cadmium replacement on connectors€¦ · connectors (with or without hexavalent chromium...

Cadmium replacement on connectors

ASETSDefense – November 19, 2014Gerald Tredan

This document and all information contained hereinis the sole property of Radiall and is subject to the confidentiality obligations of the recipient.

This document shall not be reproduced or disclosedto any third party for any purpose whatsoever or usedfor manufacturing purposes without prior written agreement from Radiall.

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Approved for release by Gerald Tredan, Jan 6, 2015

Agenda

1. Company Overview

2. Tracking of products impacted by environmental regulations

3. Alternatives to Cadmium + HCP3.1 « Moderate salt mist perf » configurations3.2 « High salt mist perf » configurations

4. Conclusions and future needs

Confidential 311/2014

Confidential 4

1. Company Overview

11/2014

1. Company Overview

Confidential 5

• Founded in 1952• Revenue 2013: 235 M€ ($325m)• Listed on NYSE-Euronext• Ownership: 87% Private, 13% Public• R&D ≈ 7 to 8% of revenue each year• 9 Manufacturing plants in America, Asia

& Europe• 3,000 Employees Pierre Gattaz (CEO)

11/2014

1. Company Overview

Confidential 6

RF Coaxial Connectors

RF CableAssemblies

MicrowaveComponents

RF - µWaveSwitches

Antennas MultipinConnectors

Space QualifiedComponents

Fiber Optics

11/2014

1. Company Overview

Radiall has offices on 5 continents, 13 countries and is represented in over 75 areas around the

world

America38.8%

France14.7%

Rest of Europe

18.5%

Asia & Rest of World

28%

% of sales 2013

7

9 plants worldwide

11/2014

1. Company Overview

Aerospace37%

Defense & Space30%

Automotive4%

Industrial16%

Telecom13%



Radiall Products approach

1. Identification 2. Prioritization 3. Strategy

Implementation of an environmental database

Environmental regulations

Substances concerned

End product impacted

Depending on criticality

• REACH sunset date • Sales volumes• Strategic customers• Etc…

Define best option to be in conformance

• Plating modification• Design changes• Subcontracting

outside EU• Authorization

requirement• Loss of market

Current priorities: Hexavalent chromium and Cadmium


3. Alternatives to Cadmium + HCP over aluminium

3.1 « Moderate perf » configurations

3.2 « High perf » configurations


3. Alternatives to Cad + HCP over aluminium

Cadmium used on a wide range of aluminium connectors (with or without hexavalent chromium passivation)

Main advantages for electrical connectors: • High electrical continuity• Harsh environment resistance• Material potential close to aluminium one

Two levels of corrosion resistance

(Neutral Salt Spray - ASTM B117)

Moderate: 48h or 96h NSS

High: 500h NSS


3. Alternatives to Cad + HCP over aluminium

Process already qualified by Radiall

Substitutes Qualified basismaterials

Sacrificialprotection

TCP AlSi9Cu3, Série 6000 Yes

Zinc + Cr III

Electroless NickelAll aluminium alloys

used by Radiall NoElectroless +

electrolytic nickel

3.1 48h / 96h NSS applications


Radiall initiated an active project for substitution of high perf

cadmium in 2009

Evaluation of Zn-Ni alloys, pure aluminium, ENPTFE

ENPTFE was identified as the only process where corrosion

resistance and electrical performance can be reached without HCP

according preliminary test

Confidential 14

3. Alternatives to Cad + HCP over aluminium3.2 500h NSS applications

11/2014

3. Alternatives to Cad + HCP over aluminium3.2 500 hours NSS applications3.2.1 EN-PTFE Properties

8

0

0,4

0,8

ENPTFE

Ni electro

BronzeSnPb

Uniform deposit

Wear resistance

IntrinsicProperties

Non-reflective aspect

Non-Magnetic deposit

Amorphous structure (observed by XRD)

Cadmium


8

Bronze

ENPTFE

ENHP

-0,4

0

ENPTFE

Cadmium

Zn-NiTCP / HCP

Cor

rosi

on P

oten

tiel (

V/E

CS

)

