<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>鍍前處理預鍍鎳光亮硫酸鹽鍍銅全光亮鍍鎳。在電鍍過程中發(fā)現鍍件從光亮鍍銅槽出來后<span lang="EN-US">,</span>銅鍍層呈鏡面光亮。經過鍍光亮鎳后<span lang="EN-US">,</span>發(fā)現光亮鎳鍍層表面出現白塊、白條等疵病。當時給操作者的感覺是故障出在光亮鍍鎳工序。經查找<span lang="EN-US">,</span>光亮鍍鎳工序沒發(fā)現問題<span lang="EN-US">,</span>故障仍未解決。起初為了維持生產<span lang="EN-US">,</span>鍍完亮鎳后只得進行拋光<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>經過鍍亮鎳后才發(fā)現故障。這樣給我們造成鍍亮鎳出現故障的假象。</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>又出現了上述故障<span lang="EN-US">,</span>加入上述兩種增黑物質后故障才清理。這樣反復進行<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>天僅補充一次<span lang="EN-US">,</span>增黑劑每天只補充一次。上述增黑物質的補充<span lang="EN-US">,</span>顯然屬反�，F象。經過檢查和試驗<span lang="EN-US">,</span>確認鍍液中的銅、鋅等雜質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>短時間內雜質也被配位<span lang="EN-US">,</span>隨著電鍍過程的進行<span lang="EN-US">,</span>配位劑有所消耗<span lang="EN-US">,</span>雜質的干擾作用就反復出現<span lang="EN-US">,</span>并且影響黑度。在同一鍍槽內<span lang="EN-US">,</span>當黑度開始下降、有條紋時<span lang="EN-US">,</span>加入增黑物質<span lang="EN-US">,</span>故障現象有所減輕或清理<span lang="EN-US">,</span>使操作者誤認為是缺少增黑劑所引起的故障的假象。而這一故障現象的真相卻是金屬雜質所引起的。<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;">實例<span lang="EN-US">3</span>　鍍鎳或鍍低錫青銅的鍍件<span lang="EN-US">,</span>經過電化學除油、清洗后<span lang="EN-US">,</span>再經過<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行鍍鉻<span lang="EN-US">,</span>發(fā)現鍍鉻層有白花。如不經電化學除油<span lang="EN-US">,</span>上述故障立即出現<span lang="EN-US">,</span>并且電化學除油時間越長<span lang="EN-US">,</span>上述現象越嚴重<span lang="EN-US">,</span>給我們造成電化學除油工序存在問題的假象。對除油液采取稀釋、調整等措施<span lang="EN-US">,</span>故障還不能清理。經查找<span lang="EN-US">,</span>發(fā)現故障原因是弱腐蝕用的工業(yè)級硫酸。由于該硫酸質量低劣<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;">故障現象是故障原因的外部表現。在大多數情況下<span lang="EN-US">,</span>故障的假象出現在一個工序中<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;">實例<span lang="EN-US">1</span>故障現象為亮銅件鍍亮鎳后表面出現白條、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;">實例<span lang="EN-US">2</span>故障現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;">實例<span lang="EN-US">3</span>故障現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;">當故障出現時<span lang="EN-US">,</span>要檢查和觀察與故障現象有關的因素。</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過的有關工序</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;">實例<span lang="EN-US">1</span>中<span lang="EN-US">,</span>初始時認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。經查找<span lang="EN-US">,</span>發(fā)現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>藍膜<span lang="EN-US">”,</span>但鍍一會上述現象消失<span lang="EN-US">,</span>形成光亮鍍層。亮銅鍍液正常時<span lang="EN-US">,</span>雖然鍍件一進槽不馬上光亮<span lang="EN-US">,</span>但卻不出現以上現象。通過研究、觀察<span lang="EN-US">,</span>發(fā)現亮銅鍍液中泡沫少<span lang="EN-US">,</span>補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>應該做的有關工作以外<span lang="EN-US">,</span>還應該檢查和觀察鍍件在發(fā)生故障現象前的表面狀態(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。故障出現在鍍鉻。應首先檢查低錫青銅鍍件的表面狀態(tài)<span lang="EN-US">,</span>發(fā)現色澤不好<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>出現了上述故障現象。鍍層發(fā)白<span lang="EN-US">,</span>錫含量高是上述故障現象的原因<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行跳躍試驗</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<span lang="EN-US">,</span>就是跳過電鍍過程中某一可能產生故障的工序后進行電鍍試驗的方法。</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;">實例<span lang="EN-US">1</span>中<span lang="EN-US">,</span>決定現象是否假象也可以利用跳躍法進行識別。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;">識別故障現象要作對比試驗<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。所謂對比試驗<span lang="EN-US">,</span>就是用良好的溶液代替可能有故障的溶液進行對比試驗的方法。</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<span lang="EN-US">,</span>曾把電化學除油工序跳過<span lang="EN-US">(</span>此故障不能用跳躍法排除<span lang="EN-US">),</span>當時故障清理。使得操作者就更認為是電化學除油工序的問題了<span lang="EN-US">,</span>就想把除油溶液更換。經研究<span lang="EN-US">,</span>為了慎重起見又做了一次對比試驗<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>按原工藝流程進行了試驗<span lang="EN-US">,</span>結果故障現象再現。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<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)現鍍液的反�，F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)現了某種成分增長或降低的反�，F象。槍黑鍍層不黑了<span lang="EN-US">,</span>有時是要增加增黑物質<span lang="EN-US">,</span>但增加如此頻繁<span lang="EN-US">,</span>卻有些反常。經檢查、試驗<span lang="EN-US">,</span>確認是金屬雜質干擾<span lang="EN-US">,</span>頻繁添加發(fā)黑物質是一個假象。<span lang="EN-US"></span></span></span></span></p>