What Is Electroless Nickel Plating?
Electroless nickel deposition (END) is a method of applying nickel plating using a chemical reaction. The ions of nickel are reduced to the metallic state using a chemical reducing agent (sodium hypophosphite).
END is used to substantially improve protection from corrosion due to saltwater, carbon dioxide, oxygen, and hydrogen sulfide.
Electroless nickel also provides an even and consistent finish across the surface area which includes complex areas where a plate would otherwise not fill (slots, holes, and tube internal surfaces).
The success of electroless plating is reliant on sufficient surface preparation because rough, uneven surfaces, such as those with burrs or cold shuts will encounter bonding issues or accumulations which can make a bad situation worse.
The objective of this process is to provide protection against wear, abrasion, and corrosion while improving surface performance. This is a very effective and economical way to obtain a durable, high-quality finish.
What is the Electroless Nickel Plating Process?
The electroless nickel process is a widely available and flexible surface finish utilized in a number of industries (e.g., automotive, aerospace, electronics, manufacturing).
Electroless nickel plating is not an electroplating process; it is an auto-catalytic chemical deposition process capable of producing a uniform durable nickel-phosphorus or nickel-boron alloy coating but does not rely on electrical current to deposit the nickel.
Like many manufacturing technologies, electroless nickel plating will depend on proper surface preparation, successful chemical activation, and control throughout the stages of the process to realize success when using the process; and in turn quality complication.
Understanding the total process is essential for manufacturers and engineers that wish to obtain the best adhesion following plating, corrosion protection, wear protection and functionality of the surface.
Surface Preparation
Prior to nickel plating, the substrate surface must be cleaned and pre-treated to remove surface contaminants, grease, oils, and other organic or inorganic contaminants that may adversely affect the adhesion and/or uniformity of the electroless nickel coating.
Surface contaminants can be removed from the substrate surface with industrial degreasers, alkaline cleaners, and ultrasonics to remove any grease, fingerprints, machining oils, and other organic or inorganic contaminants.
The surface preparation of the substrate before plating is an important step that will affect the consistent thickness of plating, coating adhesion, and ultimately long term performance in corrosive environments.
Activation
Once the substrate has been appropriately cleaned, the next significant step is surface activation. The surface activation step will use an acid solution, such as hydrochloric or sulfuric acid, to remove the unwanted, residual oxide film that was left on the clean surface.
Once the oxide film is removed and the original fresh metal surface is exposed, there will be rapid conversion of surface oxides to non-oxides that will improve catalytic activity and promote bonding.
Surface Activation is primarily important for non-ferrous metals and complex alloys, so that the electroless nickel-plated layer does not inhibit bonding to the base material.
Activating the surface of the substrate is important to minimize defects that will be plated into the substrate such as, pitting, blistering, or delamination that affect the function and aesthetics of each part.
Pre-Treatment
The type of substrate (e.g. steel, aluminum, copper, or plastic) may require specific pre-treatment processes to improve adhesion and improve corrosion and wear resistance.
Pre-treatment processes are typically applied immediately before the plating bath stage, such as zincate treatment of aluminum and palladium or platinum as a catalyst for non-conductive substrates.
Surface preparation is an essential step in creating strong metallurgical bonding and even nickel deposit thickness to define the safe use of the electroless coating in heavy-use cases.
Electroless Nickel Plating
In the electroless, or chemical, nickel plating process, the pretreated substrate is immersed in an aqueous solution consisting of nickel ions, a reducing agent (sodium hypophosphite or sodium borohydride), stabilizers, and a number of proprietary additives (also sometimes called levelers).
When the substrate is exposed, the reducing agent reacts with the nickel ions to create a controlled reduction-oxidation reaction in which an autocatalytic deposition occurs, resulting in the deposition of a thick, even nickel-phosphorus alloy or nickel-boron alloy layer on every surface of the substrate that is exposed including inside holes and other potentially complex geometries.
Unlike electrolytic plating, electroless nickel finishes are much more uniform and consistent in their thickness and coverage. These benefits are extremely important in applications with high dimension specifications, higher hardness, and improved chemical impingement.
Post-Treatment
When the process of electroless plating is complete, the plated part will go through important post-treatment processes designed to improve performance features.
The rinsing and drying will take off any residual chemicals left from the plating process, while additional processes like baking (heat treatment) will enhance the hardness and crystal structure (brassiness) of the nickel deposit.
