1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Ver. 4 2008 07 18 N-STATUS Replaced by WSS-M1P83-C2 G. Weber, FNA 2006 05 09 Revised Updated format 1981 11 06 Released CEL2-790032-C Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, Inc. Page 1 of 5 BRIGHT DECORATIVE
2、 ELECTROPLATING OVER ABS, PPO, OR ESA-M1P47-D MINERAL FILLED NYLON - EXTERIOR NOT TO BE USED FOR NEW DESIGN 1. SCOPE This specification defines the performance requirements for finished coatings of mechanically or chemically deposited conductor coat (copper or nickel) and electrodeposited copper, ni
3、ckel, and chromium for the decoration and protection of ABS, polyphenylene oxide (PPO) or mineral filled nylon. 2. APPLICATION This specification was released originally where a bright decorative finish is required for exterior parts, specifically wheel covers and ornaments. 3. REQUIREMENTS Material
4、 specification requirements are to be used for initial qualification of materials. 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1 APPEARANCE All parts shall hav
5、e the finish (bright, low gloss or paint overlay) specified on the engineering drawing. The plated parts shall be free from surface imperfections such as rough or orange peel conditions, crazing, cold shuts, sink marks, weld lines, delamination, splays, pits, slivers, dullness, stains, discoloration
6、, breaks in the plate, and wheel marks or buff lines to the extent required by specifications for the visual inspection of appearance items established by the product engineering office having design responsibility. Low gloss parts shall match the approved Styling master sample for appearance. 3.1.1
7、 Buffing of Plating Because of the potential adverse effect on corrosion resistance, buffing of final chromium plating on exterior parts is not permitted. Brushing or other approved mechanical treatment on nickel coatings are permitted provided that minimum plating thickness requirements are met aft
8、er treatment. 3.2 ADHESION The plate shall have satisfactory adhesion to the base plastic and show no more separation between the layers of plate than is defined in para 3.5.2.5. Plate adhesion should be tested as follows: ENGINEERING MATERIAL SPECIFICATION ESA-M1P47-D Printed copies are uncontrolle
9、d Copyright 2008, Ford Global Technologies, Inc. Page 2 of 5 3.2.1 Sawing Position the part in a vise or holding fixture so that the plated surface is perpendicular to the saw blade and the cutting motion of the blade is in a direction which tends to pull the plating away from the base plastic. 3.2.
10、2 Bending Any Section of the part containing a significant plated surface (para 3.3.1) shall be positioned in a vise or holding fixture and subjected to repeated bending until fracture of the section and the plate occurs. 3.3 PLATING THICKNESS Minimum plating thickness requirements are shown in para
11、 3.3.3. 3.3.1 Significant Surfaces All unpainted surfaces visible on a part as assembled in a vehicle or surfaces which can be the source of corrosion products visible on a vehicle are significant surfaces. Except as noted on the engineering drawing, all significant surfaces shall meet the corrosion
12、 and plate thickness requirements, as detailed in para 3.3, 3.4, 3.5 and 3.6. (Paint surface requirements are specified in ESB-M2P69.) 3.3.2 Plating Thickness Measurement The optical measurement of copper and nickel deposits on significant surfaces shall be considered the standard thickness test met
13、hod (ASTM B 487). The chromium plate thickness on significant surfaces shall be checked by the spot test as described in ASTM B 556 or by the Coulometric method, ASTM B-504. In case of difference, ASTM B 504 shall be the umpire method. 3.3.3 Minimum Plating Thickness in (m) inches Requirements These
14、 requirements apply to all significant surfaces. Copper (15.4) 0.0006 Low Sulphur-Bright Nickel (9.0) 0.00035 Post Nickel Strike (PNS) (1.3) 0.00005 Chromium (0.25) 0.000010 a) All significant surfaces must be completely covered with copper, nickel, and chromium, with no evidence of plating disconti
15、nuities in low density areas. Discontinuities can be determined by careful visual examination. b) Post nickel strike promotes microcracking in the chromium layers and offers better corrosion resistance. 3.4 MICROCRACKED, min 600 to 1200 (93 to 186) cracks/in2 (cracks/ cm2) (FLTM BQ 103-06) ENGINEERI
16、NG MATERIAL SPECIFICATION ESA-M1P47-D Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, Inc. Page 3 of 5 3.5 THERMAL CYCLE - CORROSION TEST There shall be no evidence of plating failure on significant surfaces or failure of the plastic due to corrosion in excess of that detai
17、led in 3.5.2.1, 3.5.2.2, 3.5.2.3, 3.5.2.4 and 3.5.2.5 for engineering approval and/or initial sample approval when components are subjected to three complete cycles consisting of the following: 3.5.1 Requirements for Engineering Approval and/or Initial Samples (1) 82 +/- 2 C for 2 h (2) 23 +/- 2 C f
18、or 1 h (3) -34 +/- 1 C for 2 h (4) 23 +/- 2 C for 1 h (5) 16 h CASS Test (BQ 105-01) Note: Parts shall be rinsed with tap water only, after each CASS test cycle. Scrubbing, abrasive cleaning, or polishing is not permitted. Parts are then examined for corrosion defects. 3.5.2 Plating and Corrosion De
19、fects 3.5.2.1 Cracks and Crazing Cracks and crazing of the plate are caused by expansion and/or contraction due to temperature change. The total length of a crack shall be counted in the grid method of determining blue-green corrosion whenever the crack penetrates through the bright nickel layer as
