Dixie Industrial Finishing Company 4925 S. Royal Atlanta Drive Tucker, GA (770) Jim Jones –Vice President Terry Windham, CEF – Sales/Quality

PLATING: What is it? Also called electroplating, plating is the mechanically bonding of one metal to another for the purpose of corrosion protection, decorative appeal, hardness, electrical conductivity, reflectivity, and/or wear resistance Also called electroplating, plating is the mechanically bonding of one metal to another for the purpose of corrosion protection, decorative appeal, hardness, electrical conductivity, reflectivity, and/or wear resistance In a nut shell, plating modifies the surface properties of the base metal to make it more suitable for its intended useIn a nut shell, plating modifies the surface properties of the base metal to make it more suitable for its intended use

Typical Properties Achieved Through Plating Corrosion resistance Appearance Abrasion resistance Value (silver/gold, etc) Solderability Rubber Bonding Electroforming Electrical Resistance Reflectivity Diffusion Barrier Lubricity High Temp. Resistance

CRITICAL STEPS IN PLATING Racking/Loading (position, number of parts)Racking/Loading (position, number of parts) Amperage (amount of current for the number of parts)Amperage (amount of current for the number of parts) Cleaning (strength, temperature, time)Cleaning (strength, temperature, time) Pickling/Acid (strength, temperature, time)Pickling/Acid (strength, temperature, time) Rinsing (time, flow of water, cleanliness)Rinsing (time, flow of water, cleanliness) Plating process (Zn, Ni, Sn, Ag, Au, etc.)Plating process (Zn, Ni, Sn, Ag, Au, etc.) Chromates (strength, pH, temperature, time, age of chromate)Chromates (strength, pH, temperature, time, age of chromate) Post-dips (strength, age, temperature, pH)Post-dips (strength, age, temperature, pH)

Typical Zinc Plating Cycle SOAK CLEANER ELECTRO- CLEANER RINSEACIDRINSE PLATING TANK RINSE BRIGHT DIP OTHER CHROMATE BRIGHT DIP RINSE CHROMATE RINSE HOT RINSEDRY Direction of Work Flow Multiple, counterflow rinses usually used Pre-dips, post treatments. etc., may be used

What happens to steel? Steel is the cheapest structural material available for countless usesSteel is the cheapest structural material available for countless uses However, steel is not very resistant to corrosion (red rust)However, steel is not very resistant to corrosion (red rust) Steel Part (Unplated) Red Rust Rust damages (pits) the surface of the base metal

The Plating Tank PART Zn++ ZINCBALLS ++ (-) (-) (-) CathodeAnodeAnode ZincPlatingSolution

What happens to zinc? Steel Part Zinc metal will corrode (white corrosion) if not protected by a chromate finishZinc metal will corrode (white corrosion) if not protected by a chromate finish As the zinc corrodes, it fails to protect the base metal and red rust of the base metal occursAs the zinc corrodes, it fails to protect the base metal and red rust of the base metal occurs Rust damages (pits) the surface of the base metal Zinc Plating White corrosion

Steel Part Plated Metal (Zinc) ChromateFinish ZINC PLATED PART The part is protected from corrosion by the zinc platingThe part is protected from corrosion by the zinc plating The zinc plating is protected from corrosion by the chromate finishThe zinc plating is protected from corrosion by the chromate finish

CHROMATES TYPES OF CHROMATES Hexavalent Hexavalent - Clear - Clear - Yellow - Yellow - Bronze - Bronze - Black - Black - Olive Drab / Green - Olive Drab / Green Trivalent Trivalent - Blue Bright (Clear) - Blue Bright (Clear) *Thin Film *Thin Film - Non-hex thick film passivates (non- colored, black). Can be dyed. - Non-hex thick film passivates (non- colored, black). Can be dyed.

Hexavalent Chromates Excellent corrosion protection properties Excellent corrosion protection properties Fairly inexpensive Fairly inexpensive Easy / fast to room temperature Easy / fast to room temperature Variety of colors Variety of colors Self-healing properties Self-healing properties Can not be baked Can not be baked Carcinogenic / health issues Carcinogenic / health issues Considered environmentally non-friendly (do not meet ELV, RoHS, WEEE requirements) Considered environmentally non-friendly (do not meet ELV, RoHS, WEEE requirements)

Why the elimination of hexavalent chromium? To meet the requirements of ELV, RoHS and WEEE directives Hexavalent chromium is carcinogenic by nature. Hexavalent chromium compounds can slip through cell membranes and react with DNA causing cell mutations/cancer Hexavalent chromium is a strong oxidant that poses a threat to biological systems

ELVELV Extended Life Vehicle (ELV) Directive 2000/53/EC Directive 2000/53/EC Pb, Hg, Cd, Cr +6 Banned from automotive coatings as of Pb, Hg, Cd, Cr +6 Banned from automotive coatings as of Objective: prevention of waste from vehicles plus reuse, recycle, & recovery of end-of life vehicles & components. 85% recycled by 2006, 95% by 2015 Objective: prevention of waste from vehicles plus reuse, recycle, & recovery of end-of life vehicles & components. 85% recycled by 2006, 95% by 2015 Vintage & historic vehicles are exempted Vintage & historic vehicles are exempted Components, materials, as well as spare & replacement parts are also covered Components, materials, as well as spare & replacement parts are also covered Automotive component manufacturers to provide appropriate information to treatment facilities, concerning dismantling, & reuse Automotive component manufacturers to provide appropriate information to treatment facilities, concerning dismantling, & reuse Extended Life Vehicle (ELV) Directive 2000/53/EC Directive 2000/53/EC Pb, Hg, Cd, Cr +6 Banned from automotive coatings as of Pb, Hg, Cd, Cr +6 Banned from automotive coatings as of Objective: prevention of waste from vehicles plus reuse, recycle, & recovery of end-of life vehicles & components. 85% recycled by 2006, 95% by 2015 Objective: prevention of waste from vehicles plus reuse, recycle, & recovery of end-of life vehicles & components. 85% recycled by 2006, 95% by 2015 Vintage & historic vehicles are exempted Vintage & historic vehicles are exempted Components, materials, as well as spare & replacement parts are also covered Components, materials, as well as spare & replacement parts are also covered Automotive component manufacturers to provide appropriate information to treatment facilities, concerning dismantling, & reuse Automotive component manufacturers to provide appropriate information to treatment facilities, concerning dismantling, & reuse

WEEE EC Directive on Waste from Electrical and Electronic Equipment EC Directive on Waste from Electrical and Electronic Equipment 2002/96/EC Jan /96/EC Jan 2003 Required all 25 EU member states to implement into law within 18 months (Aug 2004) a requirement that appliances and electrical devices be manufactured in such a manner that they can be recycled/recovered at a recovery rate of 70-80% based on type of appliance. Required all 25 EU member states to implement into law within 18 months (Aug 2004) a requirement that appliances and electrical devices be manufactured in such a manner that they can be recycled/recovered at a recovery rate of 70-80% based on type of appliance. As of 8-05 all EU members except Malta and UK had at least a framework regulation. As of 8-05 all EU members except Malta and UK had at least a framework regulation.WEEE EC Directive on Waste from Electrical and Electronic Equipment EC Directive on Waste from Electrical and Electronic Equipment 2002/96/EC Jan /96/EC Jan 2003 Required all 25 EU member states to implement into law within 18 months (Aug 2004) a requirement that appliances and electrical devices be manufactured in such a manner that they can be recycled/recovered at a recovery rate of 70-80% based on type of appliance. Required all 25 EU member states to implement into law within 18 months (Aug 2004) a requirement that appliances and electrical devices be manufactured in such a manner that they can be recycled/recovered at a recovery rate of 70-80% based on type of appliance. As of 8-05 all EU members except Malta and UK had at least a framework regulation. As of 8-05 all EU members except Malta and UK had at least a framework regulation. WEEEWEEE WEEE Man represents 3.3 tons of electronic waste generated by each citizen of the UK in a lifetime

