Finishing materials by alloy plating processes
URN: SEMMPF340
Business Sectors (Suites): Materials Processing and Finishing Suite 3
Developed by: Enginuity
Approved on:
2020
Overview
| This standard identifies the competencies you need to carry out rack and barrel alloy plating activities, in accordance with approved procedures. You will be required to access the appropriate specifications, to check that these are the current issue and to extract all necessary information in order to carry out the alloy plating operations. You will be expected to prepare and adjust plating solutions and equipment parameters to give satisfactory deposits at optimal productivity levels. You will be expected to identify any plating defects and to carry out the necessary actions and adjustments to equipment or solutions in order to correct them. You will need to carry out tests on the components to ensure that the deposited layers meet the specification requirements. 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 or with the materials and equipment used, that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying alloy plating procedures. You will understand the alloy plating process and its application, in adequate depth to provide a sound basis for carrying out the activities, correcting faults and ensuring the finished components are to the required specification. Your knowledge will also include effluent treatment for the waste streams from the plating and associated processes. You will understand the safety precautions required when carrying out the alloy plating operations. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace and towards the environment. |
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 relevant job instructions and specifications 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 required operating conditions and levels 5. carry out finishing according to operating procedures and to meet specifications 6. check 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 types of specifications that are used during the alloy plating activity and how to check that they are current 6. how to identify the coating specifications and advise customers about plating thicknesses and post-treatments 7. how to decide whether components are suited to alloy plating or other processing techniques 8. the properties of alloy plated deposits 9. the basic principles of operation of the alloy plating process plant and equipment 10. how to set up and check that the alloy plating plant, equipment and consumables are fit for purpose 11. how to carry out the alloy plating process and the sequence of operations that are required 12. how to decide whether components are suited to rack or barrel plating, jigging or wiring techniques 13. how to make up plating solutions, safely and correctly 14. how to clean components prior to processing and assess cleanliness 15. the importance of agitation and of keeping the absorption of air into alkaline plating solutions to a minimum 16. the limitations of geometry and its effect on throwing power 17. how to identify processing faults and how to correct them 18. the importance of achieving the correct alloy deposits 19. the mechanisms of corrosion protection arising from alloys as a surface layer 20. the properties of different passivation and the effects of sealants and torque control additives 21. how to test coated components for specification compliance 22. how to carry our visual assessment of workpieces for colour and brightness 23. how to control and assess brightener and other additive dosing rates 24. how to neutralise and precipitate out effluent waste streams 25. the effects of contaminants in plating solutions and how to remove these 26. how to clean and maintain processing equipment 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. Complete the alloy plating process by carrying out all of the following activities: 1. use the correct issue of process and other related specifications 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. ensure that the equipment is correctly prepared for the plating operations, including any post-plate, thermal treatment ovens required 4. ensure that any meters and gauges to be used are within their calibration periods 5. clean all tools and equipment on completion of the plating activities 6. complete the production documentation (such as condition/pre-treatment of substrates, coating material preparation, equipment settings, confirmation of standard of finish) 7. leave the work area in a safe and clean condition 2. Carry out one of the following alloy plating processes: 1. brass plating 2. zinc-iron plating 3. nickel-iron plating 4. zinc-cobalt plating 5. tin-lead plating 6. zinc-nickel plating 7. bronze 8. other alloy plating process 3. Measure and (where applicable) correct two of the following alloy plating process conditions: 1. levels of basic constituents of plating solutions 2. temperature of plating solutions 3. carbonate levels (where applicable) 4. plating efficiencies 5. contaminants in plating solutions 6. brightener and other additive dosing levels 4. Use one of the following methods for securing components during the alloy plating process: 1. rack plating 2. barrel plating 3. wiring components for plating with or without the use of frame jigs 4. other securing method 5. Control alloy composition by adjusting one of the following: 1. process temperature 2. current density 3. metal ratios in solution 4. agitation 6. Carry out three of the following activities: 1. replace filter media safely and correctly 2. dispose of process solutions and other solutions, safely and correctly 3. clean out tanks safely 4. prepare new solutions safely and correctly from basic additives 5. check and maintain heat exchangers 7. Check the coated components for two of the following characteristics: 1. throwing power of plating solution 2. colour of the deposit 3. brightness / variation of brightness of deposit 4. evenness of passivation 5. overall coverage 6. presence of blisters or nodules 7. evidence of burning or poorly applied coatings 8. alloy composition 9. quality of deposit around holes and welded areas (such as a tendency to blow or mis-plate) 8. Carry out one of the following quality control procedures: 1. thickness testing by microsectioning 2. corrosion testing (NSST or a specified method) 3. thickness testing electromagnetic induction 4. adhesion of deposit 5. thickness testing eddy current permeability 6. brittleness of deposit 7. thickness testing X-ray fluorescence 8. torque tension testing 9. Check coatings applied to components by alloy plating comply with one of the following quality and accuracy standards 1. military or aviation standards 2. current industry standards and codes of practice 3. international standards 4. company standards and requirements 5. customer 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
MPF3.40
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
5221
Keywords
Engineering; manufacturing; processing; finishing; alloy plating; brass; nickel-iron; tin-lead; zinc-nickel; zinc-iron