<p style="margin: 0cm 0cm 0pt; line-height: 20pt; mso-line-height-rule: exactly;"><span style="font-size: small;"><span style="font-family: 宋體;"><span style="color: #333333;" lang="EN-US">1.1</span><span style="color: #333333;">　關(guān)于故障中的假象問題<span lang="EN-US"></span></span></span></span></p> <p style="margin: 0cm 0cm 0pt; text-indent: 24pt; line-height: 20pt; mso-char-indent-count: 2.0; mso-line-height-rule: exactly;"><span style="color: #333333;"><span style="font-size: small; font-family: 宋體;">從下述三個實(shí)例<span lang="EN-US">,</span>可了解電鍍故障中的假象。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small; font-family: 宋體;">實(shí)例<span lang="EN-US">1</span>　自行車瓦蓋又稱擋泥板<span lang="EN-US">,</span>電鍍銅、鎳、鉻。工藝流程<span lang="EN-US">:</span>鍍前處理預(yù)鍍鎳光亮硫酸鹽鍍銅全光亮鍍鎳。在電鍍過程中發(fā)現(xiàn)鍍件從光亮鍍銅槽出來后<span lang="EN-US">,</span>銅鍍層呈鏡面光亮。經(jīng)過鍍光亮鎳后<span lang="EN-US">,</span>發(fā)現(xiàn)光亮鎳鍍層表面出現(xiàn)白塊、白條等疵病。當(dāng)時給操作者的感覺是故障出在光亮鍍鎳工序。經(jīng)查找<span lang="EN-US">,</span>光亮鍍鎳工序沒發(fā)現(xiàn)問題<span lang="EN-US">,</span>故障仍未解決。起初為了維持生產(chǎn)<span lang="EN-US">,</span>鍍完亮鎳后只得進(jìn)行拋光<span lang="EN-US">,</span>但過了幾天后拋光也不行了<span lang="EN-US">,</span>不得不查找電鍍亮銅工序。發(fā)現(xiàn)鍍銅液中十二烷基硫酸鈉含量偏低而引起的故障。這樣本來有問題的電鍍亮銅工序<span lang="EN-US">,</span>由于鍍件外觀光亮而看不出疵病<span lang="EN-US">,</span>經(jīng)過鍍亮鎳后才發(fā)現(xiàn)故障。這樣給我們造成鍍亮鎳出現(xiàn)故障的假象。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small;"><span style="font-family: 宋體;">實(shí)例<span lang="EN-US">2</span>　槍黑鍍鎳層不太黑<span lang="EN-US">,</span>有時還出現(xiàn)白色條紋<span lang="EN-US">,</span>加入增黑鹽、增黑劑后<span lang="EN-US">,</span>色澤立即變黑<span lang="EN-US">,</span>條紋也不存在了。但電鍍<span lang="EN-US">1h</span>左右<span lang="EN-US">,</span>又出現(xiàn)了上述故障<span lang="EN-US">,</span>加入上述兩種增黑物質(zhì)后故障才清理。這樣反復(fù)進(jìn)行<span lang="EN-US">5</span>～<span lang="EN-US">6</span>次<span lang="EN-US">,</span>而以往增黑鹽<span lang="EN-US">3</span>～<span lang="EN-US">4</span>天僅補(bǔ)充一次<span lang="EN-US">,</span>增黑劑每天只補(bǔ)充一次。上述增黑物質(zhì)的補(bǔ)充<span lang="EN-US">,</span>顯然屬反常現(xiàn)象。經(jīng)過檢查和試驗(yàn)<span lang="EN-US">,</span>確認(rèn)鍍液中的銅、鋅等雜質(zhì)積累過多而引起的故障。增黑劑中含有金屬的配位劑<span lang="EN-US">,</span>由于配位劑的作用<span lang="EN-US">,</span>短時間內(nèi)雜質(zhì)也被配位<span lang="EN-US">,</span>隨著電鍍過程的進(jìn)行<span lang="EN-US">,</span>配位劑有所消耗<span lang="EN-US">,</span>雜質(zhì)的干擾作用就反復(fù)出現(xiàn)<span lang="EN-US">,</span>并且影響黑度。在同一鍍槽內(nèi)<span lang="EN-US">,</span>當(dāng)黑度開始下降、有條紋時<span lang="EN-US">,</span>加入增黑物質(zhì)<span lang="EN-US">,</span>故障現(xiàn)象有所減輕或清理<span lang="EN-US">,</span>使操作者誤認(rèn)為是缺少增黑劑所引起的故障的假象。而這一故障現(xiàn)象的真相卻是金屬雜質(zhì)所引起的。