TL528_EN_2006-04-01

TL528_EN_2006-04-01
TL528_EN_2006-04-01

Confidential. All rights reserved. No part of this document may be transmitted or reproduced without prior permission of a Standards Department of the Volkswagen Group.

Parties to a contract can only obtain this standard via the B2B supplier platform “https://www.360docs.net/doc/2b13948093.html,”.

? VOLKSWAGEN AG

T h e E n g l i s h t r a n s l a t i o n i s b e l i e v e d t o b e a c c u r a t e .I n c a s e o f d i s c r e p a n c i e s t h e G e r m a n v e r s i o n s h a l l g o v e r n .

N u m e r i c a l n o t a t i o n a c c o r d i n g t o I S O p r a c t i c e (s e e V W 01000).

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TL 528: 2006-04

3 Requirements

3.1 General requirements

Approval of first supply and changes according to Volkswagen standard VW 011 55.

Avoidance of hazardous substances according to VW 911 01.

10 finished parts (depending on the size) are required for complete testing.

The following information shall additionally be provided for all parts under test (see table in Appendix B):

a) Part number

b) Plastic part manufacturer, location

c) Substrate material (type of plastic, manufacturer, manufacturer's designation)

d) Electroplating plant and system, location

e) Electroplating date

f) Type of plastic activation/metallizing method (e.g. standard colloidal chrome-plating method,

ionogenic method, direct metallizing, bright chrome, microporous, with micro-cracks)

g) Position/arrangement on the rack

h) Color

3.2 Molded part

3.2.1 Substrate material

Plastics designated by the substrate manufacturer as material suitable for electroplating according to Table 1. Plastic types deviating from this require basic tests with additional tests to be determined individually, if necessary.

3.2.2 Molded part

Parts shall be free of flaws such as voids or cracks. They shall be free of internal stresses, which might influence the adhesion and appearance of electroplated coatings. The person responsible for injection molding and the person responsible for electroplating shall ensure that the parts are free of stress.

The sprues shall be placed in such a way that the danger of sink marks under thermal load is minimized and there is no impairment to the visible surface when removing the sprues either before or after electroplating.

Burrs shall be avoided. Sharp edges shall be rounded off in the design with radii.

3.2.3 Surface appearance of uncoated molded part

The surface shall be smooth and free of flow lines, cracks, sink marks, craters or bursting which might impair the appearance of the finished parts. Furthermore, the surface shall be absolutely clean and free of grease and sweat. Do not use mold parting agents. The parts shall not be mechanically polished prior to coating; deburring prior to electroplating shall be avoided. Deviations shall be agreed with the relevant engineering department responsible for the release.

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TL 528: 2006-04

3.3 Finished part

The supplier is responsible for the quality of the finished part. An agreement with respect to the design and manufacture should be made at the earliest possible opportunity between the Design Engineering Department, the supplier, mold-maker, injection molder and those responsible for electroplating. If defects of the type described under No. 3 in Table 2 do arise, the cause shall be sought in all process steps (mold design, injection molding and electroplating) in cooperation with everyone involved in the supply chain.

3.3.1 Surface appearance

The parts shall have a mirror finish without traces of polishing in the visible area. The contact points for electroplating shall be positioned in a way that flaws cannot be recognized in the installed condition. The coating shall be free from pores, coarse cracks, flaws or other damage that impairs the corrosion protection or specified appearance. The compliance of the component with the released original sample chart or the original sample part in terms of gloss and color shall be verifiable using measuring instruments and/or shall be visually verifiable. If necessary, maximum deviation samples must be specified by the Quality Assurance department of the vehicle manufacturing plant.

3.3.2 Composite quality

The individual layers have to be adhesive to the substrate material and to each other and shall be free of bubbles.

Prior to testing, the parts shall be aged at room temperature for 24 hours.

3.3.3 Coating process

Provided the requirements of these supply specifications are met, the manufacturer may choose the coating procedure. Standard-production parts shall correspond to released first-sample parts in the coating procedure and coating thickness.

3.3.4 Mechanical requirements for the coated part

See Table 2.

Table2

No. Property Requirement

TL 528-A TL 528-B TL 528-C

1 Coating

Coating systems acc. to DIN 50960-1,

DIN EN 1403, DIN 12540,

see Section 4.1 PL/Cu20/Ni10b

(or d or s)/Crr

(or b or mp or

mc)

or

PL/Ni40d/Crr

(or b or mp or

mc)

PL/Cu25/Ni16,5b (or d or)/Crmp

(or mc)

For matt surfaces only Crmp

(microporous chrome) is

permissible.

