Customer Requirements

Transcription

1 Plating Awareness

2 Customer Requirements

3 Customer Requirements Identified in Epicor

4 ASTM A967-Passivation A process designed to remove foreign 05 metals from the surface of stainless and corrosion resistant steels and to promote natural tendency to surface to oxide. Does not change the apperance of the base metal. Process purifies surface and therefore improves corrosion resistance ASTM B (reapproved 2008) ASTM B Silver ASTM B633-Zinc 2011 Passivation Passivation using Electropolish White matte to very bright in appearance. Good corrosion resistance, depending on base metal. Will tarnish easily. Hardness caries from about 90 Brinnell to about 135 Brinnell depending on process and plating conditions. Solderability is excellent, but decreases with age. Best electrical conductor. Has excellent lubricity and smear characteristics for anti-galling uses on static seals, bushings, etc. Bright or dull finish is acceptable. Bright Zinc plating closely resembles bright chromium. However, bright zinc does not have the permanence of surface appearance. Zinc coated steel will not rust even when exposed by scratches because of the galvanic protection of the zinc. On weathering, zinc turns to a drab color. Zinc should be deposited directly on the base metal (Nickel is permissible undercoat if base metal is a corrosion resisting steel). Parts having a hardness greater that Rc-40 must be given a heat treatment prior to plating. Springs having a hardness over Rc-40 must be given an after plating baking of F for 3 hours I % II % III % II - With colored chromate (typically gold III - colorless chromate N - has had no supplementary tarnish resistant (chromate) treatment S - has had supplementary tarnish resistant treatment - not suitable for food service applications FeZn 25 FeZn 12 FeZn 8 FeZn 5 A - Matte; electrodeposits without luster B - Bright; obtained by use of brighteners in bath c - Bright; obtained by polishing Grade A D - Semibright; obtained by use of additional agents in bath SC 4 (very severe) SC 3 (severe) SC 2 (moderate) SC 1 (mild) PASSIVATE PER ASTM A PASSIVATE PER ASTM B SILVER PLATE PERASTM B ZINC PLATE WITH CLEAR CHROMATE CONVERSION PER ASTM B FE/ZN5 (SC1) TYPE III ROHS CERTIFICATION REQUIRED Insert Cosmetic Class

5 Common Plating Defects If you see any of these, alert your supervisor.

6 Blistering Low carrier or wetter concentration High brightener concentration Hexavalent chrome contamination Organic contamination Too High plating current density and low zinc concentration Too high plating current density and poor or no agitation Can be stripped and re-plated if hardware not installed and not painted

7 Black Spots Contamination in zinc tank Hole in anode bag Thin plating in low current density areas High iron in plating bath Can be stripped and re-plated if hardware not installed and not painted

8 Water Spots / Stains Occurs on all plating Caused by poor rinsing Can be stripped and re-plated if hardware not installed and not painted

9 Cloudiness Occurs on zinc over steel Caused by too thick zinc plating Excess organics in chromate tank Can be drawn out by the heat of baking in paint or silkscreen Can be stripped and re-plated if hardware not installed and not painted

10 De-Lamination of Chromate Occurs on zinc over steel Caused by Excess organics in chromate tank Insufficient cure time after plating Can be stripped and re-plated if hardware not installed and not painted Poor rinsing Old chromate

11 Hook Marks Occurs on all substrates where plating is electrodeposited Caused by electrode wires too close to body of part Can be stripped and re-plated if hardware not installed and not painted Can potentially be minimized by adding a note on drawing stating PLATING HOOK MARKS NOT ALLOWED Parts with critical holes or tight tolerance features need a drawing to define racking

12 High Current Density Occurs on zinc over steel Caused by improper racking of parts Current higher at edges of parts, attracts too much zinc Can be stripped and re-plated if hardware not installed and not painted

13 Oxidation Occurs on steel substrates Caused by presence of rust prior to plate Insufficient etch Rust that is too deep to etch out Can be stripped and re-plated if hardware not installed and not painted heavy rust will leave shadow

14 Bleed Out Most common on zinc, nickel and tin coatings Substrate can be steel, copper or aluminum Caused by inability of adequate rinse on closed hems or parts, riveted or spot-welded prior to plate Can be reduced or eliminated by the use of open hems, spotweld dimples, and the practice of riveting after plating Can be stripped and re-plated if hardware not installed and not painted, but may reoccur

15 Quiz 1) Cloudiness occurs as a result of. a) Excess organics in chromate tank b) Insufficient cure time after plating c) Poor rinsing d) Old chromate e) All of the above 2) Bleedout can occur a) On any part with a closed hem b) At the edge of a part c) Only on aluminum 3) T/F - Oxidation can be removed, but may leave a shadow 4) T/F High Current Density is caused by poor cleaning 5) Black Spots occur mostly on a) Contamination in zinc tank b) Hole in anode bag c) Thin plating in low current density areas d) High iron in plating bath e) All of the above

16 6.2 Viewing Condition

17 6.2 Viewing Condition

18 Eyesight Testing

19 Eyesight Testing All inspectors have to take eyesight testing with Cisco Inspection Template. If you can not see all defects in the template from 18, You need eyeglasses or contact lenses. Inspectors need to see Flash ( Size : Dim ) from 18.

