Overall dullness of an Alkaline Non-Cyanide Zinc Deposit could be an indication of:

Low Brightener or Low Starter (Carrier)

High Zinc Metal Concentration
Bath Contamination
Poor Water Quality
High or Low Temperature
Poor Cleaning
Electrical Problems
Poor Filtration

HCD Burning of an Alkaline Non-Cyanide Zinc Deposit could be an indication of:

Low Temperature
High or Low Zinc Metal Concentration
Low Starter (Carrier)
Low Caustic Concentration
Parts too close to Anodes
Excessive Current
Low Brightener
Current too High in Electrocleaner

Dull LCD of an Alkaline Non-Cyanide Zinc Deposit could be an indication of:

Low Brightener
Low Purifier
High or Low Temperature
Poor Filtration
Low Caustic Concentration
Bath Contamination
Improper Pickling
Sulfide Contamination

Mottled or Blotchy Alkaline Non-Cyanide Zinc Deposit could be an indication of:

Poor Cleaning
Excessive Water Hardness

Roughness of an Alkaline Non-Cyanide Zinc Deposit could be an indication of:

Poor Filtration
High Current
Low Carrier Concentration
Low Anode Area
Magnetized Particles
Copper in Pickle

Brittle Deposits of an Alkaline Non-Cyanide Zinc Deposit could be an indication of:

High Brightener
Bath Contamination
Low Carrier Concentration

Pitting of an Alkaline Non-Cyanide Zinc Deposit could be an indication of:

High Brightener
Bath Contamination
Poor Filtration

Blisters or Poor Adhesion of an Alkaline Non-Cyanide Zinc Deposit could be an indication of:
Low Temperature
Poor Cleaning
Organic Contamination
Chromium Contamination
High Brightener
Low Starter (Carrier)
Metallurgical Characteristics
Low Caustic Concentration
Copper in Pickle
Current Interruptions

Poor Throw in an Alkaline Non-Cyanide Zinc Solution could be an indication of:

Low Carrier Concentration
High Zinc
Low Anode Area
Low Current
High or Low Temperature
Poor Cleaning
Low Caustic Concentration
Low Brightener
Metallurgical Characteristics
Inadequate Agitation

No Plate from an Alkaline Non-Cyanide Zinc Solution could be an indication of:

Electrical Problems
Over Pickling
Metallurgical Characteristics
Low Temperature
Chromium Contamination
High Voltage (Barrel Plating)

Poor Efficiency of an Alkaline Non-Cyanide Zinc Solution could be an indication of:

Low Zinc
High Carrier
High Caustic
Electrical Problems
Low Anode Area
Low Temperature
High Brightener
Bath Contamination

Post-Plate Staining of an Alkaline Non-Cyanide Zinc Deposit could be an indication of:

Insufficient Rinsing
Rinses Contaminated
Bright Dip Contaminated
Excessive Dwell Time between the Plating tank and the
Chromate tank
Metallic Contamination

Post-Storage Staining of an Alkaline Non-Cyanide Zinc Deposit could be an indication of:

Insufficient Rinsing
Improper Passivation
Poor Drying and Handling
Corrosive Environment
Metallic Contamination

Falling Zinc Level in an Alkaline Non-Cyanide Zinc Solution could be an indication of:
Anodes Polarized
Low Anode Area
Improper Steel to Zinc Ratio in Generator Tank
Poor or No Solution Movement in Generator Tank
Titanium Baskets in the Circuit

Rising Zinc Level in an Alkaline Non-Cyanide Zinc Solution could be an indication of:
Too Much Anode Area
High Caustic Concentration

High Additive Consumption in an Alkaline Non-Cyanide Zinc Solution could be an indication of:
Organic Contamination
High Temperature
Incompatible cleaners
High Drag-In, Drag-Out

Lack of Brightness

This problem is most usually caused by low brightener levels in the bath or low zinc levels. Analyse the
bath for zinc metal content. If the zinc content is lower than the recommended value, correct this before
making additions of brightener. If the zinc content is correct, the bath requires an additon of brightener.
Perform a Hull Cell test and check the metal deposit thickness on the panel. Make a brightener addition,
retest and recheck the thicknesses. If the plating efficiency of the bath is still OK (check with the data
sheet for the relevant process), proceed with the brightener addition.

Dullness in LCD Areas

This problem is due to a high zinc concentration in the bath, low sodium hydroxide concentration or lack
of brightener (or carrier in the case of Envirozin 100, 120 or Genesis). The method of correction for this
fault is as follows:

1. Analyse and, if necessary, correct the sodium hydroxide and zinc concentration in the bath. It is
important that no additions are made to correct faults until the basic bath composition is correct.

2. After correction of the basic parameters, perform a Hull Cell test. If the LCD problem is still
apparent, an addition of brightener is required in the case of Envirozin 5 or 6. Follow the data
sheet for these additions. In the case of Envirozin 120 or Genesis, lack of Carrier can also
produce this defect. The first thing to do in the case of these processes is to add 1 ml/l of Base
Additive (Envirozin 120) or Carrier (Genesis) and repeat the Hull Cell test. Measure the
thicknesses on both the original panel and the panel with the Carrier added. If the difference is
more than 20%, do not add carrier. If the LCD problem persists, do not add Carrier or Base
Additive to the process tank. In these cases, brightener rather than Base Additive or Carrier is
required.

