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Electroplating Process:
Alternative to Cadmium Plating
Grace F. Hru
Boeing Materials Technolcgy
Boeing Commercial Airplane Ca.
Seattle. WA
'
provide low hydrogen embrittlement (LHE)
(6,7,8,9).
Mechanical plating, ion vapor deposition
(IVD) of aluminum, aqueous coating dispersion,
and bonded solid-film lubricants are mentioned
(10,lI) as possible alternative candidates to
cadmium plating. However, there is no
3
Porous Cyanide Cadmium Plating - 1960
.L
Cyanide Cadmium-Titanium Plating - 1962
.L
NonCyanide Zinc-Nickel Alloy Plating. - 1983
Boeing Proprietary
c. Boeing Zinc-Nickel
Alloy Deposit
b. Cyanide Cadmium-
Titanium Deposit
4
In 1962, a cyanide cadmium-titanium single process is a viable alternative to Cd
(Cd-Ti) plating bath w a s adopted by Boeing for plating for both high and low strength steels.
coating high-strength structural steel (15,16). For high-strength steel parts, a flow chart of a
Figure 2b illustrates that the cyanide typical plating process sequence is shown in
cadmium-titanium deposit is a more Figure 3.
continuous plating of less porosity than The microstructure of the zinc-nickel
cyanide porous cadmium deposit. One deposit, as shown in Pigure 2c, is continuous
interesting feature of Figures 2a and 2b is that and level. The plate porosity has been
coarsegrained structures are exhibited in both optimized to permit baking-out of hydrogen,
deposits. introduced during plating, and to minimize
Although not utilized by Boeing, potential re-embrittlement due to service
researchers at Beijing !nstitute in 1970 environment.
invented a noncyanide cadmium-titanium alloy
plating process which w a s stated to be LHE EXPERIMENTAL TESTING
(17).
LOW HYDROGEN EMBRITTLEMENT
Notched tensile specimens ( N E )
-
ZINC-NICKEL ELECTROPLATING
BACKGROUND manufactured and tested in accordance with
ASTM F519 Type l a (26) w e r e used to evaluate
Zinc-nickel alloy w a s commercially hydrogen embrittlement of plated high-
deposited as early as 1905 (18). Since then, strength steels. The plated and baked
many zinc-nickel alloys have been suggested specimens were tested by static tensile
for electroplating onto steel to provide loading t o 75 percent of established notch
corrosion protection (19,20,21). However, ultimate tensile strength continuously for 200
most of the applications for these alloys have hours. Thespecimens that withstand the
been only suggested for high-speed plating loading for more than 200 hours exhibit
techniques, which are unsatisfactory for rack satisfactory LHE characteristics.
or barrel platings. More than 150 specimens, representing
S. la. Popov (22) proposed an ammoniacal more than 40 plating conditions, were
electrolyte to deposit a zinc-nickel alloy. evaluated by dry notched tensile testing. Only
However, this process, which uses low current three conditions produced "IS failures:
densities, has led to a relatively high degree of o Without proprietary additives in
hydrogen embrittlement in plated high- the bath
strength steel parts. o Contamination of the bath with a
Rynne (23) disclosed an alloy plating tvvical cvanide cadmium
containing 95% by weight or greater zinc with biight en&
the balance being nickel. Prom literature
o Without bakine after olatine
Initial correlation OF BoeiG platkg
(19.24.25) and the authofs experimental data, porosity meter (BPPM) and N T S testing has
the above alloys are not in the best alloy been established.
composition range to provide corrosion
protection of steel parts.
-
Hydrogen Analysis To further confirm
t h e LHE characteristics of the process, the
hydrogen contents in the above N T S were
BOEING'S ZINC-NICKEL ELECTROPLATING determined by an ultrasensitive hydrogen
PROCESS analyzer developed by Boeing (27). The data
shows that when the substrate hydr
A noncyanide, zinc-nickel alloy
electroplating process has been developed at
Y
content of 4340 steel (260 t o 280 ksi was
below 1.0 ppm, no N T S failures were observed.
