1、 ENGINEERING MATERIAL SPECIFICATIONDate Action Revisions 2003 07 29 Revised Para 3.0 inserted; Para 3.9 & 4 deleted 1988 04 20 SM/ER 3841 TC Released J. Burke, JAF, MP. NAAO. J. Lines. EAO. Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 1 of 5 PLATING, BRIGHT OR
2、LOW GLOSS DECORATIVE WSB-M1P77-B1 OVER ZINC ALLOY - INTERIOR PLATING, BRIGHT OR LOW GLOSS DECORATIVE WSB-M1P77-B2 OVER ZINC ALLOY - GENERAL EXTERIOR PLATING, BRIGHT OR LOW GLOSS DECORATIVE WSB-M1P77-B3 OVER ZINC ALLOY - SPECIAL EXTERIOR PLATING, BRIGHT OR LOW GLOSS DECORATIVE WSB-M1P77-B4 OVER ZINC
3、ALLOY - SPECIAL EXTERIOR 1. SCOPE These specifications define performance requirements for finished coatings of electrodeposited copper, nickel, and chromium for the decoration and protection of zinc alloy surfaces. 2. APPLICATION These specifications were released originally where a bright or low g
4、loss decorative and protective metallic finish is required on zinc alloy surfaces. Four levels of performance are defined as follows: WSB-M1P77-B1 Interior part applications WSB-M1P77-B2 General exterior part applications WSB-M1P77-B3 Special exterior part applications requiring superior appearance.
5、 WSB-M1P77-B4 Special exterior part applications requiring superior appearance and improved durability. CAUTION: Based upon field survey and accelerated laboratory testing experience, plated parts with designs that are not in conformance with the Corporate Plated Part Design Restrictions Booklet (se
6、e para 5.1 of this specification) or the grille design guidelines 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 the parts per rack ratio, e
7、tc. FEASIBILITY If the requirements of this specification cannot be met due to part design restrictions, the supplier will inform the responsible product engineering office. 3. REQUIREMENTS All requirements identified for each specification must be met to achieve acceptable field durability. No one
8、requirement, 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
9、para 5.2 unless otherwise specified on the engineering drawing. ENGINEERING MATERIAL SPECIFICATIONWSB-M1P77-B1/B2/B3/B4Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 2 of 5 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers m
10、ust 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
11、 SQA. 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 engin
12、eering 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 p
13、arts 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 co
14、nform 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 te
15、sts. 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-M1P77-B1/B2/B3/B4Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc
16、. Page 3 of 5 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 followi
17、ng values: 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 pro
18、cessing 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 sur
19、faces 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 pla
20、ting thickness requirements identified below represent minimum values in micrometers and apply to all areas of significant surfaces. WSB-M1P77 B1 B2 B3 B4 Bright Leveling Acid - 15 - 15 Copper Total Copper 8 20 8 18 Semi-bright Nickel (a) - 20 38 38 Bright Nickel (b) plus 8 10 10(g) 10(g) Special Ni
21、ckel (c) or Low Gloss Nickel (d) Total Nickel (e) 8 30 48 48 Microporous Chromium (f) - 0.18 - Regular Chromium 0.25 - 0.25 0.25 (a) The 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 soluti
22、on 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 and control. (b) The sulphur content in the bright nickel bath shall be
23、 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 determine conformance to the sulphur content requirement is essential to est
24、ablish and maintain process capability and control. ENGINEERING MATERIAL SPECIFICATIONWSB-M1P77-B1/B2/B3/B4Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 4 of 5 (c) If a special nickel is employed to produce discontinuities in the chromium deposit, the thickness
25、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 deposit. (d) Low gloss
26、 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 low gloss nickel is specified
27、, 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 thickness. (f) Microporous chromium plating systems acceptable under this
28、 specification are defined as those being capable of producing microporosity in conformance with para 3.6. (g) The WSB-M1P77-B3 and B4 specifications require buffing of the bright nickel deposit prior to chromium plating unless otherwise specified on the engineering drawing. The indicated thickness
29、represents the minimum bright nickel thickness after buffing. 3.6 MICROPOROSITY, min 10,000 pores/cm2(FLTM BQ 103-06) Note: Applies only to WSB-M1P77-B2. 3.7 ACCELERATED CORROSION RESISTANCE (ASTM B 368) WSB-M1P77-B1 4 h (1 cycle of 4 h) WSB-M1P77-B2 44 h (two 22 h cycles) WSB-M1P77-B3 44 h (two 22
30、h cycles) WSB-M1P77-B4 66 h (three 22 h cycles) Note: 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. Following CASS exposure for the appropriate duration as s
31、pecified, failure is to be noted as follows: . Any evidence of base metal corrosion deposits or blisters on significant surfaces shall constitute failure of the part. . Any pit larger than 1.5 mm in diameter visible on any significant surface shall be considered failure of the part. ENGINEERING MATE
32、RIAL SPECIFICATIONWSB-M1P77-B1/B2/B3/B4Printed copies are uncontrolled Copyright 2003, Ford Global Technologies, Inc. Page 5 of 5 3.8 SIMULTANEOUS THICKNESS AND ELECTROCHEMICAL POTENTIAL TEST (S.T.E.P.) (ASTM B 764) Note: Applies only to WSB-M1P77-B2, B3 and B4. 3.8.1 The semi-bright nickel layer mu
33、st 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 mv noble (ca
34、thodic) to the bright nickel layer. 5. GENERAL INFORMATION The information given below is provided for clarification and assistance meeting the requirements of these specifications. 5.1 PLATED PART DESIGN RESTRICTIONS BOOKLET Booklet #80-14-154 (Ford Stationery Order Number) entitled, “Influence of
35、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 SIGNIFICANT SURFACES Unless otherwise specified on the engineering drawing, significant surfaces are d
36、efined 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. 5.3 MATERIAL REFERENCE Zinc alloys meeting the requirement
37、s of the following material specifications or industry standards are recommended as platable substrates: . SAE 903 - Zinc Die Casting Alloys (SAE J 469a) . SAE 925 - Zinc Die Casting Alloys (SAE J 469a) . ESB-M2A98-A - Zinc Alloy (Sheet and Strip) 5.4 SAMPLING AND INSPECTION As specified in Quality
38、Control Specification Q-101, Appendix D, and consistent with the appropriate engineering specification (ES) as released by the responsible design engineering activity. 5.5 CASTING PRACTICE Die cast parts intended for plating by this specification must be cast in keeping within the best commercial practice to achieve low porosity and ensure good plateability. Porosity can result in part failure by loss of plating adhesion.