Many times, there are additional post-treatments performed like passivation, or the use of a protective topcoat, sealant or anti-corrosion agents to help prolong the lifespan of the finished part.
Which post-treatments to use is dependant on the considerations of end-use requirements including friction reduction, weldability, and to achieve certain surface finishes to meet environmental, medical or engineering requirements.
By following all the steps in the electroless nickel plating process, manufacturers can achieve dependable, consistently acceptable surface engineering solutions.
The goal of enterprises to utilize custom electroless nickel plating services, allows for the establishment of a complete and controlled workflow which enables finished components to successfully meet the ever-growing demands of industry standards for corrosion protection, surface hardness, and acceptable aesthetics.
For those facing the challenge of deciding on the best plating solutions for the parts or applications, the acquisition of this information on process steps will aid in selecting the most suitable coating technologies of considerations of performance, cost and compliance.
Who are the leading manufacturers of Electroless Nickel Plating machines?
Electroless nickel plating machines are valuable pieces of machinery in the modern world of industrial finishing. These machines provide even and uniform deposits, as well as corrosion and wear resistance electroless nickel coats on a variety of surface substrates.
Fully automated plated systems are vital to industries such as automotive, aerospace, electronics, energy, and manufacturing, where reliability and product performance are essential.
These dedicated systems produce robust plating solutions through advanced surface engineering, providing additional corrosion protection to components, extending service life, and allowing for enhanced functionality in a critical or high volume set of parts.
Below, we present a selection of well-known electroless nickel plating machine manufacturers and their leading models that are available in both the USA and Canada, with a focus on the specialty features, versatility and applications of the equipment to suit individual or unique production environments.
Brand: SIFCO Applied Surface Concepts
Model: SIFCO Process® Equipment
SIFCO Applied Surface Concepts is a leader in selective plating and surface technology. SIFCO provides a large selection of equipment available for electroless nickel plating.
These products will accommodate every customer from end users to OEMs with industrial production plating processes to customers with highly portable equipment.
The SIFCO Process® Equipment is specifically designed for reliable and controlled nickel-phosphorus deposition. This equipment can support in-place repair localizes for all sorts of industries as well as production scale processing.
The accommodations of the SIFCO Process are programmable with settings to provide precision control of bath chemistry, immersion time, temperature, and agitation to ensure deposit quality and finalized surfaces are optimally engineered.
Advanced technology provides fully integrated filtration and circulation to maintain stable bath chemistry with minimal contamination and government-restricted downtime for equipment maintenance.
The user-experience interface is simple to navigate and efficient, energy-conscious design enables higher volume incorporation, all of which provide quality, productivity, and durability governments expect from a metal finishing solution.
Brand: Technic Inc.
Model: Techni EN-BM Series
The Techni EN-BM Series from Technic Inc. is the latest offering of electroless nickel plating systems for fully and semi-automated production environments.
The Techni EN-BM Series is designed for process repeatability and tight quality control in the manufacturing process. Programmable logic controllers (PLC’s) lets operators regulate nickel and other solution parameters such as nickel ion count, pH, solution flow rate, and temperature.
These nickel electroplating systems utilize solutions management, automatic dosing, and on-line monitoring to reduce defects in production and fast operation.
These systems come with built-in filters and agitation to maximize the metal solution quality for improved nickel deposits, also enhancing corrosion protection and purity.
The HMI system and modular structure of the system for interaction into the operators production process provides safer integration with improved true long term uptime, with the designed-in safety features to reduce risk.
Any organization or contract manufacturer producing parts from precision components in the aerospace, electronics, and automotive industry must meet functional and regulatory standards of their customers, ensuring all parts being produced are to require strict quality levels.
Brand: C. Uyemura & Co., Ltd.
Model: Miralloy Series
C. Uyemura & Co., Ltd. presents a worldwide brand name in surface finishing technology and their Miralloy Series offers customized electroless nickel plating products for unlimited industrial applications.
As part of the product designation, the Miralloy Series provides robust flexibility for a wide range of substrates and plating processes, including nickel-phosphorus and nickel-boron alloys.
Each piece of equipment is designed with intelligent operating controls enabling continuous monitoring and adjustment in real-time for critical bath parameters that include solution temperature, chemistry dosing, pH non-variation and organic stabilizer amounts.
