1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 2 2015 01 22 Editorial See Summary of Revisions S. Draheim, NA 2015 01 07 Editorial See Summary of Revisions S. Draheim, NA 2014 11 05 Released S.Draheim , NA Controlled document at www.MATS Copyright 2015, Ford Global Technologies, LLC
2、Page 1 of 6 ELECTROPLATING, BRIGHT OR LOW GLOSS DECORATIVE FINISH WSS-M1P83-E1 OVER ABS, PC/ABS OR FILLED NYLON INTERIOR 1. SCOPE This specification defines the performance requirements for finished coatings of mechanically or chemically deposited electrical conductor coat and electrodeposited coppe
3、r, nickel, and chromium for the decoration and protection of acrylonitrile butadiene styrene (ABS) or polycarbonate/acrylonitrile butadiene styrene (PC/ABS) or filled nylon (PA) parts. 2. APPLICATION This specification was released originally where a bright or low gloss decorative and/or protective
4、finish is required for interior parts. Unless otherwise specified on the engineering drawing, all parts shall be finished with a final coating of chromium. 3. REQUIREMENTS All requirements identified for each specification must be met to achieve acceptable field durability. No one requirement, exclu
5、sive 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) un
6、less otherwise specified on the engineering drawing. Test specimens must be aged for at least 72 hours prior to testing. 3.1 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements For Production Materials (WSS-M99P1111-
7、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, representative panels or plaques may be substituted for production parts with approval from responsible Design Engineer. The use of re-grin
8、d or recycled substrate material is prohibited. 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 parts shall be free from surface imperfections. Parts shall mat
9、ch the approved Styling Master sample for appearance from Color & Trim and the Approved Boundary Sample. ENGINEERING PERFORMANCE SPECIFICATION WSS-M1P83-E1 Copyright 2015, Ford Global Technologies, LLC Page 2 of 6 3.4 PLATING ADHESION Acceptance criteria for sections 3.4.2, 3.4.3, 3.4.4, 3.4.5: No p
10、eeling, flaking, or lifting of the electroplate from the substrate or between the layers. Residual stress in part substrates are areas of potential weak adhesion. Performing the residual stress test below will identify the molded in stresses of the part. Parts not requiring the residual stress test
11、should be tested in the location of the largest area of significant surface. 3.4.1 Residual Stress Test (ABS Substrate only) Report should include (Not required for PC+ABS or PA substrates) photos of tested part (Only for parts with significant surfaces 20 sq. cm and control part or greater) Test Me
12、thod: Totally immerse the un-plated part in Glacial Acetic Acid, 99% purity at 24C +/-3 (75F +/-5F), for 30 seconds Immediately rinse the part in IPA water to remove the Acetic Acid and allow to dry at room temperature. Any color change from the control indicates concentration of residual or molded-
13、in- stresses. These areas should be circled and photographed for the test report. Adhesion tests should be carried out as specified in table 2. 3.4.2 Grind-Saw (ASTM B 571, The saw blade shall have 16 to 18 teeth/inch.) The number of tests and locations should be carried out as specified in table 2.
14、 No peeling, flaking, or lifting of the electroplate from the substrate or between plating layers. 3.4.3 Bend Test (ASTM B 571 paragraphs 3.1 or 3.2 permissible) The number of tests and locations should be carried out as specified in table 2. No peeling, flaking, or lifting of the electroplate from
15、the substrate or between plating layers. 3.4.4 Scribe-Grid Test (ASTM B 571, except as modified below) The number of tests and locations should be carried out as specified in table 2. This test is not required for parts too small to scribe 1 (0.5cm X 0.5cm) square stated below. Use the following mod
16、ifications to the method: ENGINEERING PERFORMANCE SPECIFICATION WSS-M1P83-E1 Copyright 2015, Ford Global Technologies, LLC Page 3 of 6 Lightly hand sand plated surface (10 double rubs, moderate pressure) with P600 paper until dull. Clean area with Isopropyl Alcohol. With a hardened steel, 30 tip bla
17、de, scribe eight lines in a square grid in 0.5 cm increments or smaller. If part surface area does not allow room for the 9 squares, scribe as many 0.5cm squares that can fit. Use 3M No. 898 pressure sensitive tape. An equivalent tape can be used if agreed upon by Materials Engineering as long as th
18、e Adhesion Strength is greater or equal to the 3M 898 tape (80N/mm per ASTM D 3330). No peeling, flaking, or lifting of the electroplate from the substrate or between plating layers. 3.4.5 Thermal Shock Rating 20 min (FLTM BI 107-05) The number of tests and locations should be carried out as specifi
19、ed in table 2. No peeling, flaking, or lifting of the electroplate from the substrate or between plating layers. 3.5 PLATING THICKNESS (ASTM B 487, ASTM B 504, ASTM B 568) It is the suppliers responsibility to identify the plating thickness distribution for each unique part design and rack design by
20、 mapping the plating racks and plated parts. Areas of low and high current density are to be 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 Sp
21、ectrometry (ASTM B 568). Exceptions to the minimum plating thickness are to be shown as a detail 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
