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Rust formation in CRCA Caps

Dear Sir ,
We are doing nickel plating on battery caps being mounted on the dry cell . We are obtaining rust in the form of small dent after plating . The dent grows periodically after a few days.
The quality requirement is it has to pass a test of NaCl (3%) for 8 hours and there should be no rust in the components. The rust is being formed at the inner cavity of the caps. Please find us a solution to overcome this problem. The base material is CRCA (cold rolled cold annealed steel).

Thanking you, Regards,

Shreesha Acharya
a plating company - Bangalore, Karnataka, India
2003

How can anybody make any suggestions? You have not told us a single thing about your plating other than it is not working. We are platers, not mind readers. To start with, there are lots of different nickels that are electrolytic, then there is electroless, then there is rack vs barrel then there is pre process and post process. Your problem could be at any point.

James Watts
- Navarre, Florida
2003

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October 16, 2008

Hi. If I have understood, the rust is beginning at an inside corner where the plating will be thinnest. Electroless nickel plating will probably solve the problem, but perhaps at too much expense. Other than that, you must make the plating thicker in this area; it is hard to explain how to achieve this when -- as James notes -- we know nothing about your plating parameters. Get back to us with details if you can.

Regards,

Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey