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Corrosion Resistant Coatings, Zinc Alloy Plating Print E-mail


Zinc Alloy Plating: Superior Corrosion Protection

Improvements in corrosion protection are an important consideration for many of today’s industrial applications, where the use of traditional zinc coatings are not possible because of its limited performance capabilities. Zinc alloys provide increased corrosion protection over zinc. The use of alloys has developed because of the need to extend component service life through enhanced coating properties.

Zinc Iron and Zinc Nickel
Image of Cyanide-Free alkaline electrolyte
Protedur Plus: Cyanide-Free alkaline electrolyte for highly corrosion-resistant and ductile zinc-iron alloy coatings

Atotech processes under the Protedur (ZnFe) and Reflectalloy (ZnNi) brands are at the forefront in zinc alloy electroplating. These innovative and patented chemistries provide improved coating performance to meet the highest corrosion standards. These cost effective and production proven processes are ideally matched to barrel and rack electroplating.

Protedur Plus (Zinc Iron)

The Zinc Iron alloy represents an economical coating for effective corrosion protection in combination with aesthetic appeal. Atotech zinc iron processes use cyanide-free alkaline electrolytes with our innovative chemical additives. They deposit a constant Fe alloy over the entire current density range, which results in uniform coating properties. The alloy produced provides superior protection against ‘white rust’ corrosion compared to pure zinc coatings.

Atotech zinc iron processes are easy to operate and gentle to production environments. Advantages include excellent coating thickness distribution and outstanding ductility.

Reflectalloy (Zinc Nickel)

Our zinc nickel alloys offer the highest overall protection against red rust corrosion, even after heat treatment, so they meet the most stringent of industry standards. White rust corrosion products are less voluminous compared to pure zinc coatings, making it ideal for assemblies where low volume corrosion products are desired. When in contact with light metals such as aluminum, zinc nickel is recommended because of reduced contact corrosion. Additional benefits such as increased deposit hardness and improved wear resistance make it a versatile coating. New Atotech zinc nickel technologies are now available that provide a post bendable coating. This approach has proven ideal for the post forming of fluid livery tubing.

Atotech zinc nickel processes use an alkaline electrolyte with specialized chemical additives. They are easy to use in production and deposit a consistent nickel alloy over the complete current density range, which achieves uniform coatings properties. Deposits are semi-bright with excellent adhesion.

Zinni AL 450 (Alkaline Zinc Nickel)
Image of Fasteners plated with Zinni AL 450
Fasteners plated with Zinni AL 450

Zinni AL 450 is an alkaline zinc nickel process for plating in barrel application providing excellent current efficiency. It is suitable for plating of hardened steel parts.

Features and Benefits at a Glance
  • Alkaline process for plating in barrel application
  • Homogenous nickel incorporation of 12-15%
  • Excellent corrosion protection by forming γ-phase zinc nickel
  • Providing excellent current efficiency
  • Reliable plating of hardened steel parts
  • Easy to use
Zinni AC AF 210 (Acid Zinc Nickel)
Image of Zinni AC AF 210
Zinni AC AF 210: Ammonia-free acid zinc nickel process with excellent corrosion protection for direct plating of cast iron

Zinni AC AF 210 is an ammonium-free acid zinc nickel process which produces an attractive bright coating with excellent corrosion protection due to the formation of true γ-phase structure.
It has been especially designed for direct plating of cast iron and is approved by the brake caliper industry. Likewise it is also beneficial for the plating of steel fasteners due to its very high current efficiency in barrel application. Compared to an alkaline zinc nickel electrolyte the plating cost can be reduced by about 30% as a result of significantly higher plating rate and reduced cost for wastewater treatment.

Features and Benefits at a Glance
  • Ammonia-free process for rack and barrel plating
  • Wide operating window for reliable production
  • Excellent performance in LCD area
  • Simple wastewater treatment
  • High current efficiency allows increased throughput
  • Reduced plating cost compared to alkaline zinc nickel
  • Easy handling
 
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