Do’s & Don’ts

Donald W. Baudrand, Consultant

621 NE Harrison St.
Poulsbo, Washington 98370-8453
E-mail: [email protected]

Do’s & Don’ts of Bright Zinc Plating

Part I: Alkaline Zinc

A little history deposit characteristics, the zinc post-plating coating characteristics

Zinc plating became popular when in 1933 the automotive industry and the ability to accept post treatments.
took on the cadmium bearing. They bought up all but about 40%
of the available cadmium. Cadmium plating had been useful for Selection
corrosion resistance applications. The result was a shortage of and This is the controversial part of this editorial. I prefer acid zinc-
a high price for cadmium. The alternative was to use zinc for cor- nickel where the nickel content is 9.5 - 10%. At this nickel con-
rosion protection applications. centration the reception of chromates and other post treatments is
Today there are many choices of zinc plating solutions. The good. The neutral salt spray performance ranges from 750 to 1,000
oldest solutions used sodium cyanide to complex the zinc. The hours. It is the most ductile and is suitable for plating cast iron,
deposits were very good. The brightening addition agents were malleable and carbonitrided surfaces.
capable of producing very bright and attractive zinc coatings. The Zinc-cobalt can also plate onto the above metals. Zinc-iron
deposits were relatively easy to chromate. Clear bright chromates deposits are weldable and are the most ductile, but they deteriorate
were possible and light and dark yellow chromates provided sig- when exposed to heat.
nificant corrosion protection. Zinc plating could support lubricants
and were used for fasteners of all kinds. Cyanide zinc plating solutions and typical
When cyanide solutions lost favor, alkaline non-cyanide solu- formulas
tions were developed. There was only a small change in brighten-
ers and no change in the use of chromates. The acid chloride elec-
trolytes (plating solutions) were the next generation of zinc plating Formulations 1. High cyanide 2. Low cyanide
solutions. The success of the cyanide-based deposits depended on Zinc as metal
the complete purification of the zinc plating solution. This was 4 - 6 oz/gal 1.0 oz/gal
(usually added as
accomplished by treating the solution with zinc dust, wherein (30 - 45 g/L) (7.5 g/L)
zinc cyanide)
metallic contaminants were removed by chemical replacement of
the zinc dust. DuPont introduced sulfides as a purification process. Total sodium 10 - 19 oz/gal 2.0 oz/gal
A number of zinc plating solution brighteners were developed that cyanide (75 - 142 g/L) (15 g/L)
produced bright durable zinc deposits.
The next generation was alkaline non-cyanide zinc plating solu- Ratio: total cyanide-
2.5 - 3:1 2:1
tions, including alkaline zinc-nickel, followed by acid zinc chlo- to-Zn metal
ride processes developed by Max Schloetter. The acid chloride for- 10 - 15 oz/gal 10 oz/gal
mulations allowed the use of alloying metals such as zinc-cobalt, Sodium hydroxide
(75 - 112 g/L) (75 g/L)
zinc-iron, zinc-manganese, zinc-nickel and zinc-tin
Bright dips and chromates were used as post plating steps, Sodium carbonate 3 oz/gal 15 oz/gal
including dilute nitric acid and Dubpernell and Soderberg’s chro- (Max.) (22.5 g/L) (112 g/L)
mic acid and sulfuric acid. The least popular was the hydrogen
Proprietary
peroxide and sulfuric acid solution of Kepfer of DuPont. The As required As required
brighteners
next development was chromate technology by Allied Research.
The Allied Research olive drab became the standard for Army Temperature 85°F (30°C) max 85°F (30°C) max
Ordnance and is still used for camouflage and zinc protection.
Purifier As required As required
Zinc and zinc alloys: Which one should I select?
There are alkaline-cyanide formulas, alkaline non-cyanide, alka-
line zinc-cobalt, zinc-iron, zinc-nickel and acid zinc formulas, Sodium carbonate increases with bath age. The maximum is about
including zinc alloys such as zinc-cobalt, zinc-copper, zinc-iron, 15 oz/gal (112 g/L). High carbonate decreases cathode efficiency.
zinc-manganese, zinc-nickel, zinc-tin, and variations of each one. Carbonates are absorbed from the air and from decomposition of
Each process has specific applications, depending on the desired sodium cyanide.

