1、 ENGINEERING MATERIAL SPECIFICATION Date Action Revisions Rev. 00 2017 12 13 Released S. Draheim and Global Team Controlled document at www.MATS.com Copyright 2017, Ford Global Technologies, LLC Page 1 of 12 DECORATIVE CHROME ELECTROPLATED PART PERFORMANCE WSS-M1P83-F1 REQUIREMENTS, POLYMERIC/PLASTI
2、C SUBSTRATES, GENERAL INTERIOR USE 1. SCOPE This specification defines the performance requirements for copper, nickel, and chromium electroplated acrylonitrile butadiene styrene (ABS), polycarbonate/acrylonitrile butadiene styrene blend (PC/ABS) and polyamide (PA) parts for interior applications. 2
3、. APPLICATION This specification was released originally where a decorative chrome finish is required for interior applications, including, but not limited to, handles, finish panels, bezels, knobs and buttons. 2.1 LIMITATIONS No coating (paint, ink, etc.) may be applied over chrome plating unless a
4、pproved by Materials Engineering. This specification does not cover non-electro plated metalized surfaces. 2.2 REFERENCES Appendix A: PPAP Report Template Appendix B: Reference Images 3. REQUIREMENTS This specification is performance based and does not have approved sources. All requirements identif
5、ied for this specification must be met to achieve acceptable field durability. No one requirement, exclusive of others, is capable of insuring satisfactory performance. Any deviations to the requirements of this specification may be subject to additional performance requirements. Testing at Design V
6、erification (DV), Material Color Durability/Compliance Certification (MCDCC), and Process Validation (PV) must be conducted per Table 3. For MCDCC approval, parts from DV and/or PV testing may be submitted in lieu of separate test parts, as long as the quantity of parts per Table 3 is met. Additiona
7、l routine testing for process control may be required and if so, would be in the Special Characteristics Communication and Agreement Form (SCCAF). The SCCAF will define the required number and frequency of samples agreed to by Ford Design and Release Engineering (D&R) and Supplier Technical Assistan
8、ce (STA). 3.1 APPEARANCE The plated parts shall be free from surface imperfections and must conform to the color requirements defined by Ford Design Quality, the Ford Color Harmony Team Styling Master and the Approved Boundary Sample. ENGINEERING MATERIAL SPECIFICATION WSS-M1P83-F1 Copyright 2017, F
9、ord Global Technologies, LLC Page 2 of 12 3.2 MOLDED SUBSTRATES Ford recommends using substrate materials approved to the following specifications: WSS-M4D836-B2/latest for ABS WSS-M4D813-B2/latest for PC/ABS WSS-M4D667-B2/Latest for PA The decision to use either ABS, PC/ABS or PA shall be directed
10、by Ford D&R engineering Part geometry influences the capability of the plating process. Designs should be optimized to ensure the plating process is capable of meeting this specification. The use of regrind or recycled material for substrates in plated applications is prohibited. Material must be pr
11、ocessed per Global Manufacturing Standard W-IMMS - Control of Plastic Injection Molding Processes, located on the Ford Supplier Portal, STA Global Technical Services, Plastic Molding, https:/ The parts shall be smooth and without flow lines, knit lines, visible porosity, cracks, sink marks, or other
12、 molding defects, which may detract from the part appearance or performance. Molded substrates must also be free of any residual stresses which would impact electroplate adhesion, dimensional stability, or appearance. Mold flow analysis should be conducted to minimize residual stress in molded subst
13、rates. Parting lines, flash and other characteristics of molding may impact part durability and must be minimized. Any rework of parting lines prior to plating must be reviewed and approved by STA before use in the production process. Testing to this standard must be completed on parts with the rewo
14、rk process and submitted to STA for approval. 3.3 FINISHED PARTS Design Verification testing must be completed on program specific part geometry plated with the production representative process. Production Validation testing must be done on actual production level parts. Where part dimensions limit
15、 testing, or other exceptions exist, substitution of surrogate parts or plaques requires approval of D&R, STA, and Ford Materials Engineering. All visible surfaces of the component, including terminating exterior edges visible after assembly, shall conform to the full requirements of this specificat
16、ion, unless otherwise specified in the SCCAF or on the engineering drawing. Plated test specimens prepared for investigations according to this specification must be aged a minimum of 2 hours at 23 +/- 2 C prior to testing. 3.4 PROCESS OPTIMIZATION Process development is to be completed prior to any
