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On complex and large manufacturing applications of electroplating, conversion coating, anodizing and painting writing a good operating procedure is essential. There is disparity in our practices within the industry. The standard to write a procedure change based on the region, industry, the sector, an engineer and the management. On most cases there are opportunities for improvement and the performing team in some ways reflect on the effectiveness of the operation procedure (s).

Many applicators encounter one or more challenges given below:

• Variations in analytical variables
• Unexpected equipment breakdowns
• Effects of product non-conformances and its influence on delivery
• Delayed implementation of an operative task

None of these are challenges if one has abundant resources and time! But we require lean processes and fewer resources to compete in the market. Writing a good standard operating procedure is the foundation to overcome these challenges. This short paper adds colour on three important attributes of an exemplary procedure and highlights the benefits.

Grammar:

The writer must use simple future tense, active voice and be direct on the departmental and standard operating procedures. The document must be lucid and must have all pertinent information in order and most information must be available in a single read. A reader will find an added value from Advint’s short paper on concise communications released on June 01, 2019.

Complete:

The written (standard and departmental) operating procedures must be complete. What completes mean? It is subjective. Correct? While the meaning is different to all, at a rudimentary level, it must be complete for the purpose and the scope of the particular operating procedure. A procedure become redundant and a formality, when we provide only select information and allow the user to interpret or draw individual conclusions and perform the tasks accordingly. This is a source for variation and one should take cognizance!

A surface finishing operation involves the design of a process, equipment and product flow. Many manufacturing tasks possess several variables, and when touched by people it produces different results. Standardization is the solution. Examples of the tasks are processing products, electrolyte make up, optimization and control, execution of total productive maintenance (TPM), product quality and functional testing, and characterization. Writing individual tasks for all the mentioned examples in a chronological order and identifying required resources, supplies and accessories will ensure the procedure is complete.  Providing control and reaction plan for deviations on expected and historical behaviors will strengthen the procedure.

Complete does not mean excessive. Unnecessary information will decrease attention and encourage readers to minimize referencing the procedure.

A procedure gets authority when a reader refers to it with interest

We do not require staff to remember all the contents, all they need to know is, what and where the sought-after information is available.

Revisions:

Revise the procedure on every critical opportunity. Involve the user in the revision process.

Be explicit in your communication to the user that their input is valuable, and it is the joint responsibility to ensure that the procedure is valid and complete

On Sep 01, 2019 Advint on its short paper recommended 6 Process Development & Control (PDC) tools. A revision must extend from the learnings of the PDC analysis. When we precisely perform the operative task and use non-conformance as an opportunity for firming up the procedure, we can minimize variation.

Benefits:

Clarity is vital. Good procedure confirms clarity to the operating personnel. It reduces surprise, and the time spent. It increases value and reduces cost. This starts with the author putting emphasis on the readers above themselves. A written document may not realize its high point on the first go, but targeting for a complete procedure on every single opportunity and sustaining on the revisions will aid the most important satisfaction–that is employee satisfaction and thereafter the customers’. True employee satisfaction is the effect of good design, even product flow and less variation.

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Concise Communications and High-Volume Plating

A profound analysis of periodic table will help ardent electroplating professionals understand the effectiveness of the deposition of elements from the outlook of electrode potential, current efficiency, and the deposit characteristics. Use of the table provides added knowledge and supports to decipher the precise information swiftly.

As we celebrate the 150th anniversary of periodic table, we will dedicate this short paper on the properties of elements and their position in the periodic table. Regarding electroplating of elements and alloys there are a few significant relationships with the groups and periods of the table. Though these are important for all plating specialists, it particularly interests those involved in research and formulation of an electrolyte and the alloy deposit.

Here are some properties:

Water:

The presence or absence of water affects the plateability and the current efficiency of the deposit. Chromium, the group 6 element of periodic table is a good example. Ability to plate Cr using the aqueous (presence of water) chromic acid-based electrolyte is an exception. Low current efficiency property of the electrolyte shows the reason for the struggle. On other hand, one can conveniently plate neighboring elements like Ti, Zr, Hf, V, Nb, Ta, Mo and W using ionic liquid (absence of water) electrolyte, with other challenges.

Position of elements:

The position of elements in the table and their properties are insightful. The position and proximity with each other can also help determine suitable alloying elements. On another point, let us look at indium, tungsten and boron. The relevant properties of this example are hardness and melting point. The position and the properties of these elements seen with their respective neighboring elements will show a trend.

Oxide (passive) layer:

The group of elements in the table say a lot about the oxide layer of the metal or the deposit. Examples are Ti, Ta, W and Cr. The formation of an oxide layer protects the metal from corrosion and make it tough to form an adherent deposit using the conventional electrolytes. Electrode and decomposition potentials of these elements also contribute significantly towards effective plating or the challenges thereof.

There are nearly 35 elements suitable for plating and their effective deposits offer a unique and superior properties. But aqueous electrolytes can conveniently plate only ≤ 20 elements (read metals) and alloys. Certain ionic liquid formulations can electroplate all or most of the 35 elements. We will discuss the reasons and mechanism of ionic plating in another short paper. Looking at the elements in groups and periods of the periodic table will offer unique understanding on plateability and desired functional properties such as corrosion resistance, tribology, and electrical conductivity.

Refractory elements, precious metals, sacrificial protection metals, and conductive ions (cations) are in proximity among their groups on the periodic table. They are in decreasing or increasing order within the groups or periods.

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Summary:

Periodic review of the periodic table will enable electroplating professionals strengthen their understanding on the feasibility and properties of the deposit. Greater effort to interpret different properties are definitely worth it!

Creating suspense is the best way to improve customer dissatisfaction. Unpredictability is a no lesser means towards employee dissatisfaction. Dependence on a plating troubleshooting guide helps these two effects.

Why this topic?

Many Advint’s short paper readers know I consistently write on various electroplating topics for the last several months. I am also meticulously writing a course book covering all subjects related to plating. While working on these I noticed many books and articles written by consultants and experts in the past concentrated more than required on the troubleshooting guide. My mind questioned the need. And, I was musing rather shouldn’t the emphasis be on the preventative measures and good operating practices! Hence this article.

The aim is to change the direction and stress the importance of development concepts. If I do not convince you, build a large, complex, and automated plating line (plating on plastics or on Ti alloys) and come back to this thought!

Troubleshooting guides are a treasure:

The author does not aim to belittle the value of a troubleshooting guide. The focus is only on conditions where there was more implicit importance on the troubleshooting guide and less on the use of development and control tools. This is analogous to leaving the head and chasing the tail. The author had used guides (long back, not any more) and cherished the experts (and plating consultants) who wrote them. Those are valuable and must be handy, but we must use as a last option. The focus on development and control will ensure you forget the art of troubleshooting (which is a good thing). Sounds good. But how?

Process Development Control (PDC) Tools:

Advint recommends using the set of 6 Process Development Control (PDC) tools in sequence and in a cycle.

The tools are:

1) Failure Mode and Effects Analysis (FMEA)

2) Process Checklist

3) Variable Control Charts

4) Measures of Dispersion Variation

5) Pareto Chart

6) Cause and Effect Analysis

The listed tools are part of 7 quality control (QC) tools or statistical process control (SPC) tools. Most 7 QC or SPC tools are neither control nor statistical tools. Both terms are misnomers. A few is development and verification tools.

FMEA:

Quality specialists recommend starting a new unit / product or a line with a design FMEA and after a year or two conduct a process FMEA. When a process is in production mode, we recommend implementing process FMEA once a year or once in two years. No less or no more! Conducting proper FMEA’s are valuable, however it is an intense process. On processes such as automotive plastic chrome plating, FMEA is indispensable.

Process Checklist:

The purpose of the checklist is not to provide a path-breaking solution or to prevent a major potential production issues, but a few simple and frequent checks will subtly help mitigate oversights. We recommend revising the checklist once in six months or a year. The revision must include deleting redundant checks and including necessary inspections based on the feedback received from other tools and production effectiveness.

Variable Control Charts:

When you require a variable to meet only specification limit, we recommend using a run chart, and when you require a variable to meet specification and control limits, use an X-Bar R chart. One must be careful to give more emphasis on control limits when using X-Bar R charts. These charts are only effective when it set up per Dr. Shewhart’s direction and with a control and reaction plan.

Measures of Dispersion Variation:

Examples of measures of dispersion and variation are sample and population standard deviations, range, and process sigma or standard normal distribution. Sustained observations and effective reactions to these measures are influential. We can do most of these measurements on input variables such as analyses data.

Pareto Chart:

Use Pareto’s the 80/20 concept and Juran’s “the vital few and the trivial many” thinking to your benefit on plating or conversion coating applications. Periodically, we recommend isolating top 1 or 2 defect variables and conducting a cause-and-effect analysis. Review period can be monthly or quarterly based on production or quality standards. Refer to our previous post for additional information on Pareto chart.

Cause and Effect Analysis:

You can run fishbone or 5 Why’s analysis on Pareto classifications in the same frequency. Other than Pareto classifications, we also recommend running 5 Why’s on other deviations promptly. Here, promptly means = 2 business days. The examples of deviations include quality, customer service, environment, safety, breakdown maintenances (electrical, mechanical, and chemical), etc. You must subject any deviations which you do not feel right to the cause-and-effect analysis.

There are other beneficial quantitative techniques and total quality management tools, including 7 quality control (QC) tools available, which we did not mention in this paper. On plating, anodizing, and conversion coatings applications we recommend applicators to use the six PDC tools implemented in sequence and continuously cycle for the best results.

Use of some of these tools are not as simple as it appears, as there are tricks and there are several variables intricately involved. Advint is with you on your quality quest.

Refer to other short papers on this site or contact adviser@theadvint.com for questions or further insights.