Separate functions for these four parametersprovide consistency and high-performance nickel plating by improving stability and control over the plating process.
The filtration and purification technology employed reduces contaminant generation and prolongs solution life, further reducing operating costs and achieving a smaller environmental footprint.
These electroless plating systems are ideal for manufacturers searching for quality assurance, rapid process scaling, and operating process efficiency.
Brand: Sharretts Plating Company
Model: Custom Electroless Nickel Plating Systems
Sharretts Plating Company specializes in the custom engineering and manufacturing of electroless nickel plating equipment according to specifications defined by customers.
Their systems allow granular control of all bath constituents, temperature, fluid contribution, and process characteristics required to reproduce precise plating, regardless of the application.
Heavy-duty agitation, automated replenishment, digital process indicator, and smart control touch panels are typical equipment features that allow for full control and testing capabilities to increase productivity and quality.
Known as a defender of system strength, durability, and technical help training, Sharretts Plating Company specializes in ways to adapt their systems to the unique manufacturing situations that require adaptable solutions with maximum tolerance, finish support, and durability in terms of the operational life and actual plating volumes whether they are low or high volume, as well as the adherence to various industry certifications.
Brand: Metal Chem, Inc.
Model: Auto Catalyst 2000 Series
Metal Chem, Inc. is recognized for process technology innovations in the plating business, and the Auto Catalyst 2000 Series is a next generation electroless nickel plating system for automated, continuous, high volume production.
Important features include the ability to completely automate the plating process and control operations, intelligent dosing for bath maintenance, and in-line filtration for better solution purity.
This high-volume equipment is designed to reduce cycle times, increase ROI, and provide exceptional throughput while ensuring rigorous quality control throughout all deposited coatings.
The Auto Catalyst 2000 Series’ integrated and automated solution management, industry leading simple operator control interface, and adherence to modern and safe industrial health and safety standards make this equipment an obvious choice for companies with around-the-clock processing needs and different substrate materials that occur in applications found in the automotive, heavy equipment, and electronics segments.
Choosing an Electroless Nickel Plating Equipment:
When purchasing an electroless nickel plating system, think about your needs, such as bath capacity, degree of automation, personal preferences for particular alloys, uniform coatings and the high-phosphorus range, the structure of the equipment and what kind of maintenance it requires, patterns of uptime reliability when in use, and support for monitoring or collecting data for your process.
You will need to evaluate how easy it will be to integrate the machine or other equipment you consider with your current processes, and make sure the equipment you choose will operate in compliance with your region’s regulatory system and aligns with your sustainability objectives.
Many specifications and technical aspects may change, so it is worthwhile for any buyer to look into industry resources and also reach out to machine manufacturers, or their authorized sales agents, directly.
Request marketing material, technical material, and/or a demo or on-site demonstration to identify the best electroless nickel plating machines, and their associated equipment, for the needs of your operation.
What are the different types of nickel plating processes?
One of the characteristics of nickel plating is the number of different processes which can be used to complete nickel plating. Each of the processes uses the name plating and every type has its own distinct purpose and uses.
No matter what type of plating process is being used, they are all meant to improve upon and improve nickel and the resistance to rust and corrosion.
Electroplating
Electroplating is the process of using an electrical current to deposit a layer of metal coating onto a metal object. In electroplating, the object to be plated is wired to the negative terminal of a direct current dc power supply, while the metal to be plated onto the object is wired to the positive terminal of the power supply.
An electrolyte solution, which contains metal ion, is used to move ions through to the object. This allows the ions to adhere to the object. Electrolytic plating depends on electrical current and must use a conductive object; this is different from electroless plating.
Brush Plating
Brush plating is a process that produces a metal deposit to a portion of a metal object using an electroplating solution and a brush.
In the brush plating process, the brush connected to the positive terminal of a direct current power source is immersed in the electroplating solution and then makes contact with the object that is provided to the negative terminal of the power source.
The brush is immersed in the electroplating solution that contains metal ions, which are transferred as a deposit to the localized surface of the object. Brush plating is mainly used for localized repair rather than metal coating of an entire surface.
Hard Chrome Plating
Hard chrome plating is an electroplating process to apply a thick layer of chromium to a metal substrate.
