Applying alloy plating processes

URN: SEMMPF241
Business Sectors (Suites): Materials Processing and Finishing Suite 2
Developed by: Enginuity
Approved on: 2020

Overview

This standard identifies the competences you need to carry out material finishing operations by alloy plating processes, in accordance with approved procedures. You will be expected to confirm with the authorised person, such as your immediate supervisor, that the equipment is ready for the plating operations to be performed, and that all the required components/materials and consumables are available. You will be required to operate the alloy plating equipment, in line with safe working practices and approved procedures, continuously monitoring the plating operations and, where necessary, making minor adjustments or seeking help from the authorised person to make the required adjustments, in order to ensure that the work output is to the required quality. Meeting production targets will be an important issue, and your production records must show consistent and satisfactory performance. Your responsibilities will require you to comply with organisational policy and procedures for the alloy plating activities undertaken, and to report any problems with these activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with a minimum of supervision, taking personal responsibility for your actions and for the quality of the work that you carry out. Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will enable you to adopt an informed approach to applying alloy plating procedures. You will have an understanding of the alloy plating process and its application, and will know about the equipment, materials and consumables in adequate depth to provide a sound background for carrying out the activities, recognising and reporting plating defects and ensuring that completed components are to the required specification. You will understand the safety precautions required when working with alloy plating equipment and solutions. You will be required to demonstrate safe working practices throughout. You will also understand your responsibilities for safety, the environment, and the importance of taking the necessary safeguards to protect yourself and others in the workplace.

Performance criteria

You must be able to:

1. work safely at all times, complying with health and safety legislation,  regulations, directives and other relevant guidelines 2. follow work instructions and specifications for alloy plating processes 3. ensure the material surfaces to be treated are prepared for the finishing operations 4. check that the finishing equipment and treatment solutions are set up and maintained at satisfactory operating conditions and levels 5. carry out the treatment process following operating procedures and to meet the component specification requirements 6. ensure that the treated workpiece achieves the required characteristics and meets the finishing specification 7. deal promptly and effectively with problems within your control and report those that cannot be solved 8. ensure that work records are completed, stored securely and available to others, as per organisational requirements 9. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements

Knowledge and Understanding

You need to know and understand:

1. The specific safety precautions to be taken whilst carrying out the  activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials) 2. the health and safety requirements of the work area  and the activities, and the responsibility these requirements place on you 3. the hazards associated with  the activities, and how to minimise them and reduce risks 4. the personal protective equipment and clothing (PPE) to be worn during the activities 5. the importance of keeping the work area clean and tidy (the use of tools to enable this such as 5S techniques) 6. how to obtain and interpret the production documentation and drawings required during the plating activity 7. the basic principles of the operation of alloy plating equipment 8. how to make up the processing solutions, safely and correctly 9. the visual checks to be made on components prior to plating 10. the pre-treatments to be carried out on components prior to plating 11. the methods used to hold/secure components during the plating process 12. the importance of monitoring the equipment settings and process solutions during the alloy plating process 13. how to make additions to the process solutions, safely and correctly 14. The types of adjustment that can be made to equipment settings to maintain component quality 15. how to identify alloy plating process faults (including blistering, missed plating, burning, poor substrate colour, adhesion and brightness, roughness) 16. the basic quality checks to be carried out on alloy plated components 17. the procedure for the safe disposal of waste materials 18. how to pack and store finished components  to avoid damage 19. the importance of completing the production documentation throughout the alloy plating process 20. the different measuring plating techniques such as micrometers, XRF, salt spray, adhesion, visual, hydrogen embrittlement. 21. the methods used for masking unplated areas 22. the different solution analysis techniques (including atomic absorption, wet, hull cell) 23. the importance of understanding national standards for plating processes 24. the effect of contaminants (such as carbonates, organics breakdown) 25. the different types of electrolyte used (acid or alkali) 26. the different types of post treatments (including chromate, trivalent, heat treatments) 27. the extent of your own responsibility, and whom you should report to if you have problems that you cannot resolve 28. how to access, use and maintain information to comply with organisational requirements and legislation

Scope/range


Scope Performance

1. Apply alloy plating, carrying out all of the following activities: 1. use the correct issue of process documentation (specifications, job cards, quality control documentation) 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. confirm with the authorised person that the plant is ready for carrying out the alloy plating operations 4. maintain sufficient quantities of process materials and components during the production cycle 5. seek any necessary instructions/training on the operation of the alloy plating equipment 6. follow the defined operating procedures ensure that the equipment settings and process solutions are adjusted (either by yourself or the authorised person) to maintain the correct customer specification 7. leave the work area in a safe and clean condition 2. Carry out alloy plating processes on one of the following substrates: 1. ferrous                            2. non-ferrous 3. Apply alloy plating to components, using one of the following processes: 1. brass plating                          2. zinc-nickel plating                        3. other alloy coating system 4. nickel-iron plating                   5. zinc-iron plating 6. tin-lead plating                       7. zinc-cobalt plating 8. other plating process 4. Carry out four of the following activities during the alloy plating process: 1. segregate any defective components or batches (pre and post plating) 2. prepare the solutions from basic additives 3. carry out pre-treatments (such as cleaning, de-greasing, pickling, rinsing, undercoats such as electroless nickel, strikes) 4. load components safely into plant 5. wiring/racking 6. monitor the process settings and solutions (such as time, levels,   temperature, pH, current densities) 7. safely make adjustments to solutions or process settings 8. check and maintain heat exchangers 9. check on agitation methods (such as cathode rod or airless agitation systems) 10. change/maintain filters 5. Identify all of the following types of defects in alloy plated components: 1. blistering                       2. burning            3. poor plating adhesion          4. missed plating 6. Carry out four of the following checks on alloy plated components: 1. freedom from damage                                               2. freedom from contamination 3. surface quality/appearance                                        4. completeness of alloy plating operations 5. colour of deposit                                                         6. brightness of deposit 7. thickness of deposit                                                   8. percentage of alloying materials in deposit 9. other specific check 7. Carry out three of the following completion activities: 1. check that components are dry before packing 2. place components in the specified container/area 3. store components in the correct quantities/weight 4. use the correct packaging so as to avoid damage 5. complete the production documentation 6. place all labels/production documentation in the specified location 7. clean the tools and equipment 8. Check  coatings applied to components by alloy plating, to comply with one of the following quality standards: 1. military or aviation 2. current industry standards or codes of practice 3. international standards 4. customer standards and requirements 5. company standards and requirements

Scope Knowledge


Values


Behaviours


Skills


Glossary


Links To Other NOS


External Links


Version Number

2

Indicative Review Date

2023

Validity

Current

Status

Original

Originating Organisation

Semta

Original URN

MPF2.41

Relevant Occupations

Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives

SOC Code

8115

Keywords

Engineering; manufacturing; processing; applying; alloy plating; brass; nickel-iron; tin-lead; zinc-nickel