温州市佳能真空电镀设备科技有限公司

<p style="margin: 0cm 0cm 0pt; line-height: 20pt; mso-line-height-rule: exactly;"><span style="font-size: small;"><span style="font-family: 宋体;"><span style="color: #333333;" lang="EN-US">1.1</span><span style="color: #333333;">　关于故障中的假象问题<span lang="EN-US"></span></span></span></span></p> <p style="margin: 0cm 0cm 0pt; text-indent: 24pt; line-height: 20pt; mso-char-indent-count: 2.0; mso-line-height-rule: exactly;"><span style="color: #333333;"><span style="font-size: small; font-family: 宋体;">从下述三个实例<span lang="EN-US">,</span>可了解电镀故障中的假象。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small; font-family: 宋体;">实例<span lang="EN-US">1</span>　自行车瓦盖又称挡泥板<span lang="EN-US">,</span>电镀铜、镍、铬。工艺流程<span lang="EN-US">:</span>镀前处理预镀镍光亮硫酸盐镀铜全光亮镀镍。在电镀过程中发现镀件从光亮镀铜槽出来后<span lang="EN-US">,</span>铜镀层呈镜面光亮。经过镀光亮镍后<span lang="EN-US">,</span>发现光亮镍镀层表面出现白块、白条等疵病。当时给操作者的感觉是故障出在光亮镀镍工序。经查找<span lang="EN-US">,</span>光亮镀镍工序没发现问题<span lang="EN-US">,</span>故障仍未解决。起初为了维持生产<span lang="EN-US">,</span>镀完亮镍后只得进行抛光<span lang="EN-US">,</span>但过了几天后抛光也不行了<span lang="EN-US">,</span>不得不查找电镀亮铜工序。发现镀铜液中十二烷基硫酸钠含量偏低而引起的故障。这样本来有问题的电镀亮铜工序<span lang="EN-US">,</span>由于镀件外观光亮而看不出疵病<span lang="EN-US">,</span>经过镀亮镍后才发现故障。这样给我们造成镀亮镍出现故障的假象。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small;"><span style="font-family: 宋体;">实例<span lang="EN-US">2</span>　枪黑镀镍层不太黑<span lang="EN-US">,</span>有时还出现白色条纹<span lang="EN-US">,</span>加入增黑盐、增黑剂后<span lang="EN-US">,</span>色泽立即变黑<span lang="EN-US">,</span>条纹也不存在了。但电镀<span lang="EN-US">1h</span>左右<span lang="EN-US">,</span>又出现了上述故障<span lang="EN-US">,</span>加入上述两种增黑物质后故障才清理。这样反复进行<span lang="EN-US">5</span>～<span lang="EN-US">6</span>次<span lang="EN-US">,</span>而以往增黑盐<span lang="EN-US">3</span>～<span lang="EN-US">4</span>天仅补充一次<span lang="EN-US">,</span>增黑剂每天只补充一次。上述增黑物质的补充<span lang="EN-US">,</span>显然属反常现象。经过检查和试验<span lang="EN-US">,</span>确认镀液中的铜、锌等杂质积累过多而引起的故障。增黑剂中含有金属的配位剂<span lang="EN-US">,</span>由于配位剂的作用<span lang="EN-US">,</span>短时间内杂质也被配位<span lang="EN-US">,</span>随着电镀过程的进行<span lang="EN-US">,</span>配位剂有所消耗<span lang="EN-US">,</span>杂质的干扰作用就反复出现<span lang="EN-US">,</span>并且影响黑度。在同一镀槽内<span lang="EN-US">,</span>当黑度开始下降、有条纹时<span lang="EN-US">,</span>加入增黑物质<span lang="EN-US">,</span>故障现象有所减轻或清理<span lang="EN-US">,</span>使操作者误认为是缺少增黑剂所引起的故障的假象。而这一故障现象的真相却是金属杂质所引起的。<span lang="EN-US"></span></span></span></span></p> <p style="margin: 0cm 0cm 0pt; line-height: 20pt; mso-line-height-rule: exactly;"><span style="color: #333333;" lang="EN-US"><span style="font-size: small; font-family: 宋体;">    </span></span><span style="color: #333333;"><span style="font-size: small; font-family: 宋体;">实例<span lang="EN-US">3</span>　镀镍或镀低锡青铜的镀件<span lang="EN-US">,</span>经过电化学除油、清洗后<span lang="EN-US">,</span>再经过<span lang="EN-US">5%</span>～<span lang="EN-US">10%</span>硫酸溶液的弱腐蚀及清洗后进行镀铬<span lang="EN-US">,</span>发现镀铬层有白花。如不经电化学除油<span lang="EN-US">,</span>上述故障立即出现<span lang="EN-US">,</span>并且电化学除油时间越长<span lang="EN-US">,</span>上述现象越严重<span lang="EN-US">,</span>给我们造成电化学除油工序存在问题的假象。对除油液采取稀释、调整等措施<span lang="EN-US">,</span>故障还不能清理。经查找<span lang="EN-US">,</span>发现故障原因是弱腐蚀用的工业级硫酸。