Measuring points of coating thickness, extent of micro-cracks, micropores and potential differences are defined by the engineering department responsible for the release in agreement with the supplier.

1.1 Copper coating thickness acc. to

DIN EN ISO 2177

≥ 20 μm ≥ 25 μm

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TL 528: 2006-04

No. Property Requirement

TL 528-A TL 528-B TL 528-C 1.2 Semi-bright nickel coating thickness acc. to

DIN EN ISO 2177 and Test Specification

PV 1065

– ≥ 7,5 μm

1.3 Bright nickel coating thickness (also matt

nickel coating thickness for matt surfaces)

acc. to DIN EN ISO 2177 and PV 1065

≥ 10 μm ≥ 7,5 μm

1.4 Coating thickness of microporous nickel

acc. to PV 1065

– ≥ 1,5 μm

1.5 Chrome coating thickness acc. to

DIN EN ISO 2177 ≥ 0,3 μm Crmc: ≥ 0,8 μm

Crmp: 0,3 μm to 0,5 μm

1.6 Potential step between porous nickel/bright

nickel (or satin nickel) acc. to PV 1065 – ≥ 20 mV

The microporous nickel must be

nobler than the bright nickel.

1.7 Potential step between bright nickel (or satin

nickel)/semi-bright nickel acc. to PV 1065 – ≥ 100 mV

The semi-bright nickel must be

nobler than the bright nickel

1.8 Crack density acc. to PV 1058

Pore density acc. to PV 1063 – Crmc: 250 to 800 cracks/cm Crmp: ≥ 8 000 pores/cm2

Deviations from coating thickness, extent of micro-cracks and micropores and potential differences are defined by the engineering department responsible for the release in agreement with the supplier.

2 Adhesive strength of total structure

2.1 Crosscut test acc. to DIN EN ISO 2409

(3 mm),

see Section 4.2 With removal of adhesive tape, no stripping of coating (Gt: 0)

2.2 Crosscut test (St. Andrew’s cross),

see Section 4.3 With removal of adhesive tape, no stripping of coating

2.3 Relative peel strength acc. to DIN EN 1464

Test rate: 50 mm/min

Specimen width: where possible 10 mm to

20 mm; the edges must be ground smooth

Mean value of maximum peak forces The test shall be performed in arbitration cases. The locations of the measuring strips shall be defined on measuring the arbitration samples by the engineering department responsible for the release.

ABS/PC: ≥ 3,5 N/cm

ABS: ≥ 7 N/cm

3 Temperature and environmental cycle resistance

3.1 Dimensional stability under heat in ASSY

and as individual part

ABS: 6 h at +100 °C

ABS/PC: 6 h at +110 °C

PA6: 6 h at +110 °C

(or acc. to drawing)

No change in appearance. The adhesion requirements acc. to Table 2, No. 2 shall be fulfilled.

3.2 Temperature resistance after aging in

mechanical circulation oven 500 h at +90 °C (only if

specified in the drawing)

240 h at

+110 °C (or

acc. to

drawing) No change in appearance. The adhesion requirements acc. to Table 2, No. 2 shall be fulfilled.

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TL 528: 2006-04 No. Property Requirement

TL 528-A TL 528-B TL 528-C 3.3 Environmental cycle test

3.3.1 Acc. to PV 1200 (short term) in ASSY and

as individual part

8 cycles acc. to PV 1200

No change in appearance (e.g. cracks, bubbles, pores, folds, sink marks). The adhesion requirements acc. to Table 2, No. 2 shall be fulfilled.

3.3.2 Acc. to PV 2005 (long term) in ASSY and as

individual part

Only for function parts in mechanically

loaded areas (e.g. door operating

mechanism, brake lever release button,

anchor plates for selector, radio buttons

etc.) 50 cycles acc. to PV 2005

No change in appearance (e.g. cracks, bubbles, pores, folds, sink marks). The adhesion requirements acc. to Table 2, No. 2 shall be fulfilled.

4 Corrosion resistance

4.1 CASS test acc. to DIN 50021 24 h CASS,

test in as-

installed

position or in

consultation

with the

responsible

department 48 h CASS, test in as-installed position or in consultation with the responsible department

No change in appearance, no visually discernible corrosion when assessed from a distance of 60 cm under optimal lighting. Prior to the assessment, adhering salt residue must be removed.

