Common Challenges in Nickel Plating and How to Overcome Them

Nickel plating is a commonly used surface treatment process with numerous applications across many industries. Nickel plating enhances an object’s corrosion resistance, appearance, and hardness. Nickel plating can be applied to a wide variety of metal components used in automotive, electronics, or industrial equipment to maximize their value.

However, Nickel plating, like most industrial processes, can bring some problems, some of which can cause variations in the quality of the finished products, additional expenses in production, or pausing operations.

So, here in this blog, we will walk you through some common challenges in nickel plating, along with practical solutions to overcome them.

1. Poor Adhesion on Base Metal

Adhesion problems arise when nickel does not adhere to the base material. This commonly occurs in carbon steel nickel plating, where the oxide layer and other surface contaminants, such as oils and rust, are present.

Solution –

The most effective way to create a strong adhesion is by adequately preparing the surface. The steel must be properly cleaned and activated before plating. You can use acid pickling, abrasive blasting, or electrocleaning to remove unwanted layers. Additionally, nickel plating with a strike layer can help with adhesion and prevent peeling.

It would be wise to work with a zinc-nickel plating company or nickel plating specialist who already has established pre-treatment procedures.

2. Uneven Coating Thickness

Variability in thickness can impact both the performance and appearance of plated components. Also, some areas get too much nickel while others can be undercoated.

The Solution:

Control is the key. Parameters like temperature, current density, and solution agitation must be controlled. Rack design also impacts the process, and poor rack design will yield uneven thickness due to poor positioning on the rack. It is also good practice to use computerized systems and/or rectifiers to balance current distribution smoothly.

3. Pitting and Roughness

Small holes or dimples on the surface, known as pitting, can greatly affect the integrity of nickel-plated parts. We typically see pitting caused by impurities in the plating bath or a lack of filtration.

Solution –

Keep your plating bath clean and well-filtered. Use high-quality chemistry and replenish it at regular intervals. Air agitation or pump circulation can reduce localized concentrations of contaminants. Ultimately, you should work with a company that has strict quality control of its plating processes.

4. Hydrogen Embrittlement

Hydrogen embrittlement can be a serious issue during carbon steel nickel plating as it weakens the metal and increases the chance of cracking due to stress.

Solution –

The established method of releasing trapped hydrogen from your plated steel is post-plate baking. Post-plate baking is a heat treatment that is usually performed at 190–230°C for several hours and provides recovery of the mechanical properties of the part.

NOTE: Ensure that your plating partner follows post-plating treatments as a part of their process checklist.

In The End

Nickel plating can be a very effective method of extending the life and performance of metal parts. However, in order to reap the benefits of nickel plating, organizations must recognize the risks and know how to reduce them.

Whether you are researching carbon steel nickel plating or looking for a reputable zinc nickel plating company, there are three important factors to consider: quality, experience, and technology. When you have a competent service provider with maintenance and process controls that ensure the provision of their statements, and knowledgeable technicians working with you, the quality of the service can be guaranteed every time.