22、thickness must be approved by the responsible Design Engineer. The plating thickness requirements identified below applies to all areas of significant surfaces (as per paragraph 4.3). Copper 13 m min. Semi-bright Nickel - Bright Nickel plus 5 m min. Special nickel or Low gloss Nickel Total Nickel 5
23、m min. Microporous Chromium Regular Chromium 0.18 m min. 3.6 THERMAL CYCLE - CORROSION TEST (4 cycles) 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: 3.6.1
24、Requirements for Testing (1 cycle defined below) This cycle assumes 30min. ramp time between dwell temperatures and allows a ENGINEERING PERFORMANCE SPECIFICATION WSS-M1P83-E1 Copyright 2015, Ford Global Technologies, LLC Page 4 of 6 maximum of 24 hrs. between thermal cycling and CASS test. -30 +/-
25、2 C for 2 h 23 +/- 2 C for 1 h and 50 +/- 5% relative humidity 90 +/- 2 C for 2 h 23 +/- 2 C for 1 h and 50 +/- 5% relative humidity 4 h CASS Test (ASTM B 368) Parts shall be rinsed with demineralized water only, after each CASS test cycle. Scrubbing, abrasive cleaning, or polishing is not permitted
26、. The cycled part shall show no evidence of warpage, deformation, cracks, crazing, delamination, blistering or corrosion on significant surfaces (per paragraph 4.3) 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of this spe
27、cification. Contact for questions concerning Engineering Material Specifications. 4.1 MATERIAL REFERENCE The following stress free plateable grade substrates are recommended: ABS WSS-M4D836-B2/Latest PC/ABS WSS-M4D813-B2/Latest Plating Grade Mineral Filled Nylon WSK-M4D667-A/Latest 4.2 MOLDED PARTS
28、 Plastic parts intended for plating by this specification must be molded in keeping within the best commercial practice to achieve stress-free parts to ensure proper adhesion. Molded-in stresses can result in part failure by loss of plating adhesion, blistering, and/or cracking of the plastic and/or
29、 plating when subjected to service temperature extremes. 4.3 SIGNIFICANT SURFACES Significant 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. 4.4 DUCTILITY (ASTM B 490) Although th
30、is is 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 MCDCC Material Color Durabilit
31、y Compliance Certificate (MCDCC) will be required for the Appearance Approval Report (AAR) to be approved by Design Quality. The MCDCC form for chrome parts ENGINEERING PERFORMANCE SPECIFICATION WSS-M1P83-E1 Copyright 2015, Ford Global Technologies, LLC Page 5 of 6 is used to verify a plater has the
32、 capability to match the specified color master and meet the requirements of this specification on a specific resin used for the substrate of a part. Parts must be reviewed with Ford Design Color and Materials group for color sign off on the MCDCC. All tested parts must be reviewed by Materials Engi
33、neering for the final sign off on the MCDCC. Any part geometry can be used for this testing but it must have a minimum 10mm by 20mm rectangle area on the significant surface. Please contact Materials Engineering if there are any questions. 4.6 DV/PV REQUIREMENTS PV must be conducted on Production ru
34、n at rate parts. X= Required TABLE 1 Sample Size DV / MCDCC testing PV testing 3.4.1 Residual Stress 2 X X 3.4.2 Grind-Saw 3 X X 3.4.3 Bend Test 3 X X 3.4.4 Scribe-Grid Test 3 X X 3.4.5 Thermal Shock 3 X X 3.5 Plating Thickness 3 X X 3.6 CASS Thermal Cycle 3 X X ENGINEERING PERFORMANCE SPECIFICATION
35、 WSS-M1P83-E1 Copyright 2015, Ford Global Technologies, LLC Page 6 of 6 4.7 ADHESION TESTING REQUIREMENTS TABLE 2 For parts not requiring residual stress test For parts requiring Residual Stress Test No high stress locations identified 1 high stress location identified 2 high stress locations identi
36、fied 3 high stress locations identified 4 high stress locations identified, 3.4.2 Grind Saw 3.4.3 Bend test 3.4.4 Scribe Grid 3.4.5 Thermal Shock Test 3 parts, 2 at the location of high stress and 1 at the location of the largest area of the significant surface. Test 3 parts, 2 parts at the stress l
37、ocation with the highest significant surface area and 1 at the other stress location Test 3 parts each part at each of the different high stress locations. Test 4 parts each part at each of the different high stress locations. 4.8 HISTORY OF SUFFIX CHANGE This specification was based on WSS-M1P83-D1
38、 with changes in the following areas: 3.2 Added re-grind restriction 3.4 Added Residual Stress Test and clarifications 3.4.2 Added grind saw test 3.4.3 added clarifications to bend test 3.4.4 Defined minimum testable size and added clarifications 3.4.5 Added clarifications to thermal shock 3.6 Chang
39、ed thermal cycle to start with cold instead of hot and defined times between temperatures and CASS. 3.6.2 Deleted plating and corrosion defects 4.3 Clarified wording 4.5 Added MCDCC information 4.6 Added Residual Stress test and added more PV testing required. 4.7 Added table 2 for adhesion testing
40、requirements. 5. SUMMARY OF REVISIONS 2015 01 22 Editorial Corrected number of squares in section 3.4.4 2015 01 07 Editorial - Corrected numbering in table 1 section 4.6 DV/PV requirements Test 3 parts in the location of the largest area of significant surface Test 3 parts in the location of the largest area of significant surface Test 3 parts, all in the location of the high stress Test 3 parts, all in the location of the high stress Test 3 parts, all in the location of the high stress Test 3 parts, all in the location of the high stress
