To obtaining quality deposits it is important to monitor and control electrochemical deposition (ECD) processes. This is also essential for an automatic plating system designed to minimize operator attention to production operations. A skilled and knowledgeable operator can maintain a reasonable plating quality with little supporting equipment. However, trends to more automation to reduce costs with higher processing speeds, application of plating to higher value products, and assurance of quality plating make it necessary to utilize many monitoring and control facilities.Electroplating process results are dependent on process stability and control and on the chemical composition of the plating bath. This makes it important to monitor the concentration of the various species in the bath. At a minimum, it is usually important to monitor the concentration of the metal ions and the supporting electrolyte. It may also be necessary to monitor constituents that interact in trace amounts or organic additives that modify the behavior of the process.Electroless plating, as described elsewhere, is an autocatalytic process initiated by a catalyst such as palladium and then catalyzed by the deposited metal itself [1]. Electrochemically, the system is quasi-stable, as it must be to work. This necessitates a closer control of bath chemistry than that required for electroplating solutions. Frequent electroless bath analysis and maintenance are necessary, especially when fast plating is involved, due to the speed with which the chemistry changes. Fast electroless metal deposition or poor bath control can result in spontaneous bath decomposition, causing metal particles to form and strip the solution of all metallic ions. Manual bath sampling and analysis are often not practical. Machines have been developed which automatically take samples and analyze and reconstitute the bath chemistry [2]. These will be discussed in Section 25.2.11. This chapter has three sections: process monitoring, bath constituent concentration monitoring and replenishment, and product monitoring. The first section focuses on sensors and techniques for monitoring the plating and associated processes and how to use these to increase the automation level of plating equipment. Because the concentration monitoring and control of chemistries used in the plating processes are so important and may be handled by equipment separate from the electroplating equipment in some cases, these topics are given their own section. Finally, a short section on product monitoring and quality control is included, although the reader should understand that product monitoring should be dictated more by the product requirements than by the process used to produce it. This section is meant merely as a reference to some of the common monitoring methods in use and how they are applied to control plating processes.
PROCESS MONITORINGPlating processes, whether electrolytic or electroless, are utilized for many varied purposes. These may be for the manufacture of simple and cheap parts o...