由于该硫酸质量低劣<span lang="EN-US">,</span>浓度太低<span lang="EN-US">,</span>对除油清洗后的残留碱液没有完全中和能力<span lang="EN-US">,</span>因此<span lang="EN-US">,</span>出现上述故障。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">1.2</span></span><span style="font-size: small;"><span style="font-family: 宋体;">　故障现象中的假象原因<span lang="EN-US"></span></span></span></span></p> <p style="margin: 0cm 0cm 0pt; line-height: 20pt; mso-line-height-rule: exactly;"><span style="color: #333333;" lang="EN-US"><span style="font-size: small; font-family: 宋体;">    </span></span><span style="color: #333333;"><span style="font-size: small; font-family: 宋体;">故障现象是故障原因的外部表现。在大多数情况下<span lang="EN-US">,</span>故障的假象出现在一个工序中<span lang="EN-US">,</span>而它的原因却存在于另一个工序中。也有两者都出现和存在于同一工序中<span lang="EN-US">(</span>同一镀槽的溶液中<span lang="EN-US">)</span>。因此<span lang="EN-US">,</span>很容易给操作者造成错觉<span lang="EN-US">,</span>形成假象。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small; font-family: 宋体;">实例<span lang="EN-US">1</span>故障现象为亮铜件镀亮镍后表面出现白条、白块。故障原因是亮铜镀液中的十二烷基硫酸钠缺少。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small; font-family: 宋体;">实例<span lang="EN-US">2</span>故障现象为枪黑镀件表面不黑<span lang="EN-US">,</span>有条纹。故障原因是金属杂质所引起的。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small; font-family: 宋体;">实例<span lang="EN-US">3</span>故障现象为镀铬层表面呈白花状。故障原因之一是弱腐蚀的硫酸浓度太低<span lang="EN-US">,</span>工业级硫酸的质量差。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">2</span></span><span style="font-size: small; font-family: 宋体;">　怎样识别电镀故障中的假象</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small; font-family: 宋体;">关于识别假象的方法<span lang="EN-US">,</span>介绍如下。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">2.1</span></span><span style="font-size: small;"><span style="font-family: 宋体;">检查和观察与镀件有关的因素<span lang="EN-US"></span></span></span></span></p> <p style="margin: 0cm 0cm 0pt; text-indent: 24pt; line-height: 20pt; mso-char-indent-count: 2.0; mso-line-height-rule: exactly;"><span style="color: #333333;"><span style="font-size: small; font-family: 宋体;">当故障出现时<span lang="EN-US">,</span>要检查和观察与故障现象有关的因素。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    (1)</span></span><span style="font-size: small; font-family: 宋体;">检查和观察镀件所经过的有关工序</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small; font-family: 宋体;">实例<span lang="EN-US">1</span>中<span lang="EN-US">,</span>初始时认为问题出在镀亮镍工序<span lang="EN-US">,</span>但亮镍故障没有找到<span lang="EN-US">,</span>重新检查镀件在亮铜镀液中的情况。经查找<span lang="EN-US">,</span>发现镀件一入亮铜镀槽后<span lang="EN-US">,</span>一开始时镀层发暗、<span lang="EN-US">“</span>蓝膜<span lang="EN-US">”,</span>但镀一会上述现象消失<span lang="EN-US">,</span>形成光亮镀层。亮铜镀液正常时<span lang="EN-US">,</span>虽然镀件一进槽不马上光亮<span lang="EN-US">,</span>但却不出现以上现象。通过研究、观察<span lang="EN-US">,</span>发现亮铜镀液中泡沫少<span lang="EN-US">,</span>补充加入十二烷基硫酸钠后<span lang="EN-US">,</span>故障清理。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    (2)</span></span><span style="font-size: small; font-family: 宋体;">检查和观察镀件在故障前的表面状态</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small; font-family: 宋体;">除了<span lang="EN-US">(1)</span>应该做的有关工作以外<span lang="EN-US">,</span>还应该检查和观察镀件在发生故障现象前的表面状态<span lang="EN-US">,</span>包括镀件表面的平滑度、光亮度、色泽、表面有无氧化物等。