Metal finishing Q&As since 1989

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Flux Contained Nickel

2007

Dear Sir
We are gonna use Ni-containing Flux. According to some galvanizers, there is no enhancement utilization of Ni-flux in the comparison of not including Ni. However, I do not agree with the domestic galvanizer.
And stirring or mixing of Ni-contained Flux can affect the final quality when we compare with not including Ni in terms of the reactiveness of flux?
Besides of these, can you give any response on the subject of temperature range of flux? (Ni-Contained or not)?
Thanks,
Best Regards,

Hakan Esen, Material Engineer(BSc.)
galvanizing plant manager - Bursa, Turkey

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Sir:

Ni is a cancer causing agent. Unless the kettle (flux) smoke is fully collected it would expose workers to lung and throat cancer. The Hazardous book from CDC states that Ni has a 5 to 50 year delay for cancer onset.

I have plated Ni onto reactive steels (silicon and phosphorus) and the zinc coating thickness is reduced. I suspect that Ni gets depleted from Ni containing fluxes and would then not be available for reducing zinc thickness. Stirring the flux would not likely affect the performance since the nickel chloride is in solution.

In North America fluxes (especially triple salt and quadraflux) are normally operated at 160 F (71 C).

Regards,

Dr. Thomas H. Cook
Galvanizing Consultant - Hot Springs, South Dakota, USA
2007

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Turkey may or may not consider nickel a cancer causing agent though, Dr. Cook. Please keep in mind that the assessments are made by fallible (and often whacko) humans and are not free of local political influence.

When I googled "nickel cancer", the top hit was www.oehha.ca.gov/air/toxic_contaminants/html/Nickel.htm, a report from the State of California Air Resources Board. I am far from an industry apologist, and I believe that many of us in industry suffer from a knee-jerk anti-environmental reflex, and that nickel may be more dangerous that we would like to admit, but I defy anyone to read this kind of "science" paper with a straight face :-)

Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
2007

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Sir:
In the NIOSH Pocket Guide To Chemical Hazards, U.S. Department of Health and Human Services, Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, June 1994 Edition (publication number 94-116) on pages 224-225 for Nickel (metal and other compounds (as nickel)) is stated "Target organs: Nasal cavities, lungs, skin [lung & nasal cancer].

On google 1.3 million "hits" are found under nickel cancer. When galvanizers in North America started using nickel metal in their zinc at about 0.05% (a patented process), I became aware of the nickel-cancer claim. I contacted the Nickel Development Organization and it was stated (by them) that nickel presented no problem. They sent me an article to calm my concerns. The article documented the case of a town in England that refined nickel. The town (of about 12,000 if I recall correctly) was named the "town of the walking dead."
To date I have not heard about any ill effects of galvanizers using nickel in their zinc to reduce %GZU.
Regards,

Dr. Thomas H. Cook
Galvanizing Consultant - Hot Springs, South Dakota, USA
2007

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Thanks. We'd all love to be able to put every element into a table of two headings, either "safe" or "dangerous", but it's not that easy. Glass is perhaps the most proven and demonstrably safe material in the history of civilization, but swallowing a mouthful of shards will probably prove fatal, and airborne glass fibers are doubtless a major inhalation hazard in some industries. Nickel is far more complicated.

Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
2007

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2007

Ted:
Excellent response.
Regards,

Dr. Thomas H. Cook
Galvanizing Consultant - Hot Springs, South Dakota, USA

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Mr.Mooney,
In our factory,there is surely enclosure system to prevent the breathing of some hazardous gases and/or particle matters.We are gonna install a filter system in any short time. And OF COURSE, we know that Ni is a hazardous material. All precautions have been taken for environment and worker in terms of health & safety such as incorporation of anti-vapor agent into acid tanks.
Thanks

Hakan Esen, Material Engineer(BSc.)
galvanizing plant manager - Bursa, Turkey
2007

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2007

Hello, Hakan. I certainly did not mean to imply the contrary! I was responding to Dr. Cook, and countering the possible inference that the U.S. EPA dictates what installations in Turkey should do. Sorry if it confused the issue.

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