Decorative Chrome Electroplated Part Performance WSS-M1P83-E2 Requirements, Abs or Pc/Abs Substrates, General Exterior Use 1. Scope

ENGINEERING MATERIAL SPECIFICATION
DECORATIVE CHROME ELECTROPLATED PART PERFORMANCE WSS-M1P83-E2

REQUIREMENTS, ABS OR PC/ABS SUBSTRATES, GENERAL
EXTERIOR USE
1. SCOPE
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This specification defines the performance requirements for copper, nickel, and chromium electroplated
acrylonitrile butadiene styrene (ABS) and polycarbonate/acrylonitrile butadiene styrene blend (PC/ABS)
parts for exterior applications.
2. APPLICATION
This specification was released originally where a decorative chrome finish is required for exterior
applications, including, but not limited to, grilles, door handles, badges, belt moldings, and mirror caps.
2.1 LIMITATIONS
No coating (paint, ink, etc.) may be applied over chrome plating per Ford Design Rule OR-010812-
0001.
2.2 REFERENCES
Appendix A: Applicable Design Rules

Appendix B: PPAP Report Template
Appendix C: Reference Images
Appendix D: Example SCCAF
3. REQUIREMENTS
This specification is performance based and does not have approved sources.
All requirements identified for this specification must be met to achieve acceptable field durability. No one
requirement, exclusive of others, is capable of insuring satisfactory performance. Any deviations to the
requirements of this specification may be subject to additional performance requirements.
Testing at Design Verification (DV), Material Color Durability/Compliance Certification (MCDCC), and
Process Validation (PV) must be conducted per Table 7. For MCDCC approval, parts from DV and/or PV
testing may be submitted in lieu of separate test parts, as long as the quantity of parts per Table 7 is met.
Routine testing for process control shall be conducted per Table 7, or as directed on the Special
Characteristics Communication and Agreement Form (SCCAF). An example SCCAF can be found in
Appendix D. The required number and frequency of samples may be changed due to part geometry or
production concerns and at the discretion of Ford Design and Release Engineering (D&R) and Supplier
Technical Assistance (STA).
3.1 APPEARANCE
The plated parts shall be free from surface imperfections and must conform to the color
requirements defined by Ford Design Quality, the Ford Color Harmony Team Styling Master and the
Approved Boundary Sample.
Date Action Revisions Rev. 00
2016 12 20 Released M. Katz, NA

Controlled document at www.MATS.com
Copyright Ford Motor Company
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WSS-M1P83-E2
3.2 MOLDED SUBSTRATES
Material substrates used for exterior plated applications and tested to this specification must be
approved to the Approved Source List (ASL) for one of the following Ford Material Specifications:
WSS-M4D836-B1/latest for ABS

