1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions Rev. 2 2008 10 29 Activated Replaces WSS-M1P83-C2; Split Int. & Ext., Split Ext. into 2 parts, Sec. 3.9, Table 1 C. McComb, FNA 2006 11 10 Activated C. McComb / J. Crist Printed copies are uncontrolled Copyright 2008, Ford Global Technologies,
2、 LLC Page 1 of 7 ELECTROPLATING, BRIGHT OR LOW GLOSS DECORATIVE FINISH WSS-M1P83-D2 OVER ABS EXTERIOR, LOW TEMPERATURE APPLICATIONS ELECTROPLATING, BRIGHT OR LOW GLOSS DECORATIVE FINISH WSS-M1P83-D3 OVER PC/ABS EXTERIOR, HIGH TEMPERATURE APPLICATIONS 1. SCOPE These specifications define the performa
3、nce requirements for finished coatings of mechanically or chemically deposited electrical conductor coat and electrodeposited copper, nickel, and chromium for the decoration and protection of acrylonitrile butadiene styrene (ABS) or polycarbonate/acrylonitrile butadiene styrene (PC/ABS). 2. APPLICAT
4、ION These specifications were released originally where a bright or low gloss decorative and/or protective finish is required for interior or exterior parts. Unless otherwise specified on the engineering drawing, all parts shall be finished with a final coating of chromium. Two performance levels ar
5、e defined as follows: WSS-M1P83-D2 Exterior applications Low impact applications such as badges or in an operating environment less than or equal to 82 C WSS-M1P83-D3 Exterior applications High impact applications such as grilles or in an operating environment greater than 82 C For coating (paint or
6、 ink) over chrome applications, part must meet requirements in the latest version of WSS-M2P191. 2.1 LIMITATIONS Materials used in all systems shall withstand a paint repair surface temperature of 115 oC for 20 minutes without deformation, functional damage or loss of appearance or other physical ch
7、aracteristics. If the part cannot meet this requirement, it must be capable of being protected (e.g. shielding) during repair processing of the vehicle. 3. REQUIREMENTS All requirements identified for each specification must be met to achieve acceptable field durability. No one requirement, exclusiv
8、e 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 paragraph 4.3) unles
9、s otherwise specified on the engineering drawing. Testing to be done a minimum of 72 hours after plating. ENGINEERING PERFORMANCE SPECIFICATIONWSS-M1P83-D2/D3Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 2 of 7 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS M
10、aterial suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-A). 3.2 FINISHED PARTS Testing must be done on actual production parts or a section of the part whenever possible. Where part dimensions limit equipment access, representati
11、ve panels or plaques may be substituted for production parts with approval from responsible Design Engineer. Testing to be conducted at Design Verification (DV) or Process Validation (PV) per Table 1, Section 4.6, unless otherwise agreed to by responsible Design Engineer. 3.3 APPEARANCE The plated p
12、arts shall be free from surface imperfections. Parts shall match the approved Styling master sample for appearance from Color & Trim and the Approved Boundary Sample. 3.4 PLATING ADHESION (For acceptance criteria, reference Section 4.6) 3.4.1 Residual Stress Test, D2 only Report should include (Test
13、 Method: Dip entire unplated part in Glacial photos of tested part Acetic Acid, 95% purity, for 30 seconds) and control part. Any color change from the control indicates concentration of residual or molded-in-stresses. The intent of this test is to illustrate to the engineering team where these stre
14、sses are located within the molded part. Adhesion tests should be performed in areas of high molded-in-stress and documented on a part map indicating locations. (Reference Section 4.2). 3.4.2 Grind-Saw (The saw blade shall have 16 to 18 teeth/inch.) (ASTM B 571) No peeling, flaking, or lifting of th
15、e electroplate from the substrate. 3.4.3 Bend Test (ASTM B 571) No peeling, flaking, or lifting of the electroplate from the substrate. 3.4.4 Scribe-Grid Test 5% plating removal (ASTM B 571) Use the following modifications to the method: Lightly hand sand plated surface (10 double rubs, moderate pre
16、ssure) with P600 paper until dull. Clean area with Isopropyl Alcohol. With a hardened steel, 30 tip blade, scribe eight lines in a rectangular grid in 0.5 cm increments. Use 3M No. 898 pressure sensitive tape. ENGINEERING PERFORMANCE SPECIFICATIONWSS-M1P83-D2/D3Printed copies are uncontrolled Copyri
