Electroplating.

Zinc Electroplating of Ground Bar.

Martinez Esteves, Luis Alfredo
June 26, 2014
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Introduction
This report was born due a surged problem with the plating process of a ground-bar. This ground
bar tends to corrosion, to prevent this corrosion this bar must be pass throw a plating process. Also
this bar has PEM inserts, these inserts are made of stainless steel. A recommendation is to plate the
ground bar first then insert the PEMs but this causes a longer work time, also, more documentation.
or each process, the part number changes, for e!ample" This ground bar has the part number #$-
#%&'(%-##) when is finished in Turrets, then, an e!ternal compan* plates the part and when the part
is back, it has another part number +))-#%&'((-##),. The piece goes now to the PEM station where
gets another number" #$-#%&'(--##).
A suggestion is to send the pieces alread* PEMed to the plating process, this save us time and it
would generate .ust two part numbers instead of three. The emerged problem is that nobod* knows if
this is a secure option.
The purpose of this report is to provide the actual situation with the ground bar used in Toning
/ousings and its plating. This report also gives us more information about what is the plating process,
benefices, limitations and suggestions to avoid future problems.
Description
This bar is made of 0))# copper. 0opper is chosen due to its high thermal and electrical
conductivit* and great resistance to corrosion.
The natural color of copper is peach* or pinkish-white, with a bright metallic luster and when is
freshl* e!posed the surface has a reddish-orange color but the color of copper turns green after
e!posure to air and moisture because the chemical reaction of salts, o!*gen and the copper itself
forming a thin la*er on the surface known as Patina (Figure 1). Patinas can provide a protective
covering to the material that would otherwise be damaged b* corrosion or weathering. The* ma* also
be aestheticall* appealing.
1n the other hand, the plating process consist in avoid this patina forming +0orrosion,. 2ut wh*
remove all this great natural protective cover3 The answer
is conductibilit*.
4es, this natural protective cover of the copper is great5 it
protects the material of almost ever*thing, including
e!ternal .oints. 6f *ou tr* to connect something on this
ground bar, like a conductive cable, this protective cover
wont allow an effective conductibilit* causing a bad
connection and a bad grounding. To avoid this corrosion on
the material surface, the pieces are electroplated.