Dullness / Streaking in MCD Areas

This problem is caused by a lack of Conditioner (Envirozin 5, 6, 100,120) or Replenisher (Genesis). The
concentration of these components can be analysed in our Technical Centre and we would recommend
that this analysis is carried out at least once every month. Follow the data sheet recommendations for
each process but bear in mind that in hard water areas, or when carbonate levels in the bath are high
(Envirozin5, 6), a higher concentration of Conditioner or Replenisher may be required.

Pitting or Burning

This problem is caused either by excessive zinc concentration or lack of Carrier in the bath. Again, the
bath should be analysed for zinc concentration before any addition is made. If the zinc concentration is
 correct, the bath requires a Carrier addition. In the case of Envirozin 5, 6 and 100 the carrier components
are incorporated in the brightener as a "one shot" additive. In the case of Envirozin 120 and Genesis, it
is added as a separate additive. The concentration of this component in both of these processes is critical
to bath performance (efficiency and deposit thickness distribution) so be sure to follow the data sheets
carefully.

If an addition of Base Additive (Envirozin 120) or Carrier (Genesis) increases the amount of burning on
the panel, this indicates excessive chloride contamination of the bath. Chloride is a serious contaminant
which can lead to an intolerance of Carrier. Eventually, this will lead to problems of blistering and poor
throwing power. If excessive chloride is suspected, send a sample of the plating bath to our Technical
Centre for diagnostic analysis.

Poor Thickness Distribution

This problem may be caused by excessive zinc concentration or lack of sodium hydroxide in the bath.
Again, before any additions are made, the bath should be analysed for zinc and sodium hydroxide and
corrected. If the basic composition of the bath is correct, then the bath is low in Carrier (Genesis) or Base
Additive (Envirozin 120). Follow the data sheet for the correct additions for each process.

Poor Plating Efficiency

This problem may have several causes. These are as follows:

 Low Bath Temperature

 Very High Carbonate (above 80 g/l)
 Low Zinc Concentration
 High Additive Concentration
 Bath Contamination

The temperature and zinc concentration can easily be checked and corrected. High carbonate can be a
problem in solutions with low dragout. It can be removed by "freezing out", either using special equipment
or pumping out the bath after winter shutdown.

High additive concentration can be a potential problem. It can happen if additions are not properly
monitored or if dosing pumps become faulty. Carrier or Base additive can build up in baths and can take a
very long time to plate out. Bath contamination is quite common. Pretreatment is rarely perfect on
commercial zinc plating lines and oil or other contaminants can be dragged into the bath.

Poor Adhesion / Blistering

This can be caused by several factors:

 Poor Pretreatment
 High Zinc Concentration
 High Additive Concentration
 Low Bath Temperature
 Bath Contamination
 Lack of Carrier

Lack of Brightness
This problem is most usually caused by low brightener levels in the bath or low zinc levels. Analyse the
bath for zinc metal content. If the zinc content is lower than the recommended value, correct this before
making additions of brightener. If the zinc content is correct, the bath requires an additon of brightener.
Perform a Hull Cell test and check the metal deposit thickness on the panel. Make a brightener addition,
retest and recheck the thicknesses. If the plating efficiency of the bath is still OK (check with the data
sheet for the relevant process), proceed with the brightener addition.

Dullness in LCD Areas

This problem is due to a high zinc concentration in the bath, low sodium hydroxide concentration or lack
of brightener (or carrier in the case of Envirozin 100, 120 or Genesis). The method of correction for this
fault is as follows:

1. Analyse and, if necessary, correct the sodium hydroxide and zinc concentration in the bath. It
is important that no additions are made to correct faults until the basic bath composition is correct.

2. After correction of the basic parameters, perform a Hull Cell test. If the LCD problem is still
apparent, an addition of brightener is required in the case of Envirozin 5 or 6. Follow the data
sheet for these additions. In the case of Envirozin 120 or Genesis, lack of Carrier can also
produce this defect. The first thing to do in the case of these processes is to add 1 ml/l of Base
Additive (Envirozin 120) or Carrier (Genesis) and repeat the Hull Cell test. Measure the
thicknesses on both the original panel and the panel with the Carrier added. If the difference is
more than 20%, do not add carrier. If the LCD problem persists, do not add Carrier or Base
Additive to the process tank. In these cases, brightener rather than Base Additive or Carrier is
required.

Dullness / Streaking in MCD Areas

This problem is caused by a lack of Conditioner (Envirozin 5, 6, 100,120) or Replenisher (Genesis). The
concentration of these components can be analysed in our Technical Centre and we would recommend
that this analysis is carried out at least once every month. Follow the data sheet recommendations for
each process but bear in mind that in hard water areas, or when carbonate levels in the bath are high
(Envirozin5, 6), a higher concentration of Conditioner or Replenisher may be required.

Pitting or Burning

This problem is caused either by excessive zinc concentration or lack of Carrier in the bath. Again, the
bath should be analysed for zinc concentration before any addition is made. If the zinc concentration is
correct, the bath requires a Carrier addition. In the case of Envirozin 5, 6 and 100 the carrier components
are incorporated in the brightener as a "one shot" additive. In the case of Envirozin 120 and Genesis, it is
added as a separate additive. The concentration of this component in both of these processes is critical to
bath performance (efficiency and deposit thickness distribution) so be sure to follow the data sheets
carefully.

