for exterior parts
Version 1.2
Table of content:
1.General (3)
2.Relevant standards (4)
3.Requirements for the blank (5)
3.1.Material (5)
3.2.Structure and Surface (5)
4.Requirements on the coating (6)
4.1.Layer properties (6)
4.1.1.Process definition for the electroplating process (6)
4.1.2.Coating thickness (6)
4.1.3.Potential difference (6)
4.1.4.Number of pores (6)
5.Validation (7)
5.1.Validation of the coating layers (8)
5.1.1.Measurement of coating thickness (8)
5.1.2.Measurement of the potential difference (8)
5.1.3.Measurement of the number of pores (8)
5.1.4.Ductility test (8)
5.2.Validation of the performance of the coating (9)
5.2.1.CASS Test / Corrosion resistance test (9)
5.2.2.Climate change test with following CASS test (9)
5.2.3.Resistance after alternating temperature test w/o CASS test (9)
5.2.4.Hot storage test / Cold storage test (10)
5.2.5.CaCl2 corrosion test (10)
5.2.6.X-cut adhesion test (11)
6.Frequency of the validation / approval (12)
Change description
Version Status Person in charge Date Description
1.0 Stadtlehner E. 09.05.2011
First DRAFT
1.1 Stadtlehner E. 25.05.2011
Release
o DIN EN ISO 4628 added o chapter 5 updated
o chapter 5.1.1. updated
1.2. Stadtlehner E. 27.05.2011
Relevant standard updated
1. General
•This technical specification / appendix have to be used in connection with the “Technical specification book – General trim”.
•Limiting samples to define the optical limits to be defined by CQAC quality department.
Appearance (gloss/color/…) according the released limiting samples.
The limiting samples (the requested appearance) will show/define the need of sulfur/sulfur-free, brilliance/semi-brilliance/matt-nickel and the need of mechanical polishing – according DIN EN ISO 1456/chapter 4.1.d
•The manufacturer must inspect a suitable number of samples in regular intervals (to be discussed/confirmed with CQAC quality department) and must provide access to the documentation for the customer. The supplied parts must correspond to the initial sample.
•For the initial sample and the first delivery, the supplier must provide a test report in which the results of all tests specified in this specification are contained. The test certificate is to be sent directly to the CQAC quality department.
•Contact points for the electroplating process must not lie within the visible area •Tolerance and dimensional accuracy see drawing
•Deviations to standard written down in this technical specification / appendix has to be pointed out to the engineering department
•Drawing entry:
- According Technical specification book – General trim
2. Relevant standards
DIN EN ISO 1463
Metallic and oxide coatings - Measurement of coating thickness, microsopical method DIN EN ISO 2177
Metallic coatings – measurement of coating thickness, coulometric method by anodix dissolution
DIN EN ISO 3497
Metallic coatings – measurement of coating thickness, X-ray spectrometric methods DIN ISO EN ISO 1456
Metallic and other inorganic coatings, …
MSF Standard N70045
Climatic change test
MSF Standard N70111
Hot storage test / Cold storage test
DIN EN ISO 9227
Corrosion tests in artificial atmospheres (CASS-test)
DIN EN ISO 4628-1 / 2 / 3 / 4 / other parts if necessary
Paints and varnishes - Evaluation of degradation of coatings - Designation of quantity and size of defects, and of intensity of uniform changes in appearance.
- Part 1: General introduction and designation system
- Part 2: Assessment of degree of blist
- Part 3: Assessment of degree of rusting
- Part 4: Assessment of degree of cracking
- Part x: if necessary3. Requirements for the blank
3.1. Material
The base material for the blank has to be a well known “standard”-material for decorative electroplating.
Examples:
o ABS galvanic type
o PC+ABS galvanic type
The material has to be approved/discussed with the engineering department.
3.2. Structure and Surface
The surface shall be smooth, free of flow lines, cracks, sink marks, craters or any other “mistakes” which may influence the approved appearance or part properties.4. Requirements on the coating
4.1. Layer properties
4.1.1. Process definition for the electroplating process
Micro porous (mp) chromium plating Cr3+
4.1.2. Coating thickness
Copper >25 µm
Semi-brilliant nickel >5µm
Brilliant/matt nickel >5µm
Micro porous nickel 1-2µm
Chromium 0,3-0,5µm
Minimum plate thickness as specified in this technical specification / appendix applies to all significant surfaces. Significant surfaces are those normally visible, directly or by reflection, on the finished part when assembled in car position or which can be the source of corrosion deposits that deface visible surfaces on the assembled vehicles.
4.1.3. Potential difference
Micro porous nickel + 20mV - 40mV to brilliant/matt nickel
Semi-brilliant nickel >+120mV to brilliant/matt nickel
4.1.4. Number of pores
Minimum 10.000 pores/cm² (on each measuring area)
5. Validation
All tests must be performed on finished parts out of one production run.
The parts have to be chosen from different positions of the rack (side position, middle position,…).
For every test one tested part (with a clear identification marking) has to be sent to: Magna Steyr Fahrzeugtechnik
Liebenauer Hauptstraße 317
z.H. Hrn. Ewald Stadtlehner
8041 Graz
Austria
All tests must be documented with detailed test reports with the minimum following content:
a. Detailed test description (according standard)
b. Details for the tested samples (part name, part number, position on the rack…)
c. Detailed to the production run (e.g.: production date for the plastic part and for
the electroplating process….)
d. Detailed pictures of the tested samples before and after the test
e. Results
f. Summary
g. Next steps (if the result is not ok)
5.1. Validation of the coating layers
5.1.1. Measurement of coating thickness
According DIN EN ISO 1463 or DIN EN ISO 2177 or DIN EN ISO 3497.