WSS-M4D813-B1/latest for PC/ABS
The decision to use either ABS or PC/ABS shall be directed by the part specific Global Material
Strategy located at https://www.edms.ford.com/webtop/drl/objectId/0b00cad9803f607d and all
applicable Ford Design Rules, including those listed in Appendix A.
Part geometry must be conducive to plating, in accordance with all applicable Ford Design Rules,
including those listed in Appendix A.
The use of regrind or recycled material for substrates in plated applications is prohibited.
Material must be processed per Global Manufacturing Standard W-IMMS - Control of Plastic
Injection Molding Processes, located on the Ford Supplier Portal, STA Global Technical Services,
Plastic Molding, https://web.qpr.ford.com/sta/Ford_GTS.html.
The parts shall be smooth and without flow lines, knit lines, visible porosity, cracks, sink marks, or
other molding defects which may detract from the part appearance or performance. Molded
substrates must also be free of any residual stresses which would impact electroplate adhesion,
dimensional stability, or appearance. Mold flow analysis should be conducted to minimize residual
stress in molded substrates.
Parting lines, flash and other characteristics of molding may impact part durability and must be
minimized. Any rework of parting lines prior to plating must be reviewed and approved by STA
before use in the production process. Testing to this standard must be completed on parts with the
rework process and submitted to STA for approval.
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3.3 FINISHED PARTS
Design Verification testing must be completed on geometrically representative parts plated with the
production process. Production Validation testing must be done on actual production parts. Where
part dimensions limit testing, or other exceptions exist, substitution of surrogate parts or plaques
requires approval of D&R, STA, and Ford Materials Engineering and documentation on the SCCAF.
All visible surfaces of the component, including terminating exterior edges visible after assembly
shall conform to the full requirements of this specification, unless otherwise specified in the SCCAF
or on the engineering drawing.
Plated test specimens prepared for investigations according to this specification must be aged a
minimum of 2 hours at 23 +/- 2 °C prior to testing.
3.4 PROCESS OPTIMIZATION
Process development is to be completed prior to any qualification testing to this specification (DV,
PV, etc.). Repetition of these tests may be necessary in order to optimize molding and plating
parameters for successful part performance. Once optimization of all parameters is complete, all
testing, including tests in Section 3.4, must be conducted at the production parameter levels. Only
results of the final tests, with production levels of all parameters, are required to be submitted as
part of the PPAP package.
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WSS-M1P83-E2
3.4.1 Residual Stress Test No cracking
Residual stresses in molded plastic parts are areas of potential weak electroplate adhesion.
Testing for residual stress must be conducted for new parts, when any molding parameter
changes, or when adhesion issues may be due to molding stress. Repetition of this test
may be necessary in order to optimize molding parameters for reduction of molded-in
stresses before all additional testing is completed.
Areas with high contrast between light and dark indicate locations of high molded-in stress
(Appendix C, Figures 1 and 2). High stress areas should be documented as “adhesion
points” or “A-points” in the SCCAF at the direction of the D&R. A minimum of two “A-points”
per part must be indicated. All subsequent adhesion testing per Section 3.5 must be
conducted at these locations.
Completely immerse the unplated part in glacial acetic acid, 99% purity, at 23o C +/- 3 °C
for 30 seconds. Remove and immediately rinse the part with water to remove acid from the
surface and allow to dry at room temperature. Review and photograph the part, noting any
areas of uneven whitening.
Return the part to the glacial acetic acid bath for up to the duration indicated by Table 1
below.
Table 1: Glacial Acetic Acid Test Time

Substrate Time
ABS 120 seconds
PC/ABS 180 seconds
After the specified time has elapsed, immediately rinse the part with water to remove acid
from the part surface and allow to dry at room temperature. Review and photograph the
part again, noting any areas of uneven whitening.
Report must include photos of the part before testing, after 30 seconds, and after 120-180
second durations. These photos must be retained for process control validation of the
optimized molding process.
3.4.2 Scanning Electron Microscopy (SEM) Report Only
In order to document the level of etch obtained on the surface of successfully tested parts,
PV testing submissions must include SEM images at 500X magnification of the etched,
unplated plastic surface. Images should be taken in high and low stress areas (whitened
and dark areas), as determined by the Residual Stress Test in Section 3.4.1.
Examples of under-etched, over-etched and properly etched surfaces can been seen in
Appendix C, Figures 3, 4 and 5, respectively.
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Improper molding of the part may cause elongated etch sites, which reduce adhesion of the
electroplate to the substrate. An example of this condition can be found in Figure 6.

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3.4.3 Simultaneous Thickness and Electrochemical Potential Test (STEP)

(ASTM B764)
The graph of the STEP test, along with the calculated difference of potentials shall be
provided with the submission package. An example STEP curve can be found in Appendix
C, Figure 7.
3.4.3.1 Semi-bright nickel to decorative nickel 100 mV min
3.4.3.2 Discontinuous nickel to decorative nickel 20 – 90 mV
3.4.4 Minimum Discontinuities

(ASTM B604, X4)
Exterior applications require a discontinuous chromium layer (microporous or

microcracked) on a multiple layer nickel system. Microporous systems are the preferred
method for corrosion resistance of plastic parts. Microcracked system usage should be
limited and pre-approved by the D&R and Materials Engineering.
The active sites method shall be the preferred method used to determine microporosity.
Images at proper magnification taken before and after CASS exposure must be recorded.
For Satin finishes, the active sites method and a SEM must be used to determine
microporosity.
Evaluation of microcracks may be done directly by counting the cracks that intersect a
straight line with length of at least 1 mm with a microscope at 100X and calculating to the
appropriate units.
Plating sources are required to maintain minimum discontinuities as defined in Table 2.
Table 2: Minimum Discontinuity Quantities