<span lang="EN-US"></span></span></span></span></p> <p style="margin: 0cm 0cm 0pt; line-height: 20pt; mso-line-height-rule: exactly;"><span style="color: #333333;" lang="EN-US"><span style="font-size: small; font-family: 宋體;">    </span></span><span style="color: #333333;"><span style="font-size: small; font-family: 宋體;">實(shí)例<span lang="EN-US">3</span>　鍍鎳或鍍低錫青銅的鍍件<span lang="EN-US">,</span>經(jīng)過電化學(xué)除油、清洗后<span lang="EN-US">,</span>再經(jīng)過<span lang="EN-US">5%</span>～<span lang="EN-US">10%</span>硫酸溶液的弱腐蝕及清洗后進(jìn)行鍍鉻<span lang="EN-US">,</span>發(fā)現(xiàn)鍍鉻層有白花。如不經(jīng)電化學(xué)除油<span lang="EN-US">,</span>上述故障立即出現(xiàn)<span lang="EN-US">,</span>并且電化學(xué)除油時間越長<span lang="EN-US">,</span>上述現(xiàn)象越嚴(yán)重<span lang="EN-US">,</span>給我們造成電化學(xué)除油工序存在問題的假象。對除油液采取稀釋、調(diào)整等措施<span lang="EN-US">,</span>故障還不能清理。經(jīng)查找<span lang="EN-US">,</span>發(fā)現(xiàn)故障原因是弱腐蝕用的工業(yè)級硫酸。由于該硫酸質(zhì)量低劣<span lang="EN-US">,</span>濃度太低<span lang="EN-US">,</span>對除油清洗后的殘留堿液沒有完全中和能力<span lang="EN-US">,</span>因此<span lang="EN-US">,</span>出現(xiàn)上述故障。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">1.2</span></span><span style="font-size: small;"><span style="font-family: 宋體;">　故障現(xiàn)象中的假象原因<span lang="EN-US"></span></span></span></span></p> <p style="margin: 0cm 0cm 0pt; line-height: 20pt; mso-line-height-rule: exactly;"><span style="color: #333333;" lang="EN-US"><span style="font-size: small; font-family: 宋體;">    </span></span><span style="color: #333333;"><span style="font-size: small; font-family: 宋體;">故障現(xiàn)象是故障原因的外部表現(xiàn)。在大多數(shù)情況下<span lang="EN-US">,</span>故障的假象出現(xiàn)在一個工序中<span lang="EN-US">,</span>而它的原因卻存在于另一個工序中。也有兩者都出現(xiàn)和存在于同一工序中<span lang="EN-US">(</span>同一鍍槽的溶液中<span lang="EN-US">)</span>。因此<span lang="EN-US">,</span>很容易給操作者造成錯覺<span lang="EN-US">,</span>形成假象。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small; font-family: 宋體;">實(shí)例<span lang="EN-US">1</span>故障現(xiàn)象為亮銅件鍍亮鎳后表面出現(xiàn)白條、白塊。故障原因是亮銅鍍液中的十二烷基硫酸鈉缺少。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small; font-family: 宋體;">實(shí)例<span lang="EN-US">2</span>故障現(xiàn)象為槍黑鍍件表面不黑<span lang="EN-US">,</span>有條紋。故障原因是金屬雜質(zhì)所引起的。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small; font-family: 宋體;">實(shí)例<span lang="EN-US">3</span>故障現(xiàn)象為鍍鉻層表面呈白花狀。故障原因之一是弱腐蝕的硫酸濃度太低<span lang="EN-US">,</span>工業(yè)級硫酸的質(zhì)量差。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">2</span></span><span style="font-size: small; font-family: 宋體;">　怎樣識別電鍍故障中的假象</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small; font-family: 宋體;">關(guān)于識別假象的方法<span lang="EN-US">,</span>介紹如下。