1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 07 30 Revised Para 3.0 inserted; Para 3.11 & 4 deleted 1990 05 31 C01031536 Typographical Correction Clause 3.5 1988 04 20 SM/ER 3842 TC Released J. Burke, JAF, MP. NAAO. J. Lines. EAO Printed copies are uncontrolled Copyright 2003, Ford
2、Global Technologies, Inc. Page 1 of 6 PLATING - BRIGHT OR LOW GLOSS DECORATIVE WSB-M1P78-B1 OVER FERROUS SURFACES - INTERIOR PLATING - BRIGHT OR LOW GLOSS DECORATIVE WSB-M1P78-B2 OVER FERROUS SURFACES - GENERAL EXTERIOR PLATING - BRIGHT OR LOW GLOSS DECORATIVE WSB-M1P78-B3 OVER FERROUS SURFACES - SP
3、ECIAL EXTERIOR PLATING - BRIGHT OR LOW GLOSS DECORATIVE WSB-M1P78-B4 OVER FERROUS SURFACES - SPECIAL EXTERIOR 1. SCOPE These specifications define performance requirements for finished coatings of electrodeposited copper, nickel, and chromium for the decoration and protection of ferrous surfaces. 2.
4、 APPLICATION These specifications were released originally where a bright or low gloss decorative and protective metallic finish is required on ferrous surfaces. Four levels of performance are defined as follows: WSB-M1P78-B1 Interior part applications. WSB-M1P78-B2 General exterior part application
5、s. WSB-M1P78-B3 Special exterior part applications requiring superior appearance and improved durability. WSB-M1P78-B4 Special exterior part applications requiring improved durability. CAUTION: Based upon field survey and accelerated laboratory testing experience, plated parts with designs that are
6、not in conformance with the Corporate Plated Part Design Restrictions Booklet (see para 5.1) will not be capable of consistently meeting the requirements of these specifications on a production basis without the use of extraordinary processing techniques, e.g., use of auxiliary anodes, reduction in
7、the parts per rack ratio, etc. FEASIBILITY If the requirements of this specification cannot be met due to part design restrictions, the supplier will inform the responsible product engineering office. Additionally, a “Bumper Plating Restrictions“ Booklet (see para 5.2) was developed to identify thos
8、e bumper design parameters that provide a basis for consistently meeting the requirements of these specifications without the use of extraordinary processing techniques. 3. REQUIREMENTS All requirements identified for each specification must be met to achieve acceptable field durability. No one requ
9、irement, exclusive of others, is capable of insuring satisfactory performance. Any deviations to the requirements of these specifications may be subject to additional performance requirements. All part testing requirements apply to those areas of the part identified as a significant surface per para
10、 5.3 unless otherwise specified on the engineering drawing. ENGINEERING MATERIAL SPECIFICATIONWSB-M1P78-B1/B2/B3/B4Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 6 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must
11、conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.1 STATISTICAL PROCESS The following characteristics shall form part of the Control Plan but shall in no way preclude the control of additional characteristics deemed significant by the supplier and/or Ford SQA
12、. Significant Characteristics (See requirement values within the body of these specifications) . Plating Thickness . Plating Ductility . Microporosity . S.T.E.P. Potential . Sulphur Content 3.2 APPEARANCE All parts shall have the finish (bright, low gloss or paint overlay) specified on the engineeri
13、ng drawing. The plated parts shall be free from surface imperfections. Low gloss or black parts shall match the approved Styling master sample for appearance. 3.2.1 Buffing of Plating Because of the potential adverse effect on corrosion resistance, buffing of final chromium plating on exterior parts
14、 is not permitted. Brushing or other approved mechanical treatment on nickel coatings are permitted provided that minimum plating thickness requirements are met after treatment. 3.3 PLATING ADHESION (ASTM B 571) Adhesion of the electroplate to the base metal and between layers of plating must confor
15、m to the requirements of the following test methods per ASTM B 571 unless otherwise indicated. 3.3.1 Bend Tests (Bend the part or sections of the part) No peeling, flaking, or lift-off of the electroplate from the substrate or between layers of the electroplate is permitted following the Bend Tests.