Boeing t o ensure long-term corrosion Preliminary data indicates that the hydrogen
protection of aircraft steel parts. This zinc- content of the substrate is the determining
nickel deposit provides low-hydrogen- factor for LHE characteristics, not the total
embrittlement and corrosion protection hydrogen or the hydrogen in the deposit. Even
properties equivalent or superior t o t h e when the Boeing zinc-nickel deposits were 4 to
currently used Cd and Cd-Ti deposits. The use 6 times the nominal thickness (0.0005 inches),
or conversion of conventional electroplating hydrogen contents of the substrate were also
\
tank facilities is feasible. In addition, this analyzed to be below 1.0 ppm. All NTS
3 failures correlate with high hydrogen contents
in the substrate.
-- 5
I YaDor Degrease I
;
I
J
I Cold Water Rinse I
7
Eoeing,Zn-Ni plating
- Irm
-am
SOhlUM
potential
(MVISCE)
I I I I
0 2 4 6
Neutral salt spray test (months)
WHITE
RED CORROSION
RUST
8
Near scribe l i n e
blistered area
(paint removed
Enamel by tape t e s t )
4130 steel
Near scribe l i n e
blistered area
(paint removed
Enamel by tape test)
Primer
Boeing
Zn-Ni
Plating
(Proprietary )
4130 Steel
9
Table 1. The Average Galvanic Current D e n s i t y 3 for AI 7075-T6 in 3.5% NaCl : '1
~~~
-
mzzI Fracture
(at indfcated time)
specification
A
Minimum
10
No Fracture (removed from t e s t
I
577 a f t e r indicated time)
11
LORD VERSUS 10RDUE
-
Feature Benefit
o Norrcadmium, non-cyanide process o Exceeds EPA standard and
o Minimizes waste treatment costs
o Low hydrogen embrittlement o Protects highstrength steels
o Low hydrogen re-embrittlement o Increases in-service protection
o Sacrificial protection o Provides long-term corrosion
protect ion
o Damage tolerance o Provides excellent service life
o Compatible with aluminum o Provides galvanic protection to
aluminum alloys
o Torque tension values o Can be used on fasteners
equivalent to cadmium
o Conventional electroplating process o Minimizes facilities investment
o Good paint adhesion o Further corrosion protection
o Stablebath o Ease of control and
o Fewer rejects
ACKNOWLEDGEMENTS REFERENCES
The author thanks Mr. R.C. Colonel for 1. "Cadmium Colloquy," Plating and
his valuable suggestions and Dr. J.H. Jones and Surface Finishing, Nov. 1979, pp. 8-14.
Mr. P.3. Saelid for their excellent technical 2. R.E. Marce, ''Cadmium Plating
guidance. Still a Must," Industrial Finishing, Aprir 1978,
pp. 34-37.
3. P. Baeyens, "No More Cadmium
APPENDIX Plating, Are There Processes to Replace It,"
Galvanotechnik, 68,7 (1977). pp. 590-597
Licensing of this process will be (from German), U.S. Department of
available after successful completion of Commerce. National Technical Information
manufacturing feasibility. For information Service, Nov. 1978.
concerning licensing, contact Mr. B.A. 4. V.C.R. McLouEhlin. T h e
Donahue (206-394-3101)or Mr.R.E. Suter (206- Replacement of Cadmium-for the Coating of
394-3100). Mailing address: Patents and Fasteners in Aerospace Applications,"
Licensing, Boeing Commercial Airplane Co., Transactions of the Institute of Metal
P.O. Box 3707, MS 9H-82, Seattle, WA 98124 Finishing, vol. 57, 1979, pp. 102-104.
13
.'
5. E.J. Dyckman, "Cadmium 22. S. Ia. Popov, Proceeding Fourth
Utilization and Environmental Impact," Convention on Electrochemistry, Acad. Sci.
Defense Industrial Resources Support Office, US.S.R. Press, 1959.
J u n e 26, 1975. 23. G.B. Rynne, U.S. Patent No.
6. W.L. Cotton," Hydrogen Embrittle- 4,285,802, 1981.
ment of High Strength Steels During 24. L. Domnikov, Zinc-Nickel Alloy
Cadmium, Chromium and Electroless Nickel Electroplated Coatings," Metal Finishing, Aug.
Plating," Plating, vol. 47, Feb. 1960, pp. 169- 1963, pp. 49-54.
175. 25. V.A. Averkin, "Electrodeposition of
7. H.J. Read, "Hydrogen Alloys," Israel Program for Scientific
Embrittlement in Metal Finishing," Reinhold Translation, Jerusalem, 1964, pp. 102-115.