20、evidenced by blue-green corrosion bleed out after one 16 h CASS Test. See para 3.5.2.2 “Grid Method for Evaluation of Defects.“ Cracks which do not exhibit green corrosion shall not be included in the evaluation. 3.5.2.2 Blistering and Corrosion Blisters, defined as “pop-ups“, can be caused by impro
21、per molding or plating, or result from corrosion. Failure is to be noted as follows: . Any blister larger than 1/4 in (6.4 mm) in diameter visible on any significant surface shall be considered failure of the part. . More than 2.0% blisters (grid method) of the entire significant surface area, inclu
22、ding blisters and green corrosion, shall be considered failure of the part. . 15% or more blisters and corrosion in a grid section containing 100 1/4 x 1/4 in (6.4 x 6.4 mm) spaces placed anywhere on the significant surface (local corrosion) shall be considered failure of the part. ENGINEERING MATER
23、IAL SPECIFICATION ESA-M1P47-D Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, Inc. Page 4 of 5 Grid Method for Evaluation of Defects . A grid is defined as having a surface area of 6.25 in2 (40.3 cm2) and is divided into 100 1/4 x 1/4 in (6.4 x 6.4 mm) squares. The dimensio
24、ns of the grid may vary from 1/4 x 25 in (6.4 x 635 mm) to 2-1/2 x 2-1/2 in (64 x 64 mm). . For evaluation, the entire significant surface of the part is divided into 1/4 in (6.4 mm) squares. . If any specific 1/4 in (6.4 mm) square contains one or more defects, that entire 1/4 in (6.4 mm) square is
25、 considered to have failed. . If more than 2% of the 1/4 in (6.4 mm) squares are rated as failures, the part is considered to have failed. . If more than 15% of the 1/4 in (6.4 mm) squares in single grid section are rated as failures, the part is considered to have failed. 3.5.2.3 Green Corrosion Gr
26、een corrosion results when penetration through the nickel to the copper occurs in a corrosive environment. Copper corrosion products are blue-green in color when CASS tested. Nickel corrosion will show as a yellow-green color. Failure is noted when: . Any site (hole) larger than 1/16 in (1.6 mm) on
27、any significant surface (not including rundown stain) shall be considered failure of the part. . More than 2.0% corrosion of the entire significant surface area (including rundown stain) shall be considered failure of the part. Note: Blue-green corrosion may be added to blisters for local and overal
28、l corrosion ratings. 3.5.2.4 Pitting - Nickel Corrosion Pitting can result when the bright nickel is too reactive or in the absence of micro discontinuous chromium (micro discontinuous chromium normally prevents nickel pitting). Light yellow-green surface corrosion of the nickel is often seen after
29、48 hrs. CASS testing when micro discontinuous chromium is used. . Any grid area (100 1/4 in (6.4 mm) squares) that contains more than 10 spots 0.048 in (1.22 mm) in diameter or larger shall be considered failed for surface pitting corrosion. Pits less than 0.048 in (1.22 mm) shall be disregarded. Su
30、rface corrosion is not rated with blisters or blue-green corrosion as corrosion defects since surface corrosion is less objectionable than blisters or blue-green corrosion. ENGINEERING MATERIAL SPECIFICATION ESA-M1P47-D Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, Inc. P
31、age 5 of 5 3.5.2.5 Peeling - Plate to Substrate and Plate to Plate Plate peeling from the substrates is caused by molded-in stresses in the plastic (substrate) resulting from improper molding and/or plating processes. Plate-to-plate separation is due to plating machine breakdowns, malfunction of rec
32、tifiers, improper rinsing, bi-polar effects, etc. Separations sometimes occur between electroless copper or nickel and copper or nickel strikes, strike and copper plate, copper plate and semi-bright nickel, semi-bright and bright nickel, bright nickel and special bright nickel, or within the individ
33、ual deposits. Parts shall be examined after Thermal Cycle CASS Test for peeling and blistering (i.e. para 3.5.2.2). . Failure is also to be noted during sawing when the plate peels back from the plastic substrate 1/4 in (6.4 mm) or more or if there is any separation of more than 1/16 in (1.6 mm) bet
34、ween plates. The part shall be bent, twisted, or deformed in any manner (i.e. para 3.2.2). . If there is evidence of lifting between plates or layers of plate, a knife should be used to determine if the bond is poor. Any lifting between plates or within the plate greater than 1/16 in (1.6 mm) shall
35、constitute failure. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this specification. 5.1 MATERIAL REFERENCE . Plating Grade ABS Plastic ESB-M4D241 . Plating Grade Polyphenylene Oxide ESB-M4D351 (Modified) . Plating Gra
36、de Mineral Filled Nylon ESB-M4D353-A4 5.2 MOLDED PARTS Plastic parts intended for plating by this specification must be molded in keeping within the best commercial practice to achieve stress-free parts and insure good plateability. Molded-in stresses can result in part failure by loss of plating ad
37、hesion (blistering) and/or cracking of the plastic and/or plating when subjected to service temperature extremes. 5.3 SAMPLING AND INSPECTION As specified in Quality Control Specification Q-101 and consistent with the appropriate engineering specification (ES) as released by the responsible design engineering activity.