If an addition of Base Additive (Envirozin 120) or Carrier (Genesis) increases the amount of burning on
the panel, this indicates excessive chloride contamination of the bath. Chloride is a serious contaminant
which can lead to an intolerance of Carrier. Eventually, this will lead to problems of blistering and poor
throwing power. If excessive chloride is suspected, send a sample of the plating bath to our Technical
Centre for diagnostic analysis.

Poor Thickness Distribution

 This problem may be caused by excessive zinc concentration or lack of sodium hydroxide in the bath.
Again, before any additions are made, the bath should be analysed for zinc and sodium hydroxide and
corrected. If the basic composition of the bath is correct, then the bath is low in Carrier (Genesis) or Base
Additive (Envirozin 120). Follow the data sheet for the correct additions for each process.

Poor Plating Efficiency

This problem may have several causes. These are as follows:

 Low Bath Temperature

 Very High Carbonate (above 80 g/l)
 Low Zinc Concentration
 High Additive Concentration
 Bath Contamination

The temperature and zinc concentration can easily be checked and corrected. High carbonate can be a
problem in solutions with low dragout. It can be removed by "freezing out", either using special equipment
or pumping out the bath after winter shutdown.

High additive concentration can be a potential problem. It can happen if additions are not properly
monitored or if dosing pumps become faulty. Carrier or Base additive can build up in baths and can take a
very long time to plate out. Bath contamination is quite common. Pretreatment is rarely perfect on
commercial zinc plating lines and oil or other contaminants can be dragged into the bath.

If the carbonate is low, the zinc concentration correct, the bath temperature OK and plating efficiency still
poor, send a sample of the process solution to our Technical Centre for diagnostic analysis.

Poor Adhesion / Blistering

This can be caused by several factors:

 Poor Pretreatment
 High Zinc Concentration
 High Additive Concentration
 Low Bath Temperature
 Bath Contamination
 Lack of Carrier

By far the most common cause of poor adhesion and blistering of the deposit is poor pretreatment. This
should be investigated thoroughly before suspecting any other cause. Please refer to our section on
preferred pretreatment systems for our recommendations.

Absolutely it can be high organics such as brightener, carrier or drag in of oils. To check for high
brightener I run a 5 amp 15 minute Hull Cell panel. If the panel is full bright you are too high in brightener
you should have a 1/2" of dullness in the HCD, if there is a wavy pattern you are too high in the carrier
system. One other thing you might want to check is the rinsing after the HCl, if the pH of the rinse right
before you enter the alkaline zinc bath is low 5.0 or lower you may be setting up salts on the surface of
the parts, probably chlorides which will give delayed blistering up to 1 month later. It is not a good practice
to go from a low pH into a high pH bath for this reason.
Question:
We are having trouble with blisters in our chloride zinc barrel line and our alkaline zinc barrel line. The
substrate is hardened steel. Our lines are traditionally configured, except we don’t have triple rinsing after
each step. I can provide detailed line schematics if you like, but I’m looking for some basic advice initially.
B. W.
Answer:
It seems that ever since we left classic cyanide zinc plating behind, the problem of blisters has been a
major issue in both chloride and alkaline zinc plating. The first place to start when troubleshooting plating
problems is with your chemical vendor. Most suppliers have troubleshooting information available and
usually have technical expertise to help solve the problems. Assuming you have exhausted this route
here are some things to consider.

Let’s start with the alkaline non-cyanide zinc bath. Some common causes of blistering are:
Possible Cause Action
Poor cleaning Review cleaning process and upgrade
Brightener concentration high Reduce concentration using vendor recommended methods
(carbon treat)
Bath temperature low Increase bath temperature to recommended value
Metallic contamination Zinc dust treatment
Organic contamination Carbon treat per vendor specifications
Incorrect plating bath chemistry Analyze bath and make necessary changes

With the chloride zinc plating bath there are a couple of causes of blistering:
Possible Cause Action
Poor cleaning Review cleaning process and upgrade
Boric acid concentration low Analyze bath and make necessary changes

In both types of zinc plating, cleaning and surface preparation are the most critical steps.

The Metal Finishing Guidebook & Directory, 2003 edition has a number of chapters on the proper
cleaning of surfaces. The Products Finishing web site, www.pfonline.com, also has useful information.
Another web site, www.cleantechcentral.com, also has good information on the proper cleaning of
materials.

Q: Dear sir. Can you please answer the following: 1. What is the indicator that we can see on the part if
the alkaline non-cyanide solution is contaminated with lead? 2. What is the minimum concentration of
lead? 3. How can we remove lead contamination in an alkaline non-cyanide zinc solution ?

Lead contamination will have an overall dark/iridescent appearance after the chromate is applied. It is not
recommended operating the process with contamination levels over 5 mg/L.
Treat plating solution with 1 pound zinc dust per 1,000 gallons of plating solution. Spread the zinc dust
evenly over the entire surface of the plating solution and allow to mix a minimum of 1 hour. It is not
recommended treating the bath during operation; the zinc dust will cause roughness.