End Point:

Employee satisfaction is a prerequisite for customer satisfaction. Eliminating suspense and confirming the processes are predictable using 6 PDC tools will increase satisfaction. Always keep the plating troubleshooting guide handy, but dependence or frequent use is detrimental. Prevention is better than disposition. Good operating practices and focus on the development efforts can ensure you forget the art of troubleshooting. So influential are these tools.

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Electroless Ni-P and Ni-B process management had improved significantly within the last two decades. In this paper I’ll write about the science of autocatalytic plating as practiced now and the criterions for advancement at a higher level.

The purpose is to offer reader’s deeper information to achieve consistent deposit physical characteristics and the functional properties of electroless nickel plating.

We will go over the functions of a reducing agent, stabilizer (or catalytic inhibitor), and complexing agent related to thermodynamic property of an electrolyte and mixed potential theory.

Temperature (energy), electrolyte flow (current density), solution volume, and the concentrations balance determine the effectiveness of the deposition mechanism and consistency of the deposit in the long term. Gibbs free energy and its relationship with volume, temperature, and energy influence the required concentrations and ratios of a reducing agent, stabilizer, and the complexing agent. An understanding of Gibbs ∆G value with the stability, instability and absolute stability of the electrolyte is imperative. Per mixed potential theory, the deposition reaction is a combination of cathodic and anodic partial reactions taking place at separate electrodes. Redox potentials of sodium hypophosphite, dimethyl amine borane (DMAB), and sodium borohydride play a significant role in a reduction step and the concentrations of stabilizers and complexing agents.

To confirm sustained deposit characteristics, electrolysis mechanism and control or management of by products release are important. Geometrical properties such as

• tank and pump design,
• electrolyte volume, flow rate and pattern,
• process control of temperature, pH, metal ion concentration, reducing agent, stabilizer, and complexing agent

will ensure stability.

When Gibbs free energy and partial electrode reactions (anodic and cathodic) are within the optimum range plating rate, deposit composition (Ni and P or B weight percentages), and formation of uniform eutectic compounds of Ni-P or Ni-B will be effective and consistent.

Corrosion and tribology properties depend on the consistency of the deposit composition and phase formation. Out of range ∆G value can lead to unstable or absolute stability of the electrolyte. This will lead to either electrolyte decomposition or very low plating rate. The concentrations of a reducing agent, stabilizer, and the complexing agent determine the stability of the electrolyte. Plating rate depends on electrolyte temperature and pH.

Summary:

Other than simple control and changes done to temperature and chemical constituents, due diligence on the following variables considering the aforementioned concepts will advance the attained deposit characteristics:

1. Optimize tank design, flow pattern and temperature stratification
2. Aim for consistent deposit composition
3. Observe deposit phase formation and aim for consistency if it is economically viable.

One can improve the bath life and the effectiveness of any deposit by giving more attention to the fundamental concepts and conscientiousness on the input variables. 

Though the examples cited in this paper are for electroless Ni, the recommendations apply to all electroless processes including Cu, Ag, Pd, Au, etc.

Readers – You are welcome to post questions, comments or thoughts.

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Evolution of Cleaner Formulations in the Industry

Formulating cleaners such as alkaline soak cleaner and electro cleaner are imperative, though not as significant and lucrative as formulating plating baths containing primary and secondary brightener systems.

Unlike quite a few decades ago, current cleaner formulations contain methodically investigated inorganic and organic ingredients which are effective and comply with the environmental regulations. 

Different sectors and industries use solvent, alkaline soak and electro cleaners uniquely. Does the industrial practice catch up with scientific advancement? Good formulations are available! Did the market seize the opportunity?

This blog highlights the value of a good cleaner, identifies a simple step in choosing a cleaner, and list a few potential ingredients and their properties.

A carefully chosen cleaner can remove organic residues from the substrate thoroughly. Decrease the cleaning time and (or) improve cleanliness. Cut cost by increasing the cleaner life and minimize environmental impact.

Go over a material safety data sheet (MSDS) to select a cleaner, however, a proprietary chemical supplier could throw a curve ball. Section 2 of an MSDS must contain hazardous ingredient listed with Chemical Abstracts Service (CAS) registry number and the concentration. The reader can find specific CAS related information on this link.

Before considering the inorganic and organic ingredients, process owner must know their processes and supply chain well. Knowing and considering the substrate(s) and their corrosion properties in most cases are explicit. Sometimes information is hidden and implicit on aspects such as oils, lubricants, and kinds of paraffin used. Application time, heat treatment (if applicable) and their intricate factors on some instances might not be clear. Source and purity of water, properties such as temporary and permanent hardness are vital for the makeup of cleaner solution and rinsing.

Alkalinity, buffer, water softening, chelation, and surface tension are a few important solution properties to observe. The process owner should assess the presence and concentrations of sodium hydroxide, carbonate, phosphate, silicate, amines, and surfactants and relate to the application (s). A surfactant can be anionic, non-ionic and (or) amphoteric. It changes the surface tension and wettability of the solution.

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Briefly put, irrespective of reasons and justifications, focussing on cleaners and improving the cleaning performance is worth the effort and not a hard nut to crack using the listed suggestions.