the validation tests.  Although equipment from two of the manufacturers could 
easily be upgraded to accept plated-ferromagnetic-steel-based quarter dollar coins, the third 
manufacturer would be unable to do so with the sensors that are currently used in their fielded 
coin acceptors.  The Dura-White-plated zinc quarter dollar nonsense pieces had the narrowest 
acceptance windows of all nonsense pieces that were evaluated; the three sets of Dura-White­
plated zinc nonsense pieces (having plating thicknesses of 5, 8 and 10 microns, respectively) 
would offer a signature approximately as unique as the incumbent quarter dollar coin relative to 
other coins and slugs available throughout the world. 
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