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Fiure 1 Comparison between natural
copper color (left) and patina coered
copper (rig!t!
Another benefit of plating is avoiding the galvanic corrosion. 7alvanic corrosion occurs when two
dissimilar metals come into electrical contact with a conductive electrol*te, usuall* rainwater or
groundwater, even air pollution. 6n this process, a metal atom is o!idi8ed, during which it leaves its
bulk metal after losing one or more electrons and is then transferred to another site, this causes
destruction of the material. The site where the metal atoms lose electrons is called the anode, while
the site where the electrons are transferred is called the cathode. 6f this copper bar gets in contact, for
e!ample, with an aluminum wire this corrosion could occur. 0opper and aluminum have widel*
different electrochemical potentials, so when the* are combined in a .oint, galvanic corrosion is likel*.
7alvanic corrosion erodes the metal, causing bad electrical conduction over time.
The plating chosen for the copper is 8inc plating. This process forms
a thin 8inc la*er all over the bar. According to the table of 9tandard
:eduction Potentials, the standard reduction potential of 8inc is about
-).-( volts. The standard reduction potential of copper is about -#.;(
volts. This difference in reduction potential means that <inc would
o!idi8e much faster than copper would. 6n fact, 8inc would o!idi8e
completel* before copper would begin to react. <inc acts like a
sacrificial anode also give more staticall* look.
Plating Process
Plating involves the coating of a thin metallic la*er onto the surface of a substrate material
)
. There
are several plating methods, and man* variations, in our case we use Electroplating.
Electroplating, also known as
electrochemical plating is an electrol*tic
process in which metal ions in an electrol*te
solution are deposited onto a cathode
workpart. The anode is generall* made of
the material being plated and thus serves as
the source of the plate metal. =irect current
from an e!ternal power suppl* is passed
between the anode and the cathode. The
electrol*te is an a>ueous solution of acids,
bases, or salts5 it conducts electric current b* the movement of plate metal ions in solution. or
optimum results, parts must be chemicall* cleaned .ust prior to electroplating.
Zinc Plating on Copper Process
1
"ubstrate #aterial$ The reactant which is consumed during the chemical reaction.
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Fiure 2 E&ample of galanic
corrosion.
Fiure " Electroplating
Process
9tep ), 0leaning the 9ubstrate" 0leaning of the substrate is done in order to remove an* dirt, rust,
oil, etc., from the surface. An alkaline detergent is used to clean the surface to ensure the 8inc
electroplating is of good >ualit*, and the plating remains intact for a long period of time. 6mproper
cleaning usuall* results in a variet* of plating defects like peeling or blistering over a period of time.
The process of cleaning an ob.ect involves two steps" alkaline bath and electrocleaning. 9oaking
the metal in an alkaline bath for ( - )# minutes, at about )(#? is usuall* enough to get rid of most of
the soil and dirt. After this, the parts are cleaned further in an electrocleaner. An electric charge is
applied to the metal either at its cathode or anode end, which results in the release of o!*gen or
h*drogen from the solution, cleaning the parts at a micro level. The time and temperature factors are
much the same as for the alkaline soak process.
9tep &, Activation or Pickling of the 9ubstrate" Activation or pickling of the metal involves removal of
o!ides and scales from the surface b* using various acid solutions. These la*ers of o!ides and scales
are formed on the metal surface during their manufacturing, or while storage and handling. Pickling is
commonl* done using acids like sulfuric acid or hydrochloric acid. The t*pe of metal and the thickness
of the scales present on the metal decide the t*pe of acid, the dipping time, and the temperature
re>uired for activation process.
9tep ;, 0leaning of the copper piece" 6n all electro-plating operations the articles to be plated must
be perfectl* smooth and free from even the slightest scratches or imperfections, as these will show
ver* plainl* after plating. The* must then alwa*s de dipped and rinsed until all traces of grease of
foreign matter are removed, before being places in the plating solution. irst the piece must be
polished to remove an* corrosion on the material and then cleaned in a chemical solution. This is a
water and Potassium cyanide or nitric acid formula. Then pieces must be dried and heated.
9tep %, <inc Electroplating" Proper cleaning and
activation of the parts and pieces cleaning ensure that
the* are read* for 8inc electroplating. A direct current
+=0, is applied at the anode for a fi!ed amount of time.
This results into the deposition of 8inc ions at the
cathode, i.e. the metal surface. or achieving uniform
electroplating, it is necessar* that the anode and the
cathode are positioned suitabl* into the a>ueous
solution and the current flows uniforml* over the entire
area of the metal surface. 6f the current flow is not
uniform, it will lead to thicker la*ers of 8inc plating over
the areas receiving more amount of current, while
forming thinner la*ers over the recesses.
A variet* of chemical agents are used along with 8inc electroplating in order to achieve the desired
chemical and ph*sical properties of the final product. The properties can be altered b* suitable
variations in the chemical agent being used, duration of soaking, electric charge applied, and the time
and temperature factors.
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9tep (, :insing and =r*ing the inished Product" The general rule is to rinse the parts with water
after ever* step of the electroplating process. After the metal has been electroplated, it is washed in a
water container to remove an* contamination of the surface, followed b* dr*ing. 6n case of more
contamination, water rinsing ma* be done multiple times. The parts are either cleaned in a rinsing
tank or under running water, depending on the level of contamination and the e!tent to which the
surface needs to be diluted in order to remove the contamination.
Zinc Plating on Stainless Steel
6t is possible to 8inc-plate a stainless steel piece, +PEM inserts, in a similar wa* to copper, but the
process is a bit completel* different.
The first difference is the metal cleaning. The cleaning solution is made of water and muriatic acid
or potash.
The other greater difference is that stainless steels contain sufficient chromium to form a passive
film of chromium o!ide, which prevents further surface corrosion b* blocking o!*gen diffusion to the
steel surface and blocks corrosion from spreading into the metal@s internal structure, and due to the
similar si8e of the steel and o!ide ions the* bond ver* strongl* and remain attached to the surface.
This does not allow the 8inc to be added to the surface of the steel. or this reason stainless steel
needs other whole process, usuall* must start with a nickel strike to activate the surface.
0oating on stainless steel is ver* difficult because the problem in activation of that surface. The pre-
treat mental processes pla* a ver* important role in getting a good protective coating on stainless
steel. 9uccessful deposition depends on the removal of thin, passivating surface o!ides la*er on the
stainless steel. This was accomplished b* an initial cleaning.
This nickel la*er acts like a .oiner of the steel and 8inc, if this process is skipped, the 8inc will not be
added well to the stainless steel surface, causing a bubbled finish.
#onclusion
The option of send our pieces with the PEMs alread* inserted is not a viable option. 6f pieces are
plated b* the copper method, the PEM inserts will be ruined with a bubbled finish and color changed.
6f the pieces are plated b* the stainless steel method, this will increase the price too much and
some problems could surge. There is a copper problem known as AThe copper cancerB. This AcancerB
surges when chloride salts, atacamite and paratacamite appear over the piece surface, it is ver*
destructive.
0upric chloride and cupric chloride, combined with the o!*gen of the air and the water produce
h*drochloric acid causing soft, powder* pale green spots on the surface of the metal, corroding the
material and producing more corroding copper chlorides, starting again the reaction to produce more
h*drochloric acid, and so on up to disappear the metal.
This contact with chemical could occur in the nickel plating process.
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M* recommendation is to change these stainless steel inserts to steel inserts, making a research on
how these inserts affect the ground piece and the finish good.
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