16、 3.3.2 Grind-Saw Test No lifting or peeling of the electroplate from the substrate or between layers of the electroplate is permitted following the Grind-Saw Test. ENGINEERING MATERIAL SPECIFICATIONWSB-M1P78-B1/B2/B3/B4Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Pa
17、ge 3 of 6 3.4 DUCTILITY (ASTM B 490) Although this is considered a portion of the process control and not a requirement of part performance, the ductility of the electrodeposit on a finished part is considered acceptable when foils plated in the individual nickel baths meet or exceed the following v
18、alues: Semi-bright Nickel 80% Bright Nickel 20% 3.5 PLATING THICKNESS (ASTM B 487, ASTM B 556) It is the suppliers responsibility to identify the plating thickness distribution for each unique part design and rack design by mapping the plating racks and plated parts and to employ any special process
19、ing techniques, e.g., the use of auxiliary anodes and/or shields, reducing the number of parts per rack etc., which may be required to consistently meet the specified minimum plating thicknesses on all significant surfaces. The optical measurement of copper and nickel deposits on significant surface
20、s shall be considered the standard thickness test method (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. The plating
21、 thickness requirements identified below represent minimum values in micrometers and apply to all areas of significant surfaces. WSB-M1P78 B1 B2 B3 B4 Copper or Nickel Strike Optional for B1, B2, B3 and B4 Bright Leveling Acid Copper (g) - - 15 (g) 15 Total Acid Copper plus Strike - - 20 15 Semi-bri
22、ght Nickel (a) - 25 20 25 Bright Nickel (b) plus Special 10 8 10 8 Nickel (c) or Low Gloss Nickel (d) Total Nickel (e) 10 33 30 33 Microporous Chromium (f) - 0.18 0.18 0.18 Regular Chromium 0.25 - - - (a) The sulphur content in the semi-bright nickel bath shall be less than 0.005% (weight %). The su
23、lphur content is specified to indicate the type of nickel plating solution that is to be used and may be measured per the test procedures identified in ASTM B 456. In-process testing to determine conformance to the sulphur content requirement is essential to establish and maintain process capability
24、 and control. (b) The sulphur content in the bright nickel bath shall be greater than 0.03% (weight %). The sulphur content is specified to indicate the type of nickel plating solution that is to be used and may be measured per the test procedures identified in ASTM B 456. In-process testing to dete
25、rmine conformance to the sulphur content requirement is essential to establish and maintain process capability and control. ENGINEERING MATERIAL SPECIFICATIONWSB-M1P78-B1/B2/B3/B4Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 4 of 6 (c) If a special nickel is emp
26、loyed to produce discontinuities in the chromium deposit, the thickness of the special nickel shall be added to the measurement of the bright nickel deposit to meet the combined bright nickel plus special nickel minimum thickness requirement. If a special nickel layer is not used, the minimum thickn
27、ess requirement applies only to the bright nickel deposit. (d) Low gloss nickel may be produced by one of the following methods: Co-deposit containing inorganic particles insoluble in the plating bath. Soluble addition agents co-deposited with the nickel. Mechanical treatment of a bright nickel depo
28、sit, e.g., brushing or bead blasting. When low gloss nickel is specified, special nickel need not be applied. (e) The semi-bright nickel thickness shall be greater than or equal to 60 % of the total nickel thickness. The bright nickel thickness shall be less than or equal to 40% of the total nickel
29、thickness. (f) Microporous chromium plating systems acceptable under this specification are defined as those being capable of producing microporosity in conformance with para 3.6. (g) The B3 specification requires buffing of the copper deposit prior to nickel plating unless otherwise specified on th
30、e engineering drawing. The indicated thickness represents the minimum copper thickness after buffing. Copper can be used for the B1 and B2 specifications, but may not be substituted for nickel. 3.6 MICROPOROSITY, min 10,000 pores/cm2(FLTM BQ 103-06) Note: Applies only to WSB-M1P78-B2, B3 and B4. 3.7
