PS-PLATING译文.doc

DAIMLERCHRYSLER CORPORATION NO: PS-PLATINGProcess Standard Date Published: 2003-12-10Category Code: H-1 Change: ZEASL Req. YesRestricted: No*ZINC- MECHANICAL AND ELECTROPLATED*机械镀锌与电镀锌1.0 GENERAL 总则1.1 Purpose of the Standard* 本标准的目的*This standard outlines the procedures and requirements for electroplated zinc, and mechanically plated zinc coatings on iron and steel parts for corrosion protection.本标准概述了有关钢铁零件的防腐蚀的电镀锌和机械镀锌涂层的工艺规程和要求。1.2 Purpose of the Process* 过程的用途*This standard provides the procedures and requirements for producing electroplated zinc deposits. Parts with a hardness of HRC 32 or higher MUST be electroplated according to PS-4220 which requires a mandatory bake operation to relieve hydrogen embrittlement. PS-4220 is identical to PS-79 respectively, except for the mandatory bake. This standard also covers the requirements for mechanically plated zinc deposits. The following Process Standards, which were formerly all individual standards and are still referenced on drawings as such, are covered by this one standard:本标准对生产电镀锌层提供了工艺规程和要求。硬度达到或大于 HRC32 的零件的电镀“必须”按照 PS-4220，其要求强制烘培过程以消除氢脆性。除去强制烘培，PS-4220与 PS-79 完全相同。本标准同样包含对于机械镀锌层的要求。本标准覆盖，过去所有单独的和至今图纸上仍然涉及的以下标准：PS-79 Zinc-ElectroplatedPS-4220 Zinc-Electroplated - Hardened Steel PartsPS-1536 Zinc-Mechanically PlatedPS-79 电镀锌PS-4220 电镀锌-硬化钢PS-1536 机械镀锌1.3 Part Drawings 零件图纸A. Requirements shown on the part drawing shall take precedence over the requirements specified in this standard.B. Unless otherwise specified on the drawing, all brazing, welding, machining, forming, and heat treatment shall be completed before parts or assemblies are plated. Staking operations may be performed after the parts are plated.C. The desired deposit thickness must be specified after the process standard number using a code designation. See Section 2.3.2.D. A chromate, chemical surface treatment, PS-1207, is normally applied to the deposits covered by this standard and should be referenced on the drawing. See Section 2.9.E. The symbol has been substituted for the diamond symbol in this standard to identify critical but non-regulatory items that require continuous Statistical Process Control (SPC). Refer to PS-7300.F. The notion QAR per PS-7300 shall appear in the Part Drawing Standards Block.A. 零件图纸所示要求应当优先于本标准规定的要求。B. 除非图纸另有规定，所有钎焊、焊接、切削加工、非切削加工和热处理应当在零件或装配件镀层完成。（螺母垫圈的）卷边锁紧操作可在零件锻后完成。C. 所要求的镀层厚度必须在以“code”指明的过程标准号后规定。参见2.3.2节。D. 以铬酸盐化学表面处理 PS-1207，通常被应用于本标准涵盖的镀层且应当参考图纸。参见2.9 节。E. 在本标准中确定为要求连续统计过程控制（SPC）的非规定之关键项目的标记已经被菱形标记替代。参考 PS-7300。F. 标识“ QAR per PS-7300”应当在零件图纸标准块中出现。 2.0 PROCESS 步骤2.1 Finish Requirements of Significant Surfaces 重要表面的处理要求The plating shall be smooth, adherent, uniform in appearance, free of blisters, pits, nodules, burning and other defects but not necessarily bright. For parts with an HRC greater than 36, no more than a dull luster is preferred. Coverage shall be uniform and complete on significant surfaces电镀的表面应该是光滑的，致密连接的、外观均匀的，而没有缩孔、气泡、空洞、裂纹和其他缺陷，但也没必要太明亮。硬度大于HRC36的零件，只是偏向于暗的光泽。在重要部位的镀层应该均匀且完整。Unless otherwise specified on the part drawing, significant surfaces for plating thickness and corrosion resistance determination are all surfaces that can be touched by a 19 mm (0.75 in.) diameter sphere. The threads of threaded fasteners are not classified as significant surfaces. However, the entire head area of screws and bolts, and the unthreaded shanks of bolts are significant surfaces.除非零件图上另有说明，对镀层厚度和耐腐蚀性测定的重要表面可用19mm(0.75 in.)