Dave:

It is unclear what you mean by 'breakdown" in your plating tanks, but one of
the questions that you want to look at when analyzing this problem, and
ultimately solving it, is to look at whether or not break down occurs only at
the edges.  If so, it is possible that the problem could be excessive current
density.  High CD could cause gas evolution at the work, and this would lift
the film.

All of this overlooks the possibility that you may need better cleaning,
shorter hold times etc.  Why don't you lay out your whole process for us,
from beginning of cleaning, to plating, so that we don't have to guess at
what may be going on.  Put down times, temperatures, hold times, and number
of rinse tanks, etc.

Rudy Sedlak
RD Chemical Company