31、 ACCELERATED CORROSION RESISTANCE Parts for accelerated corrosion evaluation may be tested either by para 3.7.1 CASS or para 3.7.2 Corrodekote, with the CASS test being the preferred method. 3.7.1 CASS Test (ASTM B 368) WSB-M1P78-B1 4 h WSB-M1P78-B2 22 h WSB-M1P78-B3/B4 44 h Note: Parts shall be rin
32、sed with demineralized water only, then examined for corrosion defects. Scrubbing, abrasive cleaning, or polishing is not permitted. ENGINEERING MATERIAL SPECIFICATIONWSB-M1P78-B1/B2/B3/B4Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 5 of 6 3.7.2 Corrodkote Test
33、 (FLTM BQ 004-01) WSB-M1P78-B1 4 h WSB-M1P78-B2 16 h WSB-M1P78-B3/B4 32 h Following CASS or Corrodkote exposure, failure is to be noted as follows: Any pit or blister larger than 1.5 mm in diameter visible on any significant surface shall be considered failure of the part when examined after 22 h CA
34、SS or 16 h Corrodkote. For WSB-M1P78-B2 only, base metal corrosion shall not exceed 1 spot/930 cm2of significant surface area. Corrosion spots exceeding this level may be cleaned with MgO, recoated (Corrodkote), then re-exposed for 4 h to determine conformance. Any re-exposed parts exceeding 1 spot/
35、1900 cm2shall be considered failure of the part. For WSB-M1P78-B3/B4, there shall be no base metal corrosion after 44 h CASS or 32 h Corrodkote. 3.8 SIMULTANEOUS THICKNESS AND ELECTROCHEMICAL POTENTIAL TEST (S.T.E.P.) (ASTM B 764) Note: Applies only to WSB-M1P78-B2 and B3. 3.8.1 The semi-bright nick
36、el layer must be more noble (cathodic) than the bright nickel layer by a minimum of 100 millivolts. 3.8.2 If a microporous top nickel layer is used, it shall be equal to or more noble than the bright nickel layer potential. However, the potential of the microporous nickel shall not be more than 20 m
37、v noble (cathodic) to the bright nickel layer. 3.9 CLEANING PRIOR TO ELECTROPLATING Steel parts containing 0.35% carbon or more at the surface, or heat treated from Rockwell C 30 to 39, shall be cleaned using the principles defined in ASTM B 242, “Preparation of High Carbon Steel for Electroplating“
38、. Steels containing less than 0.35% carbon at the surface, or lower than Rockwell C 30 in hardness, shall be cleaned using principles defined in ASTM B 183, “Preparation of Low Carbon Steel for Electroplating“. Steel parts heat treated to Rockwell C 39 or higher shall not be electroplated. 3.10 BRIT
39、TLENESS OF PLATED PARTS Parts shall be free from the detrimental effects of hydrogen embrittlement or other factors which result in part brittleness. The requirements of WSS-M99A3-A apply to parts plated to this specification. ENGINEERING MATERIAL SPECIFICATIONWSB-M1P78-B1/B2/B3/B4Printed copies are
40、 uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 6 of 6 5. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of the specification. 5.1 PLATED PART DESIGN RESTRICTIONS BOOKLET Booklet #80-14-154 (Ford Stationery O
41、rder Number) entitled, “Influence of Design on the Electroplating of Exterior Injection Molded Plastic Components and Zinc Die Castings“. Note: Purchased parts suppliers should request a copy of this booklet from their Ford buyer. 5.2 BUMPER PLATING RESTRICTIONS BOOKLET Prepared by Body and Assembly
42、 Operations. Note: Purchased parts suppliers should request a copy of this Booklet from their Ford buyer. 5.3 SIGNIFICANT SURFACES Unless otherwise specified on the engineering drawing, significant surfaces are defined as those surfaces of the finished part that: . Are directly visible and/or visibl
43、e by reflection when the finished part is assembled in car position, and/or . Can be the source of corrosion products directly visible or visible by reflection. 5.4 SAMPLING AND INSPECTION As specified in Quality Control Specification Q-101, Appendix D and consistent with the appropriate Engineering
44、 Specification (ES) as released by the responsible design engineering activity. 5.5 CORROSION PROTECTION When specified on the engineering drawing all chromium bumpers plated to this specification must have a rust preventative compound, ESB-M7C68, ESB-M7C53 or equivalent applied to the backside of the bar after plating. The compound must be properly cured prior to packaging and shipping.
