ENGINEERING MATERIAL SPECIFICATION

PLATING - BRIGHT OR LOW GLOSS DECORATIVE WSB-M1P78-B1

OVER FERROUS SURFACES - INTERIOR
PLATING - BRIGHT OR LOW GLOSS DECORATIVE WSB-M1P78-B2
OVER FERROUS SURFACES - GENERAL EXTERIOR
PLATING - BRIGHT OR LOW GLOSS DECORATIVE WSB-M1P78-B3
OVER FERROUS SURFACES - SPECIAL EXTERIOR
PLATING - BRIGHT OR LOW GLOSS DECORATIVE WSB-M1P78-B4
OVER FERROUS SURFACES - SPECIAL EXTERIOR

1. SCOPE

These specifications define performance requirements for finished coatings of electrodeposited copper,
nickel, and chromium for the decoration and protection of ferrous surfaces.

2. APPLICATION

These specifications were released originally where a bright or low gloss decorative and protective
metallic finish is required on ferrous surfaces. Four levels of performance are defined as follows:

WSB-M1P78-B1 Interior part applications.

WSB-M1P78-B2 General exterior part applications.
WSB-M1P78-B3 Special exterior part applications requiring superior appearance and improved
durability.
WSB-M1P78-B4 Special exterior part applications requiring improved durability.

CAUTION: Based upon field survey and accelerated laboratory testing experience, plated parts
with designs that are not in conformance with the Corporate Plated Part Design
Restrictions Booklet (see para 5.1) will not be capable of consistently meeting the
requirements of these specifications on a production basis without the use of
extraordinary processing techniques, e.g., use of auxiliary anodes, reduction in the
parts per rack ratio, etc.

FEASIBILITY

If the requirements of this specification cannot be met due to part design restrictions, the supplier will
inform the responsible product engineering office.

Additionally, a "Bumper Plating Restrictions" Booklet (see para 5.2) was developed to identify those
bumper design parameters that provide a basis for consistently meeting the requirements of these
specifications without the use of extraordinary processing techniques.

3. REQUIREMENTS

All requirements identified for each 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 these specifications may be subject to additional performance requirements.

All part testing requirements apply to those areas of the part identified as a significant surface per para
5.3 unless otherwise specified on the engineering drawing.

Date Action Revisions

2003 07 30 Revised Para 3.0 inserted; Para 3.11 & 4 deleted
1990 05 31 C01031536 Typographical Correction Clause 3.5
1988 04 20 SM/ER 3842 TC Released J. Burke, JAF, MP. NAAO. J. Lines. EAO
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 ENGINEERING MATERIAL SPECIFICATION

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3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS

Material suppliers and part producers must conform to the Company's Standard Requirements
For Production Materials (WSS-M99P1111-A).

3.1 STATISTICAL PROCESS

The following characteristics shall form part of the Control Plan but shall in no way preclude the
control of additional characteristics deemed significant by the supplier and/or Ford SQA.

Significant Characteristics

(See requirement values within the body of these specifications)

. Plating Thickness
. Plating Ductility
. Microporosity
. S.T.E.P. Potential
. Sulphur Content

3.2 APPEARANCE

All parts shall have the finish (bright, low gloss or paint overlay) specified on the engineering
drawing. The plated parts shall be free from surface imperfections. Low gloss or black parts
shall match the approved Styling master sample for appearance.

3.2.1 Buffing of Plating

Because of the potential adverse effect on corrosion resistance, buffing of final

chromium plating on exterior parts is not permitted. Brushing or other approved
mechanical treatment on nickel coatings are permitted provided that minimum plating
thickness requirements are met after treatment.

3.3 PLATING ADHESION

(ASTM B 571)

Adhesion of the electroplate to the base metal and between layers of plating must conform to
the requirements of the following test methods per ASTM B 571 unless otherwise indicated.

3.3.1 Bend Tests (Bend the part or sections of the part)

No peeling, flaking, or lift-off of the electroplate from the substrate or between layers
of the electroplate is permitted following the Bend Tests.

3.3.2 Grind-Saw Test

No lifting or peeling of the electroplate from the substrate or between layers of the
electroplate is permitted following the Grind-Saw Test.