17、 qualification testing to this specification (DV, PV, etc.). Repetition of these tests may be necessary in order to optimize molding and plating parameters for successful part performance. Once optimization of all parameters is complete, all testing, including tests in Section 3.4, must be conducted
18、 at the production parameter levels. Only results of the final tests, with production levels of all parameters, are required to be submitted as part of the PPAP package. ENGINEERING MATERIAL SPECIFICATION WSS-M1P83-F1 Copyright 2017, Ford Global Technologies, LLC Page 3 of 12 The use of SEM analysis
19、 of the part surface after the etching process is recommend. This can indicate under etching, over etching, and/or elongation of bond sites. All witch can decrease adhesion performance. See reference pictures in appendix B Figures 3 through 6. 3.4.1 Residual Stress Test and Identifying Adhesion poin
20、ts No cracking Residual stresses in molded plastic parts are areas of potential weak electroplate adhesion Residual Stress Test is not required for PA (Nylon) substrate material but see below for Identifying Adhesion points (A-points) The results of this test will identify the test location for the
21、adhesion grind saw test in paragraph 3.5.1 Testing for residual stress must be conducted for new parts, when any molding parameter changes, or when adhesion issues may be due to molding stress. Repetition of this test may be necessary in order to optimize molding parameters for reduction of molded-i
22、n stresses before all additional testing is completed. Test Procedure: Completely immerse the unplated part in glacial acetic acid, 99% purity, at 23o C +/- 3 C for 30 seconds. Remove and immediately rinse the part with water to remove acid from the surface and allow to dry at room temperature. Revi
23、ew and photograph the part, noting any areas of uneven whitening. Return the part to the glacial acetic acid bath for up to the duration indicated by Table 1 below. Table 1: Glacial Acetic Acid Test Time Substrate Time ABS 120 seconds PC/ABS 180 seconds After the specified time has elapsed, immediat
24、ely rinse the part with water to remove acid from the part surface and allow to dry at room temperature. Review and photograph the part again, noting any areas of uneven whitening. Identifying Adhesion points (A-points) Areas with the highest contrast between light and dark indicate locations of the
25、 highest molded-in stress (Appendix B, Figures 1 and 2). The highest stress areas should be documented as “adhesion points” or “A-points”. A minimum of two “A-points” per part must be indicated. For parts that do not show obvious areas of high contrast, the minimum two “A-points” will be: 1) at a po
26、int on the significant surface closest to the gate, 2) at a knit line. If no knit line exists, the second point should be at a location on the significant surface at end of flow or along a narrow channel if one exists. For Nylon parts, the A-points should be identified using the same method as parts
27、 that do not show obvious areas of high contrast. ENGINEERING MATERIAL SPECIFICATION WSS-M1P83-F1 Copyright 2017, Ford Global Technologies, LLC Page 4 of 12 Report must include photos of the part before testing, after 30 seconds, after 120-180 second durations. These Photos must be of high enough re
28、solution and quality to show no color change or to show where high contrast locations exist. Photos must also be provided identifying the selected A-points. These photos must be retained for process control validation of the optimized molding process. 3.4.2 Minimum Plating Thickness (ASTM B487, ASTM
29、 B504, ASTM B568) Minimum plating thicknesses are defined in Table 2. For typical plating construction, refer to Appendix B, Figure 7. Plating thickness should be met for all DV tested parts and optimized prior to PV testing to ensure all requirements of the specification are met. The use of auxilia
30、ry anodes is recommended, where applicable. Thickness measurement locations should be at the high and low thickness locations across the rack. A picture must be provided of a full rack of parts showing the following 3 items: 1) High and Low current density areas identified 2) Part with low thickness
31、 location circled (This most likely will be in low current density area and the farthest point from the anode) 3) Part with High thickness location circled (This most likely will be in the high current density area and the closest point to the anode) Copper and nickel layer thickness to be determine
32、d by Microscopic Examination (ASTM B487). Chromium layer thickness to be determined by Coulometric Method (ASTM B504), or X-Ray Spectrometry (ASTM B568). Table 2: Plating Layer Minimum Thickness Requirements Plating Layer Interior Minimum thickness (m) Copper 13 Semi Bright Nickel Not Required Decor
