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THE ZINC PLATING PROCESS

Rust is the greatest enemy of just about any type of metal, and its corrosive effects can be devastating.
According to NASA, the cost of corrosion-related losses to United States industries totals approximately
$276 billion annually, with the worldwide figure approaching $1 trillion. The industries most heavily
impacted by corrosion include production and manufacturing, transportation, government, utilities and
infrastructure.

A process known as zinc plating is frequently used to protect metals such as iron and steel against the
relentless forces of corrosion. Zinc plating involves the electrodeposition of a thin coating of zinc metal
onto the surface of another metal object, known as a substrate. The zinc coating creates a physical barrier
that prevents rust from reaching the underlying metal surface. Zinc is chosen because of its innate ability
to fight corrosion. In fact, zinc is often referred to as the corrosion -prevention workhorse

While the use of zinc compounds began more than 2,500 years ago, the production of metallic zinc first
occurred in India around the 15 th century. Today, nearly one-third of all zinc metal is used for
galvanization, which is the coating of a metal surface to protect against rust. Zinc plating is the most
commonly used method of galvanization.

Plating With Zinc: A Bio-Friendly Alternative

Plating with zinc is a relatively recent process, and it did not gain widespread use until approximately 1980.
Prior to that time, cadmium was the preferred metal for electroplating in applications where maximum
protection against corrosion was required. However, cadmium is a highly toxic substance that can have a
cumulative poisoning effect over an extended period of time.

While zinc cannot quite match cadmium in terms of its anti -corrosion capabilities, it is viewed as a more
bio-friendly alternative. These days, the use of cadmium plating is generally rest ricted to applications
where plating with zinc wont provide sufficient corrosion protection or additional levels of protection are
required. However, the use of cadmium in plating operations must comply with current environmental
regulations.

The Step-by-Step Zinc Plating Process

Zinc plating is a relatively complex process that requires a high level of expertise. Specialized equipment
and machinery is also required, including a rectifier, plating station, ancillary tank for proper dissolution of
the zinc anode and a reservoir. Heres an overview of how a typical zinc plating process works:

Preparing and cleaning the surface Its essential to thoroughly clean the surface of the substrate prior to
plating. Any debris or contaminants remaining on the surface will prevent proper adhesion of the zinc
coating. An alkaline detergent solution is typically used for surface cleaning, which is followed by the
application of an acid treatment to remove surface rust. This latter procedure is referred to as pickl ing.
Preparing the plating solution Zinc plating requires the immersion of the substrate into a specially
formulated electrolyte solution, which is referred to as the plating bath. The bath consists of the zinc metal
ionic solution and various chemicals that facilitate plating processes. They also help produce the desired
chemical and physical properties of the finished product. Specific types of zinc electrolyte solutions include:
Acid zinc This is a widely used plating technology known for its high ef ficiency, fast deposition and
superior covering power. However, acid zinc also provides poor throwing power and thickness distribution.
 Alkaline zinc This offers less plating efficiency than acid zinc and a slower electrodeposition rate, but it
provides better thickness distribution and ductility
Choosing the appropriate zinc plating procedure After solution preparation, the parts are ready for
plating. The chosen method could involve rack plating, where larger parts are affixed to metal racks which
are placed inside the tank containing the plating bath. The parts remain stationary during plating. Barrel
plating is normally used for smaller parts instead of a plating tank, the parts are placed inside a barrel and
rotated, which provides a more uniform finish.
Introducing the electrical current Electroplating is also known as electrodeposition because an electrical
current is used to deposit metal ions onto the surface of the substrate. In the case of zinc plating, the
substrate serves as the cathode. A DC current originating at the anode is introduced into the bath and flows
to the substrate. The zinc ions are then deposited onto the surface. The current flows from the cathode back
to the anode to complete the circuit.
Post-treatment procedure Upon completion of the electrodeposition process, the parts are ready for
post-treatment. This normally involves rinsing the parts in water to remove any remaining contaminants and
plating bath remnants. In cases of heavy contamination, the parts may need to be rinsed several times. The
final step is to thoroughly dry the zinc-plated parts. In situations where additional corrosion protection is
required, the application of passivates and sealers can be included in the post-treatment process.