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3.4 DUCTILITY
(ASTM B 490)

Although this is considered a portion of the process control and not a requirement of part
performance, the ductility of the electrodeposit on a finished part is considered acceptable when
foils plated in the individual nickel baths meet or exceed the following values:

Semi-bright Nickel 80%

Bright Nickel 20%

3.5 PLATING THICKNESS

(ASTM B 487, ASTM B 556)

It is the supplier's responsibility to identify the plating thickness distribution for each unique part
design and rack design by mapping the plating racks and plated parts and to employ any
special processing techniques, e.g., the use of auxiliary anodes and/or shields, reducing the
number of parts per rack etc., which may be required to consistently meet the specified
minimum plating thicknesses on all significant surfaces.

The optical measurement of copper and nickel deposits on significant surfaces shall be
considered the standard thickness test method (ASTM B 487).

The chromium plate thickness on significant surfaces shall be checked by the spot test as
described in ASTM B 556 or by the Coulometric method, ASTM B-504. In case of difference,
ASTM B 504 shall be the umpire method.

The plating thickness requirements identified below represent minimum values in micrometers
and apply to all areas of significant surfaces.

WSB-M1P78 B1 B2 B3 B4

Copper or Nickel Strike Optional for B1, B2, B3 and B4

Bright Leveling Acid Copper (g) --- --- 15 (g) 15
Total Acid Copper plus Strike --- --- 20 15
Semi-bright Nickel (a) --- 25 20 25
Bright Nickel (b) plus Special 10 8 10 8
Nickel (c) or Low Gloss
Nickel (d)
Total Nickel (e) 10 33 30 33
Microporous Chromium (f) --- 0.18 0.18 0.18
Regular Chromium 0.25 --- --- ---

(a) The sulphur content in the semi-bright nickel bath shall be less than 0.005% (weight
%). The sulphur content is specified to indicate the type of nickel plating solution that
is to be used and may be measured per the test procedures identified in ASTM B 456.
In-process testing to determine conformance to the sulphur content requirement is
essential to establish and maintain process capability and control.

(b) The sulphur content in the bright nickel bath shall be greater than 0.03% (weight %).
The sulphur content is specified to indicate the type of nickel plating solution that is to
be used and may be measured per the test procedures identified in ASTM B 456. In-
process testing to determine conformance to the sulphur content requirement is
essential to establish and maintain process capability and control.

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 ENGINEERING MATERIAL SPECIFICATION

WSB-M1P78-B1/B2/B3/B4

(c) If a special nickel is employed to produce discontinuities in the chromium deposit, the
thickness of the special nickel shall be added to the measurement of the bright nickel
deposit to meet the combined bright nickel plus special nickel minimum thickness
requirement. If a special nickel layer is not used, the minimum thickness requirement
applies only to the bright nickel deposit.

(d) Low gloss nickel may be produced by one of the following methods:

Co-deposit containing inorganic particles insoluble in the plating bath.

Soluble addition agents co-deposited with the nickel.

Mechanical treatment of a bright nickel deposit, e.g., brushing or bead blasting.

When low gloss nickel is specified, special nickel need not be applied.

(e) The semi-bright nickel thickness shall be greater than or equal to 60 % of the total
nickel thickness. The bright nickel thickness shall be less than or equal to 40% of the
total nickel thickness.

(f) Microporous chromium plating systems acceptable under this specification are
defined as those being capable of producing microporosity in conformance with para
3.6.

(g) The B3 specification requires buffing of the copper deposit prior to nickel plating
unless otherwise specified on the engineering drawing. The indicated thickness
represents the minimum copper thickness after buffing. Copper can be used for the
B1 and B2 specifications, but may not be substituted for nickel.

3.6 MICROPOROSITY, min 10,000 pores/cm2

(FLTM BQ 103-06)

Note: Applies only to WSB-M1P78-B2, B3 and B4.

3.7 ACCELERATED CORROSION RESISTANCE

Parts for accelerated corrosion evaluation may be tested either by para 3.7.1 CASS or para
3.7.2 Corrodekote, with the CASS test being the preferred method.