Publishing Corporation, 1961. 26. ASTM P519, "Standard Method for
8. W. Beck, E.J. Jankowsky, and P. Mechanical Hydrogen Embrittlement Testing
Fischer, "Hydrogen Stress Cracking of High of Platinp: Processes and Aircraft Maintenance
Strength Steels," center report NADC-MA- Chemic&."
7140, Naval Air Development Center, 27. K.B. Des. "An Ultrasensitive
Warminster, Pennsylvania, 1971. Hydrogen Detector,; Hydrogen Embrittlement
9. A.W. Thompson, "Metallurgical Testing, ASTM STP 543, American Society for
Characteristics of Hydrogen Embrittlement," Testing and Materials, 1974, pp. 106-123.
Plating and Surface Finishing, Sept. 1978, pp. 28. F. Mansfeid, D.H. Hengstenberg,
36-44. and J.V. Kenkel, "Galvanic Corrosion of 41
10. "Alternatives toCadmilm Pisti!!! Alloys, 1. Effect of Dissimilar Metal,"
Reflections Five Years Later," Plating and Corrosion, voL 30, no. 10, Oct. 1974, pp. 343-
Surface Finishing, Nov. 1982, pp. 1%3. 353.
11. E.P. Cornwall. "Alternatives to 29. E.R. Pannin, "Ion Vapor Deposited
Cadmium Plating." Boeing Document. March Aluminum Coatings for Improved Corrosion
1979. Protection," MCAIR No. 78-007, presented at
12. D.M. Eriwein, "Environmental AGARD Meeting, Florence, Italy, Sept. 26-28,
Effect on Notched Tensile Specimens," Boeing 1978.
Progress Report, 1962.
13. J.G. Rinker and R.F. Hochman,
"Hydrogen Embrittlement of 4340 Steel as a
Result of Corrmion of Porous Electroplated
Cadmium," Corrosion, voL 28, June 1972, pp.
231-232.
14. D. Altura, Tostplating
Embrittlement," Metal Finishim.
pp. 45,46,50.
.
-. Smt. 1974.
15. K. Takada, US. Patent No.
3.083.150.
. . 1963.
16. K. Takada, US. Patent No.
3,139,325, 1964.
17. S.S. Wane. J.K. Chai. Y.M. Shui
and J.K. Liang, "CbTi Eletmdeposits from a
Noncyanide Bath," Plating and Surface
Finishing, Dec. 1981. pp. 62-64.
18. C.B. Jacobs, "Some Observations
on the Deposition of Alloys from Mixed
Solutions," J. Am. Chem. Soc. 27, 1905, pp.
972-976.
19. D.H. Schantz, US. Patent No.
2,419,231, 1947.
20. E.J. Roehl. US. Patent No.
3,420,754, 1969.
_ _ E.J. Roehl and R.H. Dillon. U.S.
21.
~
. 1
14
1 SCOPE
a. This specification establishes the requirements for the electro-deposition of zinc-nickel
alloy plating.
b. Do not plate steels heat treated to strength levels above 220 ksi (1510 MPa). For steels
which are heat treated to strength levels above 220 Ksi (1510 MPa), contact Liaison
Engineering.
c. Plating in accordance with this specification is compliant with AMs 2417.
d. Zinc-nickel alloy plating is considered a substitute for BAC 5701, cadmium plating and
QQ-P-416.
2 CLASSIFICATION
This process specification consists of the following Types, Classes, Grades, etc., as specified.
2.1 TYPE (POST-PLATE TREATMENT)
a. Trpe I - As plated (no supplementary treatment)
..
b. Type I1 - with supplementary treatment
2.2 CLASSES (THICKNESS)
a. Class 1 - 0.0005 inch (13 pm) thick minimum
b. Class 2 - 0.0003 inch (8 pm) thick minimum
c -
Class 3 0.0002 inch (5 r m ) thick minimum
This process and bath are covered by U.S. Patent 4,765.871 and corresponding foreign
patents andlor applications. Articles made by this process a r e covered by U.S. Patent
4,765,871, U.S. Patent 4,818,632 and corresponding foreign patmts andlor applications.