Q: Dear sir: I have two alkaline zinc baths--one is 1500 liters, zinc metal-8.9 g/l NaOH - 120 G/L; the other
is of 2500 liters zinc metal-9.02 g/l NaOH- 130 G/L. I am doing the same plating over plain carbon steel
and alloy carbon steel. I am facing blisters on the same when we heat the same component on 100
degree centigrade. Delay blistering is very common on these plated articles. The process sequence is as
follows: 1-Hot soak 2-WR x 3 3-pickling 4-WRx2 5-Hot Anodic 6- WRx3 7-Acid activation 8-WRx2 9-
NaOH neutralizer 10-Plating 11-drag out 12-WRx3 13- Nitric dip 14- Tri-passivation 15-WRx2 16-sealer
Please tell me the solution of the same problem and send me the pretreatment sequence for the same if it
differs from the existing. Thank you.

A: Some of the most difficult substrates to process through an alkaline non-cyanide zinc plating
process are high carbon or heat-treated steels. Although these substrates are challenging to process,
improved adhesion is achievable with the proper pretreatment sequence.

There are two basic options for the pretreatment of high carbon or heat-treated steel substrates. These
options will perform exactly what you would expect from an excellent pretreatment system. They will
remove oils, scale and excessive smut/carbon that are found on high carbon or heat-treated substrates.

Option #1 and Option #2 do have similarities. First, both use an acid inhibitor in the hydrochloric acid
pickle. An acid inhibitor, specially formulated for use in electroplating lines, will greatly reduce or even
eliminate the formation of carbon on the surface of the high carbon or heat-treated substrate. Excessive
carbon on the surface of the substrate will greatly decrease the overall adhesion of the zinc deposit.
Second, both options will cycle through an anodic cleaning station prior to entering into the alkaline non-
cyanide plating solution. Reverse current or anodic cleaning is critical for the removal of any carbon
residue. As mentioned previously, any carbon remaining on the substrate prior to plating will reduce
adhesion of the zinc deposit.

OPTION #1

HOT ALKALINE SOAK CLEANER

Temperature - 65°to 85°C

Concentration - 60 to 90 g/L

Time - 4 to 6 minutes

HOT ALKALINE ELECTRO-CLEANER

Temperature - 65°to 85°C

Concentration - 60 to 90 g/L*

Time - 4 to 6 minutes

Current density - 2 to 15 amperes/dm 2

TWO TO THREE COLD WATER CASCADING OR COUNTER FLOWING RINSES

Flow rate - 4 to 8 Liters per minute

Temperature - Ambient

HYDROCHLORIC ACID PICKLE

Temperature - Ambient

Concentration - 30 to 50% by volume

Time - 3 to 5 minutes

Acid Inhibitor - 0.2% to 2.0% by volume

TWO TO THREE COLD WATER CASCADING OR COUNTER FLOWING RINSES

Flow rate - 4 to 8 Liters per minute

Temperature - Ambient

ELECTRO-CAUSTIC

Temperature - Ambient

Concentration - 100 to 150 g/L Sodium Hydroxide

Time - 1 to 2 minutes

Current density - 2 to 15 amperes/dm 2

ALKALINE NON-CYANIDE PLATE

OPTION #2

HOT ALKALINE SOAK CLEANER

Temperature - 65°to 85°C

Concentration - 60 to 90 g/L

Time - 4 to 6 minutes
TWO TO THREE COLD WATER CASCADING OR COUNTER FLOWING RINSES

Flow rate - 4 to 8 Liters per minute

Temperature - Ambient

HYDROCHLORIC ACID PICKLE

Temperature - Ambient

Concentration - 30 to 50% by volume

Time - 3 to 5 minutes

Acid Inhibitor - 0.2% to 2.0% by volume

TWO TO THREE COLD WATER CASCADING OR COUNTER FLOWING RINSES

Flow rate - 4 to 8 Liters per minute

Temperature - Ambient

HOT ALKALINE ELECTRO-CLEANER

Temperature - 65°to 85°C

Concentration - 60 to 90 g/L*

Time - 4 to 6 minutes

Current density - 2 to 15 amperes/dm 2

TWO TO THREE COLD WATER CASCADING OR COUNTER FLOWING RINSES

Flow rate - 4 to 8 Liters per minute

Temperature - Ambient

ALKALINE NON-CYANIDE PLATE

As you can see, Option #1 will most likely be the best sequence for your application. A simple
modification to the NaOH Neutralizer would be needed to improve the overall plating quality.

Q: Dear sir i have two alkaline zinc bath one is 1500 liters, zinc metal-8.9 g/l NaOH - 120 G/L another is of
2500 liters zinc metal-9.02 g/l NaOH- 130 G/L.I am doing the same plating over plain carbon steel and
alloy carbon steel. I am facing Blisters on the same when we heat the same component on 100 degree
centigrade. Delay blistering is very common on these plated articals. . The process sequence is ..... 1-Hot
soak 2-WR x 3 3-pickeling 4-WRx2 5-Hot Anodic 6- WRx3 7-Acid activation 8-WRx2 9-NaOH nutriliser
10-Plating 11-drag out 12-WRx3 13- Nitric dip 14- Tri-passivation 15-WRx2 16-sealer Dear sir please tell
me the solution of the same problem and send me the pretreatment sequence for the same if it differs
from the existing.

Q: Hi Jeff Grodecki, I have two alkaline zinc plating bath of capacity 1200Lts with Zn metal 8g/L, NaOH
120g/L and sodium carbonate 100g/L. With this I used to get 8-12microns thickness within 30 -35 min
( 5V 180 to 200Amps) but from the last 10 days it is taking 70-80 min to get 8-12 microns in both the
baths with parameters being same as earlier. I checked the rectifier output; it is normal. I analyzed the
solution concentration found as mentioned above. What might be causing this problem? Thanks &
regards, Shetty.