Coating thickness measurements shall include a mapping of specific areas of the part.
For the location of measurements of the coating thickness a proposal from the supplier before the measuring is expected (has to be confirmed by the engineering department).
The measurement points have to be chosen in that way, to validate the areas with the expected minimum and maximum layer thickness.
If not otherwise designated, at least five measurements shall be made per part.
5.1.2. Measurement of the potential difference
According DIN EN ISO 1456 / Appendix E (STEP Test)
If not otherwise designated, at least five measurements shall be made per part.
5.1.3. Measurement of the number of pores
According DIN EN ISO 1456 / Appendix A (Dubpernell test) or DIN EN ISO 1456 / Appendix B (Fuhrmann test)
If not otherwise designated, at least five measurements shall be made per part.
5.1.4. Ductility test
According DIN EN ISO 1456 / Appendix C
Minimum requirement: > 8% elongation without any surface defects on all significant surfaces when examined at normal reading distance 0.5 ± 0.1 m with the unaided eye and uniform diffused light.
If not otherwise designated, at least five measurements shall be made per part.
5.2. Validation of the performance of the coating
5.2.1. CASS Test / Corrosion resistance test
According DIN EN ISO 9227 duration 48h.
Plated components shall be free of any surface defects and free of corrosion on all significant surfaces when examined at normal reading distance 0.5 ± 0.1 m with the unaided eye and uniform diffused light.
Assessment according: DIN EN ISO 4628-1 / 2 / 3 / 4 / others if necessary
At least three parts shall be used for the validation.
5.2.2. Climate change test with following CASS test
o Climatic change test (MSF standard) N70045
o48h DIN EN ISO 9227 CASS-test
o Before the interpretation corrosion products from the test shall be removed (according DIN EN ISO 9227)
Plated components shall be free of any surface defects and free of corrosion on all significant surfaces (see chapter 1) when examined at normal reading distance 0.5 ± 0.1 m with the unaided eye and uniform diffused light.
Assessment according: DIN EN ISO 4628-1 / 2 / 3 / 4 / others if necessary
5.2.3. Resistance after alternating temperature test w/o CASS test
o Climatic change test (MSF standard) N70045
Plated components shall be free of any surface defects on all significant surfaces (see chapter 1) when examined at normal reading distance 0.5 ± 0.1 m with the unaided eye and uniform diffused light.
Assessment according: DIN EN ISO 4628-1 / 2 / 3 / 4 / others if necessary
5.2.4. Hot storage test / Cold storage test
o According MS Standard N70111
o Allow parts to cool to room temperature and inspect.
Plated components shall be free of any surface defects on all significant surfaces (see chapter 1) when examined at normal reading distance 0.5 ± 0.1 m with the unaided eye and uniform diffused light.
Assessment according: DIN EN ISO 4628-1 / 2 / 3 / 4 / others if necessary
5.2.5. CaCl2 corrosion test
Creation of the “CaCl2 – paste”:
In a water bath (+40°C) - with deionized water - a saturated CaCl2 solution has to be prepared
5mL out of this CaCl2 solution has to be mixed with 3g Kaoline
This compound has to have a pH value of 6,5 - 7,5
Preparation of the test pieces:
The test piece has to be cleaned with ethyl alcohol.
The prepared paste has to be applied in a cycle to the test pieces (mass and diameter see the chart below.
Diameter [mm] Mass of the paste [mg]
18 120 – 150
15 80 – 100
12 50 – 70
10 40 – 50
7 about 20
Heat chamber:
a.) 168h with +23 +/- 2 °C
b.) 48h with +60 +/-2 °C
Cleaning of the test pieces:
After cooling down the part has to be cleaned with water and then cleaned with a commercial chromium cleaning agent.
Assessment:
Assessment and documentation (pictures) of the change on the surface (corrosion, change of the color, …)
There is no requirement about the change of the surface.
Test should show possible changes of the process.5.2.
6. X-cut adhesion test
The electroplated plastic components have to fulfill an “X-cut adhesion test”, with no evidence of lifting / peeling between the plated layers or between plated layers and substrate.
Test to be done on 5 parts on two different areas.
For the location of X-cut adhesion test a proposal from the supplier before the measuring is expected (has to be confirmed by the engineering department). Procedure:
o The surface of the part must be clean and dry. Otherwise it must be cleaned.
(for example with isopropyl alcohol)
o Create an X-cut with an “Edding Cutter M9” (or similar) with a sharp blade. It is very important, that the cutting edges are in a very good condition. The X-cut to be made through the complete film to the substrate which intersect near their middle with a small angle of between 30 and 45° (Picture 1) o Place an adhesion tape (“Tesa 4657” from the company Tesa AG), approximately 10 to 20 mm wide over the cut edge (leaving sufficient length of tape to grasp between fingers for quick removal). Place the center of the tape at the intersection of the cuts with the tape running in the same direction as the smaller angles (Picture 2)
o Press it until you can see the intrusion of the scratch in the tape.
o Quickly pull the tape toward the acute angle off. The direction should be approximately 90 degrees to the surface of part (Picture 3)
o Examine for evidence of lifting of electroplate.
Pic. 1: X-cut Pic. 2. Tape Pic. 3. Pull off6. Frequency of the validation / approval
The frequency of the validation / approval has to be discussed and confirmed by the quality department CQAC.
Proposal:
Validation Serial part Measurement of the layer thickness (chapter 4.1.1) continuously Measurement of the potential between the layer (chapter
continuously
4.1.2)
Measurement of the number of pores (chapter 4.1.3) continuously Climate change test / CASS test (chapter 4.2.1) continuously
CASS test (chapter 4.2.7) continuously下载本文
