Dixie Industrial Finishing Company 4925 S. Royal Atlanta Drive Tucker, GA 30084 (770) 934-7100 Jim Jones –Vice President Terry Windham, CEF – Sales/Quality.

Dixie Industrial Finishing Dixie Industrial Finishing CompanyCompany

4925 S. Royal Atlanta Drive4925 S. Royal Atlanta DriveTucker, GA 30084Tucker, GA 30084(770) 934-7100 (770) 934-7100

Jim Jones –Vice PresidentJim Jones –Vice PresidentTerry Windham, CEF – Sales/QualityTerry Windham, CEF – Sales/Quality

PLATING: What is it?PLATING: What is it?

• Also called electroplating, plating is the Also called electroplating, plating is the mechanically bonding of one metal to another mechanically bonding of one metal to another

for the purpose of corrosion protection, for the purpose of corrosion protection, decorative appeal, hardness, electrical decorative appeal, hardness, electrical conductivity, reflectivity, and/or wear conductivity, reflectivity, and/or wear

resistanceresistance•In a nut shell, plating modifies the surface In a nut shell, plating modifies the surface

properties of the base metal to make it more properties of the base metal to make it more suitable for its intended usesuitable for its intended use

Typical Properties Typical Properties AchievedAchieved

Through PlatingThrough PlatingCorrosion Corrosion resistanceresistance

AppearanceAppearance

Abrasion Abrasion resistanceresistance

Value Value (silver/gold, etc)(silver/gold, etc)

SolderabilitySolderability

Rubber BondingRubber Bonding

ElectroformingElectroformingElectrical Electrical ResistanceResistanceReflectivityReflectivityDiffusion BarrierDiffusion BarrierLubricityLubricityHigh Temp. High Temp. ResistanceResistance

CRITICAL STEPS IN CRITICAL STEPS IN PLATINGPLATING

• Racking/Loading (position, number of parts)Racking/Loading (position, number of parts)• Amperage (amount of current for the Amperage (amount of current for the

number of parts)number of parts)• Cleaning (strength, temperature, time)Cleaning (strength, temperature, time)

• Pickling/Acid (strength, temperature, time)Pickling/Acid (strength, temperature, time)• Rinsing (time, flow of water, cleanliness)Rinsing (time, flow of water, cleanliness)• Plating process (Zn, Ni, Sn, Ag, Au, etc.)Plating process (Zn, Ni, Sn, Ag, Au, etc.)

• Chromates (strength, pH, temperature, time, Chromates (strength, pH, temperature, time, age of chromate)age of chromate)

• Post-dips (strength, age, temperature, pH)Post-dips (strength, age, temperature, pH)

Typical Zinc Plating CycleTypical Zinc Plating Cycle

SOAKCLEANER

ELECTRO-CLEANER

RINSE ACID RINSE

PLATINGTANK

RINSE

BRIGHTDIP

OTHERCHROMATE

BRIGHT DIPRINSE

CHROMATERINSE

HOT RINSEDRY

Direction of Work Flow

Direction of Work Flow

•Multiple, counterflow rinses usually used•Pre-dips, post treatments. etc., may be used

What happens to steel?What happens to steel?

•Steel is the cheapest structural Steel is the cheapest structural material available for countless usesmaterial available for countless uses•However, steel is not very resistant However, steel is not very resistant

to corrosion (red rust)to corrosion (red rust)

Steel PartSteel Part(Unplated)(Unplated)

Red RustRed Rust

Rust damages (pits) the surface of the base Rust damages (pits) the surface of the base metalmetal

The Plating The Plating TankTank

PARTPART

Zn++

Zn++

Zn++

Zn++

Zn++

Zn++

Zn++

Zn++

Zn++

ZINCZINCBALLSBALLS++ ++(-)(-)

(-)(-)

(-)(-)

CathodeCathode AnodeAnodeAnodeAnode

ZincZincPlatingPlatingSolutionSolution

What happens to zinc?What happens to zinc?