Type Minimum Discontinuity
Micropores 10,000 pores/cm2
Microcracks 250 cracks/cm
Micrographs used for determination of discontinuities and the calculated values must be
included in submissions. Example images of discontinuities are available in Appendix C,
Figures 8, 9, 10, and 11.
3.4.5 Minimum Plating Thickness

(ASTM B487, ASTM B504, ASTM B568)
Minimum plating thicknesses are defined in Table 3. For typical plating construction, refer to
Appendix C, Figure 12.
Plating thickness should be optimized prior to PV testing to ensure all requirements of the
specification are met. To achieve this, electroplated part suppliers must identify the plating
thickness distribution for each unique part and rack design by mapping the system per Ford
Design Rule CPG10801-0032. An example of a single layer analysis of chromium can be
found in Appendix C, Figure 13. The plating thickness distribution must be examined for
both the production rack and the production part geometry for each plating layer. This
process is used to demonstrate that the minimum metal plating thicknesses can be
obtained for the entire part or to alert Ford to any potential metal thickness concerns. The
use of auxiliary anodes is recommended, where applicable.
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Areas of low and high thickness must be documented in the SCCAF on a part and rack
level as “pick points”, and submitted to the D&R as part of DV. The lowest thickness part
shall also be documented on the SCCAF.
Areas with exceptions to the minimum metal thickness requirements must be approved in
writing by the D&R and shown in detail on the SCCAF. Formal deviation is not required.
Details must include the area or areas below the minimum and the allowed thickness
exception for each. An example of a documented exception can be found in the example
SCCAF, Appendix D, item number 2. Parts with these exceptions must meet all other
applicable specification and SDS/CDS requirements.
Copper and nickel layer thickness to be determined by Microscopic Examination (ASTM

B487). Chromium layer thickness to be determined by Coulometric Method (ASTM B504),
or X-Ray Spectrometry (ASTM B568).
Table 3: Plating Layer Minimum Thickness Requirements

Plating Layer Minimum thickness (μm)
Copper 18
Semi Bright Nickel 15
Decorative Nickel 6
Microporous Chromium 0.18
Microcrack Chromium 0.8
The percent of the total nickel thickness which is composed of semi-bright nickel and
decorative nickel shall be as indicated in Table 4.
Table 4: Percent of Semi-Bright to Decorative Nickel

Nickel Type Percent of Total Nickel
Semi Bright Nickel At least 60%
Decorative Nickel No more than 40%
3.5 PLATING ADHESION
All adhesion testing must be completed on the part at the “A-points” in areas of high stress as
indicated by Section 3.4.1, Residual Stress Test, unless otherwise noted. Where a single part is
produced by multiple cavities, testing at PV must be completed on parts molded from the tool cavity
that produces the highest stress conditions, as determined by Section 3.4.1.
3.5.1 Grind-Saw Test

(ASTM B571, with modifications below)
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Testing will be performed using a handheld hacksaw with 6-8 teeth/cm, cutting from the
substrate toward the plating. The cut will be made with the plane of the saw 90 degrees to
the test area and the blade angled at 45 degrees towards the part (visual representation in
Appendix C, Figure 14). A minimum 5 cm cut shall be made at a rate of approximately 1
stroke per second. If part geometry doesn’t allow the minimum cut length, the part shall be
cut at the maximum length possible. Bandsaws shall not be used for this test.
Testing shall be completed in both “A-points” per Section 3.4.1, and in high thickness “pick
points” per Section 3.4.5.

