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Syllabus
Surface Finishing Foundation Course and Distance Learning Module The course and module is designed to provide personnel in surface finishing and related technologies the opportunity to improve and increase their knowledge. Further, it will also be of value to line-management and sales personnel to improve their knowledge of the processes operated within the company.
It will enable those attending to broaden their knowledge and thus be able to deal with shop floor problems more effectively.
The course was first introduced in 1988 and has proved to be of immense value to those persons who wish embark on the continuing education and training programme of the Institute either by the tutored or distance learning route, and further can be the underpinning knowledge for NVQs.
The course and module consists of a total of thirteen units (some of which are mandatory). These generally equate to a teaching/learning time of approximately 24 hours. In 2005 the number of available units was increased to include other topics such as organic finishing. The study of seven units is mandatory, Unit 1 Surface Finishing, Unit 2 The Principles and Use of Electroplating, Unit 3 Plant & Equipment, Unit 4 Cleaning and Pretreatment, Unit 11 The Environment & Surface Finishing, Unit 12 Care & Maintenance of Solution & Product Quality and Unit 13 Health & Safety. The remaining 6 are then selected from the optional ones by the students in conjunction with the course tutor. If you are undertaking an in-house bespoke company course, the units selected will be decided by the Tutor and the Company’s training manager.
If you are taking a Distance Learning module, you will need to contact the Chairman of the Education & Training Committee to discuss and select the appropriate units in order to satisfy your individual requirements. In the first instance, please contact David Meacham at Exeter House on 0121 622 7387.
Following the conclusion of the course there is a multi-choice examination of 36 questions for which students who achieve a pass mark of 40% and over, are awarded the Foundation Certificate. Achieving a pass mark over 60% will gain a pass with merit and over 75% a pass with distinction.
Additionally, after successfully passing the Foundation examination you may be eligible to apply for the grade of Associate of the Institute of Metal Finishing (AssocIMF) – the first rung on the ladder of professional grade of membership of the IMF.
Unit 1 – Surface Finishing
1.1 A definition of surface finishing.
1.2 An appreciation of alternative surface finishing technologies.
1.3 Understand that coatings may be deposited onto a substrate.
1.4 Understand that substrate surfaces may be changed from the metal to a metal compound.
1.5 An awareness and brief explanation of the alternative processes and in particular: Anodising, Conversion Coating, Electroless Plating, Electroplating, Galvanising, Mechanical Plating, Paint Lacquer &Varnish, Powder Coating, Thermal Spraying, Vacuum Deposition and Vitreous Enamelling.
Unit 2 – The Principles and use of Electroplating
2.1 A definition of electroplating.
2.2 An awareness of the effects of electroplating.
2.3 Appreciate the advantages and disadvantages of electroplating.
2.4 Appreciate how electroplating and a simple chemical explanation.
2.5 Suspension of components for electroplating – rack and barrel – and advantages and disadvantages of use.
2.6 Use of masking and stopping-off techniques.
2.7 Recognise the requirements for an electroplating solution and the function of the chemical constituents.
2.8 Understand a simple explanation of primary and secondary cathode reactions.
2.9 Understand the meaning and significance of Cathode Current Efficiency and appreciate why some types of solutions are more or less efficient than others due to the production of hydrogen.
2.10 Appreciate the reasons for soluble and insoluble anodes.
2.11 Know the definition of pH, and understand its importance in electroplating and how to measure it.
2.12 An introduction to quantitative electrolysis and how it can be used to calculate plating times, current and deposit thickness.
2.13 Understand the meaning and significance of the terms “covering power”, “throwing power” and “burning”.
2.14 Understand how deposit thickness and uniformity can be effected by changes in current density and cathode current efficiency.
Unit 3 – Plant and Equipment
3.1 An awareness of materials for the construction of tanks and the necessity for some tanks to have a lining.
3.2 Understand the function of the items of electrical equipment needed for electroplating and how they are linked together.
3.3 Recognise the needs of items of equipment for heating, cooling, and agitation and the reasons for its use.
3.4 Understand the use of filtration and the various types of filtration equipment available.
3.5 An awareness and reasons for the materials of construction for Jigs and Racks.
3.6 Be aware of the types of semi-automatic and fully automatic plants available for rack and barrel processing.
3.7 Be aware of how the types of plants can be arranged for optimum production.
3.8 Appreciate the methods available for the drying of components after processing.
Unit 4 – Cleaning and Pretreatment
4.1 Appreciate the importance of cleaning and pretreatment for all surface finishing technologies.
4.2 Understand the differences in types of soils that require removal.
4.3 Appreciate the need for different methods for removal of soils by organic solvents and aqueous based solutions.
4.4 Have an awareness of the different chemical materials present in aqueous based solutions and the function served by these constituents.