20 Eyesight Testing I can see Dia here Fail I can see all from 18 Inch 15 Inch 18 Inch If you fail the test, You need to calibrate your eyesight.

21 Standards and Viewing Time

22 Finished Surfaces The terms Grade 1, Grade 2 and Grade 3 correspond to terms commonly used in the Telecom industry Class 1, Class 2 and Class 3 where Grade 1/Class 1 are the most stringent requirements.

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24 Finished Surfaces Grade 1 Surfaces Surfaces frequently viewed in the finished product by the final customer (Examples: Front covers, module covers, faceplates, filler panels, heat ramps, external labels, etc.). Grade 1 surfaces shall be free of blisters, clamp or brake marks, extrusion lines, gouges, nicks, pits, runs, scratches, extraneous or irregular sanding lines, spotweld craters, voids, or other defects which detract from the general appearance. Appearance of a grade 1 surface is as important as form, fit, and function.

25 Finished Surfaces Grade 2 Surfaces Surfaces occasionally viewed in the finished product by the final customer (Examples: Internal labels and surrounding area, inside of accessible covers, side panels visible from the front, outside of rear covers, outdoor equipment enclosures, etc.). Grade 2 surfaces may have slight surface imperfections/scratches if they are not readily noticeable from a distance of 18 inches. Appearance of a grade 2 surface, while important, is secondary to form, fit, and function. Consideration should be given to how the flaw affects the general appearance.

26 Finished Surfaces Grade 3 Surfaces Surfaces infrequently or never viewed in the finished product by the final customer (Examples: Normally concealed surfaces, bottom plates, top plates, internal surfaces of assemblies, etc.). Grade 3 surfaces are allowed to have a limited number of minor flaws that would be considered non-conforming in Grade 1 and 2 as long as form, fit, and function of the part are not affected. Scratches that are visible at a distance of 457 mm [18.0 in] are allowed providing the scratch does not expose the base material. Form, fit, and function are the primary considerations when evaluating a grade 3 surface.

27 Manipulation Class A & B Class C

28 Viewing Time The following is a general guideline for inspection times and may be adjusted as necessary. Viewing duration shall be based on part size as well complexity. Do you understand this meaning?

29 Concept of Viewing Time Complex Part Plain Surface 5 second s Viewing Time that an average person can detect defects on Plain Surface. Longer time may be required for complex part. Can not inspect complex part ( Class B ) within 5 seconds. It s also 50 Sq, it s not all surface on chassis.

30 Viewing Area Do you know the size of 50 Sq?? Roughly 7.5 X 7.5

31 If you don t understand 6.2 Viewing Conditions correctly, You will create the following critical problem!!. The 6 was wrong assembly You overlooked a defect!!

32 Light Condition

33 Light Condition Need Foot Candles at Part Surface! It s not only Final Inspection Area!!

34 Bad Practice Wrong Inspection by Flash Light Bad Practice Over foot candles by Flash Light Do not inspect products in side of rack

35 Good Practice The part surface is foot candles No Inspection with Flash Light!

36 Can we use magnification glass to verify defect type? Yes we can use magnification. This is not inspection, It s verification to verify defect type correctly.

37 MASS Precision Handling/Packaging Standards Some parts may have surfaces with different classes always package to the higher class If you receive parts not packaged as shown STOP; call Outside Services If you disagree with anything on the Purchase Order STOP; call Outside Services Quantity Received Price Date Required BLADES Treat as Class B although some may be wrapped individually

38 CLASS A HANDLING ALWAYS CHECK COSMETIC CLASS ON DRAWING ALWAYS CHECK NEXT OPERATION STACK PARTS STRAIGHT ANDEVEN SAME NUMBER OF PARTS ON EACH ROW FOR EASY COUNTING PLACE CARDBOARD BETWEEN PARTS AND FOAM BETWEEN CLASS A SURFACE NO METAL TO METAL CONTACT PARTS SHOULD NOT HANG OFF PALLET DO NOT STACK PARTS TOO HIGH! PARTS CAN GET DAMAGED AND CREATE A SAFETY HAZARD

39 CLASS B HANDLING NO METAL TO METAL CONTACT ON CLASS B SURFACE ALWAYS CHECK COSMETIC CLASS ON DRAWING ALWAYS CHECK NEXT OPERATION STACK PARTS STRAIGHT ANDEVEN SAME NUMBER OF PARTS ON EACH ROW FOR EASY COUNTING PLACE CARDBOARD BETWEEN PARTS AND PAPER BETWEEN CLASS B SURFACE METAL TO METAL CONTACT NOT OK ON CLASS B SURFACE PARTS SHOULD NOT HANG OFF PALLET DO NOT STACK PARTS TOO HIGH!PARTS CAN GET DAMAGED AND CREATE A SAFETY HAZARD

40 CLASS C HANDLING DO NOT STACK PARTS TOO HIGH PARTS ARE ALWAYS STACKED STRAIGHT AND EVEN SAME NUMBER OF PARTS ON EACH ROW FOR EASY COUNTING PLACE CARDBOARD BETWEEN PARTS METAL TO METAL CONTACT OK, BUT KEPT TO A MINIMUM. PARTS SHOULD NOT HANG OFF PALLET DO NOT STACK PARTS TOO HIGH! PARTS CAN GET DAMAGED AND CREATE A SAFETY HAZARD

41 That concludes this training