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Electrically conductive aluminum coating

We currently produce items fabricated from Aluminum which are Nickel plated to provide a conductive surface. We now have a requirement for the parts to have a increased Salt spray corrosion resistance (in the region of 10,000 hours), are there any processes that can be suggested.

Dave Jackson
Manufacturing - Edmonton, Alberta
2005

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Not being privy to all the facts, I have to hesitate before saying it . . . but that's a very weird test. The question may not be what coating to use, but what accelerated test procedure. It will take 14 months to verify that the first batch of parts has passed. Are you going to pay the test lab when they start testing the part, or when they tell you they have completed a flawless 14-month test. And for that extreme a test, you probably need generators and uninteruptible power supplies. Realistically, high quality exterior automotive nickel-chrome plating lasts decades on salty northern streets. I'd say that may be the most corrosion-resistant conductive coating you going to come up with, but depending on the application they may be something better.

Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
2005

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First of two simultaneous responses -- 2005

I believe military standard IVD aluminum or cadmium plating both with chromate conversion coatings about 25 microns (1 mil) thick pass 10,000 hour salt spray tests. I believe there's also a cadmium/nickel version that is used on electrical connectors that is electrically conducting.

Jim Treglio - scwineryreview.com
PVD Consultant & Wine Lover - San Diego,
California

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Second of two simultaneous responses --

Gold electroplate about 0.001 thick shoiuld withstand the test and it will not cost as much as the test !

Robert H Probert
Robert H Probert Technical Services

Garner, North Carolina

2005