RoHS Restriction of Hazardous Substances in Electrical and Electronic Equipment (RoHS) Directive (2002/95/EC) As of July 1, 2006, this directive bans lead, mercury, cadmium, hexavalent chromium, polybrominated biphenyls (PBBs) and polybrominated diphenyl ethers (PBDEs) from all new electrical and electronic equipment sold to EU companies and manufactured in the EU. RoHS Restriction of Hazardous Substances in Electrical and Electronic Equipment (RoHS) Directive (2002/95/EC) As of July 1, 2006, this directive bans lead, mercury, cadmium, hexavalent chromium, polybrominated biphenyls (PBBs) and polybrominated diphenyl ethers (PBDEs) from all new electrical and electronic equipment sold to EU companies and manufactured in the EU. RoHSRoHS Computer Hardware is Subject to RoHS Directive Automotive Hardware is Subject to ELV Directive Computer Hardware is Subject to RoHS Directive Automotive Hardware is Subject to ELV Directive

WEEE and RoHS Product Categories 1. Large appliances 2. Small appliances 3. IT/telecom equipment 4. Consumer equipment 5. Lighting equipment 6. Electrical/electronic tools 7. Toys, sport equipment 8. Medical equipment * 9. Monitoring/control equipment * 10. Automatic dispensers *Excluded by RoHS Directive

Business Issues for Surface Finishers/Manufacturers WEEE and RoHS Directives signal new trend toward product regulation. WEEE and RoHS Directives signal new trend toward product regulation. Customers increasingly want to know the material content and planned end-of-life disposition for products they buy. Customers increasingly want to know the material content and planned end-of-life disposition for products they buy. Achieve legal complianceAchieve legal compliance Promotegreen procurementPromotegreen procurement Corporate sustainabilityCorporate sustainability Respond to stakeholdersRespond to stakeholders

Non-Hexavalent Passivates More expensive (contain expensive tri- chromium compounds, organic acids, and other metals) More expensive (contain expensive tri- chromium compounds, organic acids, and other metals) Must be heated to apply (typically 140 o F) Must be heated to apply (typically 140 o F) Slower to apply (increases cycle time) Slower to apply (increases cycle time) Not self healing (require additional top coats for protection – more expense) Not self healing (require additional top coats for protection – more expense) Lower corrosion protection than hexavalents (without topcoats/seals) Lower corrosion protection than hexavalents (without topcoats/seals) Less color variety (non-colored & black) Less color variety (non-colored & black) Cons:

TYPICAL SALT SPRAY HOURS Clear Trivalent12 – 24 hours Clear Hexavalent20 – 32 hours Black Hexavalent72 hours Yellow Hexavalent96 hours Olive Drab / Green168 hours Non-hexavalent thick film72 hours Non-hexavalent black36 – 72 hours (all results are without seals/topcoats)

Topcoats / Seals There are a variety of topcoats / seals available. Silicated dips, polymers/lacquers, cross-linking polymers, lubricating seals (torque-n- tension compounds) There are a variety of topcoats / seals available. Silicated dips, polymers/lacquers, cross-linking polymers, lubricating seals (torque-n- tension compounds) Silicated dips offer some self-healing help and increase corrosion protection. These are very thin and will not cause dimensional problems with fasteners Silicated dips offer some self-healing help and increase corrosion protection. These are very thin and will not cause dimensional problems with fasteners

Polymers / lacquers offer enhanced corrosion protection as well as scratch resistance Polymers / lacquers offer enhanced corrosion protection as well as scratch resistance Polymers / lacquers can pose some conductivity issues Polymers / lacquers can pose some conductivity issues Polymer / lacquer films can be thick and may cause fit/dimensional issues in fasteners, especially in threaded areas Polymer / lacquer films can be thick and may cause fit/dimensional issues in fasteners, especially in threaded areas Lubricating seals (torque-n-tension) offer enhanced corrosion protection, some self-healing help, and lubricity, changing torque values of the surface (automotive fastener requirements). These seals can be expensive to apply. Lubricating seals (torque-n-tension) offer enhanced corrosion protection, some self-healing help, and lubricity, changing torque values of the surface (automotive fastener requirements). These seals can be expensive to apply. Topcoats / Seals (cont.)

THANK YOU! A big thanks to you for allowing us the opportunity to share this information with you today. A big thanks to you for allowing us the opportunity to share this information with you today. For questions or comments, we can be reached at: For questions or comments, we can be reached at: Dixie Industrial Finishing Company, Tucker, GA Jim Jones ( ) Terry Windham (770)