Recommendation / Electroplating Nonconformance for Iron-Based Components

This document addresses issues related to internal components (iron-based parts) that require processing, electroplating, inspection, and assembly prior to installation. However, nonconforming electroplating results frequently occur during production.

Standard Nonconformance Handling Process:
1, Return defective components to the plating vendor.
2, The vendor must professionally strip all defective plating layers, perform thorough cleaning, and re-plate the components.

Unapproved Shortcut Practice:

Some suppliers occasionally use prohibited chemical agents to locally remove defective plating areas without full stripping, followed by direct re-plating. This method evades detection during routine inspections and standard salt spray testing (e.g., ASTM B117).

Latent Failure Case Study: 
During a German port strike (3+ months container detention), components endured:
Extreme high temperatures (exceeding 50°C)
Excessive humidity (95% RH sustained)
High salinity levels (coastal atmospheric corrosion)
Result:
Complete internal rusting of iron components
Corrosion propagation to external stainless steel parts
Total product failure due to galvanic corrosion

Preventive Measures:
 
To mitigate such risks, we must:
Implement AS5553-based supplier quality protocols
Enforce cross-sectional microscopy verification for reworked parts
Conduct accelerated aging tests simulating 6-month marine exposure (per ISO 9223 CX-class)
Mandate electrochemical impedance spectroscopy (EIS) for coating integrity validation
This incident underscores the critical need for supplier process audits and enhanced corrosion protection standards in maritime applications.