Zinc-nickel alloy electrodeposition is a sophisticated process used to create a protective coating composed of zinc and nickel. This coating is formed in a plating solution containing zinc salts, nickel salts, conductive agents, and additives. Despite the significant difference in electrochemical potential between zinc (-0.763 V) and nickel (-0.25 V), both metals are co-deposited at the same polarization potential to form a single-phase C-type zinc-nickel alloy layer. After undergoing passivation treatment, the resulting coating exhibits excellent corrosion resistance. Depending on the desired appearance and performance, the coating can be passivated in various colors, such as white or black.
The electrodeposition process begins with pretreatment steps including degreasing, cleaning, rust removal, activation, and rinsing. Following this, the zinc-nickel alloy is electroplated, followed by three-stage counter-current rinsing, passivation, washing, drying, testing, and final packaging. The plating bath and process conditions are carefully controlled to ensure optimal nickel content and passivation properties. Coating composition and quality are analyzed using advanced techniques like the S250Mk3 scanning electron microscope, chemical gravimetric method, and spectrophotometric colorimetry. These methods provide consistent results across samples, allowing for precise control of the zinc-nickel ratio based on specific corrosion resistance and aesthetic requirements.
The zinc-nickel alloy coating also demonstrates strong thermal shock resistance. When heated to a set temperature and rapidly cooled by immersion in room-temperature water, the coating remains intact without blistering, peeling, or delamination. While bubbling and peeling may occur at temperatures above 350°C, the coating remains stable during slow cooling. This property makes it suitable for applications where thermal stress is a concern.
In terms of corrosion resistance, the zinc-nickel alloy coating offers superior protection compared to traditional galvanizing methods. It provides cathodic protection to fasteners and exhibits a much lower corrosion current density than electro-galvanized or hot-dip galvanized layers. Tests conducted using a CMB-1510B corrosion rate meter and a DF-27 multi-purpose corrosion test chamber confirmed that the corrosion resistance of the coating is closely related to its nickel content. Specifically, a Zn-13%Ni alloy showed the best performance.
This technology has been widely applied in various industries, including mining, automotive, and electronics. It has been successfully implemented in numerous coal mines, such as Sanhejian and Yaoqiao, as well as in fasteners, U-bolts, washers, anchors, and other components. Over 150 tons of zinc-nickel alloy coatings have been applied, with excellent anti-corrosion results and no signs of rust after use. Additionally, the coating is being increasingly adopted in automotive parts, guardrails, and electronic equipment.
In conclusion, zinc-nickel alloy coatings offer significantly lower corrosion current densities and longer service life compared to traditional galvanizing methods. Their low corrosion rate and high durability make them an ideal choice for long-term protection of steel components. The trend is moving toward replacing conventional electroplating, hot-dip galvanizing, and cadmium plating with this advanced coating technology. In mine environments and other industrial settings, zinc-nickel alloy coatings have proven to be the preferred solution for long-term corrosion protection.
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