Zinc Nickel Electroplating: A High-Performance Solution for Metal Protection

Zinc nickel electroplating is a cutting-edge process that offers superior corrosion resistance and durability for metal products. Unlike conventional zinc coatings, zinc nickel combines the best of both metals to create a coating that can withstand harsh environments and demanding applications. In this blog post, we will explore the alloy composition, the electroplating process, and the applications of zinc nickel electroplating, as well as the reasons why manufacturers are increasingly adopting this solution for their metal protection needs.

Alloy Composition and Chemistry

Zinc nickel alloy is a mixture of zinc and nickel in varying proportions. The nickel content can range from 6% to 20%, depending on the desired properties and performance of the coating. The higher the nickel content, the higher the corrosion resistance, hardness, and thermal stability of the coating. However, the higher the nickel content, the more difficult and costly the electroplating process becomes. Therefore, the optimal nickel content is usually between 12% and 15%, which provides a balance between coating quality and process efficiency.

The synergy between zinc and nickel creates a coating that exhibits exceptional corrosion resistance, especially in alkaline and saline environments. Zinc nickel coatings can provide up to 10 times more protection than conventional zinc coatings and can resist up to 1000 hours of salt spray testing. Zinc nickel coatings also offer sacrificial protection, meaning that they corrode preferentially to the base metal, thus preventing the spread of corrosion. Additionally, zinc nickel coatings have good wear resistance, electrical conductivity, and solderability, making them suitable for a variety of applications.

Electroplating Process Unveiled

J&M Plating automated Zinc Nickel Electroplating line

Electroplating is the process of applying a metal coating on another metal by using an electric current. Electroplating can be performed in different types of electrolytic baths, such as acid, alkaline, or neutral. Zinc nickel electroplating is usually done in an alkaline bath, which has several advantages over other types of baths, such as lower toxicity, higher stability, and better throwing power. Throwing power is the ability of the electroplating solution to coat the recessed or hidden areas of the metal object.

The electroplating process involves meticulously controlling factors such as current density, temperature, and bath chemistry. These factors affect the thickness, composition, and quality of the coating, as well as the plating efficiency and cost. The electroplating process typically involves the following steps:

1. Preparation: The metal object to be electroplated is cleaned and prepared to ensure good adhesion of the zinc-nickel coating. This may include degreasing, pickling, rinsing, and activating the metal surface. The preparation step is crucial for achieving a high-quality and uniform zinc-nickel coating.

2. Electroplating: The metal object is placed in a zinc-nickel electroplating solution, and an electric current is applied. This causes the zinc and nickel ions in the solution to deposit onto the metal object, forming a thin zinc-nickel coating. The thickness and composition of the zinc-nickel coating can be controlled by adjusting the parameters of the electroplating process, such as the current density, voltage, temperature, and time. The zinc-nickel electroplating solution may also contain additives, such as brighteners, levelers, and inhibitors, to improve the appearance and performance of the zinc-nickel coating.

3. Post-processing: The metal object is rinsed and dried to remove any residual electroplating solution. The zinc-nickel coating may also undergo further treatments, such as passivation, chromatin, or sealing, to enhance its corrosion resistance and aesthetic properties. The post-processing step can also affect the color, gloss, and hardness of the zinc-nickel coating.

Applications Across Industries

Zinc nickel electroplating is a versatile solution with applications spanning various industries. Some of the common applications of zinc-nickel electroplating are:

Zinc Nickel product staged to review and process

• Automotive: Zinc nickel electroplating is used to protect automotive components, such as brake calipers, fasteners, fuel system components, and exhaust components, from corrosion, wear, and high temperatures. Zinc nickel electroplating can also improve the friction and noise properties of the metal parts, as well as reduce the weight and cost of the vehicle.

• Electronics: Zinc nickel electroplating is used to protect electronic components, such as circuit boards, connectors, housings, and heat sinks, from corrosion, wear, and high temperatures. Zinc nickel electroplating can also improve the electrical conductivity and solderability of the metal parts, as well as provide a smooth and uniform surface for the attachment of other components.

• Aerospace: Zinc nickel electroplating is used to protect aerospace components, such as weapons systems, vehicles, and aircraft, from corrosion, wear, and high temperatures. Zinc nickel electroplating can also improve the strength and fatigue resistance of metal parts and reduce the weight and cost of aerospace equipment.

• Construction: Zinc nickel electroplating is used to protect construction materials, such as rebar, guardrails, and fasteners, from corrosion, wear, and high temperatures. Zinc nickel electroplating can also provide a decorative finish to the metal structures, as well as improve their weldability and paintability.