Patent licenses are available. For further information contactr. Chief Patent Counsel,
Boeing Commercial Airplanes, P. 0. Box 3707. Mail Stop 6Y-25, Seattle, Washington,
98124. U S A .
- ..-
REFER TO NUMERICAL INDM FOR PSO A C T " INFORMATION
CVL.
,.
3 REFERENCES
The current issue of the following documents shall be considered a p a n of this specification to the
I
4 CONTENTS
-
Section Subject
1 SCOPE 1 i
2 CLASSIFICATION 1
2.1 TYPE (POST-PLATE TREATMENT) 1
2.2 CLASSES PHICKNESS) 1
3 REFERENCES 2
4 CONTENTS 2
5 MATERIALS CONTROL 4
6 FACILITIES CONTROL 6
6.1 GENERAL NOTES 6
6.2 PRECONDITIONING O F PLATING TANK I
AND FILTER SYSTEM
6.3 ZINC AND NICKEL ANODE PRETREATMENT I
I DEFINITIONS 8
a MANUFACTURING CONTROL 8
8.1 GENERAL NOTES 9
8.2 FLOW CHART 10
8.3 CLEANING PRIOR TO MASKING 11
4 CONTENTS (Continued)
Section Subject @
REVISED:
RIGINAL ISSUE: 8-21-92
5 MATERIALS CONTROL
Equivalent materials may be used provided that they meet all the requirements of this
specification. Approval from Boeing Materials Technology is required prior to use.
MATERIAL SOURCE
a. Abrasive Materials
(1) Pumice Open
(2) Tripoli Powder Open
(3) Silicon Carbide Abrasive Paper Open
(4) Scotch-Brite Pads, No. 744B. Silicon Carbide 3M Company, St. Paul,
Minn.
b. Ammonium chloride, (plating grade) free of 3M Company, or other
humectants. anti-caking agents or organic additives plating
SUPPIY
C. Ammonium hydroxide (aqua ammonia), 28 percent. Open
technical
d. Anodes
(1) Platinium plated titanium Open
(2) Nickel anodes, 99 percent nickel rolled depolarized, Open
or carbon-nickel cast and rolled.
(3) Platinum wire Open
(4) Zinc anodes, high purity, ASTM B 6 (99.9 percent), Open
slab
e. Anode bags, Dynel or polypropylene Open
f. Anode hooks, titanium or monel Open
I 5637
5 MATERIALS CONTROL (Continued)
P. Maskants:
Other maskants may be used provided that production
experience has proven them to be satisfactory.
(1) AC-850 Adcoat, Inc.
(2) AC-854 Adcoat, Inc.
(3) Miccroshield Stopoff Lacquer Michigan Chrome andl
Chemical Company
(4) ripe, yellow, pressure sensitive, platers Sequoia Manufactunnl
Company, or other
plating supply
9. Nickel chloride, hexahydrate, technical Open
r. Nickel sultate, hexahydrate, technical Open
S. NitTic acid, technical, 40 to 42 degree Be', 0-N-350 Open
t. Supplemental 'Iteatment - CorroBan IC-A . . Pure Coatings, Inc.
West Palm Beach, F1.
U. Supplemental Tkeatment - CorroBan IC-B Pure Coatings, Inc.
West Palm Beach, Fl..
V. Sodium hydroxide, flake, bead o r 50 percent liquid Open
concentrate, technical
W. Zinc dust, plating grade Open
X. Zinc oxide, 0.005 percent lead maximum, plating grade Open
6 FACILITIES CONTROL
6.1 GENERAL NOTES
a. All surfaces of t h e plating tank, filter and associated plumbing which are in continuous
contact with the plating solution shall be made of, or lined with, one of the following
materials:
(1) rigid polyvinyl chloride or polyvinyl dichloride
(2) unfilled polyethylene or polypropylene.
It is recommended to cover the tank, when idle, with one of the above materials.
NOTE: Mold releases on plastics are detrimental to the plating bath, and should not be
used when the tanks are fabricated.
b. If filtration is used, the filter shall have sufficient capacity to turn the solution over one to
two tank volumes per hour. Filtration shall be through a 50micron or finer polypropylene
or Dyne1 cloth filter (Section Sj.). Diatomaceous earth (Section Sk.) may be used as a filter
media.
