Zinc Nickel Plating: A Beginner’s Guide

Zinc nickel plating is an advanced method of protecting metal surfaces from corrosion by simultaneously depositing zinc and nickel onto components. Favoured for its enhanced durability, zinc nickel plating typically involves an alloy containing around 11-16% nickel, with zinc making up the remainder. This composition provides excellent resistance to corrosion, significantly surpassing traditional zinc plating and even offering a viable alternative to the environmentally hazardous cadmium plating process.

Advantages and Applications of Zinc Nickel Plating

One of the standout benefits of zinc nickel plating is its superior resistance to corrosion, especially under harsh environmental conditions. Standard zinc coatings typically last about 120 hours under neutral salt spray tests before showing signs of corrosion. In comparison, zinc nickel plated surfaces can withstand over 500 hours, highlighting their exceptional protective capabilities. This is particularly advantageous in automotive, aerospace, and heavy industry applications, where parts must withstand rigorous operating conditions and extreme weather exposure.

Additionally, zinc nickel plating effectively minimises galvanic corrosion – an electrochemical process that occurs when dissimilar metals come into contact. By bridging the galvanic gap between materials such as aluminium and steel, zinc nickel plating reduces corrosion risk, extending component lifespan. Furthermore, this coating acts as a sacrificial anode, meaning it provides ongoing protection even if the plated layer suffers damage or abrasion.

Practical Considerations for Effective Plating

While zinc nickel plating offers numerous benefits, successful application requires careful consideration of several factors. Surface preparation is critical, as clean and non-porous steel significantly enhances coating adhesion and effectiveness. Porous or pitted surfaces could introduce vulnerabilities, undermining plating integrity. Surface coating providers who specialise in zinc nickel plating, such as swmf.co.uk/surface-coatings/zinc-nickel-alloy-plating, emphasise rigorous pre-treatment to ensure optimal results.

Moreover, certain components, particularly those with tensile strengths exceeding 1,000 MPa, may require additional treatments to mitigate hydrogen embrittlement, a common issue associated with electroplating processes. Correctly identifying and addressing these potential risks ensures the plated components maintain structural integrity and performance over their intended lifespan.

Understanding these considerations ensures maximum effectiveness of zinc nickel plating, enabling industries to benefit fully from this reliable, robust coating method.