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What is the best plating process for general purpose military electronics enclosures

I am considering changing the finishing process used for a variety of our products. We make electronics for military unmanned ground vehicles. Currently most of the electronics enclosures are machined from 6061-T6 aluminum, or sheet metal formed from 5052 or 6061 sheet aluminum. These parts are then Iridited (zinc chromate conversion) and then masked with tape, and the outsides are powdercoated. The problem we have is the masking process is not precise and reliable enough, and sometimes we need to remove powdercoat edges or overspray, and that can damage the Iridited surface, or leave exposed raw aluminum. The main features I am looking for are: 1) high conductivity surfaces, to reduce EMI 2) Good surface corrosion resistance (including salt spray, etc.) 3) dark color preferred, for exposed surfaces of tactical military vehicle use (low glint) 4) Compatible with low rate, high product mix prototype and LRIP manufacturing.
So, I am considering a change in process, and am asking for suggestions. Perhaps 1) glass bead blast the material surfaces to provide a uniform dull surface, them 2) electroless black nickel plate. Comments? Suggestions?

David Parish
product designer - Easton MD
January 22, 2009

We use nickel cad with a olive drab chromate on alum for parts going on the f22, then they are all painted on the areas that are not plated

Ian McCormick
- Westfield, MA, USA
February 6, 2009