Plating speed or cathode efficiency can be effected by a number of different variables within the alkaline
non-cyanide plating solution. Please review the list of variables below.

1. Zinc metal - Low concentrations of zinc metal will cause slow plating speed or poor cathode efficiency.
Zinc metal operating parameters can vary between chemical supplier. Maintaining your zinc metal
concentration at 12 to 15 g/L will help to improve plating speed, but it is recommended checking with your
supplier if any proprietary additions will be needed after the increase in zinc metal.

2. Temperature - Low bath temperatures can also cause slow plating speed or poor cathode efficiency.
Maintaining a operating temperature of 26°to 35°C can help to improve plating speed.

3. Sodium carbonates - High concentration of sodium carbonates will cause slow plating speed or poor
cathode efficiency. Concentrations of sodium carbonates above 75 g/L can very quickly reduce plating
speed. It is recommended maintaining your sodium carbonate levels below 75 g/L. A very common
treatment for high sodium carbonates would be to “batch freeze” when weather is permits. If the weather
does not permit, a bath cuts would be the your second best option.

4. Proprietary additives – Over use of BRIGHTENERS and PURIFIERS can reduce overall plating speed
or cathode efficiency. It is recommended having your supplier analyzing your plating solution for optimum
additive concentrations.

Your bath analysis does indicate a low concentration of zinc metal and a high concentration of sodium
carbonates. Making adjustments to the concentrations of zinc metal and sodium carbonates would be a
great starting point for improving your overall plating speed.

Q: I would like to know about the process of continuous wire zinc plating. Can you also provide
parameters?

Continuous wire plating is usually done in a zinc sulfate solution due to the high-speed deposition rate.
We have had good success using a low brightness/high ductility/high zinc metal alkaline non-cyanide
process for similar applications. I would recommend looking into both processes to see which one fits
your particular application

Q: Hi Jeff, we acid zinc plate cast iron parts which are naturally covered with micro porosity holes. The
parts are top coated with a thick film passivate and sealer. The problem is only during the summer
months after long storage and shipping the parts exhibit a black spotting effect. This i believe is
entrapment of plating solution which under extreme climate conditions - high humidity / temperature
migrates out and attacks the plating surface. We have been looking at the pickling process to understand
the effects on the porosity. Are we over pickling? Or should we pickle longer to open the pores to enable
better rinsing? We are looking at better ways to shot blast the components and investigating packaging. I
am sure many platers have experienced this phenomenom - have you seen this and can you offer some
thoughts.Is there a simple plating process adjustment i could try. We have just introduced additional spray
rinsing where practical on the plating line.

Unfortunately, this can be a common problem in the summer months when trying to process high porosity
steel substrates. Salts from the pretreatment and plating processes can get entrapped in the pores of the
substrate. Over time these salts will migrate through the zinc deposit, causing black discoloration or
staining. Basically, due to the high temperature, humidity and salt remaining on or in the pores of the
substrate, a corrosive environment is formed that discolors the zinc deposit.

Acid pickling high porosity steel can be difficult. Over pickling or etching high-porosity steel can cause a
smut or contamination to form on the surface of the substrate. Under pickling will not remove all of the
oxide scale deep within the pores and cause acid salts to become trapped. To improve the effectiveness
of the acid pickle, use of an acid inhibitor along with an acid accelerating salt is recommended. Using
these products together will allow for the hydrochloric acid pickle to aggressively remove the oxide scale
but not allow for the substrate to be acid etched. These products can usually be offered from your
chemical supplier. Rinsing after acid pickling is also important for consistent work.Maintaining a rinse
water flow rate of 1 to 2 gallons per minute, along with air agitation, is highly recommended.

In regards to the plating process, I suggest maintaining your proprietary CARRIER or WETTING package
on the high side of the operating range. A higher concentration of CARRIER or WETTER will improve the
rinsability of the acid zinc chloride solution from the finished work.
Rinsing after plating is also a very important step for maintain consistent work. Maintain 1 to 2 gallons per
minute flow rate with air agitation to ensure no chloride solution remains on the finished work.

Q: We are facing a delayed peel-off problem in one of our componenets that needs Zi-Ni plating. The
material of this component is 42CrMo4 having tensile strength of 1100 N/mm2. (1) What is the probable
root cause of this problem? (2) Can we do duplex plating (i.e., acid zinc [flash] and then Zi-Ni)?

Steel alloys that contain a high concentration of chrome metal can cause adhesion issues of all
electroplate if the hot alkaline soak clean, hot electro-clean, and acid pickle are not optimized to handle
this type of specialty alloy. I would recommended treating your 42CrMo4 alloyed steel similar to high
carbon/heat-treated steel substrates. Please review the following typical high carbon/heat-treat
pretreatment cycle.

1. Hot alkaline soak cleaner

2. Hot alkaline electro-cleaner
3. Rinses
4. Mild hydrochloric acid pickle (20% to 30% by volume) with the use of an acid inhibitor. The use of
an acid inhibitor will be very important to reduce the acid etch of the substrate, which will reduce
the dissolution of the chrome from the 42CrMo4 steel alloy.
5. Rinses
6. Plate

Q: We are doing zinc plating in a non-cyanide alkaline bath followed by trivalent black passivation. The
thickness of zinc plate is around 6 to 8 microns. The black coating is getting scratches during
transportation and our customer is rejecting such pieces. What is the solution to this problem?