WSS-M1P83-E2
All tested samples must indicate no evidence of peeling, flaking, or lifting of the electroplate
from the substrate or between the plating layers. The approving Ford engineer should
attempt to peel the plating away from the cut edge with a sharp blade to further evaluate the
propagation of adhesion loss.
3.5.2 Peel Strength of Metal Electroplated Plastics

(ASTM B533, Procedure A, except production plating layers on parts)
ABS 9.0 N/cm curve ave min

7.0 N/cm curve low min
PC/ABS 4.5 N/cm curve ave min

3.5 N/cm curve low min
Testing shall be completed on a flat section of the part. If no large flat area exists, or if part
size prohibits full peel size, a strip of minimum 1 cm X 5 cm can be substituted. The
resulting values must then be calculated to match the units of the requirement. Testing
must be conducted on as large of an area as possible.
For each Peel Strength graph, discard the beginning and breaking point of the curve. The
average of this center section must meet the curve average minimum requirement. No data
point in the center secion of the peel curve shall be below the curve low minimum
requirement. Average and low values must be reported for each curve. Test curves must be
provided with results. An example curve can be found in Appendix C, Figure 15.
Where part geometry or size prohibts suitable Peel Strength testing, results will be
substituted with additional test samples of 3.7 Extreme Thermal Cycle, as directed by Table
7.
3.6 CHIP RESISTANCE
Tested specimens should be taken from low plating thickness areas as identified in Section 3.4.5.
3.6.1 Test for Chip Resistance of Surface Coatings Rating 5B min

(SAE J400, 1.4 L, -20 C +/-2 °C and 23 +/- 2 °C)
3.6.2 High Performance Stone Chip Resistance Rating 6 min

(FLTM BI 157-06)
All tested samples must indicate no evidence of peeling, flaking, chipping, or lifting of the
electroplate from the substrate or between the plating layers.
3.7 EXTREME THERMAL CYCLE
Thermal cycling must be completed on individual, unassembled, chromed parts, such as single
grille bars. Temperatures to be used for Extreme Thermal Cycles are described in Table 5.
Temperature changes must be completed within one minute. Testing will consist of 10 cycles of the
following:
1 hour at Extreme Low Temperature

1 hour at Extreme High Temperature
After completing the indicated cycles, the part shall show no degradation of part appearance. There
shall be no evidence of plating failure, warpage, sink marks, deformation, cracks, blistering, or
delamination.
Copyright © 2016, Ford Global Technologies, LLC

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Table 5: Temperatures for Extreme Thermal Cycles

Substrate Extreme Low Temperature Extreme High Temperature
ABS 82 +/-2 °C
-40 +/-2 °C
PC/ABS 90 +/- 2 °C
3.8 CORROSION–THERMAL CYCLE RESISTANCE

(ASTM B 368)
Testing shall be completed on unassembled, chromed parts, oriented in vehicle position.
Parts shall be subject to four cycles, with each cycle consisting of 6 hours thermal cycle and 16
hours Copper-Accelerated Acetic Acid-Salt Spray (CASS), as indicated below.
One Cycle:
2 hours at Low Temperature
1 hour at Mid Temperature
2 hours at High Temperature
1 hour at Mid Temperature
16 hours CASS
Low, Mid and High Temperatures are indicated in Table 6.
Table 6: Temperatures for Corrosion – Thermal Cycle Test

Substrate Low Temperature Mid Temperature High Temperature
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ABS 82 +/-2 °C
-30+/- 2 °C 23 +/- 2 °C, 50 +/- 5% RH
PC/ABS 90 +/- 2 °C
Parts shall be rinsed with demineralized water only after each CASS test cycle. Scrubbing,
abrasive cleaning, or polishing is not permitted.
Tested parts shall show no degradation of part appearance. There shall be no evidence of plating
failure, warpage, sink marks, deformation, cracks, blistering, delamination or corrosion.
4. GENERAL INFORMATION
The information given below is provided for clarification and assistance in meeting the requirements of
these specifications. Contact gmfs@ford.com for questions concerning Engineering Material
Specifications.
4.1 DUCTILITY Report Only

(ASTM B490)
Although this is considered a portion of the process control and not a requirement of part
performance, the ductility percentage of Semi-bright Nickel and Bright Nickel on foils plated in the
individual nickel baths should be rated, reported, and included in the Control Plan.
4.2 MATERIAL COLOR DURABILITY/COMPLIANCE CERTIFICATION (MCDCC)
MCDCC will be required for the Appearance Approval Report (AAR) to be approved by Design
Quality. The MCDCC form for chrome parts is used to verify a plater has the capability to match the
specified color master and meet the requirements of the specification.
Parts must be reviewed with Ford Design Color and Materials group for color match sign off on the
MCDCC.