This enhances the resistance to corrosion, and wear. Hard chrome plating is different from electroless nickel plating because it is a process that transfers chromium onto the object being plated by the use of an electrical current.
The chrome finish is strong with a high reflectivity, and is good for wear resistance and abrasion resistance. The drawback is that hexavalent chromium is used which raises environmental and health concerns and has led to the development of a variety of alternative plating methods.
Unlike other coating processes, electroless nickel plating does not use an electrical current to deposit, as coating occurs through a chemical reduction reaction.
As a result, because it can deposit a uniform coating over complex-shaped parts and even in non-conductive surfaces, there is a clear benefit to this deposit process.
Electroless nickel plating provides a uniform thickness, even in hard-to-reach corners, and corrosion and wear resistance. Thus, the choice of the process will depend on the desired functionalities of the coated product.
Sulfamate Nickel Plating
Sulfamate nickel plating is an electroplating process of nickel sulfamate to generate a coating with a more pure and thicker structure.
The high-tensile strength coating can be machined, offers fantastic corrosion protection, and allows for heat application up to 1400°C (or 2552°F). The sulfamate nickel coating is a matte finish; it is often used for other repairs on worn parts.
What are the variations of the Electroless Nickel Plating process?
Electroless nickel plating refers to the plating of nickel alloy by chemical reduction, rather than by electric current, nickel phosphorus being used in most electroless nickel plating coatings and being given to a content of phosphorus of 2% to 14%.
The more phosphorus that is contained in the plating material, the better it performs in preventing corrosion. The differences in electroless nickel plating are primarily based on the: amount of phosphorus.
High Phosphorus Electroless Nickel
This type contain a higher percentage of phosphorous in the plating solution which will give a coating of superior corrosion, wear, and non-magnetic capabilities. Its primary use is in aerospace, automotive, and electronics.
Mid Phosphorus Electroless Nickel
With lower phosphorus concentrations than high-phosphorus electroless nickel, it produces a coating with good wear resistance and moderate corrosion resistance. It is commonly used in the auto and electrical industries.
Low Phosphorus Electroless Nickel
This type has very little phosphorus which results in a coating that has high brightness, good solderability, and good conductivity. It is mainly used in electronics.
Electroless Nickel Composite Coatings
Composite coatings are coatings with dispersed nanoparticles, or other materials, in the plating solution to improve properties such as wear resistance, corrosion resistance, and electrical conductivity. These coatings are used across the aerospace, automotive, and electronics sectors.
Electroless Nickel-PTFE Coatings
In this variation, the plating bath will contain particles of polytetrafluoroethylene (PTFE), which yields superior non-stick and low-friction coatings that are often used in food processing, medical, and semiconductor applications.
Electroless Nickel-Boron Nitride Coatings
This class of coatings uses boron nitride particles added to the plating solution to produce a coating with excellent lubricity and wear-resistance properties. It is commonly used in the aerospace, automotive, and electronics industries.
Electroless Nickel-Tungsten Carbide Coatings
Variation contains tungsten carbide particles suspended in the plating solution and gives a coating with excellent hardness and wear resistance, and is used in the oil and gas, aerospace, and automotive industries.
Black Electroless Nickel
This type has a proprietary combination of nickel and other materials, yielding a black matte coating. It offers aesthetics advantage mostly to the firearms industry, while we have also seen some in the electronics and automotive industries.
Electroless Nickel-Silicon Carbide Coatings
This type contains silicon carbide particles in the bath that forms a coating with good wear resistance, hardness, and thermal conductivity. It is often used in automotive, aerospace and defense applications.
Electroless Nickel-Gold Plating
This technique uses a layer of electroless nickel, then a layer of gold, taking advantage of the corrosion resistance and electrical conductivity of the electroless nickel, and the aesthetics and additional corrosion resistance of the gold. It is widely adopted in electrical and jewelry industries.
Electroless Nickel-Cobalt Plating
The process of electroless nickel followed by a layer of cobalt produces a composite with additional hardness and wear resistance while enhancing magnetic characteristics. This method is often used in the electronics and automotive industries.
Each variation has a unique application depending on its properties. For example, high phosphorus electroless nickel is used in aerospace for its better corrosion resistance, and electroless nickel-PTFE coatings are used for food processing due to their non-stick properties.