C. The plating tank shall be equipped with a temperature indicating and controlling device(s),
if required, to maintain the temperature within Table.I.requirements.
d. The plating solution should be agitated to minimize temperature and concentration
gradients. The maximum temperature gradient measured from the hottest to the coldest
points in t h e bath shall not exceed 10 F (6 C).
e. Air used for solution agitation or for drying parts shall be free of oil, water, o r solid
particles when tested in accordance with BSS 7217.
f. Power supplies shall have sufficient capacity to deliver the required current at the
minimum and the maximum anticipated plating tank loads without current interruption
during a strike or plating operation. The power supplies shall be capable of producing DC
current having less than ten percent ripple (100 times AC voltage divided by DC voltage)
over the desired plating range.
g. The power supply control panel shall be equipped with an ammeter that is readable and
accurate within -
+ 5 percent of the current over the desired plating range.
ORIGINAL ISSUE: - -
8 2 1 92
REVISED
6.2 PRECONDITIONING OF PLATING TANK AND FILTER SYSTEM
*
.
.
I
..
.
.
Ffi.? T;?.: The presence of organic material in the plating tank or associated
plumbing will affect the quality of the plating.
a. Fill tank with 1 otlgal(7.5 g/l) sodium hydroxide (Section 5v.) solution.
b. Heat solution to 140 F (60 C) minimum and operate pump, heat exchanger, and filter
system for 6 hours minimum.
C. Remove and discard t h e solution and rinse the tank thoroughly with water.
d. Fill tank with approximately 3 percent by volume hydrochloric acid (Section 5n.) and
approximately 0.1 percent by volume BOE-NIZ additive LHE (Section 5g.)
e. Operate the pump, heat exchanger, and filter system for 6 hours minimum a t ambient
temperature.
f. Allow the above leaching solution 10 stand an additional 24 hours minimum at ambient
temperature.
g. Remove and discard the solution and rinse the tank thoroughly with water.
h. New or contaminated anode bags (Section 5e.) shall be treated in the above caustic and a c
solutions to leach out any organic contaminants.
6.3 ZINC AND NICKEL ANODE PRETREATMENT
a. Manual solvent clean in accordance with BAC 5750, vapor degrease in accordance with
BAC 5408 or emulsion clean in accordance with BAC 5763. Anodes shall be completely c
prior 10 further processing.
b. Dry abrasive blast clean in accordance with BAC 5748, Type 11, Class 1.
c. Insen the anodes (Section 5d.(2) and Section S.d.(4)) in the leached anodes bags
(Section 5e. and Section 6.2h). Immerse the clean zinc and nickel anodes in the zinc-ano)
pretreatment solution (Table IV) for 2 to 3 hours to allow the formation of a dark-gray fii
on the surfaces.
d. Cold water immersion rinse. Handle the anodes carefully to prevent damaging the soft,
dark-gray film on the anodes. Transfer the anodes to the zinc-nickel plating bath.
NOTE: If the anodes become contaminated or are stored outside of the plating bath
a prolonged period of time (e& one month or longer) reconditioning in
accordance with the above procedure may be necessary.
. __ .
- .^^..* a 7 , "7 REVISED
7 DEFINITIONS
The following definitions shall apply to terms which are uncommon or have special meaning as
used in this specification.
Lot - any group of parts of approximately the same size, shape, and basis metal which have been
processed under the same conditions and submitted for inspection at the same time.
Nonfunctional Surface - a surface on which the presence of a slight plating imperfection will not
affect :he proper operation of the part.
Plating terms - see ASTM B 374 for standard definitions.
Water-break-free -
a surface which maintains a continuous water film for a period of at least 30
seconds after having been sprayed or immersion rinsed in dean water at a temperature below
100 F (38 C).
8 MANUFACTURING CONTROL
A I Some of the materials employed herein are toxic, flammable, andlor
corrosive to human tissue. Boeing personnel should refer to the
Hazard Communication Handbook (Dl-8301)located in your work area
for information contained in the tip sheets and material safety data
sheets concerning the health effects and proper control measures
associated with the use of hazardous materials. Consult the
responsible Security/Fire Protection Engineering organization
concerning appropriate facilities, equipment, and other requirements
for safe operation. For disposition of hazardous waste materials,
contact the responsible Pollution Control Monitor for appropriate
procedures.