3.7.1 CASS Test

(ASTM B 368)

WSB-M1P78-B1 4h
WSB-M1P78-B2 22 h
WSB-M1P78-B3/B4 44 h

Note: Parts shall be rinsed with demineralized water only, then examined for
corrosion defects. Scrubbing, abrasive cleaning, or polishing is not
permitted.

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 ENGINEERING MATERIAL SPECIFICATION

WSB-M1P78-B1/B2/B3/B4

3.7.2 Corrodkote Test

(FLTM BQ 004-01)

WSB-M1P78-B1 4h
WSB-M1P78-B2 16 h
WSB-M1P78-B3/B4 32 h

Following CASS or Corrodkote exposure, failure is to be noted as follows:

Any pit or blister larger than 1.5 mm in diameter visible on any significant surface shall
be considered failure of the part when examined after 22 h CASS or 16 h Corrodkote.

For WSB-M1P78-B2 only, base metal corrosion shall not exceed 1 spot/930 cm2 of
significant surface area. Corrosion spots exceeding this level may be cleaned with
MgO, recoated (Corrodkote), then re-exposed for 4 h to determine conformance. Any
re-exposed parts exceeding 1 spot/1900 cm2 shall be considered failure of the part.

For WSB-M1P78-B3/B4, there shall be no base metal corrosion after 44 h CASS or

32 h Corrodkote.

3.8 SIMULTANEOUS THICKNESS AND ELECTROCHEMICAL POTENTIAL TEST

(S.T.E.P.)
(ASTM B 764)

Note: Applies only to WSB-M1P78-B2 and B3.

3.8.1 The semi-bright nickel layer must be more noble (cathodic) than the bright nickel layer
by a minimum of 100 millivolts.

3.8.2 If a microporous top nickel layer is used, it shall be equal to or more noble than the
bright nickel layer potential. However, the potential of the microporous nickel shall not
be more than 20 mv noble (cathodic) to the bright nickel layer.

3.9 CLEANING PRIOR TO ELECTROPLATING

Steel parts containing 0.35% carbon or more at the surface, or heat treated from Rockwell C 30
to 39, shall be cleaned using the principles defined in ASTM B 242, "Preparation of High
Carbon Steel for Electroplating". Steels containing less than 0.35% carbon at the surface, or
lower than Rockwell C 30 in hardness, shall be cleaned using principles defined in ASTM B
183, "Preparation of Low Carbon Steel for Electroplating". Steel parts heat treated to Rockwell
C 39 or higher shall not be electroplated.

3.10 BRITTLENESS OF PLATED PARTS

Parts shall be free from the detrimental effects of hydrogen embrittlement or other factors which
result in part brittleness. The requirements of WSS-M99A3-A apply to parts plated to this
specification.

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 ENGINEERING MATERIAL SPECIFICATION

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5. GENERAL INFORMATION

The information given below is provided for clarification and assistance in meeting the requirements of
the specification.

5.1 PLATED PART DESIGN RESTRICTIONS BOOKLET

Booklet #80-14-154 (Ford Stationery Order Number) entitled, "Influence of Design on the
Electroplating of Exterior Injection Molded Plastic Components and Zinc Die Castings".

Note: Purchased parts suppliers should request a copy of this booklet from their Ford buyer.

5.2 BUMPER PLATING RESTRICTIONS BOOKLET

Prepared by Body and Assembly Operations.

Note: Purchased parts suppliers should request a copy of this Booklet from their Ford buyer.

5.3 SIGNIFICANT SURFACES

Unless otherwise specified on the engineering drawing, significant surfaces are defined as
those surfaces of the finished part that:

. Are directly visible and/or visible by reflection when the finished part is assembled in
car position, and/or

. Can be the source of corrosion products directly visible or visible by reflection.

5.4 SAMPLING AND INSPECTION

As specified in Quality Control Specification Q-101, Appendix D and consistent with the
appropriate Engineering Specification (ES) as released by the responsible design engineering
activity.

5.5 CORROSION PROTECTION

When specified on the engineering drawing all chromium bumpers plated to this specification
must have a rust preventative compound, ESB-M7C68, ESB-M7C53 or equivalent applied to
the backside of the bar after plating. The compound must be properly cured prior to packaging
and shipping.

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