• Agriculture: Zinc nickel electroplating is used to protect agricultural machinery and equipment, such as farm machinery, irrigation equipment, and food processing equipment, from corrosion, wear, and high temperatures. Zinc nickel electroplating can also improve the hygiene and safety of food products, as well as reduce the maintenance and replacement costs of agricultural equipment.

• Marine: Zinc nickel electroplating is used to protect marine components, such as boat propellers, hardware, and fittings, from corrosion, wear, and high temperatures. Zinc nickel electroplating can also improve the performance and efficiency of marine equipment, as well as reduce the environmental impact of marine activities.

• Oil and gas: Zinc nickel electroplating is used to protect oil and gas components, such as drilling equipment, downhole components, and valves, from corrosion, wear, and high temperatures. Zinc nickel electroplating can also improve the reliability and safety of oil and gas operations, as well as reduce the operational and environmental risks of the oil and gas industry.

Did You Know?

• Automotive endorsement: Major automotive manufacturers, such as Ford, GM, and Toyota, specify zinc nickel coatings for critical components, recognizing the longevity and performance benefits, especially in challenging conditions, such as salt spray, brake fluid, and high temperatures.

• Environmental edge: Zinc nickel is considered environmentally friendly compared to some alternative coatings, such as cadmium and hexavalent chromium, which are toxic and carcinogenic. Zinc nickel electroplating also reduces the use of natural resources and energy, as well as the generation of waste and emissions, contributing to its growing popularity in industries with a focus on sustainability.

The Shift to Zinc Nickel Electroplating

Manufacturers are making a strategic shift to zinc-nickel electroplating for several compelling reasons. The alloy’s enhanced corrosion resistance ensures that components withstand the harshest conditions, extending the lifespan of products and reducing maintenance costs. Additionally, the alloy’s ability to provide sacrificial protection adds another layer of defense against corrosion. Furthermore, the alloy’s improved mechanical and electrical properties enhance the performance and functionality of the products, as well as reduce their weight and cost. Lastly, the alloy’s environmental friendliness meets the regulatory and social demands for greener and safer products, as well as reduces the environmental impact and liability of the manufacturers.

Conclusion

Zinc nickel electroplating is a high-performance solution for metal protection. Its advanced alloy composition, precise electroplating process, and diverse applications make it a powerhouse solution for industries demanding the utmost in performance and longevity. Zinc nickel electroplating also offers other benefits, such as sustainability, electrical conductivity, and food safety. However, zinc-nickel electroplating also faces some challenges and limitations, such as hydrogen embrittlement, process complexity, and coating variability. Therefore, there is a need for continuous research and innovation in zinc nickel electroplating to overcome these issues and to meet the evolving needs and expectations of customers and society.

References

• 1: Electroplating of Zn-Ni Alloy Coating on Mild Steel and Its Electrochemical Studies | SpringerLink

• 2: Applied Sciences | Free Full-Text | Progress in Electrodeposition of Zinc and Zinc Nickel Alloys Using Ionic Liquids | HTML

• 3: Electroplating and Physicochemical Properties of Zinc–Nickel Alloy Coatings | SpringerLink

• 4: Zinc-Nickel Plating for Fasteners: What to Know | Wilson-Garner

• 5: Zinc Nickel Plating - Zinc Nickel Electroplating | Gatto Industrial Platers, Inc.

• 6: Zinc-Nickel (Zn-Ni) Plating: process and advantages

• 7: Zinc & So2 Nickel Electroplating | ZnNi Plating | AlumiPlate

Exploring the Wonders of Zinc Electroplating

Zinc electroplating is a widely used process for coating metal objects with a thin layer of zinc. It is a highly effective method for preventing corrosion and enhancing the durability of various products, from construction materials to automotive components. Zinc electroplating is also a relatively easy metal to electroplate, making it a popular choice for a variety of applications.

In this blog post, we will explore the benefits, processes, and applications of zinc electroplating, as well as some recent advances and challenges in this field.

Benefits of Zinc Electroplating

In addition to its corrosion resistance, zinc electroplating also offers a number of other advantages, such as:

• Sustainability: Zinc electroplating can help to extend the life of metal products, reducing the need for replacement. This can help to reduce waste and conserve natural resources. Zinc is also a recyclable material, which can further contribute to environmental sustainability.

• Electrical conductivity: Zinc electroplating can improve the electrical conductivity of metals. This is important for applications in the electronics industry, such as circuit boards and connectors. Zinc electroplating can also provide a uniform and smooth surface, which can improve the contact resistance and signal transmission of electrical components.

• Food safety: Zinc electroplating is used in the food and beverage industry to protect metal food cans and processing equipment from corrosion. This helps to ensure the safety of food products, as well as to preserve their quality and shelf life. Zinc electroplating can also prevent the leaching of harmful metals, such as lead and cadmium, into food products.