I PAGE 5637OF 21
8
8.1 GENERAL NOTES
a. For ferrous alloys, refer to Section 11.1 for stress relief requirements.
b. Unless otherwise specified, the zinc-nickel alloy plating shall be applied after all basis,
metal heat treatments and mechanical operations (such as machining, brazing, welding,
forming and perforating) have been completed.
C. Surfaces must be water-break-free following any immersion in any processing solution or
rinse, except following vapor degreasing, manual cleaning, emulsion cleaning o r solvent
cleaning. Reclean parts which develop a water break.
d. Auxilliary anodes (such as platinum plated titanium Sd.(l) or platinum wire 5d.(3)) may be
used, as necessary, to meet the thickness requirements of Section 11.3.
e. Place all contacts and electrode connections in a nonfunctional area. When in doubt,
consult the applicable design engineering department.
f. Filtration may be used when necessary tO remove particulates from the zinc-nickel plating
bath.
g. When t h e plating tank is inactive for more than 120 hours, the zinc anodes shall be
removed from the plaling bath. Removal is necessary to prevent degradation of the zinc
anodes.
i.2 FLOW CHART
I I
Stress Relieve as Required
(Section 11.1)
Mask andRack
(Section 8.4)
I
I
Zinc-Nickel Plating
(Section 8.6)
I Supplemental Treatment
(Section 8.8)
I
I Quality Control Inspection
(Section 10)
8.3 CLEANING PRIOR TO MASKING
If parts are greasy or oily, vapor degrease in accordance with BAC 5408, emulsion clean in
accordance with BAC 5763, solvent clean in accordance with BAC 5750, manual clean in
accordance with BAC 5744 or alkaline clean in accordance with BAC 5749. Descaling in . '
accordance with Section 8.5.la. or 8.5.h. may be accomplished prior to or subsequent to masking
(Section 8.4).
8.4 MASKING AND RACKING
OPTIONAL Parts may be masked and racked after Section 8.5.la.(l) provided the abrasively
cleaned surfaces are not contaminated (rusting, soiling or discoloration). If the
surfaces become contaminated, the parts shall be reprocessed in accordance with
Section 8.5.la.
a. Mask area not to be plated using maskants listed in Section 5p.
NOTE: To reduce the effect of shadowing and/or robbing of current, it is recommendecc
to mask any area of a metal rack, with the exception of the contact points, whicc
may be immersed in the plating solution.
b. Rack parts to prevent entrapment of gases generated during plating, and to facilitate
draining. Make firm electrical connections to the part@) to prevent arcing. Provide
sufficient contact to carry the required current.
8.5 CLEANING PRIOR TO PLATING
a. Wet processed activated surfaces shall not be allowed to dry prior to immersion in the
zinc-nickel alloy plating bath.
b. Parts which have been masked after descaling may be cleaned, if necessary, in accordance:
with BAC 5744 or BAC 5749 to remove any grease or oil from handling.
8.5.1 LOW ALLOY STEELS
a. Descale by one of the followin'g methods:
(1) Method 1
(a) Abrasive clean in accordance with BAC 5748, l j p e 11, Class 1 using glass bead or'
aluminum oxide abrasive. Use of larger particles (e.&, 80 grit aluminum oxide) ttr
produce B rougher finish will improve plating adhesion.
@) Alkaline clean and rinse in accordance with BAC 5749. If parts require masking
return to Section 8.4, otherwise, transfer to activating step (Section 8.5.lb.) withii
minute.
(2) Method 2
Descale in accordance with BAC 5625, Method 1, or BAC 5751, Method 1. WatR
rinse thoroughly. If parts require masking, return to Section 8.4, otherwise,
transfer to activating step (Section 8.5.lb.) within 1 minute.
(3) Method 3
Descale in accordance with BAC 5749, Method 3. Water rinse thoroughly. 1 f . P
require masking, return to Section 8.4, otherwise, transfer IO activating Step
(Section 8.5.1b.) within 1 minute.
8.5.1 LOW ALLOY STEELS (Continued)
b. Activate the surface by one of the following methods:
(1) Method I
(a) Immerse in dilute acid solution (hydrochloric acid or fluoboric acid in accordance
with Section 9.3) for 5 to 30 seconds.
(b) Cold water rinse for 10 to 60 seconds.
(2) Method 2
(a) Anodic clean in Isoprep 58 in accordance with BAC 5749.