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small; font-family: 宋体;">例如<span lang="EN-US">:</span>低锡青铜镀件镀铬后<span lang="EN-US">,</span>铬层发灰、发花<span lang="EN-US">,</span>甚至有的部位镀不上铬。故障出现在镀铬。应首先检查低锡青铜镀件的表面状态<span lang="EN-US">,</span>发现色泽不好<span lang="EN-US">,</span>镀层发白<span lang="EN-US">,</span>锡含量高<span lang="EN-US">,</span>是不能镀铬的。因此<span lang="EN-US">,</span>出现了上述故障现象。镀层发白<span lang="EN-US">,</span>锡含量高是上述故障现象的原因<span lang="EN-US">,</span>虽然原因出在低锡青铜工序<span lang="EN-US">,</span>故障却表现在镀铬。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">2.2</span></span><span style="font-size: small; font-family: 宋体;">识别故障中的假象要进行跳跃试验</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small; font-family: 宋体;">所谓跳跃试验<span lang="EN-US">,</span>就是跳过电镀过程中某一可能产生故障的工序后进行电镀试验的方法。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small; font-family: 宋体;">实例<span lang="EN-US">1</span>中<span lang="EN-US">,</span>决定现象是否假象也可以利用跳跃法进行识别。把工艺流程中的光亮硫酸镀铜的工序跳过<span lang="EN-US">,</span>铁瓦盖不镀亮铜<span lang="EN-US">,</span>直接入光亮镀镍槽进行电镀<span lang="EN-US">,</span>故障得到清理<span lang="EN-US">,</span>说明问题出在镀亮铜工序不在镀亮镍上。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">2.3</span></span><span style="font-size: small;"><span style="font-family: 宋体;">识别故障现象要作对比试验<span lang="EN-US">[1]</span></span></span></span></p> <p style="margin: 0cm 0cm 0pt; line-height: 20pt; mso-line-height-rule: exactly;"><span style="color: #333333;" lang="EN-US"><span style="font-size: small; font-family: 宋体;">    </span></span><span style="color: #333333;"><span style="font-size: small; font-family: 宋体;">识别故障假象要作对比试验。所谓对比试验<span lang="EN-US">,</span>就是用良好的溶液代替可能有故障的溶液进行对比试验的方法。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small; font-family: 宋体;">实例<span lang="EN-US">3</span>中<span lang="EN-US">,</span>开始遇到故障时<span lang="EN-US">,</span>也做了一次跳跃试验<span lang="EN-US">,</span>曾把电化学除油工序跳过<span lang="EN-US">(</span>此故障不能用跳跃法排除<span lang="EN-US">),</span>当时故障清理。使得操作者就更认为是电化学除油工序的问题了<span lang="EN-US">,</span>就想把除油溶液更换。经研究<span lang="EN-US">,</span>为了慎重起见又做了一次对比试验<span lang="EN-US">:</span>用试剂纯的氢氧化钠配置<span lang="EN-US">10L</span>电化学除油液<span lang="EN-US">,</span>原弱腐蚀溶液没动<span lang="EN-US">,</span>按原工艺流程进行了试验<span lang="EN-US">,</span>结果故障现象再现。因此<span lang="EN-US">,</span>怀疑弱腐蚀硫酸溶液有问题。接着又做了一次对比试验<span lang="EN-US">:</span>用试剂纯硫酸配置了<span lang="EN-US">10L</span>弱腐蚀溶液<span lang="EN-US">,</span>结果故障清理。说明故障出在弱腐蚀硫酸这一道工序<span lang="EN-US">,</span>而电化学除油工序有问题是一个假象。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">2.4</span></span><span style="font-size: small; font-family: 宋体;">　要发现镀液的反常现象</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋体;">    </span></span><span style="font-size: small;"><span style="font-family: 宋体;">实例<span lang="EN-US">2</span>中<span lang="EN-US">,</span>在解决故障时<span lang="EN-US">,</span>发现了某种成分增长或降低的反常现象。枪黑镀层不黑了<span lang="EN-US">,</span>有时是要增加增黑物质<span lang="EN-US">,</span>但增加如此频繁<span lang="EN-US">,</span>却有些反常。经检查、试验<span lang="EN-US">,</span>确认是金属杂质干扰<span lang="EN-US">,</span>频繁添加发黑物质是一个假象。<span lang="EN-US"></span></span></span></span></p>