33、ative Nickel 5 Microporous Chromium Not required Microcrack Chromium Not required Continuous Chromium 0.18 3.5 PLATING ADHESION All adhesion testing must be completed on the part at the “A-points” as indicated by Section 3.4.1 Residual Stress Test and Identifying Adhesion points, unless otherwise no
34、ted. Where a single part is produced by multiple cavities, testing at PV must be completed on parts molded from the tool cavity that produces the highest stress conditions, as determined by Section 3.4.1. 3.5.1 Grind-Saw Test (ASTM B571, with modifications below) Testing will be performed using a ha
35、ndheld hacksaw with 6-8 teeth/cm, cutting from the substrate toward the plating. The cut will be made with the plane of the saw 90 degrees to ENGINEERING MATERIAL SPECIFICATION WSS-M1P83-F1 Copyright 2017, Ford Global Technologies, LLC Page 5 of 12 the test area and the blade angled at 45 degrees to
36、wards the part (visual representation in Appendix B, Figure 8). A minimum 15mm cut shall be made at a rate of approximately 1 stroke per second. If part geometry doesnt allow the minimum cut length, the part shall be cut through the entire section. Bandsaws shall not be used for this test. All teste
37、d samples must indicate no evidence of peeling, flaking, or lifting of the electroplate from the substrate or between the plating layers. The approving Ford engineer should attempt to peel the plating away from the cut edge with a sharp blade to further evaluate the propagation of adhesion loss. 3.6
38、 CORROSIONTHERMAL CYCLE RESISTANCE Testing shall be completed on unassembled, chromed parts, oriented in vehicle position. Parts shall be subject to four cycles, with each cycle consisting of 6 hours thermal cycle and 4 hours Copper-Accelerated Acetic Acid-Salt Spray (CASS), as indicated below. One
39、Cycle: 2 hours at -30+/- 2 C 1 hour at 23 +/- 2 C, 50 +/- 5% RH 2 hours at 90 +/- 2 C 1 hour at 23 +/- 2 C, 50 +/- 5% RH 4 hours CASS (ASTM B 368) This cycle assumes 30min. ramp time between dwell temperatures and allows a maximum of 24 hrs. between thermal cycling and CASS test. Parts shall be rins
40、ed with demineralized water only after each CASS test cycle. Scrubbing, abrasive cleaning, or polishing is not permitted. Tested parts shall show no degradation of part appearance. There shall be no evidence of plating failure, warpage, sink marks, deformation, cracks, blistering, delamination or co
41、rrosion on significant surfaces (visible surface area). 4. GENERAL INFORMATION The information given below is provided for clarification and assistance in meeting the requirements of these specifications. Contact for questions concerning Engineering Material Specifications. 4.1 DUCTILITY Report Onl
42、y (ASTM B490) Although this 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. 4.2 MATER
43、IAL COLOR DURABILITY/COMPLIANCE CERTIFICATION (MCDCC) MCDCC will be required for the Appearance Approval Report (AAR) to be approved by Design Quality. The MCDCC form for chrome parts is used to verify a platers production site/facility has the capability to match the specified color master and meet
44、 the requirements of the specification. A Surrogate 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. ENGINEERING MATERIAL SPECIFICATION WSS-M1P83-F1 Copyright
45、 2017, Ford Global Technologies, LLC Page 6 of 12 Parts must be reviewed with Ford Design Color and Materials group for color match sign off on the MCDCC. All test data, including physical samples, must be reviewed by Ford Materials Engineering for Certification/final sign off of the MCDCC. 4.3 SUPP
46、LIERS ONGOING RESPONSIBILITY All materials must be equivalent in all characteristics to the material upon which approval was originally granted. Prior to making any changes to the material originally approved, whether or not such changes affect the materials ability to meet the specification require
47、ments, the supplier shall notify the affected Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering Approval, SREA. For parts and components using Ford Engineering Ma
48、terial Specifications, all samples tested to the specifications for Design Verification (DV), Production Verification (PV) and Production Part Approval Process (PPAP) sign off must be kept until Job 1. 4.4 RESTRICTED SUBSTANCE MANAGEMENT STANDARD Substance restrictions imposed by regulations or Comp
49、any direction applies to the materials addressed by this document. The restrictions are identified in the Restricted Substance Management Standard WSS-M99P9999-A1, which is updated yearly. It is the suppliers responsibility to comply with this standard on a continuing basis through IMDS and or GMAP reporting. 5. SUMMARY OF REVISIONS ENGINEERING MATERIAL SPECIFICATION WSS-M1P83-F1 Copyright 2017, Ford Global Technologies, LLC Page 7 of 12 Table 3: MCDCC, DV, PV Testing Requirements Para. Test Results
