ZINC
PLATING
Zinc, one of the most widely used
metals in the surface finishing industry,
is bluish-white and lustrous. Zinc
electroplating creates a soft, ductile,
decorative and corrosion resistant finish.
Unlike most commonly plated metals,
zinc protects the substrate by sacrificing
itself. The zinc corrodes before the base
metal, thereby protecting the base metal.
For additional corrosion resistance,
chromates are applied over the zinc.
Such films are typically very thin and
add no measurable thickness to the
overall coating. The zinc plating process
is the most economical for applications exposed to
atmospheric corrosion.
Cyanide Zinc, Alkaline Non-Cyanide Zinc and
Acid Chloride Zinc are the typical plating processes
employed. Temperature ranges for the process are
between 60oF to 130oF. Plating thicknesses range from
.1 mil to 2.0 mils (.0001” to .002”). Common uses for
zinc plating are for appearance and corrosion protection
of steel fasteners. In this instance, the plating thickness
is usually .3 mils (.0003”) due to thread gauging
requirements.
Cyanide Zinc
Cyanide zinc baths
are used for steel and
leaded steel substrates.
The plating bath consists
of zinc metal (1 to 4.5
ounces per gallon), sodium
hydroxide (10 to 12 oz/gal)
and sodium cyanide (1.5 to
14 oz/gal) with operating
temperatures ranging from
60oF to 110oF. The pH
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Specifications and information provided here are subject to change without notice.
July 2005 • Bulletin 15.0
for such baths is 12 to
13.
Plating tanks are
fabricated from steel,
fiberglass, polyvinyl
chloride (PVC)
or polypropylene.
Heating and/or
cooling coils, slab
anode hooks or anode
baskets are fabricated
from steel. Anode bags
for plating baskets
are not typically
used. Zinc anodes for this application are 99.9% pure.
Filtration and agitation are also not usually required.
Cyanide zinc is highly poisonous and corrosive to
living tissue. As a result, concerns over environmental
and occupational safety hazards have forced the plating
industry to develop and utilize cyanide-free zinc plating
systems.
Alkaline Non-Cyanide Zinc
As with cyanide based baths, alkaline non-cyanide
zinc baths are used for steel and leaded steel substrates.
These baths consist of zinc metal (.8 to 3 oz/gal) and
sodium hydroxide (10 to 20 oz/gal) with operating
temperatures ranging from 60oF to 110oF. The pH is 12
to 13. Rectification is typically 6 to 20 volts and 3 to
10 amps per square foot of part surface area for barrel
applications. Rack applications are 3 to 9 volts and 10
to 40 amps per square foot of part surface area.
The quality of the water used in this process plays
a major role in performance. Hard water causes dull
zinc deposits that can lead to increased consumption of
proprietaries and purifiers. If the quality of the water
is poor, deionized water should be used as part of the
See reverse side for more information...
bath makeup. Otherwise, using a water conditioner/
purifier is recommended.
Filtration and air agitation are essential to
remove metallic and/or organic contaminants. Such
contaminants can be caused by human error or drag-in
from the cleaner or acid tanks during the plating cycle.
Contamination affects the deposit in many ways,
including poor distribution, discoloration and burning.
Common metallic contaminants include copper,
cadmium, lead, tin, chromium and iron. The plating
bath is typically turned over 1 to 2 times per hour to
remove potential contaminants.
There are several proprietaries used in the alkaline
non-cyanide zinc plating process. Refining agents
are used to provide semi-bright uniform deposits.
Brightening agents make the zinc deposit uniformly
brighter by adding luster to it.
Purifiers treat heavy metals
and impurities introduced from
zinc anodes and caustics. Water
conditioners treat water hardness.
Finally, wetting agents put a thin
foam blanket over the surface
of the plating bath to suppress
fumes or spray created during the
operation.
Plating tanks are fabricated
from steel, PVC or fiberglass
lined with PVC or polypropylene.
Cooling is essential for this process
while heating may be needed in
colder climates. Heating and/or
cooling coils, slab anode hooks or
anode baskets are fabricated from steel. Anode bags
used for baskets are fabricated from polypropylene.
Zinc anodes used for this application are 99.9% pure.
While alkaline non-cyanide zinc plating baths
result in no toxicity to humans and the formulations are
noncorrosive to equipment, exposure to the chemicals
of these baths can be corrosive to living tissue.
