Sustainable Approach to Electroless Nickel Plating

1. Crystallinity and Corrosion of 400µ" and 455µ“ September 7 2009 A Sustainable Approach to Electroless Nickel Plating

2. Overview • What is sustainability? • History of Regulatory Impact on Surface Finishing • Examples of sustainability in surface finishing • What is driving innovation in the EN plating tank? • The Next Generation of EN • Development objectives/challenges • Reduced Ion Technology Performance Characteristics • Process/Deposit • Benefits of Reduced Ion Technology • A look to the future

3. What is sustainability? • It’s a long term mindset where ecology and economy merge into one and humans live within the limits of available resources. Where all actions taken are considered for their effect on the environment and the well being of future generations.

4. Sustainability in Surface Finishing • Surface finishing by its very nature, is a sustainable process • Surface treatment extends useful of life of many components in a wide variety of applications • Annual cost of corrosion worldwide is 3% global GDP (1) • Applying a very thin film on relatively inexpensive and readily available material vs the use of exotic alloys is a sustainable practice • Surface finishing allows the use of lighter materials that improve fuel efficiency and reduce carbon footprints (1)"Now is the Time," a paper presented by George F. Hays, PE, Director General, World Corrosion Organization.

5. Sustainability in Surface Finishing • Relevant Aspects of Sustainability • Overall concept of surface finishing is sustainable • Environmentally responsible • Stewards of the environment or just complying? • Consumption responsible • Consumer responsible

6. History of Environmental Regulations that impacted surface finishing Clean Air Act-1970 Clean Water Act-1972 RCRA-1976 TSCA-1976 LRTAP-1979 Superfund-1980 CWA 413/433-1985 Montreal Protocol-1989 NESHAP 1995 ELV-2000 MPM-2002 WEEE-2003 Stockholm convention-2004 ROHS-2006 REACH-2007 CWA 413/433 Review-2015 CAA Air Toxics Update-2015

7. Impacted Elements, Compounds and Substances • Environmental Regulations have banned or restricted the use of: • Cyanide • Solvents • CFC’s • Cr+6 • Lead • Cadmium • PFOS • Borates • EDTA • Ammonia • Cobalt • Phosphates

8. Sustainability in Surface Finishing • Examples of eco-innovations • Replacement of Halogenated Solvents with Alkaline Cleaners • Low phosphate/phosphate free cleaners • Removal of CN from Zn plating processes • Cr+6 substitutes • Fume suppressants in chrome plating • Pb and Cd replacement in EN (RoHS and ELV) • PFOS and PFC free • Borate free • EDTA free • Ammonia free • Cobalt free • Reduced surface tension • Electrodialysis for EN and acids • Water re-use and recovery • Zero discharge

9. History of Commercial EN 1st Generation ~ 1950 • Kanigen - 7-9% P, difficult to operate, general purpose EN 2nd Generation ~ 1970 - 1980 • High corrosion resistance high phosphorus EN developed by commercial pioneering companies like Elnic and Allied Kelite 3rd Generation ~ 1980 - 2000 • Wide expansion of processes, including composites, low phosphorus, ternary alloys. Many suppliers contributed 4th Generation ~ 2000 - present • Lead and cadmium free 5th Generation ~ 2012+ • Eco-optimized EN • Reduced Ion Technology • Low temperature EN

10. History of “EN”novation Drivers • 1970-1980 Performance based • Improved corrosion protection • Simplified operation • Longer solution life, faster plating speeds, brighter deposits • 1990-2000 Need to meet specific applications • Improved solderability • Increased thermomagnetic stability • Higher “as plated” hardness • Increased lubricitiy • 2000 to today Eco-responsibility and compliance • ELV,WEEE,ROHS led to cadmium/lead free systems • Waste minimization –Steady state EN, extended bath life

11. Future Drivers for “EN”novation • Reduced Environmental Impact • Waste minimization • Overall reduction of waste to treat or dispose of • Simplification of treatment • Reduction in use of strong complexors • Reduction of nickel in waste stream • Reduction of nickel in air emissions • Lower energy consumption • Reduced Carbon footprint • Improved workplaces • Nickel allergies • Air Emissions – Inhalation • Avoids European: December 2010 rule CLP 00/ATP 01 • Toxic: danger of serious damage to health by prolonged exposure through inhalation • Cost Reduction

12. EN Development Objectives to Meet Future Demands Develop EN technology with at least a 33% reduction in nickel concentration withoutsacrificing either : Intrinsic deposit characteristics Process performance Reduce process cost by minimum of 5%

13. EN Development Challenges • Earlier industry attempts to reduce nickel metal simply involved using less nickel. • Other components were never adjusted • Over 50 years of commercial R&D work was centered on 6 g/l technology • Required to optimize complexor type and concentration • Formulate chemistry to accommodate less nickel • maintain critical operating parameters within normal specifications (e.g. operating temperature and pH) • Critical stabilizer/additive selection and concentration • Selection of additives (e.g. stabilizers, brighteners, etc.) to maintain or enhance deposit characteristics while not sacrificing operating performance

14. EN Testing Matrix Process Performance Deposit Performance Corrosion and hardness performance must be maintained or increased Lower cost and increased productivity mean nothing if quality requirements aren't met Deposit tensile stress over the life of the bath must not vary considerably from 6 g/l counterpart Surface roughness and appearance must be maintained or enhanced No negative impact on deposit staining • Lower nickel must not reduce plating speed • Reduced production not an option • Adjusted complexing agent and additives must not negatively impact stability • Increased equipment plate out would be unacceptable • New chemistry must maintain or extend current expected bath life • Waste reduction and cost are technology drivers