@) Warm water rinse for 1to 3 minutes.
(3) Method3
(a) Periodic reverse clean in accordance with BAC 5749, Method 3. End with a I5 10
25 second anodic cycle.
@) Remove smut, if present, by scouring using abrasive material specified in
Section Sa. Rinse thoroughly with water.
(c) Continue periodic reverse cleaning until a water-break-free surface is obtained
(typically 2 to 10 minutes).
(d) Cold water rinse for 2 to 3 minutes.
C. Proceed to Section 8.6. Do not allow parts 10 dry.
8.5.2 CORROSION RESISTANT STEELS
a. Descale by one of the following methods:
(1) Method 1
(a) Abrasive clean in accordance with BAC 5748, q p e 11. Class 1 using glass bead or
aluminum oxide abrasive. Use of larger particles (e.& 80 grit aluminum oxide) to
produce a rougher finish will improve plating adhesion.
(b) Alkaline clean and rinse in accordance with BAC 5749. If parts require masking,
return to Section 8.4, otherwise transfer to activating step (Section 8.5.2b.) within 1
minute.
(2) Method2
Descale in accordance with BAC 5625. Method 111, or BAC 5751, "pe 11, Class 3.
Water rinse thoroughly. If parts require masking, return to Section 8.4, otherwise,
transfer to activating step (Section 8.5.2b.) within 1minute.
b. Activate surface with a Nickel Strike in accordance with BAC 5746.
I . 5637
I PLGE 13
ORIGINAL ISSUE 8-21-92 REVISED:
-
I 5637
9 MAINTENANCE CONTROL
9.1 ZINC-NICKEL PLATING SOLUTION
a. The tank and filter system shall be preconditioned prior to the initial make-up of the
zinc-nickel plating bath (Section 6.2)
NOTE: Subsequent bath make-up do not require the tank and filter system to be
preconditioned.
b. Clean tank thoroughly and fill approximately half full with warm water.
C. For each 100 gallons (379 L) of final solution, add the appropriate chemical amounts in the
following order:
(1) 142 pounds (65 kg) of ammonium chloride (Section 5b.). Mix until completely
dissolved.
(2) 61 pounds (28 kg) of nickel chloride (Section 5q.). Mix until completely dissolved.
(3) In a separate tank or container, add 2.5 gallons (9.5 L) of hydrochloric acid
(Section 5n.) to 0.5 gallons (1.9 L) Of water. Add and dissolve 9.3 Ib (4.2 kg) of zinc
oxide (Section 5x.). Add this solution to the main bath.
(4) 17 pounds (7.7 kg) of boric acid (Section 5h.). Mix until completely dissolved.
d. Fill the tank close to operating level with water.
e. Check the pH of t h e bath. Adjust the pH, if required, to 6.2 to 6.3. Ammonium hydroxide?
(Section Sc.) is used to raise the pH, and hydrochloric acid is used to lower the pH.
f. When the bath temperature has cooled 10 65 to 85 F (18 to 29 C)
13 add 3.0 gallons (11.5 L) of BOE-NIZ additive LHE (Section 5g.) per 100 gallons (379 L) off
total solution. Stir the bath thoroughly.
g. Add additional water if necessary. Recheck the pH and adjust to 6.2 to 6.3 if necessary.
h. Before placing a freshly prepared solution into production, dummy plate at 3 10 5 ASF (0.::
to 0.6 A/dm) for a period of 8 10 12 hours. Analyze and adjust in accordance with Sectiorr
9.li.
1. Maintain the plating solution within the ranges specified in Table I and adjust, when
necessary, as prescribed by the Quality Control lab.
3
5633
PAGE 15
ORIGINAL ISSUE: 8-21-92 -- REVISED
9.1 ZINC-NICKEL PLATING SOLUTION (Continued)
-I/ Remove zinc anodes when the tank is not in use for more than 120 hours.
-2/ Use anode bags with all anodes. Leach new or contaminated bags in accordance with Section 6.2.
REVISED:
ORIGINAL ISSUE
- -- ---,*,ns
8-21-92
9.2 CONVERSION COATING
a. Clean tank thoroughly. Fill tank approximately one-half full of water.