Trivalent black chromate technologies are often unique to each individual chemical supplier. Although
there is a common trend among suppliers to rely heavily on sealers or topcoats to add extra corrosion
protection and scratch resistance. It is important that these sealers or topcoats are allowed to cure
properly prior to shipment.

It is recommended that you discuss the properties of your current trivalent black technology with your
chemical supplier and determine the optimum chromate chemistry and process for scratch resistance.

Q: Why is a low cloud point causing staining problems in my acid zinc barrel? What treatment is
recommended and how can I prevent this problem in the future?

Low cloud point is an indication of a high level of organic material (contamination) that has found its way
into the plating solution. Proprietary additives for acid zinc plating are typically formulated with surfactants
and/or wetting agents that have high cloud point properties, which prevent the additives from “oiling out.”
When the cloud point falls below a given standard (somewhere between 120°to 150°F) there is an
indication of organic contamination, which can interfere with the proprietary additives. As your plating
solution’s temperature approaches the cloud point, organic contamination becomes insoluble in the
plating solution. This insoluble material can coat the surface of the zinc deposit or even be co-deposited
with the zinc, causing a white stain or a cloudy deposit.

A good way to improve/raise cloud point is to treat the plating solution with potassium permanganate. A
slurry of potassium permanganate and water is poured evenly over the top of the plating solution, using
two pounds potassium permanganate per 1,000 gallons of plating solution. The plating solution should be
allowed to mix for at least one hour and filtered before plating is resumed. Be sure to wear goggles,
gloves, and other protective clothing when handling potassium permanganate. It will likely be necessary
to add small amounts of proprietary additives back to the bath for optimum brightness.
While permanganate treatments are effective at improving/raising cloud point, it is important to eliminate
the source of contamination. The most common culprits are overworked or spent cleaning solutions,
which cause oils and other organic contamination to be dragged down the line into the plating tank.
Increasing pretreatment rinse water flow rates can help, but dumping and making up new cleaners and
then maintaining an appropriate dump/makeup schedule is the most effective way of preventing cloud
point and staining problems.

Q: I am an alkaline non-cyanide job shop plater in Michigan. We are having a plating appearance issue
that does not respond to any proprietary additives. The problem is an overall lack of brightness in the
deposit. All of the work coming out of the line just does not have the snap that we and our customers are
accustomed to seeing. Our chemical supplier has analyzed our plating solution and has indicated that all
proprietary additives are within the recommended operating ranges, but that the bath is contaminated
with organics. Their recommendation has been to treat the plating solution with carbon or potassium
permanganate. These treatments are effective but require extensive maintenance on the equipment that
can slow down my production. Are there any other treatments or additives available to help with organic
contamination?

Alkaline non-cyanide zinc plating solutions that do not respond to additions of proprietary additives
usually suffer from one of two things. They either contain excessive amounts of proprietary brighteners or
have organic contamination (dragged in oils and soils from the pretreatment cleaning cycle). Since an
analysis of the plating solution did not show a high concentration of proprietary brighteners, let’s assume
that the problem is caused by organic contamination.

Although treatments with potassium permanganate and carbon are extremely effective, they can be harsh
on the maintenance crew. Both are messy propositions with alkaline plating solutions, clogging up filters
and taking away from production time. A great alternative is treating the bath with commercial-grade
sodium hypochlorite. Sodium hypochlorite is a strong oxidizing agent and is commonly found in or known
as bleach. Treatments with sodium hypochlorite are very effective on organic contamination and do not
require heavy maintenance on the filtration system or long shut-down periods.

A full treatment is considered to be 10 gallons of commercial-grade sodium hypochlorite (12% active) per
1,000 gallons of plating solution. Slowly add the sodium hypochlorite over the entire surface of the plating
solution. Good solution movement is recommended to ensure adequate oxidization of the organic
contaminant. Note that sodium hypochlorite is a strong oxidizing chemical and necessary safety
precautions must be followed, such as wearing appropriate eye protection, gloves, and other personal
protection equipment. A minimum of one hour shut-down time is necessary for this treatment.

A “hypo” treatment along with small additions of your proprietary additives should bring back the
brightness and luster that you expect from your alkaline non-cyanide zinc bath.
Q: I manufacture and finish conduit tubes for the electric industry. The conduit is roughly 10 feet long and
will have various diameters depending on the customer requirements. We use alkaline non-cyanide zinc
electrolyte for optimum plate distribution and thickness over the entire 10-foot piece. Recently, we have
run into a plating issue on the conduit area where the rack hook meets each individual piece. We are
seeing a very dull/dark mark with no zinc thickness; it looks as though the piece has been burnt by the
electrical contact point. Reducing the current only makes the dull/dark mark larger. Increasing the current
does show improvement, but we are afraid we will burn or over-plate the work. Any thoughts on what can
be done to improve the plating quality.

The situation you describe is actually a fairly common problem that can occur in high-output alkaline non-
cyanide zinc plating lines. The problem, commonly called “rack marks,” is most likely caused by poor
throwing power. The area where the rack hook meets the conduit tube is typically a very low current
density area. Rack marks will worsen with reduced current and improve when current is increased.