WSS-M1P83-E2
All test data, including physical samples, must be reviewed by Ford Materials Engineering for
Supplier Test Data and Certification of the MCDCC.
4.3 SPECIAL CHARACTERISTICS COMMUNICATION AND AGREEMENT FORM (SCCAF)
All chrome plated parts must conform to the part specific SCCAF, which is controlled by Supplier
Technical Assistance and Product Development. An example SCCAF for chrome plated exterior
parts can be found in Appendix D.
4.4 ELECTROPLATER APPROVAL PROCESS
Suppliers of chrome plated parts must be approved by Supplier Technical Assistance (STA).
Approval of new suppliers requires completion of a self-assessment and STA site audit, using the
STA Manufacturing Process Checklist, available through STA.
4.5 SUPPLIER'S ONGOING RESPONSIBILITY
All materials must be equivalent in all characteristics to the material upon which approval was
originally granted.
Prior to making any changes to the material originally approved, whether or not such changes affect
the material's ability to meet the specification requirements, the supplier shall notify the affected
Supplier Technical Assistance (STA), Purchasing, and Materials Engineering activities of the
proposed changes (with reasons) by submission of a completed Suppliers Request for Engineering
Approval, SREA.
For parts and components using Ford Engineering Material Specifications, all samples tested to the
specifications for Design Verification (DV), Production Verification (PV) and Production Part
Approval Process (PPAP) sign off must be kept until Job 1.
4.6 RESTRICTED SUBSTANCE MANAGEMENT STANDARD
Substance restrictions imposed by regulations or Company direction applies to the materials

addressed by this document. The restrictions are identified in the Restricted Substance
Management Standard WSS-M99P9999-A1 which is updated yearly. It is the supplier’s
responsibility to comply with this standard on a continuing basis through IMDS and or GMAP
reporting.
5. SUMMARY OF REVISIONS
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WSS-M1P83-E2
Table 7: DV, MCDCC, PV and Routine Process Testing Requirements

Routine
Process Test
DV Testing MCDCC PV Testing No. of Parts per Routine Process
1 2
Para. Test Test Location/s Results to Be Submitted No. of Parts No. of Parts No. of Parts Color Testing Frequency
Molding Process
Tested Parts and/or
3.4.1 Residual Stress Whole Part One N/A Every Cavity One Change and Monthly
Photographs
for Each Part
3.4.2 S.E.M. A-points SEM Images N/A N/A One N/A N/A
High and Low Potentials (mV)
3.4.3 S.T.E.P. One Three Three One Any Ford Part per Day
Thickness Areas Attach Graphs
2
Micropores/cm or
High and Low Any Ford Part per
3.4.4 Discontinuities Microcracks/cm One Three Three One
Thickness Areas Week
Micrographs
Layer thicknesses (μm)
High and Low One High,
Percent Semi-Bright
3.4.5 Plating Thickness Thickness Areas Low and Three Six One Weekly for Each Part
Micrographs
across the Rack CAE Report
CAE Mapping Report
A-points on High
3
Stress Cavity Part Molding or Plating
3.5.1 Grind Saw Tested Parts One Three Six One
and High Process Change
Thickness Areas
Not for Resale, 11/21/2017 05:37:01 MST
Tested Parts
A-points on High 2 4
3.5.2 Peel Test 3 Peel Strength (n/cm ) N/A N/A Six One Weekly for Each Part
Stress Cavity Part
Attach Graphs
Stone Chip
Low Thickness Three Three
3.6.1 At 23 °C Tested Parts N/A One Weekly for Each Part
Areas Per Temp Per Temp
At -20 °C
High Performance Low Thickness
3.6.2 Tested Parts N/A Three Three One Weekly for Each Part
Stone Chip Areas
Extreme Thermal 4
3.7 Whole Part Tested Parts One N/A Six One Monthly for Each Part
Cycle
Corrosion -Thermal Lowest Thickness
3.8 Tested Parts N/A Three Three One Weekly for Each Part
Cycle Whole Part
Plate Thickness (μm)
4.1 Ductility N/A N/A N/A One Sample One Once per Week
Ductility Percents
1
A-points, High Thickness Areas, Low Thickness Areas, and Low Current Density Parts are identified and defined using Sections 3.4.1 and 3.4.5. See
D&R for specific number and location of test sites per part.
2
The minimum number of samples is indicated. Required number of samples may be changed at the discretion of D&R/STA in the SCCAF.
3
Parts must be from the tool cavity which produces the most residual stress per Section 3.4.1 testing.
4
Where part size/geometry prevents Peel Strength testing, Extreme Thermal Cycle must be conducted at increased frequency of Weekly per Part.
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WSS-M1P83-E2
Appendix A: Design Rules
OR010812-0001
CP010801-0001
CP010801-0002
CP010801-0003
CP010801-0004
CP010801-0005
CP010801-0006
CPG10801-0028
CPG10801-0031
CPG10801-0032
OR010801-0033
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Appendix B: PPAP Report Template
Part Number: Program:

Supplier Substrate Plating
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Molder: Material Specification: Styling Master:

Plater: Material Supplier: Discontinuities: Microcrack Microporous
Test Facility: Product Name: Trivalent: Yes No
Chloride or Sulfate
Passivation: Yes No
Passivation Type:
Whole Adhesion Points High and Low Thickness Areas

Test Method Condition Part A-point 1 A-point 2 A-point 3 High 1 High 2 High 3 Low 1 Low 2 Low 3
Residual
3.4.1 Per spec.
Stress
3.4.2 SEM Per spec.
Semi-Bright to
Decorative Nickel
3.4.3 S.T.E.P. ASTM B 764

Discontinuous to
Decorative Nickel
3.4.4 Discontinuities ASTM B 604
Copper
ASTM B 487, Semi-Bright Nickel

Plating
3.4.5 ASTM B 504, Decorative Nickel
Thickness
ASTM B 568 Discontinuous Nickel
Chromium
3.5.1 Grind Saw ASTM B571
ASTM B 533,
3.5.2 Peel Test
modified
At 23 C
3.6 Stone Chip SAE J 400
At -20 C
3.7 Grit Blast FLTM BI 157-06
3.8 Thermal Cycle Per spec. Ten cycles
CASS Thermal
3.9 ASTM B 604 Four cycles
Cycle
4.1 Ductility ASTM B 490

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Appendix C: Reference Images
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Figure 1: High contrast indicates high levels of stress on the part surface.
Figure 2: Lower contrast shows a reduction in stress on the part surface.

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Figure 3: Ideal etching of ABS part. Scale bar represents 20 microns.
Figure 4: Under-etching of ABS part. Scale bar represents 10 microns.

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Figure 5: Over-etching of ABS part. Scale bar represents 10 microns.
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Figure 6: Unacceptable elongation of etch sites in ABS part are shown.

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Figure 7: Sample of STEP Graph.
Figure 8: 1000 pores/cm2, 100X magnification
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Figure 11: An example microcrack chrome sample, showing 250 cracks/cm, where the red line is 1 mm
long.
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Figure 12: Sample of decorative chrome plating construction.

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Figure 13: An example CAE analysis of chromium thickness. The high thickness areas would be
the darkest red area within the black circle on the highest part above. The low
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thickness areas would be the light blue area on the lowest part, as circled in red above.
The lowest part in the image would be the “Low Thickness Part”.

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Figure 14: Angles and directions for Grind-Saw adhesion testing.
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Figure 15: Example curve for Peel Strength Test. Only the center area (between the red lines) would be
considered for the requirements. The blue line indicates the lowest value on the curve.


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Appendix D: Example SCCAF

Special Characteristics Communication and Agreement
1. DFMEA and 1A. PFMEA &
Type ONLY in
potential special Type ONLY in Yellow Boxes Special Green Boxes Special Characteristics for:
characteristics Characteristics
Lead / Support roles and

Ford PD engineer / Mfg Manufacturing/ Ford PD
timing for each stage
Special Characteristics Approvals required at UPV2 / UNV2 as per FAP 03-111
Ford D & R Engineer Signature Date
Program: Part Number:
Approval/Date:
Supplier Engineering Release Ford STA Engineer Signature Date
Name/Plant: Number: Approval/Date:
Ford Craftsmanship/Sys Engr'g Signature Date
Supplier SIM Code: Design Lead Brand: Ford
Approval/Date:
Supplier Plant Quality Manager Signature Date
Part / System Name: Ford Customer Plant:
Approval/Date:
Note: approvals may be electronic: complete the approval block above to identify the
approvers, and include "/s/" ahead of the name typed into the "signature" box to indicate
electronic approval and approve in e-mail with this file as an attachment.
Key: From DFMEA: From PFMEA:

Sev 5-8 AND Occ 4-10. Significant
YC Sev 9,10. Potential CC. CC Sev 9,10 (Part). Critical Characteristic. SC Characteristic.
-- SC
Sev 5-8 and may require
special control to maintain Sev 5-8 AND Occ 4-10. High Impact
YS process capability. Potential OS Sev 9,10 (Process). Operator Safety. HI Characteristic.
SC.
HI
Not Applicable Not applicable
Special Characteristic Totals: YC YS CC OS SC HI

Note 1: Automatic calculation of totals (for guidance only).
Note 2: Count of SCs may be less than count of YSs 0 0 0 0 0 12
Special Characteristics Communication and Agreement for all UN content is required by UNV2. Special Characteristics Communication and Agreement for all UP content is required by UPV2.
Stage 1. DFMEA Stage 1A. PFMEA
DFMEA PFMEA
No.
Characteristic Description Specification & Tolerance (dimensions in mm) Process Control Method
Class Class
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Glacial Acetic Acid [DV/PV - per set up/process change/monthly]. A-points for testing
1 [Chrome] Residual Stress Initial: A-points for testing locations selected from GAA part HI
locations will be selected from GAA part reviewed by PD Engr.
signed by D&R. Images with marked A-points attached.
2 [Chrome] Peel Test WSS-M1P83-E2 HI [DV/PV - 1/week]
3 [Chrome] Thermal Cycle WSS-M1P83-E2 HI [DV/PV - 1/month ] If peel testing is acceptable size, if not, do 1x/week
4 [Chrome] Stone Chip/Gravelometer WSS-M1P83-E2 (-20C and 23C) HI [DV/PV - 1/week]

[DV/PV - 1/week] Select Min of two points in High/Low Density area as identified from
5 [Chrome] Destructive Plating Thickness WSS-M1P83-E2 HI
CAE analysis.
6 [Chrome] Microporosity WSS-M1P83-E2 - ASTM B604 HI [DV/PV - 1/week] Not part specific. For Satin parts use SEM
7 [Chrome] S.T.E.P. WSS-M1P83-E2 - ASTM B764 HI [DV/PV - 1/week] Not part specific. Should be checked 1x/day per nickle tank
8 [Chrome] CASS Thermal Cycle WSS-M1P83-E2 HI [DV/PV - 1/week]

[DV/PV - daily] Low/High Current Density Location. If failures occur, must do destructive
9 [Chrome] Plating Thickness (Non-Destructive) WSS-M1P83-E2 - ASTM B 568 HI
testing
10 [Chrome] Ductility WSS-M1P83-E2 HI [DV/PV - 1/week] Not part specifc. Should be cheked 1x/day per nickle tank
PV/PSW & Per Process Change. Use pick points from GAA test on high/low stress area.
11 [Chrome] SEM Analysis WSS-M1P83-E2 HI
Must provide pictures for sign-off.
WSS-M1P83-E2/Design Rule CPG10801-0032
Initial: CAE Report, indicating high and low thickness areas
(pick points) and low thickness part, attached. Any areas
12 [Chrome] Software Simulation/CAE Analysis HI Design Fease/PPAP
with exceptions to thickness minimums are signed off on the
CAE report by D&R. Example Exception: Decorative Ni -
12 microns, Cr - 0.16 microns.