Electroless Nickel Plating on Plastic
Electroless nickel plating on plastic examines wear resistance, surface hardness, electrical conductivity, or the aesthetic appearance of parts.
While the plating process was introduced in the 1960s, it was some time before a successful method could be developed to create a strong bond between the nickel coating and the plastics substrate.
The challenge was tackled by using chromic acid to etch the surface of the plastic, allowing the surface to become adhesive under the right conditions. This process was incorporated into automotive production to produce grilles, emblems, and light bezels after overcoming the original issues.
In addition, for the effectiveness of the plating of the plastics to be effective one needs to have the plastics properly molded so that the plastics are stress free and defect-free.
Once the plastic is ready to be plated, the plastic surfaces need to be metallized to improve adhesion which can be accomplished with electroless or other metal deposition processes upon the plastic substrate surfaces.
Etching is accomplished with acidic materials like chromium trioxide or sulfuric acid, which allows the etched parts to absorb fluids and also create microscopic pores within the surface of the plastic part so that the metals can become part of the surface and bond to each other.
A number of different plastics surface treatment systems were reviewed, and it became clear, that through pre-etching, in almost every case improvement of the adhesive properties and eliminating the stress levels of the surface layer of the plastic on the entire part was possible.
What are the benefits of Electroless Nickel Plating?
Nickel plating has a number of advantages, and it is with good reason that it has been considered for more than 150 years. Nickel was discovered in the eighteenth century and was called kupfernickel, which is German for “devil’s copper.” Nickel is strong, corroded, durable, and an attractive finish.
Nickel plating was invented during the first industrial revolution by an Italian chemist. A viable method of nickel plating was developed near the end of the nineteenth century and became the methodology for nickel plating.
Corrosion Resistance
Electroless nickel plating provides exceptional corrosion protection, protecting parts and components against rust and other corrosive agents. This process provides a protective coating on the surface, preventing moisture and corrosive agents from contacting the underlying metal.
Wear Resistance
The use of this plating method also increases wear resistance and prolongs the life of parts that endure high levels of friction and abuse.
This increased wear resistance is a result of the hardness of the nickel coating, which provides not only enhanced durability with respect to scratches and abrasions, but also provides resistance to other forms of wear.
Uniformity and Thickness Control
With electroless nickel, it is easy for the plating solution to be precisely controlled in both thickness and uniformity, meaning a consistent coating with rich coverage. With accurate coatings, the best protection and performance can be achieved over the coated parts.
Adhesion
Electroless nickel plating has great adhesion to a variety of substrates including, but not limited to, metals, ceramics, and plastics.
By demonstrating great adhesion with virtually all materials, electroless nickel plating does not require additional primers or adhesives, therefore helping the coating process to be more efficient, and more cost effective.
Surface Finish
This plating technique provides a smooth, consistently finished surface, meaning no blemishes or defects. This not only provides aesthetic benefits to parts but synergistically improves their function and overall performance.
Electrical Conductivity
Electroless nickel plating provides good electrical conductivity, making it suitable for application to electronic and telecommunications components, and improving the conductivity of various electronic and telecommunication components, connectors, and printed circuit boards
Chemical Resistance
The coating exhibits excellent resistance to a wide variety of chemicals, making it suitable for parts which are subjected to extreme chemical environments. Resistance of the coating protects the part for future use which can lead to greater service life.
Non-Magnetic Properties
Electroless nickel plating can be designed with non-magnetic properties, which is beneficial for parts located in magnetic environments such as medical devices like MRI machines.
Cost-Effective
Electroless nickel plating provides a cost-effective means of coating parts and components when compared to other methods of coating like electroplating or vacuum deposition.
The electroless nickel plating process is simpler than other methods and uses relatively little equipment which also leads to the overall lower costs.
The above is just a few of the many benefits of electroless nickel plating. Other benefits could include high heat resistance, hardness, and wear resistance at elevated temperatures.
What are the common uses for Electroless Nickel Plating?
Electroless nickel plating is used across many different industries since its conception. In many industries there is a demand for products to be more durable, and the consumer expectation for durability and product appearance is high.
Because of the growing demand for longevity and appearance for products, more manufacturers are choosing to implement electroless nickel plating for the added benefits.
Aerospace
Aerospace parts manufacturers had issues with corrosion and wear on aluminum components used in landing gear systems. Electroless nickel plating is a consistently applied corrosion-resistant coating that can extend the life of the aluminum components and limits the cost of expensive replacements.