As always, the first step when troubleshooting a plating problem is to ensure that the part is being
sufficiently cleaned prior to plate and to verify that plating bath chemistry (level of zinc and caustic soda in
this case) is within the supplier’s specifications. Levels of zinc and caustic soda affect both plating speed
and throwing power. Assuming that these check out okay, the next step is to examine the addition rates
of the proprietary additives.

The most common cause of rack marks is low proprietary brightener additives. Generally, proprietary
additives are added to the zinc plating solution based on amp-hours. These additives control
appearance/brightness, ductility and plate distribution of the zinc deposit. However, in high drag-in/drag-
out operations like plating tubes, it is often necessary to increase the addition rate of the additive(s)
responsible for covering/throwing power. Basically, these additives slow the zinc deposition rate in the
high current density areas and increase it in the low current density areas—such as where the rack meets
the tube. Increasing the addition rate of these additives will eliminate the dark mark and increase deposit
thickness at the rack/tube interface, without increasing unwanted build-up of zinc on other areas of the
tube.

Lisa, I would like to start by clarifying that the type of chromate or passivate being used has nothing to do
with the blistering problem.
Blistering can come form many sources.
#1.Poor cleaning and poor activation before plating.
#2.Highly stressed zinc deposits originating from improper bath chemistry balance, using improper current
density to plate, and or overload of brightening agents can open the door to many post plating problems
including blistering or latent blistering. Improper bath chemistry can and will cause high organic inclusion
in the plate and can cause stress. Baking at a high temperature may cause the plating to "pop" due to
stress and or poor adhesion from improper part preparation.
#3. Extremely high thickness of zinc deposit. You don't mention what type of zinc plating is used here but
there are definite problems that can be associated with each of the three main zinc plating baths used
today. The most common baths used would be alkaline non cyanide, acid chloride, and alkaline cyanide
zinc. There are potential problems with each bath. The most forgiving bath being the alkaline cyanide zinc
bath. It is also perhaps the most least used in todays world. Alkaline non cyanide deposits can be
problematic if the bath chemistry not kept in proper parameter.

Have you verified the thickness of zinc plate?

Lisa, If I would assume that this is a job that has shown success in the past, then I would have to point to
making sure the base material is not causing the problem,(nothing has changed?), then look specifically
at the part cleaning and activation prior to entering the plating bath, then look at the plating deposit itself.

If I would assume that this is a brand new job, with a new process, I would also look at the operation of
applying the rubber seal to innsure that the temperatures, and any chemicals being used, are under
control.

At the metal stamping company where I work we stamp out parts from COLD ROLLED STEEL, CQ,
ASTM A-109, (HRB 40-65) and then send then to our supplier for Zinc Plate Trivalent Chromate
per ASTM B-633 Type 111 SC2. We then ship the parts to our customer where they apply a rubber seal
around the inner edge. The parts are heated to 400 deg for approx. 2 Min and they seem o.k. but then
they go into a oven to cure for 4 hours at 400 Deg. When the parts come out approx. 60% have blistered
(looks like a bad tint job on a window). We have done brainstorming and talk to chemist and yet to come
up with an answer to why this is happening. One answer we could never get is what is the Max temp.you
can bake Zinc without causing possible damage? We were told 700 Deg but no one has a definite answer.
I would appreciate any help on this matter.

First Things First

Quick solutions to problems on an electroplating line can save thousands of dollars. Experience is by far
the most valuable tool a troubleshooter can possess. So successful troubleshooting begins when the line
is at its best!

Build your experience by walking the line when everything is running smoothly. Take note of solution
color, smells, gage settings, etc. Intimate knowledge of your plating line and its idiosyncrasies will
expedite the solution to future problems.
Now that a problem has developed, you must walk the line looking at temperature gages, current, anode
baskets, pumps, etc. You must rule out the cleaning section of the line and the post plate section of the
line. These steps may take some time but they must be done. Ninety five percent of plating problems
have nothing to do with the plating bath. Although occasionally a problem develops, which persists
despite experience.

Into the Lab

Once the problem has been determined to be a result of the plating solution or the material being coated,
the troubleshooting should be done in the laboratory.

Before starting a laboratory investigation, the first thing to do is ship samples of the plating bath and reject
work to your supplier. Suppliers often have sophisticated labs with experienced people. Follow up with a
phone call to your supplier. Speak directly with a technical service representative and discuss your
problem and investigation.
Once in the laboratory, define the condition of the bath with a routine analysis and a routine hull cell.
Correct any chemistry problems found by the routine analysis. The routine hull cell should be one you’re
used to looking at. Suggested conditions for a routine panel are:
1. A two amp, five minute, unagitated panel for acid zinc.
2. A one amp, 10 minute, agitated panel for alkaline zinc.