Decorative Chrome Electroplated Part Performance WSS-M1P83-E2 Requirements, Abs or Pc/Abs Substrates, General Exterior Use 1. Scope

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Decorative Chrome Electroplated Part Performance WSS-M1P83-E2 Requirements, Abs or Pc/Abs Substrates, General Exterior Use 1. Scope

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ENGINEERING MATERIAL SPECIFICATION

DECORATIVE CHROME ELECTROPLATED PART PERFORMANCE WSS-M1P83-E2

Appendix A: Applicable Design Rules

Date Action Revisions Rev. 00

2016 12 20 Released M. Katz, NA

3.2 MOLDED SUBSTRATES

WSS-M4D836-B1/latest for ABS

3.4 PROCESS OPTIMIZATION

Copyright © 2016, Ford Global Technologies, LLC Page 2 of 21

3.4.1 Residual Stress Test No cracking

Table 1: Glacial Acetic Acid Test Time

3.4.2 Scanning Electron Microscopy (SEM) Report Only

Copyright © 2016, Ford Global Technologies, LLC Page 3 of 21

3.4.3 Simultaneous Thickness and Electrochemical Potential Test (STEP)

3.4.3.1 Semi-bright nickel to decorative nickel 100 mV min

3.4.3.2 Discontinuous nickel to decorative nickel 20 – 90 mV

3.4.4 Minimum Discontinuities

Exterior applications require a discontinuous chromium layer (microporous or

Plating sources are required to maintain minimum discontinuities as defined in Table 2.

Table 2: Minimum Discontinuity Quantities

3.4.5 Minimum Plating Thickness

Copper and nickel layer thickness to be determined by Microscopic Examination (ASTM

Table 3: Plating Layer Minimum Thickness Requirements

Table 4: Percent of Semi-Bright to Decorative Nickel

3.5 PLATING ADHESION

3.5.1 Grind-Saw Test

Copyright © 2016, Ford Global Technologies, LLC Page 5 of 21

3.5.2 Peel Strength of Metal Electroplated Plastics

ABS 9.0 N/cm curve ave min

PC/ABS 4.5 N/cm curve ave min

3.6 CHIP RESISTANCE

3.6.1 Test for Chip Resistance of Surface Coatings Rating 5B min

3.6.2 High Performance Stone Chip Resistance Rating 6 min

3.7 EXTREME THERMAL CYCLE

1 hour at Extreme Low Temperature

Copyright © 2016, Ford Global Technologies, LLC

Table 5: Temperatures for Extreme Thermal Cycles

3.8 CORROSION–THERMAL CYCLE RESISTANCE

Testing shall be completed on unassembled, chromed parts, oriented in vehicle position.

Low, Mid and High Temperatures are indicated in Table 6.

Table 6: Temperatures for Corrosion – Thermal Cycle Test

4.1 DUCTILITY Report Only

4.2 MATERIAL COLOR DURABILITY/COMPLIANCE CERTIFICATION (MCDCC)

Copyright © 2016, Ford Global Technologies, LLC Page 7 of 21

4.3 SPECIAL CHARACTERISTICS COMMUNICATION AND AGREEMENT FORM (SCCAF)

4.4 ELECTROPLATER APPROVAL PROCESS

4.5 SUPPLIER'S ONGOING RESPONSIBILITY

4.6 RESTRICTED SUBSTANCE MANAGEMENT STANDARD

Substance restrictions imposed by regulations or Company direction applies to the materials

Copyright © 2016, Ford Global Technologies, LLC Page 8 of 21

ENGINEERING MATERIAL SPECIFICATION

Table 7: DV, MCDCC, PV and Routine Process Testing Requirements

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Appendix A: Design Rules

Copyright Ford Motor Company

ENGINEERING MATERIAL SPECIFICATION

Appendix B: PPAP Report Template

Part Number: Program:

Molder: Material Specification: Styling Master:

Whole Adhesion Points High and Low Thickness Areas

3.4.3 S.T.E.P. ASTM B 764

ASTM B 487, Semi-Bright Nickel

Copyright © 2016, Ford Global Technologies, LLC Page 11 of 20