直径的球体轻触。螺纹紧固件的螺纹表面不归类为重要表面。然而，螺钉和螺栓的整个头部以及螺栓没有螺纹的部分是重要表面。On mechanically plated parts, unless specified otherwise on the part drawing, significant surfaces for plating thickness and corrosion resistance determinations are all surfaces freely accessible to the glass bead media used in processing the parts.关于机械镀层，除非零件图上另有规定，对镀层厚度和耐腐蚀性测定的重要表面，在零件处理过程中，可用玻璃丸方法自由地与此接触。2.2 Processing Requirements for Electroplating 电镀加工要求2.2.1 Alkaline Cleaning 碱洗Light soils may be removed by soaking parts in a heated alkaline cleaner. Electrocleaning, with the parts made anodic (positive polarity), may also be used. Parts subject to hydrogen embrittlement shall not be cleaned cathodically. (Negative).在加热碱清洗机中浸泡的零件可以去除少量的脏物。电净法也可以使用，将零件作为阳极（正极性。零件不应在阴极（负极）条件下清洗，因为会氢脆。2.2.2 Rust and Scale Removal 除锈去鳞The preferred procedures for the removal of heat treat scale or rust on high-strength/high-hardness parts are tumbling, vibratory finishing or blasting with a dry, fine abrasive. Alkaline rust removers and de-scalers may also be used.在高强度/高硬度零件中，首选去除热处理产生的鳞锈的方法是滚筒清理，振动清理或喷干，细磨料清理。碱性除锈剂和去鳞机也可使用。2.2.3 Acid Cleaning 酸洗Acid cleaning is the least desirable of the available cleaning methods for hardened steel parts because it can contribute to hydrogen embrittlement. Consequently, if fasteners or hardened steel parts with a Rockwell of HRC 31 or greater are acid pickled, it is required that a procedure be established for processing the parts that limits the time in the acid to a MAXIMUM OF 10 MINUTES. Controls must be implemented and records must be kept on the type and strength of the acid used, exposure time, acid bath temperature, and the type and amount of inhibitor. It is required that records be kept on when parts entered and exited the various processing stations. Steps must also be taken to remove the parts from the acid bath during plant shutdown due to mechanical or power failure, in less than the 10 minute maximum acid exposure time.对于硬化钢零件，酸洗是最少用到的方法，因为它能使钢质零件氢脆化。因此硬度大于等于HRC31的紧固件或硬化钢零件采用酸洗。要求处理零件的酸洗时间顶多10分钟。必须执行过程控制且对酸洗的操作必须记录，包括使用酸的种类，浓度，曝光时间，酸池的温度以及抑制剂的种类和数量。当零件开始酸洗到结束酸洗过程中所经过的不同加工设备应当记录下来。由于机械或电源的原因产生了停产，零件也必须从酸洗池里移出，酸的曝光时间不大于10分钟， 2.2.4 Electroplating 电镀Acid or alkaline non-cyanide plating solutions may be used provided the finished parts meet all the requirements of this standard.倘若成品零件能满足本标准的所有要求，可以使用酸性或碱性的无氰化物电镀液。2.2.5 Post Treatment After Plating 电镀的后处理If the parts are plated in an alkaline bath, a 5 to 10 second immersion in a 0.5% by volume nitric acid solution is recommended for neutralizing any residue.如果是通过碱浴的电镀零件，推荐浸入0.5%的硝酸溶液中能抑制任何残渣。2.3 Plating Requirements 电镀要求2.3.1 Plate Thickness on Significant Surfaces 重要表面的镀层厚度The plate thickness on significant surfaces (Section 2.1) must meet the minimum thicknesses as specified by the Code designation (refer to paragraph 2.3.2). The following ASTM Standard Methods may be used to determine the coating thickness:重要表面的镀层厚度应当符合由Code规定的最小厚度（参看表2.3.2）。必须用下列ASTM标准方法来确定镀层的厚度。ASTM B 487 Microscopic Cross Section ASTM B 487 显微横截面法ASTM B 499 Magnetic Method ASTM B 499 磁性法ASTM B 504 Coulometric Method ASTM B 504 库仑法ASTM B 568 X-Ray Method ASTM B 568 X-射线法Except for the microscopic method, calibrate the test instrument using the same coating as that being measured. Magnetic instruments should be zeroed on an unplated part of the same kind as the coating is deposited on.除了显微横截面法，校准试验仪器使用正被检测的同样的镀层。磁性法的仪器应当通过未镀层的同种零件调零。2.3.2 Minimum Deposit Thicknesses 最小镀层厚度Minimum coating thicknesses are specified by a Code number suffix added to the process standard number as follows:最小度层的厚度通过Code+数字后缀来规定，过程标准号如下：TABLE 1: DEPOSIT THICKNESSES 镀层的厚度CODE 代号THICKNESS 厚度Code 0 Complete coverage only 仅完全覆盖Code 15 4 micrometers 微米 (0.00015 in) Code 25 6 micrometers 微米 (0.00025 in) Code 30 8 micrometers 微米 (0.00030 in) Code 50 - See Note(1) 13 micrometers 微米 (0.00050 in) NOTE 1: Code 50 shall not be specified on high-strength steel parts with an HRC 32 or higher. On all existing drawings where Code 50 is specified on a part with a hardness of HRC 32 or greater is hereby understood to be Code 30.注1：Code50不应规定在硬度大于等于HRC32的高强度钢零件上。在所有现有的图纸中Code50是指硬度大于等于HRC32的零件，可理解为Code号30的意思。Deposit thicknesses greater than Code 50 are generally not recommended. If thicknesses less than Code 15 or greater than Code 50 are required, drawing notes shall be used to designate the required thickness.镀层的厚度大于ode50一般是不推荐的。如果厚度需要低于Code15或大于Code50，则图纸上应该用注规定所需厚度。2.3.3 Minimum Thickness Compliance 最小厚度规格 To insure compliance with the minimum thickness requirements of this standard, the plating thicknesses shall be measured on a regular and frequent basis using acceptable sampling plans, such as recommended in ASTM B-602, B-697 and B-762 or equivalents. Control charts and records documenting compliance with the minimum thickness requirements of this standard shall be prepared and maintained.为确保符合本标准的最小厚度要求，应当通过定期的或经常的利用可行的抽样检查计划测量电镀的厚度，比如推荐使用的ASTM B-602，B-697和B-762 等等。控制图和记录应准备和保存用文件证明符合本标准的最小厚度要求。2.4 Adhesion Requirements 附着力要求2.4.1 General Adhesion 一般的附着力The coating shall have good adhesion to the substrate and to itself, and shall show no tendency toward flaking or peeling when tested in accordance with ASTM B 571.当按照ASTM B 571的测试要求时，镀层应该对基底及自身有好的附着力，且不应显示出剥离或脱落的趋势。2.4.2 Mechanical Plate Water Polish and Sealer 机械镀水抛光和密封剂Mechanically plated parts must be suitably burnished by water polishing to consolidate the coating and to minimize loose surface particles. Parts mechanically plated per PS-4850 shall additionally be coated after plating and water polishing with an approved sealer capable of bonding any loose plating particles, particularly at the thread roots and internal drive cavities of threaded fasteners. Approved sealers and the required dilution are listed at the end of this Process Standard and shall be applied and dried according to the recommendations of the manufacturer. The sealer coating shall not interfere with thread gauging or driving of fasteners or functioning of other parts.机械镀的零件必须通过适当的“水抛光”，这是为了加固涂层和减少释放表面的粒子。按照PS-4850机械镀后的零件应当再镀一层，在电镀和用被认可的能粘结任何释放镀层粒子的密封剂“水抛光”后，尤其在螺纹紧固件的螺纹根部和内驱动腔里。在本过程标准中列出了被批准的密封剂和必需的稀释物，并且应按照厂商的推荐来应用和干燥。密封镀层不应干涉螺纹规或紧固件的操控和其他零件的功能。2.4.3 Mechanical Plate Adhesion Tests 机械镀的附着力测试。Finished parts, mechanically plated per PS-1536 shall show no evidence of loosely adherent or poorly consolidated plated particles when inspected as follows:经以下检查时，按照PS-1536标准机械镀的成品件显示没有出松散的附着力或不牢固的电镀粒子的迹象。A. Parts with smooth surfaces shall be subjected to a tape test. The adhesive side of a strip oftransparent tape (e.g., 3M Scotch type 810) shall be pressed firmly against the smooth surfaces of a part to pick up any loosely adherent metallic particles. The test tape is then applied to a clean, white paper for viewing. Evidence of loose particles adhering to the tape shall result in rejection of the entire lot of parts.A光滑表面的零件应经受胶带试验。