Compare the routine hull cell panel to ones from when the problem was not present. Measure
thicknesses across the panel and again compare them to past hull cell panels. If the routine hull cell panel
appears normal, chances are your problem lies outside of the plating bath. Re-walk the line and review
your observations. Pay particular attention to the electrical portion of the plating bath, as poor electrical
connections will make the plating bath appear to be at fault. Investigate the material of the parts
exhibiting the problem. Again, material problems will not manifest themselves in the lab. If you are still
convinced that the plating bath is the source of the problem, continue with the lab investigation.
The next step is to use a hull cell to generate the problem. Make sure the conditions and time that all hull
cells were run are clearly marked on the resulting panel. Vary the conditions in the hull cell to give
yourself the best opportunity to produce the problem. Some variations, which may prove useful, are:
1. Panels run at low amperage
2. Panels run at high amperage
3. Bent panels to create a shelf area
4. Bent panels to create an extreme low current density area
5. Panels run at a high temperature
6. Panels run for 30 minutes then scribed with an exacto knife (to reproduce blistering.) Knowing
how your bath appears when operating normally will make the interpretation of these hull cells
easier. Once the problem has been produced, we can proceed to the next step.
Target Identified
With the ability to produce the problem, one now needs to know how to solve the problem. The problem
probably will fall into one of several broad categories:
1. Organic contamination
2. Metallic contamination
3. Poor filtration
4. Imbalance of proprietary chemicals
5. Unknown
With an unlimited supply of solution, take the opportunity to begin multiple treatments. After each of the
following treatments, rerun the hull cell test, which produced the problem. First, for organic contamination,
treat 300 milliliters of solution with two grams of activated carbon. Mix the solution continuously for at
least 30 minutes, then filter and run the hull cell. Second, for metallic contamination, treat 300 milliliters of
solution with one-half gram of zinc dust. Again, mix the solution continuously for at least 30 minutes, then
filter and run the hull cell. Third, filter the solution thoroughly. The solution must be clear after this step.
Use a filter aid if necessary. Fourth, if the solution is an acid bath, metallic or organic contamination may
be affected by adding one tenth of a gram of potassium permanganate to 300 milliliters and mix the
solution for five minutes. Filter thoroughly and run the hull cell. For an alkaline solution, freeze out
carbonates by putting 300 milliliters in a lab refrigerator. Cool the solution to 30°F for 15 minutes. Decant
the solution, raise the temperature and run the hull cell test. If one of these treatments affects the
problem, you may be well on your way to solving the problem. Give yourself a pat on the back! Not too
fast though. You now must translate the lab results to the production line. You must also locate and
eliminate the source of the contamination. The quick results in the lab may take a couple of days to
accomplish in production. But don’t give up. Plug away until the job is finished.
Unknown
If the above treatments did nothing to affect the problem, things just got a lot tougher. Get on the phone to
your supplier and ask for their assistance on-sight. Review their analysis of your bath. Is your bath low on
carrier, high in brightener, out of balance, etc? Many suppliers have “doctor” solutions. By comparing
notes with your supplier, they will be able to send in a new arsenal of weapons along with technical
assistance. Meanwhile, there are still a few hull cells to run:
For an alkaline bath try:
1. Adding 1% sodium hypochlorite to the hull cell
2. Adding one-half ounce per gallon of EDTA or Rochelle salts
3. Diluting the bath by 25% with “virgin” solution

For an acid bath try:

1. Heating the bath above the cloud point, then carbon treat
2. Reduce the pH of the solution with 50% hydrochloric acid to kick-out most organics. Usually a
pH of 2.5 is suf- ficient. Filter the bath, raise the pH and add carrier.
3. Diluting the bath by 25% with “virgin” solution.
Out of all the tests you have now run, hopefully something you can build on has emerged. If not, you are
into the rare problem, which falls into the “unknown” classification. This type of problem will take time and
effort to resolve. Calling in electricians, sending samples to outside laboratories, etc. are examples of the
steps that may be necessary to solve the problem. In this case, the economics of dumping the bath and
making a new one must also be considered.

Conclusion
Troubleshooting a zinc-electroplating bath will be much easier time is taken to observe the line when
things are running well. When a problem develops, split the line into a precleaning section, the plating
bath and a post-plate section. Run tests to isolate the problem to one of the three sections.
When the plating bath is identified, follow these steps:
1. Send samples and reject parts to your supplier.
2. Use the hull cell tests outlined above to treat the problem. Remember, even if you can treat the
problem, you will also have to eliminate the source of the problem.
3. Demand prompt service from your supplier.
4. Label or identify all tests run during the troubleshooting process. Once the problem is solved,
go back and review the troubleshooting process and learn from it. This will build your
troubleshooting skills and shorten the duration of future problems.

When things go wrong on a zinc electroplating line, quick solutions can save thousands of dollars. If the
answer is not pre- or post-treatment, the laboratory is the place to troubleshoot the plating bath. A quick
analysis and a few hull cells may be all it takes to put the operation back on its feet. This paper deals with
the investigative process in the laboratory.

We are using an alkaline zinc plating bath. We seem to have one significant problem with this bath: the
anodes polarize when the current is on. This does not happen all the time but we are unable to figure out
what is going on.
There are two possible reasons for polarization of zinc anodes in an alkaline zinc plating bath. The most
obvious is that your anode current density is too high. In the alkaline zinc plating bath, anode efficiency
tends to be much higher than cathode efficiency. If you’re operating a tank with a one-to-one cathode-to-
anode ratio, the zinc metal content will climb. Typically, some of the zinc anodes are removed from the
plating bath to minimize the increase of the zinc content in the solution. As a result the current density on
the remaining zinc anodes increases, and this can produce polarization.
To prevent this from happening you must replace some of the zinc anodes with steel anodes. In a typical
alkaline zinc plating bath it’s not uncommon to see 75–85% of the anode area made up of plain steel.
The second likely cause of anode polarization is improper sodium hydroxide? concentration.? This can be
easily remedied by chemical testing.
One additional comment: To prevent buildup of zinc in the plating solution during down periods, the zinc
anodes should be removed from the plating tank during idle times.