4.5 Appreciate the advantages of the use of electrolytic cleaning.
4.6 Recognise the problems of hydrogen embrittlement and how this phenomena can occur in cleaning and pretreatment and the steps that must be taken to minimise the deleterious effect.
4.7 Appreciate that mechanical treatments are used for cleaning and preparing substrates for finishing.
4.8 Recognise where there is a need for etching and activation of substrate surfaces prior to coating is beneficial.
4.9 Appreciate the need for the use of “strike plating” and its benefit in overcoming problems associated with hydrogen overvoltage, passive surfaces and reactive surfaces.
Unit 5 - Nickel Plating
5.1 Appreciate the use of nickel plating for decorative and engineering applications.
5.2 Recognise the function of the chemical constituents in a basic nickel plating solution.
5.3 Appreciate the reasons for the use of addition agents.
5.4 Recognise that different types of anode material are available and be aware that anode baskets can be used and the necessity for anodes bags.
5.5 Appreciate that nickel can be deposited without the use of electrical current and why this technique is used in industry
5.6 Recognise the principle chemical constituents and their function in electroless nickel plating solutions.
5.7 Appreciate the advantages and disadvantages of electroless nickel plating.
5.8 Be aware that the properties of electroless nickel can be modified by the use of heat treatment.
Unit 6 - Chromium Plating
6.1 Appreciation of the uses and properties of chromium electrodeposited coatings for decorative and engineering applications.
6.2 Be aware of the chemical composition of the various types of chromium plating solutions and their limitations.
6.3 Recognise the health and safety implications associated with the hexavalent form of chromium compounds.
6.4 Appreciate the benefits of using the trivalent chromium plating solution
Unit 7 - Copper, Silver and Gold Plating
7.1.1 Appreciate the use of copper for decorative, engineering and, where applicable, as an undercoat for other metal deposition.
7.2 Be aware of the various types of solutions available, their formulations and the purpose of
application.
7.3 Appreciate the use of silver and its applications.
7.4 Be aware of the types of silver plating solutions used and their formulations.
7.5 Be aware of the use of gold and its applications.
7.6 Be aware of the types of gold plating solutions used and their formulations.
7.6 Appreciate how the colour of gold coatings can be modified by additions of other metals to the plating solution.
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Unit 8 - Zinc and Cadmium Plating and Passivation
8.1 Appreciate the importance of zinc for corrosion resistance.
8.2 Be aware of the various types of zinc plating solutions available and their formulation.
8.3 Understand the toxic nature of the chemical constituents in some zinc plating formulations
8.4 Appreciate that cadmium is only permitted for specific applications
8.5 Understand the importance of passivation treatments in extending the corrosion resistance of zinc and cadmium coatings.
8.6 Appreciate that various coloured films produced by passivation films provide differing corrosion protection.
8.7 Appreciate the various chemical constituents used for the production of passivation films in particular hexavalent and trivalent chromium compounds and chromium free compounds.
Unit 9 - Anodising of Aluminium and its alloys
9.1 Appreciate that anodising is an electrolytic method of producing an oxide film unlike electroplating which deposits a metal.
9.2 Be aware of the applications and uses of anodised aluminium.
9.3 An awareness of the types of solutions and their formulations of solutions for the production of an anodised film on aluminium.
9.4 Understand the similarities and differences between anodising and electroplating.
9.5 Be aware that anodised film can be coloured by various methods.
9.6 Appreciate the importance of sealing of films.
Unit 10 - Further Principles
10.1 Understand the Electrochemical Series and the electrode potential of common metals concerned with surface finishing.
10.2 Understand that some metals may be deposited by immersion processes without the use of electricity.
10.3 Appreciate when immersion deposits are advantageous and also where such deposits are detrimental in surface finishing.
10.4 Appreciate the problems, which may occur with immersion deposits.
10.5 Be aware that deposition of alloys is achievable, the various types of alloy deposition possible and their use commercially.
10.6 Understand how the Electrochemical Series can predict the outcome of corrosion.
10.7 Understand the meaning of “sacrificial” in the protection of mild steel using zinc coatings.
10.8 Be aware how enhanced corrosion protection can be achieved by the use of specialised coatings of nickel and chromium on mild steel.
Unit 11 – The Environment and Surface Finishing
11.1 Appreciate how liquid, solid and gaseous wastes can pollute the environment.
11.2 Identify the common sources of wastes and their control under legislation.
11.3 Know that maximum limits for discharge of waste waters containing metals and other
chemical compounds are subject to “Consent to Discharge” limits.