应将透明胶带上有粘合剂的一面（比如3M Scotch 810型）对着零件的光滑表面牢固地加压以获得任何松散附着力的金属粒子。然后测试带用干净的白纸来检查。在胶带上有粘着松散粒子的迹象，应导致整批零件不合格。B. Internal drive fasteners shall be subjected to a probe test. The cavity of the drive recess shall be probed with the end of a stiff wire (e.g., a paper clip) to loosen any poorly consolidated or poorly bonded metal particles. Evidence of dislodged particles falling from the recess when the fastener is inverted over and tapped against a hard white surface shall result in rejection of the entire lot of parts.B内驱动紧固件应经受“探针测试”。应该用刚性金属丝（例：纸夹）来探测驱动槽的凹陷处松散的任何不牢固或没粘结的金属微粒。当紧固件对着硬面白色表面在上翻转或轻敲从凹槽中散落出沉积微粒的迹象应导致整批零件拒收。C. Rejected lots may be processed with a second coat of sealer provided the additional sealer does not interfere with thread gauging or driving of fasteners or functioning of other parts. Reprocessed parts must pass the original inspection for adhesion and consolidation.C. 不合格的那批零件可以经过二次密封涂层处理，只要附加的密封剂不干涉螺纹的测量、紧固件的操作以及其他零件的功能。再次加工的零件必须通过最初的附着力和牢固性的检查。2.5 Dimensional Tolerance 尺寸公差Tolerances specified on drawings are for the final dimensions unless otherwise indicated. Allowance for plating build-up must be made in the dimensions of threaded fasteners. (See Page Z-2.01 of the DaimlerChrysler Standards Parts Book for unified threads and Page MZ-2.01 for checking ISO metric screw threads.)除非另有说明，图上标出的公差是最终的尺寸。电镀镀层的容差必须计入螺纹紧固件的尺寸内。（参看戴姆勒-克莱斯勒标准零件手册Z-2.01页关于统一螺纹的标准和ISO国际标准公制螺纹的检查标准MZ-2.01页。）2.6 Accelerated Corrosion Resistance 加速防腐试验NOTE: The salt spray test is to be used for process control and process capability only and not required for lot control. Salt spray testing does not need to be completed prior to shipment of parts. The corrosion testing of fasteners must follow the procedure as outlined in SAE/USCAR-1, “Salt Spray Testing and Evaluation of Fastener Finishes.” Table 2, Zinc Performance Requirements, at the end of this standard, lists the minimum deposit thicknesses, codes and corresponding minimum salt spray requirements for the plated deposits, without supplemental chromate coatings, covered by this process standard. The salt spray test shall be conducted in accordance with ASTM B-117 for the times shown in Table 2.注：盐雾试验应只用于过程控制和过程能力方面，不用于批量控制。零件发运前，盐雾试验不是必须完成的。紧固件的腐蚀测试必须按照SAE/USCAR-1“紧固件镀层盐雾测试和评估”所列的程序。表2，镀锌的性能要求，在这个标准的最后列出了电镀镀层厚度的最小值，代号和相应的最小盐雾试验要求，没有附加的铬酸盐涂层被本过程标准所包括。盐雾试验应当按照ASTM B-117表2 中的次数要求来操作。Salt Spray corrosion test requirements DO NOT apply to deep recesses, such as small blind holes and the interior of tubing, or to non-significant surfaces. On parts with a surface area greater than 155 sq cm (24sq in.), the appearance of six or more red rust spots per 1000 sq cm (approx. one square foot) of significant surface (see Section 2.1), that are visible to the unaided eye at normal reading distance or any rust spot originating from an area larger than 1.6 mm (1/16 in.) in diameter is considered a failure. On parts smaller than 155 sq cm (24 sq in), the appearance of more than one rust spot on any significant surface or any rust spot originating from a spot larger than 1.6 mm (1/16 in.) in diameter is a failure.盐雾腐蚀试验要求不适用于深的凹壁内，比如小的盲孔和钢管内部或不重要的表面。在大于155 sq cm (24sq in.)的零件表面区域内，每1000 sq cm（约一个平方英尺）的重要表面（见2.1节）外观有6个或更多的红锈斑，在正常视觉范围内用肉眼可以看到或如果看到任何直径大于1.6 mm (1/16 in.)的锈斑，就表示不合格。小于155 sq cm (24 sq in)的零件，在重要表面上有多于1 于1.6 mm (1/16 in.)就是不合格。