Steel PartSteel Part

•Zinc metal will corrode (white corrosion) if Zinc metal will corrode (white corrosion) if not protected by a chromate finishnot protected by a chromate finish

•As the zinc corrodes, it fails to protect the As the zinc corrodes, it fails to protect the base metal and red rust of the base metal base metal and red rust of the base metal

occursoccurs

Rust damages (pits) the surface of the base metalRust damages (pits) the surface of the base metal

Zinc PlatingZinc Plating

White corrosionWhite corrosion

Steel PartSteel Part

Plated Metal (Zinc)

ChromateChromateFinishFinish

ZINC PLATED PARTZINC PLATED PART

•The part is protected from corrosion by The part is protected from corrosion by the zinc platingthe zinc plating

•The zinc plating is protected from The zinc plating is protected from corrosion by the chromate finish corrosion by the chromate finish

TYPES OF CHROMATESCHROMATES

HexavalentHexavalent

- Clear- Clear

- Yellow- Yellow

- Bronze- Bronze

- Black- Black

- Olive Drab / - Olive Drab / GreenGreen

TrivalentTrivalent

- Blue Bright (Clear)- Blue Bright (Clear)

*Thin Film*Thin Film

- Non-hex thick film - Non-hex thick film passivates (non-passivates (non-colored, black). Can colored, black). Can be dyed.be dyed.

Hexavalent ChromatesHexavalent Chromates

Excellent corrosion protection Excellent corrosion protection propertiesproperties

Fairly inexpensiveFairly inexpensive Easy / fast to apply @ room temperatureEasy / fast to apply @ room temperature

Variety of colorsVariety of colors Self-healing propertiesSelf-healing properties

Can not be bakedCan not be baked Carcinogenic / health issuesCarcinogenic / health issues

Considered environmentally non-friendly Considered environmentally non-friendly (do not meet ELV, RoHS, WEEE requirements)(do not meet ELV, RoHS, WEEE requirements)

Why the elimination of hexavalent chromium?

To meet the requirements of ELV, RoHS and WEEE directives

Hexavalent chromium is carcinogenic by nature. Hexavalent chromium compounds can slip through cell membranes and react with DNA causing cell mutations/cancer

Hexavalent chromium is a strong oxidant that poses a threat to biological systems

ELVELVELVELVExtended Life Vehicle (ELV) Extended Life Vehicle (ELV) Directive 2000/53/ECDirective 2000/53/EC

Pb, Hg, Cd, CrPb, Hg, Cd, Cr+6+6 Banned from Banned from automotive coatings as of 7-2007automotive coatings as of 7-2007

Objective: prevention of waste Objective: prevention of waste from vehicles plus reuse, recycle, from vehicles plus reuse, recycle, & recovery of end-of life vehicles & recovery of end-of life vehicles & components. 85% recycled by & components. 85% recycled by 2006, 95% by 2015 2006, 95% by 2015

Vintage & historic vehicles are Vintage & historic vehicles are exemptedexempted

Components, materials, as well as Components, materials, as well as spare & replacement parts are spare & replacement parts are also coveredalso covered

Automotive component Automotive component manufacturers to provide manufacturers to provide appropriate information to appropriate information to treatment facilities, concerning treatment facilities, concerning dismantling, & reusedismantling, & reuse

Extended Life Vehicle (ELV) Extended Life Vehicle (ELV) Directive 2000/53/ECDirective 2000/53/EC

Pb, Hg, Cd, CrPb, Hg, Cd, Cr+6+6 Banned from Banned from automotive coatings as of 7-2007automotive coatings as of 7-2007

Objective: prevention of waste Objective: prevention of waste from vehicles plus reuse, recycle, from vehicles plus reuse, recycle, & recovery of end-of life vehicles & recovery of end-of life vehicles & components. 85% recycled by & components. 85% recycled by 2006, 95% by 2015 2006, 95% by 2015

Vintage & historic vehicles are Vintage & historic vehicles are exemptedexempted

Components, materials, as well as Components, materials, as well as spare & replacement parts are spare & replacement parts are also coveredalso covered

Automotive component Automotive component manufacturers to provide manufacturers to provide appropriate information to appropriate information to treatment facilities, concerning treatment facilities, concerning dismantling, & reusedismantling, & reuse

WEEEWEEE EC Directive on EC Directive on WasteWaste from from

ElectricalElectrical and and ElectronicElectronic EquipmentEquipment

2002/96/EC Jan 20032002/96/EC Jan 2003

Required all 25 EU member states Required all 25 EU member states to implement into law within 18 to implement into law within 18 months (Aug 2004) a requirement months (Aug 2004) a requirement that appliances and electrical that appliances and electrical devices be manufactured in such a devices be manufactured in such a manner that they can be manner that they can be recycled/recovered at a recovery recycled/recovered at a recovery rate of 70-80% based on type of rate of 70-80% based on type of appliance. appliance.

As of 8-05 all EU members except As of 8-05 all EU members except Malta and UK had at least a Malta and UK had at least a framework regulation.framework regulation.

WEEEWEEE EC Directive on EC Directive on WasteWaste from from

ElectricalElectrical and and ElectronicElectronic EquipmentEquipment

2002/96/EC Jan 20032002/96/EC Jan 2003

Required all 25 EU member states Required all 25 EU member states to implement into law within 18 to implement into law within 18 months (Aug 2004) a requirement months (Aug 2004) a requirement that appliances and electrical that appliances and electrical devices be manufactured in such a devices be manufactured in such a manner that they can be manner that they can be recycled/recovered at a recovery recycled/recovered at a recovery rate of 70-80% based on type of rate of 70-80% based on type of appliance. appliance.

As of 8-05 all EU members except As of 8-05 all EU members except Malta and UK had at least a Malta and UK had at least a framework regulation.framework regulation.

WEEEWEEEWEEEWEEE

WEEE Man represents 3.3 tons of electronic waste generated by each

citizen of the UK in a lifetime

WEEE Man represents 3.3 tons of electronic waste generated by each

citizen of the UK in a lifetime

RoHSRoHSRestrictionRestriction ofof Hazardous Hazardous SubstancesSubstances in Electrical and in Electrical and Electronic Equipment (RoHS) Electronic Equipment (RoHS)

Directive (2002/95/EC)Directive (2002/95/EC)

As of July 1, 2006, this directive As of July 1, 2006, this directive bans lead, mercury, cadmium, bans lead, mercury, cadmium, hexavalent chromium, hexavalent chromium, polybrominated biphenyls (PBBs) polybrominated biphenyls (PBBs) and polybrominated diphenyl and polybrominated diphenyl ethers (PBDEs) from all new ethers (PBDEs) from all new electrical and electronic electrical and electronic equipment sold to EU companies equipment sold to EU companies and manufactured in the EU.and manufactured in the EU.

RoHSRoHSRestrictionRestriction ofof Hazardous Hazardous SubstancesSubstances in Electrical and in Electrical and Electronic Equipment (RoHS) Electronic Equipment (RoHS)

Directive (2002/95/EC)Directive (2002/95/EC)

As of July 1, 2006, this directive As of July 1, 2006, this directive bans lead, mercury, cadmium, bans lead, mercury, cadmium, hexavalent chromium, hexavalent chromium, polybrominated biphenyls (PBBs) polybrominated biphenyls (PBBs) and polybrominated diphenyl and polybrominated diphenyl ethers (PBDEs) from all new ethers (PBDEs) from all new electrical and electronic electrical and electronic equipment sold to EU companies equipment sold to EU companies and manufactured in the EU.and manufactured in the EU.

RoHSRoHSRoHSRoHS

Computer Hardware is Subject to RoHS Directive

Automotive Hardware is Subject to ELV Directive

Computer Hardware is Subject to RoHS Directive

Automotive Hardware is Subject to ELV Directive

WEEE and RoHS Product WEEE and RoHS Product CategoriesCategories

1.1. Large appliancesLarge appliances2.2. Small appliancesSmall appliances3.3. IT/telecom equipmentIT/telecom equipment4.4. Consumer equipmentConsumer equipment5.5. Lighting equipmentLighting equipment6.6. Electrical/electronic toolsElectrical/electronic tools7.7. Toys, sport equipmentToys, sport equipment8.8. Medical equipment Medical equipment **9.9. Monitoring/control Monitoring/control

equipment equipment **10.10. Automatic dispensersAutomatic dispensers

*Excluded by RoHS Directive

BusinessBusiness Issues for Surface Issues for Surface Finishers/ManufacturersFinishers/Manufacturers

WEEE and RoHS Directives signal new WEEE and RoHS Directives signal new trend toward “product regulation.”trend toward “product regulation.”