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">2.1</span></span><span style="font-size: small;"><span style="font-family: 宋體;">檢查和觀察與鍍件有關(guān)的因素<span lang="EN-US"></span></span></span></span></p> <p style="margin: 0cm 0cm 0pt; text-indent: 24pt; line-height: 20pt; mso-char-indent-count: 2.0; mso-line-height-rule: exactly;"><span style="color: #333333;"><span style="font-size: small; font-family: 宋體;">當(dāng)故障出現(xiàn)時<span lang="EN-US">,</span>要檢查和觀察與故障現(xiàn)象有關(guān)的因素。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    (1)</span></span><span style="font-size: small; font-family: 宋體;">檢查和觀察鍍件所經(jīng)過的有關(guān)工序</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small; font-family: 宋體;">實(shí)例<span lang="EN-US">1</span>中<span lang="EN-US">,</span>初始時認(rèn)為問題出在鍍亮鎳工序<span lang="EN-US">,</span>但亮鎳故障沒有找到<span lang="EN-US">,</span>重新檢查鍍件在亮銅鍍液中的情況。經(jīng)查找<span lang="EN-US">,</span>發(fā)現(xiàn)鍍件一入亮銅鍍槽后<span lang="EN-US">,</span>一開始時鍍層發(fā)暗、<span lang="EN-US">“</span>藍(lán)膜<span lang="EN-US">”,</span>但鍍一會上述現(xiàn)象消失<span lang="EN-US">,</span>形成光亮鍍層。亮銅鍍液正常時<span lang="EN-US">,</span>雖然鍍件一進(jìn)槽不馬上光亮<span lang="EN-US">,</span>但卻不出現(xiàn)以上現(xiàn)象。通過研究、觀察<span lang="EN-US">,</span>發(fā)現(xiàn)亮銅鍍液中泡沫少<span lang="EN-US">,</span>補(bǔ)充加入十二烷基硫酸鈉后<span lang="EN-US">,</span>故障清理。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    (2)</span></span><span style="font-size: small; font-family: 宋體;">檢查和觀察鍍件在故障前的表面狀態(tài)</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small; font-family: 宋體;">除了<span lang="EN-US">(1)</span>應(yīng)該做的有關(guān)工作以外<span lang="EN-US">,</span>還應(yīng)該檢查和觀察鍍件在發(fā)生故障現(xiàn)象前的表面狀態(tài)<span lang="EN-US">,</span>包括鍍件表面的平滑度、光亮度、色澤、表面有無氧化物等。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small; font-family: 宋體;">例如<span lang="EN-US">:</span>低錫青銅鍍件鍍鉻后<span lang="EN-US">,</span>鉻層發(fā)灰、發(fā)花<span lang="EN-US">,</span>甚至有的部位鍍不上鉻。故障出現(xiàn)在鍍鉻。應(yīng)首先檢查低錫青銅鍍件的表面狀態(tài)<span lang="EN-US">,</span>發(fā)現(xiàn)色澤不好<span lang="EN-US">,</span>鍍層發(fā)白<span lang="EN-US">,</span>錫含量高<span lang="EN-US">,</span>是不能鍍鉻的。因此<span lang="EN-US">,</span>出現(xiàn)了上述故障現(xiàn)象。鍍層發(fā)白<span lang="EN-US">,</span>錫含量高是上述故障現(xiàn)象的原因<span lang="EN-US">,</span>雖然原因出在低錫青銅工序<span lang="EN-US">,</span>故障卻表現(xiàn)在鍍鉻。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">2.2</span></span><span style="font-size: small; font-family: 宋體;">識別故障中的假象要進(jìn)行跳躍試驗(yàn)</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small; font-family: 宋體;">所謂跳躍試驗(yàn)<span lang="EN-US">,</span>就是跳過電鍍過程中某一可能產(chǎn)生故障的工序后進(jìn)行電鍍試驗(yàn)的方法。