TABLE I1
CONVERSION COATING CONTROL
MAKE4 PER
MATERIAL/ 100 GALLONS 100 LITERS CONTROL
CONDITION
COLTOB~II
IC-A 75 Ibs 10 to 13 oz/gal
(75 to 98 g/l)
CorroBan IC-B 1percent by volume 1percent by volume
-
1.9+ 0.2
100 + 5F
(38 r 2 C)
BAa
5637
PACE 17
__
ORIGINAL
.. -. -
ISSUE:
-I - 8 -21-92_ - REVISED:
1.3 DILUTE ACID SOLUTION
Make-up and control t h e bath as indicated in n b l e 1%
TABLE I11
DILUTE ACID MAKE-UP AND CONTROL
)
MAKE-UP PER
100 GALLONS 100 LITERS CONTROL
MATERIAL1
CONDITION
208 lbs 25 kg 30.7 to 36 ozlgal
Ammonium Chloride (230 to 270 g l l )
(Section 5b.)
REVISED: .
PROCESS WATERS
MAKE-UP WATER
Water used for solution make-up shall not contain more than 100 ppm total solids.
9.5.2 RINSE WATER
Control the total solids in the rinse water to 500 ppm maximum.
10 QUALITY CONTROL
a. Monitoring of the process and examination of end-items shall be in accordance with the
applicable Quality Assurance provisions which assure the requirements of this specification
are met. __
b. Testing shall be done with sufficient frequency to ensure compliance with the requirements
of this specification.
c Analyze the solutions at intervals that have been determined through experience.
Prescribe and record any changes that are necessary for compliance with this specifcation.
11 REQUIREMENTS
11.1 STRESS RELIEF
a. The plater must receive written verification from the parts fabricator that all stress
relieving has been accomplished in accordance with Section 1l.lb. and 11.1~.
b. Ferrous alloy pans, heat treated to 180 Ksi (1240 m a ) (160 Ksi (1100 MPa) for externally
threaded parts) or higher, shall be stress relieved prior to plating if they have been
subjected to any of the following operations after heat treatment: Grinding, machining,
straightening, cold working, or proof loading. Parts which only have been honed, lapped, 011
shot peened do not require stress relief. When stress relief is required for parts it shall be
performed in accordance with BAC 5617 and BAC 5619.
c. If more than one plating operation (including different plating or re-plating) is performed
on the pans, stress relief shall be accomplished only once.
11.2 WORKMANSHIP
a. The zinc-nickel deposit shall be smooth, fine-grained, adherent and visibly free from
blisters, pits which expose the substrate, nodules. porosity, excessive edge buildup,
indications of burning and other defects when visually inspected without magnification.
Uniformity of color is not required.
b. The Type !I supplemental treatmentlchromate conversion coating shall be continuous,
smooth, adherent, and free from powder. Loose coating which can be wiped off with a
clean cloth. exposing bare plating. is unacceptable.
I--- .n
11.3 THICKNESS
a. Unless otherwise specified. the zinc-nidel alloy plating thickness shall be C ~ S1Sfor all
hardware, except fastener hardware shall be Class 2.
I
b. Pan surfaces designated on the drawing shall be completely covered with visible zinc-nickel
alloy plating, within the capability of the throwing power of the plating Solution. Unless . I.
'
otherwise specified. measurements of plating thickness apply only to those surfaces which
can be touched by a ball 0.75 inch (1.9 cm)in diameter.
c. Unless otherwise specified, the mawimum thickness shall not exceed 0.0010 inch (25 pm).
11.4 ADHESION
. T h e deposit shall be firmly adherent when tested in accordance with BSS 7235 after baking and
supplemental treatment, if required, is completed
-.
11.5 CORROSION RESISTANCE
Zinc-nickel alloy plating with the 'ljpe 11supplemental treatment shall show neither white
corrosion products of zinc nor base metal corrosion products at the end of 96 hours when tested in
accordance with ASIU B 117. The appearance of c o d o n produas, visible to the unaided eye
at normal reading distance, shall be a cause for rejection, exccpt that white corrosion products
within 0.25 inch (0.64 cm)from the edges of the specimens shall not constitute failure.
.,
11.6 TEST SPECIMENS
Test specimens may be used in lieu of parts provided they are processed in the same manner as the
parts they represent. For corrosion tests, low-carbon steel test specimens may be used to
represent low-alloy steel parts. For other than low-alloy steel parts, corrosion test specimens may
be of a generically similar material.