Electronics
The electronics sector uses electroless nickel plating in order to improve the performance and reliability qualities of electronic components.
For example, the electroless nickel plating of printed circuit boards improved solderability and reduced defects, which increased the reliability of products made with printed circuit boards, and lowered their manufacturing expenses.
Automotive
An automotive parts supplier had experienced corrosion and wear in cast iron brake parts. Use of electroless nickel plating provided a uniform, wear resistant coating that improved durability and usefulness of the parts, while reducing or eliminating the probability of costly recalls and warranty costs.
Medical
A medical device manufacturer faced biocompatibility failure with stainless steel components in implantable devices.
By using electroless nickel plated to apply a biocompatible coating enhanced the safety and efficacy of the devices which decreased the chances of adverse effects and enhanced patient outcomes.
Oil and Gas
Electroless nickel plating is used to coat components in oil and gas exploration and production like drill bits and pipe connectors to improve wear and corrosion resistance.
The plating of drill bits with electroless nickel substantially improved the life of drill bits, which improved downtime and reduced maintenance costs.
Manufacturing
Electroless nickel plating provides a protective coating for many products in the manufacturing world, from molds to dies to rollers.
Electroless nickel plating a roller used in a paper mill increased its wear resistance and extended the roller’s service life while decreasing downtime related to roller replacement.
Chemical Processing
In chemical applications, electroless nickel plating is often selected for the added corrosion protection of assets in exposure to aggressive chemical environment.
A heat exchanger that was plated with electroless nickel had improved corrosion resistance and longer service life meaning that maintenance costs were reduced.
Food Processing
In the food processing sector, electroless nickel plating is frequently used to protect various food processing equipment.
For this purpose, electroless nickel plating coatings are especially effective with blades and mixing bowls providing ammonium hydroxide and sound wear and corrosion resistance.
Electroless nickel plating a mixing bowl in a food processing facility provided better wear resistance and less contamination, resulting in better product quality and less cleaning time.
Military and Defense
Electroless nickel plating is extensively used in military and defense markets (for example firearms) to increase wear and corrosion resistance.
In the case of firearms, the wear resistance of electroless nickel plating dramatically increased the wear resistance and reduced friction of the firearm, thus improving accuracy and reliability.
These examples illustrate the wide range and potential that electroless nickel provides as a surface finishing technology. Electroless nickel can provide a uniform, corrosion resistant coating to many substrates, increasing performance and durability for a wide range of products.
What are the applications of Electroless Nickel Plating?
Electroless nickel plating has experienced a wide expansion in versatility and utilization, ranging from aerospace and automotive manufacturing to the medical and dental implant fields.
Its improved strength and durability continued to promote the use of electroless nickel plating in newer and competitive applications.
Automotive and Aerospace Industries
In these industries electroless nickel plating is used to improve the wear and corrosion resistance of engine items, including pistons, valve bodies and fuel injectors.
Electroless nickle plating also is used as a coating on important components of jet aircraft engines and landing gear for corrosion and wear protection.
Electronics and Telecommunications
Electroless nickel electroplating is a method used when there is a need to protect electronic products from wear corrosion and improve their electrical characteristics. It is primarily used on printed circuit boards, connectors, and microwave products.
Medical and Dental Equipment
In the biomedical and dental fields, electroless nickel plating improves the biocompatibility of implants and instruments and yields a smooth, uniform surface finish. It is used extensively to protect surgical instruments, orthopedic implants, and dental devices.
Oil and Gas Exploration and Production
The oil and gas industry uses electroless nickel plating for additional corrosion and wear protection for equipment when used in harsh environments (offshore drilling and pipelines). Electroless nickel plating is often used to provide coatings for valve assemblies, pumps, and drill bits.
Industrial and Manufacturing Equipment
The process of electroless nickel plating provides increased resistance to corrosion and wear of numerous tools used in industry and manufacturing. A common application of electroless nickel plating is for coating gears, bearings, molds and dies.
Chemical Processing Equipment
The electroless nickel plating process serves a protective coating for a variety of chemical processing equipment such as tanks, valves, and pumps that can corrode or suffer wear due to aggressive chemicals and/or high temperatures.