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small; font-family: 宋體;">實(shí)例<span lang="EN-US">1</span>中<span lang="EN-US">,</span>決定現(xiàn)象是否假象也可以利用跳躍法進(jìn)行識別。把工藝流程中的光亮硫酸鍍銅的工序跳過<span lang="EN-US">,</span>鐵瓦蓋不鍍亮銅<span lang="EN-US">,</span>直接入光亮鍍鎳槽進(jìn)行電鍍<span lang="EN-US">,</span>故障得到清理<span lang="EN-US">,</span>說明問題出在鍍亮銅工序不在鍍亮鎳上。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">2.3</span></span><span style="font-size: small;"><span style="font-family: 宋體;">識別故障現(xiàn)象要作對比試驗(yàn)<span lang="EN-US">[1]</span></span></span></span></p> <p style="margin: 0cm 0cm 0pt; line-height: 20pt; mso-line-height-rule: exactly;"><span style="color: #333333;" lang="EN-US"><span style="font-size: small; font-family: 宋體;">    </span></span><span style="color: #333333;"><span style="font-size: small; font-family: 宋體;">識別故障假象要作對比試驗(yàn)。所謂對比試驗(yàn)<span lang="EN-US">,</span>就是用良好的溶液代替可能有故障的溶液進(jìn)行對比試驗(yàn)的方法。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small; font-family: 宋體;">實(shí)例<span lang="EN-US">3</span>中<span lang="EN-US">,</span>開始遇到故障時<span lang="EN-US">,</span>也做了一次跳躍試驗(yàn)<span lang="EN-US">,</span>曾把電化學(xué)除油工序跳過<span lang="EN-US">(</span>此故障不能用跳躍法排除<span lang="EN-US">),</span>當(dāng)時故障清理。使得操作者就更認(rèn)為是電化學(xué)除油工序的問題了<span lang="EN-US">,</span>就想把除油溶液更換。經(jīng)研究<span lang="EN-US">,</span>為了慎重起見又做了一次對比試驗(yàn)<span lang="EN-US">:</span>用試劑純的氫氧化鈉配置<span lang="EN-US">10L</span>電化學(xué)除油液<span lang="EN-US">,</span>原弱腐蝕溶液沒動<span lang="EN-US">,</span>按原工藝流程進(jìn)行了試驗(yàn)<span lang="EN-US">,</span>結(jié)果故障現(xiàn)象再現(xiàn)。因此<span lang="EN-US">,</span>懷疑弱腐蝕硫酸溶液有問題。接著又做了一次對比試驗(yàn)<span lang="EN-US">:</span>用試劑純硫酸配置了<span lang="EN-US">10L</span>弱腐蝕溶液<span lang="EN-US">,</span>結(jié)果故障清理。說明故障出在弱腐蝕硫酸這一道工序<span lang="EN-US">,</span>而電化學(xué)除油工序有問題是一個假象。</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">2.4</span></span><span style="font-size: small; font-family: 宋體;">　要發(fā)現(xiàn)鍍液的反�，F(xiàn)象</span><span lang="EN-US"><br /><span style="font-size: small; font-family: 宋體;">    </span></span><span style="font-size: small;"><span style="font-family: 宋體;">實(shí)例<span lang="EN-US">2</span>中<span lang="EN-US">,</span>在解決故障時<span lang="EN-US">,</span>發(fā)現(xiàn)了某種成分增長或降低的反�，F(xiàn)象。槍黑鍍層不黑了<span lang="EN-US">,</span>有時是要增加增黑物質(zhì)<span lang="EN-US">,</span>但增加如此頻繁<span lang="EN-US">,</span>卻有些反常。經(jīng)檢查、試驗(yàn)<span lang="EN-US">,</span>確認(rèn)是金屬雜質(zhì)干擾<span lang="EN-US">,</span>頻繁添加發(fā)黑物質(zhì)是一個假象。<span lang="EN-US"></span></span></span></span></p>