11.4 Appreciate why water rinsing is an important operation in all chemical processing and
that the discharge of such waters may produce pollution if not treated.
11.5 Know that water consumption can be reduced without detriment to the process.
11.6 Identify methods of reducing losses from process solution.
11.7 Be aware of the methods used for the treatment of effluent.
11.8 Appreciate how both water and process chemicals can be recovered for reuse.
11.9 Appreciate the sources of energy used in surface finishing and how such energy use may
be minimised.
11.10 Recognise the need to minimise accidental spillage and how it should be contained.
11.11 Have basic knowledge of the legislation to which the surface finishing industry is accountable.
Unit 12 – Health and Safety
12.1 Understand the terms Health and Safety and the factors that can effect it.
12.2 Recognise the difference between a “Hazard” and a “Risk”.
12.3 Appreciate the issues that are necessary in managing Health and Safety.
12.4 Be aware of the hazardous substances used in the surface finishing industry.
12.5 Understand that in the UK all companies are required to maintain a COSHH manual that identifies that identifies materials that are hazardous to health.
12.6 Appreciate where health and safety information on material in use can be obtained.
12.7 Appreciate the dangers of some specific chemical substances and how any accidental spillage should be treated.
12.8 Be aware of the need to use Personal Protective Equipment.
12.9 Know where facilities for emergency treatment can be obtained.
12.10 Be aware of the need for correct labelling of all process equipment and solution containing receptacles.
Unit 13 – Care and Maintenance of Solutions & Product Quality
13.1 Appreciate the need to maintain process solutions at their optimum conditions.
13.2 Appreciate how samples should be taken for test purposes.
13.3 Appreciate the use of test methods, chemical analysis and the use of small scale tests.
13.4 Identify sources of process solution contamination.
13.5 Recognise the need on occasions for full scale purification.
13.6 Understand the meaning of product quality.
13.7 Appreciate the importance of Product Technical Specifications between a customer and processor.
13.8 Appreciate the use of “Standards” from British, European and International sources.
13.9 Appreciate the need for quality assessment and the use of equipment to carry it out.
Unit 14 – Chemical Processes 1 – Electroless Plating
14.1 Identify examples of electroless plating by immersion, homogenous chemical reduction and autocatalytic deposition.
14.2 Appreciate the advantages, disadvantages and practical uses of such processes.
14.3 Be able to define the term “autocatalytic” and be aware of general formulations of plating solutions of this type.
14.4 Be aware of the range of autocatalytic plating processes for the production of nickel coatings.
14.5 Appreciate that autocatalytic nickel-phosphorus deposits may be classified according to phosphorus content and be aware of the properties of the coatings with different phosphorus contents.
14.6 Be aware that the properties of electroless nickel can be modified by heat treatment.
14.7 Appreciate the simplistic mechanism of electroless nickel-phosphorus deposition and be able to identify the main constituents of such solutions.
14.8 Appreciate that concentration and operating conditions affect plate properties and deposition rate.
14.9 Understand the importance of maintaining solution constituents at optimum concentrations.
14.10 Appreciate the main uses of autocatalytic copper deposition. Identify the main constituents of the solution and their functions.
14.11 Understand the importance of maintaining solution concentrations at optimum levels.
Unit 15 – Alloy Plating – General Principles
15.1 Appreciate why alloys are used in general metallurgical practice and identify the problems associated with producing alloy electrodeposits.
15.2 Recognise the main alloy electrodeposits in use and the reasons for the use of the various alloys.
15.3 Be able to recognise the essential requirements for different metals to be co-deposited as an alloy.
15.4 Understand that for alloy deposition to be possible the standard electrode potentials of the co-deposited metals must be close together in simple salt solution or brought close together by complexing.
15.5 Know the methods used to replenish the metal content of alloy plating solutions and understand how variables of current density, agitation, temperature, pH and solution formulation influences the composition of the electrodeposited alloy.
Unit 16 – Conventional Printed Circuit Processes
16.1 Appreciate the practical importance of printed circuit boards (PCBs).
16.2 Understand that the conducting tracks of a PCB can be produced by subtractive or additive methods.
16.3 Be able to list the main stages in the production of a PCB by the subtractive method.
16.4 Know the essential characteristics of a clad laminate and identify the problems caused by drilling holes for interconnection purposes in terms of burr removal, resin smear and the need to render the walls of holes electrically conductive.
16.5 Recognise the need for a catalyst, activator and autocatalytic deposition of copper as a pre-requisite for electrodeposition of copper using the copper sulphate process.
16.6 Know the function of photo-chemical plating resists and the methods used to remove non-cross linked resist prior to electrodeposition of copper and etch resist.