Process of Zinc Electroplating

The zinc electroplating process typically involves the following steps:

1. Preparation: The metal object to be electroplated is cleaned and prepared to ensure good adhesion of the zinc coating. This may include degreasing, pickling, rinsing, and activating the metal surface. The preparation step is crucial for achieving a high-quality and uniform zinc coating.

2. Electroplating: The metal object is placed in a zinc electroplating solution and an electric current is applied. This causes the zinc ions in the solution to deposit onto the metal object, forming a thin zinc coating. The thickness and composition of the zinc coating can be controlled by adjusting the parameters of the electroplating process, such as the current density, voltage, temperature, and time. The zinc electroplating solution may also contain additives, such as brighteners, levelers, and inhibitors, to improve the appearance and performance of the zinc coating.

3. Post-processing: The metal object is rinsed and dried to remove any residual electroplating solution. The zinc coating may also undergo further treatments, such as passivation, chromating, or sealing, to enhance its corrosion resistance and aesthetic properties. The post-processing step can also affect the color, gloss, and hardness of the zinc coating.

Applications of Zinc Electroplating

Zinc electroplating is used in a wide range of industries and for a variety of products. Some of the common applications of zinc electroplating are:

• Construction: Zinc electroplating is used to protect construction materials, such as steel beams, rebar, and guardrails, from corrosion. Zinc electroplating can also provide a decorative finish to the metal structures, as well as to improve their weldability and paintability.

• Automotive: Zinc electroplating is used to protect automotive components, such as chassis, bumpers, and engine parts, from corrosion. Zinc electroplating can also improve the wear resistance and friction properties of the metal parts, as well as to reduce the noise and vibration of the vehicle.

• Electronics: Zinc electroplating is used to protect electronic components, such as circuit boards and connectors, from corrosion. Zinc electroplating can also improve the electrical conductivity and solderability of the metal parts, as well as to provide a smooth and uniform surface for the attachment of other components.

• Food and beverage: Zinc electroplating is used to protect metal food cans and processing equipment from corrosion. Zinc electroplating can also prevent the leaching of harmful metals, such as lead and cadmium, into food products, as well as to preserve their quality and shelf life.

• Other industries: Zinc electroplating is also used in a variety of other industries, such as aerospace, marine, and agriculture, for similar purposes of corrosion protection and durability enhancement.

Examples of Zinc Electroplated Products

Here are some examples of products that are commonly zinc electroplated:

• Construction materials

  Steel beams, rebar, guardrails

• Automotive components

  Chassis, bumpers, engine parts

• Electronic components

  Circuit boards, connectors, heat sinks

• Food and beverage products

  Food cans, processing equipment

• Hardware and tools

  Screws, nails, nuts, bolts, fasteners, washers, springs, hinges, locks, latches, handles, knobs

• Machinery and equipment

  Gears, sprockets, bearings, pipes, valves, fittings

Recent Advances and Challenges in Zinc Electroplating

Zinc electroplating is a well-established and widely used process, but it is not without its challenges and limitations. Some of the current issues and areas of improvement in zinc electroplating are:

• Hydrogen embrittlement: Zinc electroplating involves the generation of hydrogen gas, which can diffuse into the metal substrate and cause cracking and failure under stress. This is especially problematic for high-strength steels, which are more susceptible to hydrogen embrittlement. To prevent this, zinc electroplated parts are usually baked after plating to remove the hydrogen, but this may not be sufficient or feasible for some applications. Alternative methods of reducing hydrogen embrittlement, such as using non-aqueous electrolytes, modifying the coating composition, or applying post-plating treatments, are being explored and developed. J&M effectively mitigates this concern with their use of cellular inline baking which reduces the susceptibility to hydrogen embrittlement

• Environmental impact: Zinc electroplating involves the use of toxic chemicals, such as acids, cyanides, and chromates, which can pose health and environmental hazards. The disposal and treatment of the electroplating waste and wastewater can also be costly and challenging. That is why J&M Plating has more than 1 class K certified Wastewater Treatment Operator per shift to exceed the regulatory requirements and work in an environmentally positive way.

• Coating performance: Zinc electroplating can provide a proficient level of corrosion protection, but it may not be sufficient for some harsh or demanding environments, such as high temperatures, high humidity, or salt spray. Various approaches have been proposed and tested to improve the coating performance, such as alloying zinc with other metals, such as nickel, and applying composite or multilayer coatings, which J&M can provide. This is where customers partner with J&M Plating to engineer a solution that meets or exceeds the demanding requirements, this partnership is one of the primary attributes that differentiates J&M Plating in the finishing space.