Customers increasingly want to know the Customers increasingly want to know the material content and planned end-of-life material content and planned end-of-life disposition for products they buy.disposition for products they buy.• Achieve legal complianceAchieve legal compliance• Promote“green procurement”Promote“green procurement”• Corporate sustainabilityCorporate sustainability• Respond to stakeholdersRespond to stakeholders

Non-Hexavalent PassivatesNon-Hexavalent Passivates

More expensive (contain expensive tri-More expensive (contain expensive tri-chromium compounds, organic acids, and chromium compounds, organic acids, and other metals)other metals)

Must be heated to apply (typically 140Must be heated to apply (typically 140ooF)F) Slower to apply (increases cycle time)Slower to apply (increases cycle time) Not self healing (require additional top Not self healing (require additional top

coats for protection – more expense)coats for protection – more expense) Lower corrosion protection than Lower corrosion protection than

hexavalents (without topcoats/seals)hexavalents (without topcoats/seals) Less color variety (non-colored & black)Less color variety (non-colored & black)

Cons:Cons:

TYPICAL SALT SPRAY HOURS

Clear Trivalent 12 – 24 hours Clear Hexavalent 20 – 32 hours

Black Hexavalent 72 hours Yellow Hexavalent96 hours

Olive Drab / Green 168 hours Non-hexavalent thick film 72 hours Non-hexavalent black 36 – 72 hours

(all results are without seals/topcoats)

Topcoats / SealsTopcoats / Seals

There are a variety of topcoats / There are a variety of topcoats / seals available. Silicated dips, seals available. Silicated dips, polymers/lacquers, cross-linking polymers/lacquers, cross-linking polymers, lubricating seals (torque-polymers, lubricating seals (torque-n-tension compounds)n-tension compounds)

Silicated dips offer some self-Silicated dips offer some self-healing help and increase corrosion healing help and increase corrosion protection. These are very thin and protection. These are very thin and will not cause dimensional will not cause dimensional problems with fasteners problems with fasteners

Polymers / lacquers offer enhanced Polymers / lacquers offer enhanced corrosion protection as well as scratch corrosion protection as well as scratch resistanceresistance

Polymers / lacquers can pose some Polymers / lacquers can pose some conductivity issuesconductivity issues

Polymer / lacquer films can be thick and Polymer / lacquer films can be thick and may cause fit/dimensional issues in may cause fit/dimensional issues in fasteners, especially in threaded areasfasteners, especially in threaded areas

Lubricating seals (torque-n-tension) offer Lubricating seals (torque-n-tension) offer enhanced corrosion protection, some self-enhanced corrosion protection, some self-healing help, and lubricity, changing healing help, and lubricity, changing torque values of the surface (automotive torque values of the surface (automotive fastener requirements). These seals can fastener requirements). These seals can be expensive to apply.be expensive to apply.

Topcoats / SealsTopcoats / Seals(cont.)(cont.)

THANK YOU!THANK YOU! A big thanks to you for allowing us the A big thanks to you for allowing us the opportunity to share this information with opportunity to share this information with

you today.you today. For questions or comments, we can be For questions or comments, we can be

reached at:reached at:Dixie Industrial Finishing Company, Tucker, Dixie Industrial Finishing Company, Tucker,

GAGAwww.dixie-industrial.comwww.dixie-industrial.comJim Jones (770 908-7900)Jim Jones (770 908-7900)[email protected]@dixie-industrial.com

Terry Windham (770) 908-7909Terry Windham (770) [email protected]@dixie-industrial.com