17、ght 2008, Ford Global Technologies, LLC Page 3 of 7 3.4.5 Thermal Shock (FLTM BI 107-05) No peeling, flaking, or lifting of the electroplate from the substrate. 3.4.6 Chip Resistance 3.4.6.1 Grit Blast, Split Shot, min Rating 6 (FLTM BI 157-06) 3.4.6.2 Stone Chip, 1.4 L, min Rating 5B (SAE J400, -20
18、 C +/- 2 & 23 +/- 2 C) 3.5 PLATING THICKNESS (ASTM B 487, ASTM B 504, ASTM B568) 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. Areas of low and high current density are to b
19、e documented on a part map indicating locations that plating measurements will be taken. Plating thickness to be determined by Microscopic Examination (ASTM B 487), Coulometric Method (ASTM B 504), or X-Ray Spectrometry (ASTM B 568). Exceptions to the minimum plating thickness are to be shown as a d
20、etail on the part drawing by indicating in an appropriate view the area(s) with deviated thickness(es) allowed. These exceptions must meet all other requirements of the specification and the areas of deviated thickness must be approved by the responsible Design Engineer. The plating thickness requir
21、ements identified below represent minimum values in micrometers and apply to all areas of significant surfaces (as per paragraph 4.3). Copper 18 Semi-bright Nickel (a) 15 Bright Nickel (b) plus 6 Special nickel (c) or Low gloss Nickel (d) Total Nickel (e) 21 Microporous Chromium (f) 0.18 Regular Chr
22、omium (a) (f): Refer to section 4.5 in General Information. 3.6 MICROPOROSITY 10,000 pores/cm2(FLTM BQ 103-06) 3.7 SIMULTANEOUS THICKNESS AND ELECTROCHEMICAL POTENTIAL TEST (S.T.E.P.) 3.7.1 The semi-bright nickel layer must be more noble (cathodic) than the bright nickel layer by a minimum of 100 mv
23、. 3.7.2 The potential of the microporous nickel shall be between 10 and 40 mv noble (cathodic) to the bright nickel layer. ENGINEERING PERFORMANCE SPECIFICATIONWSS-M1P83-D2/D3Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 4 of 7 3.8 THERMAL CYCLE - CORROSION TEST
24、There shall be no evidence of plating failure on significant surfaces (per paragraph 4.3) or failure of the plastic due to corrosion after completing four cycles consisting of the following: 3.8.1 Requirements for Testing, D2 82 +/- 2 C for 2 h 23 +/- 2 C for 1 h and 50 +/- 5% relative humidity -30
25、+/- 2 C for 2 h 23 +/- 2 C for 1 h and 50 +/- 5% relative humidity 16 h CASS Test (ASTM B 368) 3.8.2 Requirements for Testing, D3 90 +/- 2 C for 2 h 23 +/- 2 C for 1 h and 50 +/- 5% relative humidity -30 +/- 2 C for 2 h 23 +/- 2 C for 1 h and 50 +/- 5% relative humidity 16 h CASS Test (ASTM B 368) N
26、ote: Parts shall be rinsed with demineralized water only, after each CASS test cycle. Scrubbing, abrasive cleaning, or polishing is not permitted. Parts are then examined for corrosion defects per paragraph 3.8.4. The cycled part shall show no evidence of warpage, deformation, cracks, delamination o
27、r other failures to an extent that would affect its use in the ultimate assembly. 3.8.4 Plating and Corrosion Defects 3.8.4.1 Cracks and Crazing Cracks and crazing of the plate are caused by expansion and/or contraction due to temperature change. Cracks or crazing exceeding 6 mm in length observed o
28、n significant surfaces (per paragraph 4.3) shall be considered failure of the part. 3.8.4.2 Blistering and Corrosion Blisters defined as “pop-ups“ can be caused by improper molding or plating, or result from corrosion. ENGINEERING PERFORMANCE SPECIFICATIONWSS-M1P83-D2/D3Printed copies are uncontroll
29、ed Copyright 2008, Ford Global Technologies, LLC Page 5 of 7 Failure is noted when: Any site (hole) larger than 1.5 mm on any significant surface (per paragraph 4.3) (not including rundown stain) shall be considered failure of the part. More than 1% of part surface area with blisters and/or corrosio
30、n on significant surfaces (per paragraph 4.3) shall be considered failure of the part. More than 8% of part surface area with blisters and/or corrosion in a grid section containing 100, 6.0 x 6.0 mm spaces placed anywhere on the significant surfaces (per paragraph 4.3) shall be considered failure of
31、 the part. 3.9 THERMAL CYCLE There shall be no evidence of plating failure on significant surfaces (per paragraph 4.3) or failure of the plastic due to warpage after completing four cycles consisting of the following: 3.9.1 Requirements for testing, D2 -40 +/- 2 C for 1 h 82 +/- 2 C for 1 h 3.9.2 Re