16.7 Appreciate that the main hole wall electrical conduction is achieved by copper plating and be able to state why this system is used. Be able to identify the reasons for the use of high throw versions of the plating solutions.
16.8 Know the functions of the electrodeposited etch resist and be able to give examples.
16.9 Identify suitable methods for the removal of copper by etching.
16.10 Understand why reflowing of the etch resist is a requirement and how it is done.
16.11 Recognise the need to apply solder masks and why gold plating of edge connectors is required.
Unit 17 – Cleaning for Paint Application
17.1 Appreciate the reasons for a clean substrate prior to painting.
17.2 Know that cleaning may be carried out by both chemical and mechanical treatments.
17.3 Appreciate the need for different methods for removal of soils by organic solvents and aqueous based solutions.
17.4 Have an awareness of the different chemical materials present in aqueous based solutions and the function served by these constituents.
17.5 Know the various methods and media used for mechanical cleaning.
Unit 18 – Chemical Conversion Processes
18.1 Appreciate that chemical conversion processes produce a non-metallic coating on the surface of the substrate.
18.2 Know the reasons for the use of chemical conversion processes and the benefits they give to the coated substrate.
18.3 Know that whilst the terms ‘Chromating’ and ‘Phosphating’ are the generic terms used, there are proprietary names used by the various chemical manufacturers.
18.4 Appreciate that different substrate require different chemical formulations to produce a chromate coating.
18.5 Appreciate that chromate coating can be produced containing using chromium compounds in the hexavalent form which is a Category 1 Carcinogen and the preferred alternative trivalent form.
18.6 Appreciate that there are three basic types of coating produced by phosphating and the difference and use of the coating produced by this process.
18.7 Know the reasons for the use of phosphate coatings and the benefits they give to the coated substrate.
18.8 Know that the main use of phosphating is for the pretreatment of ferrous substrates, but can also be used on aluminium and zinc materials.
18.9 Know that the weight per square metre is variable according to the type, reason and substrate for which the phosphate coating is required.
18.10 Know that phosphating is a water based process which can be used by immersion and spray techniques.
18.11 Know that combined ‘clean and phosphate’ products are available.
Unit 19 – Conventional Paint Processes
19.1 Know the difference between the terms Inorganic and Organic and that paints are synthesised from organic compounds but that some inorganic compounds may be used as ‘additives’ for specific requirements.
19.2 Appreciate that paints are loosely classified according to their use e.g primer, undercoat, finish etc.
19.3 Know the components which make up a conventional liquid paint and the purpose for which they are used.
19.4 Appreciate the properties which make up a good paint.
19.5 Know that paints are classified according to the polymer from which they are formulated – e.g. alkyd, epoxy etc.
19.6 Know the difference between ‘Additive’ and ‘Condensation’ polymer types.
19.7 Appreciate the difference between ‘Convertible’ and ‘Non-convertible’ coatings and the difference means in how they produce a dry continuous film.
19.8 Know that solvent emitted in the use and drying of paints can be dangerous to the environment and the health and safety of people and that their use in the subject of legislation under the EU Solvents Emission Directive.
Unit 20 – ‘Phoretic’ Paint
20.1 Appreciate the difference between ‘Electrophoretic’ and ‘Autodeposition’ painting.
20.2 Appreciate how electrophoretic paints are made using water soluble resins by electroplating technology and may be deposited on the substrate which may be the anode or cathode in an AC electrical cell.
20.3 Appreciate the benefits which can be achieved by using electrophoretic paints.
20.4 Be able to specify equipment needed in the construction of an electrophoretic plant.
20.5 Know what ultrafiltration is and the reason for its use.
20.6 Appreciate why autodeposition can only be used on ferrous substrates.
20.7 Appreciate the benefits which the autodeposition process imparts to a substrate.
Unit 21 – Paint Application Methods
21.1 Know the various methods for the application of paints.
21.2 Know that the method of application is dependant on production requirements i.e. short runs, mass production, colour changing etc.
21.3 Appreciate the difference between conventional and electrostatic spraying and the benefits of using electrostatic methods.
21.4 Be able to differentiate between the techniques and equipment for mass production of components.
Unit 22 – Coating Powders and their Application
22.1 Know how coating powders are manufactured.
22.2 Appreciate that powders are split into two categories – thermoset and thermoplastic.
22.3 Appreciate which polymer types fall into the two categories how they differ after being melted or cured.
22.4 Know the two differing techniques that are using to apply powders and for which types of products/components they are best suited.
22.5 Know the various types of heating equipment and heating media used for melting/curing powders.
22.6 Know the benefits of using powders over conventional liquid paints and appreciate why powders are considered ‘Environmentally friendly’.
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