-0,8

-1,2

Electrical continuity

Wettability

Material potential

> 90°

Ni electro

Temperature resistance

Use >392 oF Temperature cycling -85 / +347 oF

IntrinsicProperties

Confidential 16

3. Alternatives to Cad + HCP over aluminium3.2 500 hours NSS applications3.2.1 EN-PTFE Properties

11/2014

Reference: ENPTFE vs ENPTFE

Dynamic Salt Spray(500h NSS /500 durability cycles) Results

1. Electrical continuity (shell-toshell): Compliant ( < 2,5mV)

2. NSS resistance : Compliant(No degradation of deposit and basematerial)

Confidential 17

3. Alternatives to Cad + HCP over aluminium3.2 500 hours NSS applications3.2.2 ENPTFE evaluation regarding MIL-DTL-38999

11/2014

Compatibility ENPTFE / Cadmium

250 h 500 h

Neutral salt spray

Total oxidationof cadmium layer

Partial oxidationof cadmium layer

Results- No degradation of base metal- Corrosion mechanism is stopped overNickel underlayer

Corrosion resistance: compliant

Confidential 18


11/2014


Impact of static NSS on electrical continuity

Results No degradation of electrical signal during the test

Confidential 19

Test No. Average (mV)

9 0,4

10 0,5


9 0,6

10 0,5

After NSS 500h

1. Electricalcontinuity 2. NSS 500h Mated shells 3. Electrical

continuity


11/2014


Impact of dynamic NSS on electrical continuity

ResultsElectrical performance very close to requirements

Mil dtl 83527 : 2,5mV Mil dtl 38999 : 5mV (after Salt spray)

1. Electricalcontinuity

2. NSS 452h mated shells + 48h unmated

3. Durabilitycycles (x450)

4. Electricalcontinuity

Confidential 20


3 0,45

4 0,56

5 0,36


3 2,5

4 2,9

5 2,2

After Dynamic NSS


11/2014

Confidential11/2014 21

ENPTFE connectors could reach all requirements of Milspecifications

So why do we still plate cadmium on our components?


Galvanic compatibility risk evaluation ?

More understanding of galvanic corrosion mechanism by using galvanic predictionmodels

Definition of key parameters to avoid galvaniccorrosion (design, materials, environement)

Risk in case of coating damage ? Define and conduct representative evaluation

Product design update Product design adjustment and run full product qualification

Damage test


3. Alternatives to Cad + HCP over aluminium3.2 500 hours NSS applications3.2.3 Additional evaluation

Scratches dimensions: Width : 0.5 mm ; Depth : 0.2 mm

Tool: Use of automated milling cutter to get repeatable scratches

Salt Spray: 500 hours exposure

Comparison of ENPTFE and Cadmium+HCP behaviour

Damage test Cross section observation to analyse behaviour inside scratches



ENPTFECadmium

Subsurface pitting corrosion

No attack of base metal

Coating

Base metal

Aluminium 2017

Aluminium 6061

Damage test



Galvanic corrosion between ENPTFE and aluminium can occurs but criticality will

depend on aluminium alloy, damage severity, environmental conditions…

Does self-healing is a requirement (not mentioned in product specifications) ?

Does such damage can occur during product life of connector applications?

How to define "representative" scratches? Acceptable result ?

Computational evaluation of multi-materials assembly criticityPartnership with CORRDESA company


3. Alternatives to Cad + HCP over aluminium3.2 500 hours NSS applications3.2.3 Additional evaluation in progress

Main goals :

Analysis polarization data from different plating materials (cadmium,Alodine, TCP, ENPTFE, HPEN, ZnNi)

Use software including logarithmic formula to analysis connectorsdesign and corrosive environment regarding corrosion speed rate ofdifferent plating materials

Define plating/materials best practices regarding products design andenvironment

Current specification and test sequences are not sufficient toqualify cadmium and chromate finish substitute

Among possible solutions to substitute cadmium, OEM have notselected a solution yet

Without clear OEM indication Radiall cannot launch processimplementation


3. Alternatives to Cad + HCP over aluminium3.2 500 hours NSS applications3.2.4 Conclusion

4. Conclusions


4. Bilan

Confidential 28

For moderate salt mist performance configurations, alternativehave been identified and product qualifications are in progress

For high salt mist performance, lot of studies performed duringseveral years by RADIALL

No perfect solution available on the market EN PTFE limitation have been highlighted and galvanic

corrosion could be an issue depending of connector design andproduct environment

Global supply chain could be impacted on connectors Mil Marketafter 2017 if we don’t improve coordination on Cad substitutionactivities between suppliers, key market players and OEM

11/2014

Current specifications and test sequences are not sufficient toqualify cadmium + chromate finish substitute

Thank you

Questions or comments ?

Gérald TREDANR&D Plating ManagerTel: +33.6.22.56.09.86

Email: [email protected]


cadmium replacement on connectors€¦ · connectors (with or without hexavalent chromium...

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