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Zinc-nickel plating on aluminum Q&A, Problems & Solutions

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"Electroplating of Zn-Fe, Zn-Co & Zn-Ni"
by V Narasimhamurthy
zincAlloyPlating_2020

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Q. I'm trying to plate an aluminum barrel with zinc nickel alloy by mixing zinc sulfate ⇦[this on eBay or Amazon affil links] and nickel sulfate ⇦[this on eBay or Amazon affil links] with boric acid ⇦[this on eBay or Amazon affil links] to make it a high sulfate electrolyte but the voltage required for both have different ranges zinc is .5v to 1.5v and nickel is i think 3.0v to 5.0v is what I've seen recommended so will the 1.5 v difference create anything other than my zinc nickel plating or is it not possible to do both and I misunderstood plz let me know but it sounded like they did both at the same time to get a smoother more even surface n it's for a paint ball gun so I need that as I only want to polish it after not sand it because I don't want to Change the caliber of the barrel.

Can I ask if these beaded wire will work for a 14 inch paint ball gun barrel in not using acids to try to get more even plating of zinc-nickel? Could I use zinc wire or nickel wire as an electrode inside the pipe to zinc- nickel plate inside the pipe towards the middle or use electromagnetism to increase the strength of the magnetic field to coat it better its a .69 inch caliber 9.5 inch length paintball gun barrel I've never done this so please tell me if I'm wrong.

Gabriel Lopez
- Phoenix Arizona
June 20, 2024

A. Hi Gabriel,

On the one hand, nothing is impossible and I certainly don't want to discourage you from trying to go where your interests lead you ...

... but on the other hand, if I'm understanding you correctly, this project sound impractical for several reasons :-)

Firstly, I think zinc-nickel plating of a bore is a bad idea. Such plating requires a chromate conversion coating which will rub right off in use. Also, plating a bore, an Internal diameter, is for experts who have previously perfected their skills. It introduces the need to control new parameters like solution depletion, agitation, and good flow-thru. And alloy plating like zinc-nickel cannot be done from a simple non-chelated acid solution for the reason you allude to -- no zinc will deposit while there is any practical amount of nickel in the solution. You need a proprietary alkaline zinc-nickel solution. Plus you can't electroplate directly onto aluminum, you need a zincating step after the cleaning, etching, and de-smutting.

Aluminum How-To
"Chromating - Anodizing - Hardcoating"
by Robert Probert

Also available in Spanish

You'll love this book. Finishing.com has sold 891 copies without a single return request :-)

Now for some better news ... If you want to practice doing some zinc-nickel plating on aluminum, and you buy a proprietary alkaline zinc-nickel plating process, you just might be able to use it without electricity as the zincate step, then apply the electricity and carry on with the zinc nickel plating. Robert Probert explains this unusual approach to activating aluminum in his book "Aluminum How-To" ⇨

Luck & Regards,

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

⇩ Related postings, oldest first ⇩

Q. I am seeking information about zinc-nickel vs zinc-cobalt plating. What are the pros and cons of each when plated on cast aluminum. we are trying to phase out cadmium plating.

Another item I need info. on is that after product is plated with one of the two, what type of corrosion protection film that will be conductive when colored black.

Joseph Lomastro
- Miami, Florida
2000

A. Are you presently using a black finish on your Cadmium? What is the application, what kind of part, and where is it used?

Tom Pullizzi
Falls Township, Pennsylvania

A. I have read your question several times and wish to offer the following information. I have had experience with folks like yourself who wish to get rid of Cadmium.

Zinc/Nickel is far superior to Zinc/Cobalt with regard to Corrosion Resistance. My suggestion would be to prepare the aluminum casting and put a layer of Electroless Nickel on it. (Thickness to be determined by your needs). After this, plate a layer of 8-10 microns of Alkaline Zinc/Nickel followed by an iridescent chromate film. I have seen such a coating that surpassed 5000 hours to corrosion of the aluminum. Any follow up questions will be responded to.

Ed Budman [dec]
- Pennsylvania
With deep sadness we advise that our good friend Ed passed away Nov. 24, 2018

Q. Hello everyone I want to electroplate Zinc-Nickel on Aluminum for XRF research purpose. I have alkaline zinc nickel plating bath. Can anyone suggest how I can do this plating successfully with good adhesion on Aluminum.

ABHISHEK KALIA
- New Delhi, INdia
June 8, 2023

A. Hi Abhishek.
Plating onto aluminum requires the proper pretreatment steps for aluminum (alkaline cleaning, alkaline etch, and desmut), followed by a zincating step (immersion in zincate with no electricity), followed by a 1st plating step that is compatible with zincate (like alkaline electroless nickel), followed by the plating of your choice.

But Robert Probert describes in his "Aluminum How To" book (see link above)
a method whereby, since alkaline zinc-nickel baths are quite similar in composition to zincate baths, it may be possible to simplify the process -- using the alkaline zinc-nickel bath without electricity for the zincate step, and then skipping the cyanide copper or electroless nickel, and applying the current to deposit the alkaline zinc-nickel plating layer.
Luck & Regards,

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

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