Conclusion

Zinc electroplating is a versatile and effective process for protecting metal objects from corrosion and enhancing their durability. It is used in a wide range of industries and for a variety of products. Zinc electroplating also offers other benefits, such as sustainability, electrical conductivity, and food safety. However, zinc electroplating also faces some challenges and limitations, such as hydrogen embrittlement, environmental impact, and coating performance. J&M Plating is a technical resource in these areas and can help you succeed in addressing your electroplating needs.

Contact us today!

J&M Plating, Inc.
4500 Kishwaukee Street, Door 2, Rockford, IL 61109
Phone: (815) 964-4975
Fax: (815) 964-1431
sales@jmplating.com

References

• Sacrificial Zn–Ni coatings by electroplating and hydrogen embrittlement of high-strength steels

• Hydrogen Embrittlement of Zinc and Zinc Alloy Coatings on High-Strength Steel

• Progress in Electrodeposition of Zinc and Zinc Nickel Alloys Using Ionic Liquids

• Electrodeposition of zinc and zinc alloys from deep eutectic solvents: A review

• Electrodeposition of Zn–Ni alloy coatings: an overview

• Recent advances in zinc electroplating: A review

Electroplating 101: A Comprehensive Guide to Metal Coating

Electroplating is a fascinating process that uses an electric current to deposit a thin metal layer onto another metal object It is a versatile and widely used technique in various industries, including automotive, electronics, and aerospace, providing multiple benefits, such as enhanced corrosion resistance, improved electrical conductivity, and desirable aesthetics.

Did you know? Electroplating is used in the process to deposit a thin layer of gold onto copper coins.

Electroplating principles

Figure 19.24 Electroplating from Principles of General Chemistry by Bruce A. Averill Patricia Eldredge

Electroplating works based on the principle of electrolysis. Electrolysis is the process of using an electric current to break down a substance into its component parts. In electroplating, the substance is broken down into a metal salt solution.

The metal salt solution is placed in a container with two electrodes: an anode and a cathode. The anode is made of metal that will be deposited onto the cathode. The cathode is the object that will be electroplated.

When an electric current is applied to the electrodes, the metal ions in the salt solution are attracted to the cathode. The metal ions then deposit onto the cathode, forming a thin metal layer.

Common applications of electroplating

Electroplating is used for a variety of purposes, including:

• Corrosion protection: Electroplating can be used to protect metals from corrosion by forming a barrier between the metal and the environment. For example, zinc electroplating is used to protect car bumpers from rust, while nickel electroplating is used to plate electrical connectors to prevent corrosion.

• Electrical conductivity: Electroplating can be used to improve the electrical conductivity of metals. For example, copper electroplating is used to enhance the electrical conductivity of circuit boards.

• Aesthetics: Electroplating can be used to give metals a decorative finish. For example, chrome electroplating is often used to provide automotive parts and appliances with a bright and shiny finish, while gold electroplating is used to plate jewelry.

Types of metals used by J&M in electroplating

A variety of metals can be used in electroplating, including:

• Zinc: Zinc is a common choice for electroplating because it is relatively inexpensive and provides suitable corrosion protection.

• Nickel: Nickel is another common choice for electroplating because it is durable and has good electrical conductivity.

• Chrome: Chrome is often used for decorative electroplating because it has a bright and shiny finish.

Why choose J&M for your electroplating needs?

At J&M, we are experts in electroplating and surface finishing. We have over 35 years of experience in the industry, and we use the latest technology and equipment to ensure the highest quality and efficiency. We offer a wide range of electroplating services, including zinc, nickel, and chrome plating, as well as custom solutions to meet your specific requirements. We also provide fast turnaround times, competitive prices, and excellent customer service.

Whether you need electroplating for corrosion protection, electrical conductivity, or aesthetics, we can help you achieve the best results. Electroplating is not only a science but also an art, and we are passionate about creating beautiful and functional metal coatings for our clients.

Contact us today for a free quote!

If you are interested in electroplating or want to learn more about our services, please get in touch with us today! We would love to hear from you and answer any questions you may have.

J&M Plating, Inc.
4500 Kishwaukee Street, Door 2, Rockford, IL 61109
Phone: (815) 964-4975
Fax: (815) 964-1431
sales@jmplating.com

References:

• American Electroplaters’ and Surface Finishers’ Society. (2011)24. Electroplating and allied processes (2nd ed.)25. Orlando, FL: AESF26.

• Electroplating: What Every Engineer Needs to Know. (2019, October 12). Retrieved from https://www.engineering.com/AdvancedManufacturing/ArticleID/19781/Electroplating-What-Every-Engineer-Needs-to-Know.aspx

• How Electroplating Works. (2023, February 15). Retrieved from https://www.explainthatstuff.com/electroplating.html

• National Institute of Standards and Technology. (2019)27. Guideline for electroplating and surface finishing23. Gaithersburg, MD: NIST28.