Food Processing Equipment
Electroless nickel plating is used in the food processing industry where products are made under acidic and salty conditions where corrosion and wear can occur. It would be found on mixing blades, choppers and conveyors.
Military and Defense Equipment
Electroless nickel plating can enhance the wear and corrosion resistance of military and defense equipment that is used under extreme conditions such as in submarines, tanks and aircraft.
Mining Equipment
This approach of plating is also applicable to mining equipment – drill bits and cutting tools – and is useful to improve durability and wear/corrosion resistance in harsh mining situations.
Renewable Energy
The renewable energy sectors of wind and solar energy industries utilize electroless nickel plating method to coat components that are exposed to outdoor elements. For example, connectors, gearboxes, and bearings are typically coated using electroless nickel plating.
Printing Industry
The printing industry uses electroless nickel plating to coat the components of printing rollers, gears, and other parts in order to reduce wear, thereby increasing the useful life of the equipment.
Textile Industry
In the textile industry, this method of plating is used to coat the parts of weaving and spinning machines, plus parts of dyeing machines, in order to reduce wear and corrosion of those parts.
Aerospace Fasteners
Electroless nickel plating is used on fasteners used in the aerospace field to provide corrosion protection and to increase parts’ durability.
Firearms
Electroless nickel plating is used on firearms to protect them from rust and corrosion in addition to improved protection.
Musical Instruments
Electroless nickel plating is used for musical instruments such as flutes and saxophones to help eliminate corrosion, and augment the musical component of the instruments.
Jewelry
Within the industry of jewelry, electroless nickel plating is used by jewellery companies to electroplate jewellery products such as bracelets and rings, which ensure durability against wear and tear from characterisation.
Marine Industry
The marine sector utilizes the process of electroless nickel plating to coat items such as propellers and valves that are subject to saltwater and harsh marine conditions.
Automotive Industry (Decorative)
In the automotive sector, electroless nickel plating is used to decorative applications such as plating wheels, trim, etc.
What are the laws and regulations regarding Electroless Nickel Plating?
Electroless nickel plating is a chemical process that must be closely monitored to protect worker and community safety, and with increasing environmental regulations on plating processes, especially with chemicals being used, we are being scrutinized more.
Electroless nickel plating in the United States is subject to various laws and regulations concerning environmental safety and worker safety.
The Clean Water Act
The Clean Water Act regulates the discharge or deposition of pollutants to navigable waters, including those that are involved in electroless nickel plating process. The Environmental Protection Agency (EPA) is responsible for enforcing the provisions of this law.
The Resource Conservation and Recovery Act
The Resource Conservation and Recovery Act regulates the management and disposal of hazardous waste, including waste generated from electroless nickel plating operations. The enforcement authority for this law also resides with the EPA.
Occupational Safety and Health Administration (OSHA) Regulations
OSHA regulations create workplace safety standards in relation to the use of chemicals that are hazardous in electroless nickel plating processes.
The Toxic Substances Control Act
The Toxic Substances Control Act (TSCA) governs the manufacture, import, and processing of chemicals, which in the case of electroless nickel plating include the chemicals of interest.
The TSCA is enforced by the EPA. In addition to federal regulations, there may also be state or local regulations that apply to electroless nickel plating processes.
Some states also have more detailed regulations concerning the management of hazardous waste and workplace safety.
On the international level, there are several agencies that regulate electroless nickel plating processes. These include:
European Union REACH Regulations
REACH (Registration, Evaluation, Authorization and Restriction of Chemicals) is a regulation in the European Union concerning the use of chemicals in several industries with techniques from the manufacture of electroless nickel plating included.
The International Agency for Research on Cancer (IARC)
The IARC is an intergovernmental agency of the World Health Organization that evaluates the carcinogenicity of various substances: this includes nickel and other chemicals used for the process of electroless nickel plating.
The International Electrotechnical Commission (IEC)
The International Electrotechnical Commission (IEC) is an international standards organization for the electrical and electronics sector that is developing standards for the use of electroless nickel plating in electronic components.
For companies that are engaged in electroless nickel plating, especially those doing so on an international basis, they must comply with these standards, whether they are public or private entities. Ultimately, compliance of policies can have significant effects on the environmental and workplace safety of their workers.
What considerations should be taken into account regarding Electroless Nickel Plating?
