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What are all the reasons for the rust problem with in a month after the plating process.(Zinc plating with yellow passivation in the sheet metal).

L.Subramani
SPEAKER MFG - Chennai, Tamilnadu, India

I don't fully pretend this is "all the reasons", but the parts not being dried is one, and storing the parts in close proximity to a plating operation (where acid vapors are in the air) is another.

Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
Ted is available for instant help
or longer-term assistance.

Porosity in the base metal is the fifth, and using pickled HR sheet assuming it is bright CRCA is the sixth. I presume you have checked the plating adhesion and thickness, right?

Khozem Vahaanwala
Saify Ind

Bengaluru, Karnataka, India

Seventh could be storage after finishing - high humidity, organic vapours - from wooden packing to name a few problems.

Martin Trigg-Hogarth
surface treatment shop - Stroud, Glos, England

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