32、quirements for testing, D3 -40 +/- 2 C for 1 h 90 +/- 2 C for 1 h Part must be transferred between temperatures within one minute. All parts shall be complete including all components packaged in the assembly and fastened onto actual or representative production support foundations that include not
33、only all attaching points but also any boundary conditions that may restrict movement, unless otherwise specified by the responsible Design and Release Engineer. The cycled part shall not show changes in appearance, such as warpage, deformation, cracks, or delamination per the print Engineering Tole
34、rance dimensions. 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of these specifications. 4.1 MATERIAL REFERENCE The following stress free plateable grade substrates are recommended: ABS WSK-M4D836-A PC/ABS WSB-M4D813-A ENG
35、INEERING PERFORMANCE SPECIFICATIONWSS-M1P83-D2/D3Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 6 of 7 4.2 MOLDED PARTS Plastic parts intended for plating by this specification must be molded in keeping within the best commercial practice to achieve stress-free pa
36、rts and ensure good plating. Molded-in stresses can result in part failure by loss of plating adhesion, blistering, and/or cracking of the plastic and/or plating when subjected to service temperature extremes. 4.3 SIGNIFICANT SURFACES Unless otherwise specified on the engineering drawing, significan
37、t surfaces are defined as those surfaces of the finished part that: - Are directly visible and/or visible by reflection when the finished part is assembled in car position. - Can be the source of corrosion products directly visible or visible by reflection. 4.4 DUCTILITY (ASTM B 490) Although this i
38、s considered a portion of the process control and not a requirement of part performance, the ductility percentage of Semi-bright Nickel and Bright Nickel on foils plated in the individual nickel baths should be rated, reported, and included in the Control Plan. 4.5 PLATING THICKNESS REFERENCE (a) Th
39、e sulphur content in the semi-bright nickel bath shall be less than 0.005% (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 determine conformance
40、 to the sulphur content requirement is essential to establish and maintain process capability and control. (b) The sulphur content in the bright nickel bath shall be greater than 0.04% (weight %). The sulphur content is specified to indicate the type of nickel plating solution that is to be used and
41、 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 and control. (c) If a special nickel is employed to produce discontinuities in the chromium depo
42、sit, 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 thickness requirement applies only to the bright nickel dep
43、osit. (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 deposit, e.g., brushing or bead blasting. - When lo
44、w gloss nickel is specified, special nickel need not be applied. ENGINEERING PERFORMANCE SPECIFICATIONWSS-M1P83-D2/D3Printed copies are uncontrolled Copyright 2008, Ford Global Technologies, LLC Page 7 of 7 (e) The semi-bright nickel thickness shall be greater than or equal to 60% of the total nicke
45、l thickness. The bright nickel thickness shall be less than or equal to 40% of the total nickel thickness. (f) Microporous chromium plating systems acceptable under this specification are defined as those being capable of producing microporosity in conformance with para 3.5. 4.6 PLATING ADHESION ACC
46、EPTANCECRITERIA REFERENCE Separation between layers of plating on adhesion tests do not indicate a failure of the test, but indicates a failure within the plating system. 4.7 TABLE 1: DV/PV REQUIREMENTS DV and PV must be conducted on parts unless approved by Design Engineer. X= Required Sample Size
47、To be done at DV testing To be done at PV testing 3.4.1 Residual Stress 2 X X 3.4.2 Grind-Saw* 3 X 3.4.3 Bend Test* 3 X 3.4.4 Scribe-Grid Test* 3 X X 3.4.5 Thermal Shock* 3 X X 3.4.6.1 Grit Blast,Split Shot 3 X X 3.4.6.2 Stone Chip 3 X X 3.5 Plating Thickness* 3 X 3.6 Microporosity* 1 X X 3.7 S.T.E.
48、P.* 1 X X 3.8.1 CASS Thermal Cycle for D2 3 X X 3.8.2 CASS Thermal Cycle for D3 3 X X 3.9.1 Thermal Cycle for D2 6 X X 3.9.2 Thermal Cycle for D3 6 X X * Samples must be tested on parts in high stress as identified from Residual Stress test 3.4.1 for D2 and Engineering Judgement for D3. See Design Engineer for number and location of test sites per part. * See Design Engineer for number and location of test sites per part.