18 Plating & Surface Finishing • December 2009

 Because of the high cost of treatment for waste disposal and the DO’S - High cyanide zinc DON’TS - High cyanide zinc
danger of poisoning, cyanide solutions are chosen less often for
zinc plating than the other options. • Use pure zinc for anode • Allow the anode to cathode
Periodic treatments or freezing-out for removal of carbonates balls. 99.99% Zn in wire area fall below 1:1
are required. Proprietary brighteners are added to improve the baskets. Use high grade
smoothness and eye appeal of bright deposits. Post treatments can chemicals.
increase the corrosion resistance of these deposits.
Anodes are usually zinc balls held in a long basket made from
steel. There can be a build-up of zinc dissolved from the anodes • Maintain the temperature • Allow the temperature to
if left in the tank when the plating bath is not in use. Most platers between 65 and 85°F (18 rise above 85°F (29°C). This
raise the anodes above the solution overnight or for other down and 29°C). destroys brighteners.
time when not plating.
• Caution: Add sodium • Add to a hot solution.
Alkaline non-cyanide zinc plating solutions and hydroxide slowly.
typical formulas
• Use high-grade chemicals • Allow carbonates to exceed
15 oz/gal (112.5 g/L).
Typical formulation

Zinc 1.0 oz/gal (7.5 g/L) • Use purifier (sulfides) • Use the zinc plating solution
for additional cleaning.
Sodium hydroxide 12 - 13 oz/gal (90.0 - 97.5 g/L)
• Maintain the correct Zn-to-
Brightening agent As required CN ratio of 2.7:1.0.

Operating temperature 70 - 80°F (21 - 27°C)

• Maintain the NaOH-to-Zn
ratio at 2.3:1.0.
The need for pollution control and ecology considerations drove
the industry to develop non-cyanide plating solutions. Non-cya-
nide zinc plating systems provided the answer. They not only DO’S - Non-cyanide zinc DON’TS - Non-cyanide zinc
eliminated cyanide, but there also were operational and functional
improvements made possible by research into non-cyanide zinc • Maintain the correct anode- • Use polysulfides to purify
processes. These included eliminating the need to remove anodes to-cathode area ratio. the bath
when the bath was not in use, brighter deposits, acceptance of post
treatments, economics of operation, minimal build-up of carbon- • Purify by using zinc dust, • Use the plating solution to
ates, improved covering and throwing power, and ease in bath low current density dummy aid cleaning
control. Alkaline zinc formulations are available for both barrel plating
and rack operation.
Since there are no cyanide or complexing agents, many of the
• Clean the items to be • Try to plate cast iron or high
typical impurities will have limited solubility. Impurities that may plated very well strength steels (no deposit).
be introduced can be easily controlled. For example, chromium is
removed by adding small amounts of sodium hydrosulfite. Copper,
lead and cadmium are removed by low current density dummy plat- • Maintain the ratio of • Air agitate
ing. Iron has no detrimental effects unless it is complexed. Some sodium hydroxide to zinc
proprietary chromium control additives contain a complexor. at 10 to 1
Anodes should be 99.99% pure zinc. Anode area is important.
The anode-to-cathode area ratio should be 1:1 to 1.4:1.0. Looking • To prevent delayed
at the anodes after or during use, they should have a light gray blistering, use good
appearance. If there is a dark film, decrease the anode area. If the cleaning.
anodes have a bright appearance or no film, increase the anode
area. P&SF • Keep zinc bath temperature
above 70°F (21°C)

• Keep thickness less that

0.005-inch (0.127 mm)

• Use a 13 oz/gal (97.5 g/L)

caustic soda pre-dip.

• Remove copper
contamination.

December 2009 • Plating & Surface Finishing 19