15. EN Testing Matrix • Tested the following criteria • Plating rate vs bath age (by weight gain and XRF) • Stability (Boiling test) • Brightness (Gloss measurements) • Specific gravity/staining • Nickel drag out • Neutral slat spray • Morphology

16. Reduced Ion MPENPlating Speed

17. Reduced Ion MPENStability ~8% increase in solution stability

18. Reduced Ion MPENSpecific Gravity • Difference of 0.026 g/cc at 5 mto’s • Comparable to rinsing in beer vs pure water • 108 lbs less of “stuff” in a 500 gallon EN tank • Consider the impact of this on drag out and staining

19. Reduction of ~50% Ni concentration in rinse water Reduced Ion MPENNickel drag out* PPM *Method: 5 panels plated consecutively with 5 sec dwell time over EN bath after plating followed by rinsing into beaker with deionized water. “Rinse water” collected and brought to standard volume in a volumetric flask and analyzed via AA spectrophotometer

20. Reduced Ion Impact on deposit staining(0.2 mils barrel plated EN on 1010 mild steel stamping) *Surface tension reduced from 50 to 32 dynes/cm

21. Reduced Ion Impact on Deposit Morphology(High Phosphorus EN, 0 metal turnovers, SEM 500X) 0.5 mil deposit 3.0 mil deposit Reduced Ion Conventional

22. Reduced Ion MPEN Deposit Brightness RI MPEN Standard MPEN Gloss meter Readings (GU 60) Metal Turnovers Improved consistency of brightness over bath life vs conventional 6 g/L MPEN

23. Reduced Ion MPEN Neutral Salt Spray RI MPEN 100 Hrs Rating System: A: 0 rust spots, B: 1-5 spots, C: 6-10 spots, D: 11-20 spots 0 MTO 7 MTO Standard MPEN 100 Hrs 0 MTO 7 MTO

24. Benefits of Reduced Ion EN Technology • ECO-benefits • Reduced Ni metal in rinse water by 50% • Longer solution life reduces bath make-up and associated treatment • Safer work environment • Reduction in nickel emissions-must confirm both experimentally and in the field • Less nickel reduces exposure for those allergic to nickel • Improved bath stability • Reduced plate out on equipment requires less work with hazardous stripping chemicals • Longer strip solution life and less generation of waste • ECO-nomical benefits • Savings for the initial tank/bath make up of 5-10% due to reduced nickel • Less nickel to treat/more creative options for treatment • Unique complexor system simplifies waste treatment of spent solution • RI users that haul spent EN away report ability to reduce waste volume by 30% when evaporating

25. Reduced Ion EN Technology in the real world • Since its limited release in 2012 there have been nearly 200 large reduced Ion EN baths made up and operated in several respected EN platers in North America and Europe • In France, it was required to avoid a placard with this phrase: • R48/23 phrase: toxic danger of serious damage to health by prolonged exposure through inhalation • Process/Deposit Performance • Slightly longer bath life • Brighter MPEN deposit • Smoother HPEN deposit • Reduced staining • Less nickel in waste stream • No impact on speed provided bath maintained above 80% activity • Approximate 5-10% cost savings realized • Reduced waste volume for those that evaporate/haul

26. Future Eco-barriersWater • Water will be the most prized commodity in the future. • By 2050, without a dramatic shift in global management of water resources more than ½ of the world’s grain production and population (4.8 B people) will be unsustainable. (1) • 45% of projected global GDP ($78 trillion) will be under stress (1) • Expect tighter discharge limits in the future and the potential for required recycling/reuse and zero discharge scenarios • (1) International Food Policy Research Institute (IFPRI) http://growingblue.com/water-in-2050/

27. Future Eco-barriersWorkplace Safety • Emphasis on safe work environments will expand • Targeted source reductions never cease • 2015 review of water soluble nickel compounds • EPA will continue to restrict emissions and Europe’s standards often will move West • Maine's attempt to place soluble nickel in top 49 toxic metal list

28. Future Eco-barriersClimate Change • Truth lies somewhere between practical science and exploitation of diverse political agendas • Safe bet is to focus on a long term, sustainable view • Reducing our demand and associated use of fossil fuels cant be a bad thing? • Pursue surface finishing technology that operates in parallel to this thinking. • Reduced operating temperatures on all process tanks • Improved insulating methods • Plating process friendly foam blankets • Air free agitation • Reduced chilling demands

29. Future Eco-barriersConsumer Impact • Our industry is being driven, more than ever, by consumer decisions • Global expansion of consumer based economies • Consumers make highly informed decisions and have numerous choices • Cost, features, color, finish, material, content safety • Consumers have integrated eco-conscious criteria in their decision making process • Dolphin safe tuna, product carbon footprint, conflict free diamonds • Consumer product companies and everyone in the supply line must: • align their objectives • react quickly • recognize that successful surface finishing companies exploit these opportunities

30. A look to the not so distant future • Chrome free etchants for POP • High performance and economical alternatives to cadmium for aerospace and electronics • Chrome free passivates for zinc and zinc alloy • Viable alternatives to Cr+6 hard chrome • Consumer safe decorative and precious metal technology

31. Closing Remarks • Suppliers and applicators share responsibility to overcome current and future barriers • Commitment to continuous investment in R&D • Partnering with Universities • Supporting industry groups both financially and with active participation • Aligning with suppliers that share this long term, sustainable view • Forward thinking companies don't wait for regulations to force their actions. • Innovative companies see barriers as opportunities; to elevate technology and their organization • Long term, successful companies will need to embrace the triple bottom line of People, Planet, Profit

32. Acknowledgment • Ambrose Schaffer who co-developed this latest generation of EN technology, conducted the lab trials and provided the bulk of the technical data herein • Christian Richter for his invaluable input on the various regulations that appear as a barrier but often act as a ladder for our industry

33. Thank you