4.2 Environmental cycle aging acc. to PV 1200,

then salt spray fog test SS test acc. to

DIN 50021

96 h

environmental

cycle aging,

followed by

240 h SS

96 h environmental cycle aging,

followed by 480 h SS

No change in appearance, no corrosion when assessing visually from a distance of 40 cm. Prior to the assessment, adhering salt residue must be removed.

4 Notes on testing

4.1 Coating system

Definition of abbreviated terms:

b = bright nickel

d = doubl

e or triple nickel

s = matt/satin nickel

mp = chrome surface with micropores mc = chrome surface with micro-cracks

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TL 528: 2006-04

4.2 Crosscut test

The crosscut test is performed using a commercial cutter knife (e.g. Edding Cutter M9 manufactured by BLB Omnilab). The cut must extend into the plastic substrate, use Tesa 4657 (by Tesa AG) as adhesive tape. Ensure the blade is sharp and undamaged.

4.3 Crosscut test (St. Andrew’s cross)

The test is performed in the same way as the crosscut test (see Section 4.2), but a St. Andrew's cross is made instead of the crosscut.

5 Referenced standards1

PV 1058 Chrome-Plated Surfaces; Determination of Microcracked Chrome Deposit

PV 1063 Chrome-Plated Surfaces; Determination of Micropore Density

PV 1065 Chrome-Plated Surfaces; Determination of Potential Differences and Layer Thicknesses of Nickel Coatings

PV 1200 Vehicle Parts; Testing of Resistance to Environmental Cycle Test (+80/-40) °C PV 2005 Vehicle Parts; Testing of Resistance to Environmental Cycle Test

VW 01155 Vehicle Supply Parts; Approval of First Supply and Changes

VW 91101 Environmental Standard for Vehicles; Vehicle Parts, Materials, Operating Fluids; Avoidance of Hazardous Substances

DIN 50021 Spray Tests with Different Sodium Chloride Solutions

DIN 50960-1 Electroplated Coatings – Designation in Technical Documents

DIN EN 1403 Corrosion Protection of Metals – Electrodeposited Coatings – Method of Specifying General Requirements

DIN EN 1464 Adhesives – Determination of Peel Resistance of High-Strength Adhesive Bonds – Floating Roller Method

DIN EN 12540 Corrosion Protection of Metals – Electrodeposited Coatings of Nickel, Nickel Plus Chromium, Copper Plus Nickel and Copper Plus Nickel Plus Chromium DIN EN ISO 2177 Metallic Coatings – Measurement of Coating Thickness – Coulometric Method by Anodic Dissolution

DIN EN ISO 2409 Paints and Varnishes – Cross-Cut Test

1 In this Section terminological inconsistencies may occur as the original titles are used.

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TL 528: 2006-04 Appendix A (informative)

Suggestion for standard-production monitoring methods for electroplated plastic parts: Standard-production monitoring of the required features also serves the purpose of monitoring the electroplating process itself, in addition to ensuring product-specific properties. As prompt monitoring of all individual articles is generally not possible for large quantities of products manufactured daily, identical versions (e.g. nameplates, strips etc.) can be combined to form product groups. Continuous monitoring of these product groups is the responsibility of the supplier. The supplier shall check an adequate number of random samples at regular intervals. The results shall be documented.

In addition to the tests required for first samples, the following product properties are subject to continuous standard-production monitoring:

1. (Minimum) coating thicknesses according to DIN EN ISO 2177

2. Potential differences and nickel coating thicknesses according to PV 1065

3. Number of micropores (or micro-cracks for coating with micro-cracks) according to

PV 1063 (or PV 1058)

4. Corrosion resistance according to DIN 50021-CASS

5. Environmental cycle test according to PV 1200

or as quick test

Coating adhesion (thermal shock test)

Heating of components to +110 °C (for ABS 1 h at +100 °C) until temperature equalization, then quenching in water (+18 ± 3) °C (no adhesion l oss of coatings).

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TL 528: 2006-04

Appendix B (informative)

Supplier details on the specimen part:

Supplier

Part number

Part designation

Plastic part manufacturer

Substrate material (type of plastic, manufacturer, manufacturer's designation)

Number of cavities in mold

Injection temperature

Mold temperature

Electroplating plant and system, location

Electroplating date

Coating structure

Type of plastic activation/metallizing method (e.g. chrome plating method, standard colloidal, ionogenic method, direct metallizing; version with micro-cracks, micropores)

Simple draft showing the setup of parts in the rack (including distance specifications)

For development parts: status of blank (injection date, improvements made)

For development parts: status of chrome-plating process (improvements made)

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