Acid Chloride Zinc
Acid chloride zinc baths are used for steel and
leaded steel. They are more flexible in comparison
with other substrates, such as high-carbon, heat-treated
and carbonized pieces (including castings without any
special treatment). Three types of bath compositions
are typically used with operating temperatures ranging
between 60oF and 130oF.
Because of its wide operating parameters, the
ammonium chloride zinc bath is the most forgiving of
the three types of acid zinc baths used. The bath consists
of zinc metal (2 to 4 oz/gal) and ammonium chloride
(16 to 20 oz/gal) with a bath pH of 5 to 6. The major
drawback of these baths is the high level of ammonia
which can cause problems in wastewater treatment.
Ammonia acts as a chelator (coordination compound
in which a central metal ion is attached by coordinate
links to two or more non-metal atoms in the same
molecule). If the rinse waters are not segregated from
other waste streams, removal of metals to acceptable
levels using standard water treatment practices can be
difficult and expensive. Ammonia is also regulated in
many communites.
Potassium chloride zinc baths are attractive because
they contain no ammonia. Such baths consist of zinc
metal (3 to 5 oz/gal), potassium
chloride (25 to 30 oz/gal) and boric
acid (3 to 5 oz/gal) with a bath pH
of 5 to 5.5. The disadvantage of
these baths is a greater tendency
to burn on extreme edges and
their higher operating costs.
These baths require the use of
relatively expensive boric acid
to buffer the solution and prevent
burning in the high current density
areas, functions performed by the
ammonium chloride in the other
bath types.
Mixed ammonium chloride/
potassium chloride zinc baths
combine the best of the ammonia
and ammonia-free processes. Because potassium
chloride is less expensive than ammonium chloride,
the maintenance costs of mixed baths are lower than
the ammonia bath and do not require boric acid. The
ammonia levels in the rinse waters are low enough that
they do not significantlty interfere with wastewater
treatment. Such baths consist of zinc metal (2 to 4 oz/
gal), ammonium chloride (4 to 6 oz/gal) and potassium
chloride (16 to 20 oz/gal) with a bath pH of 5 to 6.
Acid zinc plating baths have several advantages
over cyanide and alkaline non-cyanide baths. There
is less waste treatment since no cyanide is involved,
eliminating disposal expenses. The resultant zinc
deposits have an outstanding brightness that rivals
nickel chromium in its luster. The baths provide high
cathode efficiencies (90% to 95% compared to 70%
to 75% for cyanide and 70% to 95% for alkaline non-
cyanide baths) at normal operating current densities. Typical Zinc Plating Sequence
They provide excellent leveling and produce less
1. Soak Clean
hydrogen embrittlement. Finally, the wetting agents
2. Electroclean
typically used in the acid process are relatively rinse-
3. Rinse
free when compared to alkaline systems.
4. Acid Pickle *
Disadvantages of these baths are that they are
5. Rinse
extremely corrosive to both equipment and living
6. Zinc Plate
tissue. Surface preparation is also very important.
7. Rinse
Improper cleaning and/or pickling can lead to problems
8. Nitric Dip
in the deposits including blistering, lack of adhesion
9. Chromate
and haziness. Ductility can be lost with thick deposits.
10. Rinse
There is also a need for continuous filtration (1 to 2
11. Dry
turnovers per hour) and air agitation to remove iron
from the solutions. This iron is derived from substrates *Acid Pickle tanks are used to activate and
and/or anodes. clean parts prior to plating. They consist of
Plating tanks are fabricated from fiberglass, either 20% to 30% hydrochloric acid at room
polypropylene or steel lined with fiberglass, PVC, temperature or 5% to 15% sulfuric acid at
polypropylene or rubber. Tanks are leached with 105oF to 120oF.
acid (typically 5% to 10% hydrochloric acid) prior to
use. Heating and/or cooling coils are fabricated from
titanium or plastic. Slab anode hooks are fabricated
from either titanium or monel and are kept above
solution level. If baskets are used, they are fabricated
from titanium with anode bags fabricated from either
Dynel® or polypropylene. Zinc anodes used for this
application are 99.9% pure.
 Vulcanium® Plating Systems
Titanium Anode Baskets
Titanium & Zirconium Heat Exchangers
Dimensionally Stable Anodes
Titanium & Aluminum Fasteners
Custom Fabrications

© 2005 Vulcanium® Corporation