Each chemical reaction may have possible undesirable effects or impacts on human health and/or the Environment. They can be quite costly, as each reaction generally requires chemicals to both open and close a process.
As previously mentioned, it must be considered when thinking of when to utilize electroless nickel plating as a manufacturing step.
Health Hazards
A few of the chemical substances involved in electroless nickel plating are harmful to human health. The harmfulness comes from nickel and sodium hypophosphite in electroless nickel plating. Nonetheless, to minimize safety risks, safety practices are developed, such as the development of PPE, the consideration of proper ventilation in the work environment, etc.
Environmental Concerns
Unless disposed of properly, the chemicals linked to electroless nickel plating can present hazards to the environment. Proper disposal is essential to reduce the chance of contamination to water and soil.
Cost
Although electroless nickel plating is usually less expensive than electroplating or vacuum deposition, it may be more costly than other surface treatments like paint and powder coating.
Limited Thickness
Electroless nickel plating is limited in thickness, typically up to about 0.003 inches thick; and should be considered when thicker coatings are required.
Limited Substrate Options
This plating process may only fit specific substrates. Commonly metals and some plastics would allow for this plating method. However, it would not be used for materials such as ceramics or glass.
Complex Process
Electroless nickel plating has a number of controlling variables such as plating solution, temperature, and pH that make for a much more involved process than other processes, especially for smaller companies with limited financial capabilities.
Surface Preparation
Proper surface preparation is necessary for electroless nickel plating to succeed. Contaminants or imperfections on the surface of the part can negatively affect the coating’s adhesion and performance.
What does the future hold for Electroless Nickel Plating?
Overall, the future of electroless nickel plating appears positive and strong. There are new applications and uses of the process being developed as our metals technology continues to advance. In addition, there are many trends that bode well for electroless nickel plating to grow in importance in the future.
Increased Demand for Wear Resistance
As the demand for wear resistance capabilities in many industries, such as aerospace, automotive, and defense, continues to grow, there will likely be a rise in the demand for electroless nickel plating applications, as it has good wear resistance.
Advancements in Additive Manufacturing
Additive manufacturing processes, such as 3D printing, have generated a need for surface finishing processes that are capable of coating complicated shapes. Electroless nickel plating may be an ideal option to meet this need.
Growth in Medical Device Industry
The medical device industry is growing rapidly and electroless nickel plating has shown its usefulness in this industry. With a growing need for biocompatible coatings and antimicrobials, electroless nickel plating may continue to prosper in this area.
Development of New Electroless Nickel Alloys
Marketed enhancements in the properties of electroless nickel alloys have led researchers to develop new alloys with increased hardness, wear resistance, and corrosion resistance as more fine-grained, precipitated alloys become commercially available and electroless nickel will be used in more applications.
Environmental Regulations
Environmental regulations are becoming stricter and, as a result, there is an industry-wide shift towards more environmentally friendly coatings and plating processes.
It is possible that the industries that concern themselves with going the environmentally friendly route will adopt electroless nickel plating, as it represents a lesser environmental impact than some other processes.
Renewable Energy
Renewable energy technologies, such as solar and wind, involve specialized components that require coatings with high wear and corrosion resistance.
Electroless nickel plating demonstrates clear benefits for wind turbine components, and as renewable energy grows in importance and prominence in the future, possibly electroless nickel plating can play a larger role.
Nanotechnology
The recent advancement of beter technology has generated a big need for surface finishing processes that can coat and protect nanoscale structures. Electroless nickel plating, for example, can collectible cœur, has illicitly and could coat nanoscale materials and nanoparticles.
Electroless nickel plating may provide even further functionality such as electrical conductivity, catalytic activity modalities, and/or biocompatibility.
Biotechnology
Specialty coatings are needed for medical devices such as orthopedic implants and cardiovascular stents in the biotechnology industry. These coatings must be biocompatible, as well as antimicrobial and eventually able to withstand wear and tear.
There are medical devices with electroless nickel-plated coatings in use today, and the application of electroless nickel plating will likely grow and expand as the capabilities for applied coatings increase.
In conclusion, electroless nickel plating will emerge in a variety of industries as the technology advances into new or emerging technologies and new areas of application for electroless nickel plating continue to be developed.
Electroless nickel plating’s unique ability to provide corrosion and wear resistance, as well as a number of properties, makes this an adaptable and flexible process across many applications.