（译注：sq cm=平方厘米 sq in=平方英寸）2.7 Hydrogen Embrittlement Relief After Plating 电镀后氢脆的消除Some steel parts are subject to hydrogen embrittlement during cleaning, acid pickling and electroplating. Hardened steel parts with a Rockwell hardness of HRC 32 or higher, that are to be zinc electroplated, must be plated to the requirements of PS-4220 (zinc) and MUST BE PROPERLY BAKED (See Process Standard PS-9500,Hydrogen Embrittlement Relief) within one hour after plating, and prior to chromate coating, to prevent hydrogen embrittlement. A baking schedule based on hardness is described in PS-9500.某些钢制零件在清洗、酸洗和电镀时受到氢脆的影响。硬度大于等于HRC 32的镀锌的硬化钢零件，必须按照PS-4220的要求电镀，还要在电镀后1小时里，但在铬酸盐涂层之前为避免氢脆必须进行适当的烘烤（参看PS-9500过程标准“氢脆的消除”）。一次烘烤的时间是根据PS-9500中描述按硬度来决定。NOTE: Unless otherwise specified, high-strength steels having a hardness greater than HRC 49 shall not be electroplated. High-strength steels having a HRC 32 or greater shall not be specified to more than Code 30 (8 micrometers). On all existing drawings where Code 50 is specified for a part with a hardness of HRC 32 or greater are hereby understood to be Code 30.注：除非另有说明，硬度高于的高强度钢不应电镀。硬度大于等于的高强度钢不应规定高于代号（m）。在当前所有图纸中规定代号50的是指硬度大于等于HRC32的零件，因此被理解为代号30。2.7.1 Baking Procedure 烘烤程序See Hydrogen Embrittlement Relief, PS-9500.参看“氢脆的消除”，PS-95002.7.2 Replates 再次电镀If high-strength parts with an HRC 32 or greater are to be replated for reasons of appearance or adhesion they must be baked for 4 hours at 200 +/- 15 degrees C before stripping and replating. Alkaline strippers should be used if possible. For acid stripping, the same controls as described in section 2.2.3 on acid cleaning should be observed.如果硬度大于等于HRC32的高强度零件因为外观或附着力的原因要再次电镀，在去膜和再次电镀之前，必须在200+/-15的温度下烘烤4小时。如果可能的话就使用碱性的去膜器。对于酸去膜应遵守2.2.3节中有关酸洗相同控制的描述。2.7.3 Mechanically Plated Parts 机械镀零件High-strength/high-hardness, mechanically plated parts are not required to be baked but are to be held for 48 hours before shipping to customer. See Process Standard PS-9500 Hydrogen Embrittlement Relief.高强度/高硬度机械镀零件不用烘烤，但在运送给顾客之前要保存48小时。参看PS-9500过程标准“氢脆的消除”。2.8 Hydrogen Embrittlement Test 氢脆试验The primary supplier of the high-strengthhigh-hardness steel part or fastener is responsible for insuring that the parts are free from hydrogen embrittlement. The use of this test is mandatory every time a high-strength steel part with an HRC of 32 or higher is electroplated. For the hydrogen embrittlement test procedure, see Process Standard PS-9500,Hydrogen Embrittlement Relief.高强度/高硬度钢制零件或紧固件的主要供应商应有责任保证零件没有氢脆。每次电镀硬度大于等于的高强度零件采用这种试验是强制的。氢脆试验程序可参照PS-95000过程标准氢脆的消除。2.9 Chromate Treatment 铬酸盐处理,Additional treatments, such as a chromate conversion coating (Process Standard PS-1207), shall be applied after the baking operation.附加的处理，诸如在烘烤后应进行铬酸盐转换涂层( PS-1207过程标准) 。*TABLE 2: ZINC PERFORMANCE REQUIREMENTS* 镀锌性能要求TYPE 方式PROCESS STANDARD AND COATING THICKNESS CODE过程标准和镀层的厚度代号MINIMUM COATING THICKNESS最小镀层厚度MINIMUM SALT SPRAY HOURS TO RED RUST (1) 按红锈最小的盐雾试验时间MICRONS 微米INCHES 英寸Zinc Electroplated电镀锌PS-79 Code 0 Coverage覆盖Coverage覆盖Not required 无要求PS-79 Code 15 4 0.00015 24 PS-79 Code 30 8 0.00030 56 PS-79 Code 50 13 0.00050 96 PS-4220 Code 0 Coverage Coverage Not required PS-4220 Code 15 4 0.00015 24 PS-4220 Code 30 8 0.00030 56 PS-4220 Code 50 13 0.00050 96 Zinc-Mechanically Plated 机械镀锌PS-1536 Code 0 Coverage Coverage Not required PS-1536 Code 25 6 0.00025 56 PS-1536 Code 50 13 0.00050 96 NOTE: 1: Before required Dichromate Treatment (paragraph 2.9).注1：需要重铬酸盐处理前（2.9段）3.0 GENERAL INFORMATION 总说明Three asterisks “*” after the section/paragraph header denotes multiple technical changes to the section/para