Zinc plating is a technique that results in a coating of zinc metal over another metal. It’s a protective technique and it’s incredibly popular. Most companies rely on plating to stop corrosion, but it’s used for other reasons, such as electrical conductivity and for decoration too.
What is Zinc Plating?
Zinc plating is a technique that forces zinc ions onto another metal, forming a new compound that serves as protection. The plating process is a protective measure that follows a chemical technique. Zinc plating leads to an ultra-thin layer of zinc that’s economical while offering just the right amount of protection against rust, moisture, and other forms of aging. Most industries rely on zinc plating in one form or another today. Companies love zinc plating because it’s so affordable and it can make their products, and equipment that they use themselves, last longer.
How is Zinc Plating Applied?
There are many steps required to make zinc plating work, but the simple overview is that zinc ions are forcibly removed from a zinc starting material using electricity, and the current gives the zinc ions a positive charge, while the final metal surface is attached to the negative lead making it negatively charged. When those positive zinc ions are freed they move to the negatively charged final metal and become attached to its surface through another reaction. The final result is steel or another metal that’s coated with a thin layer of zinc.
The zinc plating process is complex and is carried out with variations based on the given application. The length of time that electricity is applied will change the thickness of the final coating. How the surface is prepared controls the final quality of the coating, and even the temperature of the reaction and the contents of the liquid solution used to transfer the zinc ions impact how the process works.
Only experts have the skills to plate metals with zinc safely and properly. When applied improperly zinc plating doesn’t offer reliable protection because it isn’t resilient. Adding the plating can also be dangerous because the chemical process deals with extreme temperatures, hazardous vapors, electrical currents, and more. If you attempt to plate objects yourself, you could be burnt or shocked, or suffer from physical harm.
Why are Companies Using Zinc Plating Still?
Zinc plating has been around for decades, but the technique is still valuable. Any vulnerable metal can be protected by adding a layer of zinc. Zinc is affordable, and even adding a thin layer of protection to a large chunk of metal makes it much more durable.
Zinc plating is used in most industries because adding the protective material helps prevent damage from scrapes and slows the development of rust.
Zinc plating is used on a variety of industrial components today, including hydraulic valves and other components exposed to moisture. Parts that typically suffer from corrosion last far longer when covered with a layer of zinc before use.
Zinc plating is also used to promote conductivity on circuit boards and in other select electronics. Zinc plating creates intricate pathways for electricity to flow, making more complex electronics function. Zinc is used alongside copper and gold in many electronics today.
Why Aren’t Galvanizing and Zinc Plating the Same?
Both galvanizing an item and applying zinc plating results in protective zinc covering the metal. There are differences between the methods though. Galvanizing results in a thicker finish than plating, and the textures are different too.
Zinc plating uses electrolysis and a chemical reaction to apply a thin coating of zinc no more than 0.025 mm normally while galvanizing relies on dipping steel in molten zinc to achieve a coating up to 1mm thick.
Zinc plating is generally used on smaller components, or for parts where a smooth finish is desirable. A galvanized finish is used in construction and more extreme cases where objects will be left outdoors for years. For the most rugged finish, a galvanized coating is often selected, but not when appearance matters. Zinc plating is often the option that’s selected when both protection and appearance are important.
How Long Does Zinc Plating Take to Wear Out?
It’s impossible to say how long zinc plating will last in any given application. In some instances, this protective coating can last for many decades, but in harsh damp environments, or when used on components that experience regular abrasion the finish will not last as long. This is what enables zinc plating to last for many years when coating these hydraulic valves, but will cause it to fail rapidly when used to coat a hand tool. A typical zinc plating application is no more than 0.025 mm thick, which is around the thickness of a single strand of hair. Such a thin layer can be scraped off quickly in rough applications where abrasions are common.
No matter how good a zinc plating application is, it will not make metal last forever. Either the plating needs to be replaced or it will fail over time.
You cannot give metals the most reliable protection by always using zinc plating. There are times when something like galvanizing is going to work better. If you’re going to manage protective coatings for your products you must know about all the different coating techniques available. This is why most company owners rely on experts to help them choose electroplating or another option.
The Alternatives To Zinc Plating
Zinc plating is just one of the protection techniques employed in different industries today. Many companies are depending on galvanizing, ceramic coating, and other techniques for their protection instead.
- E-coating – It’s a technique that sticks paint particles in a layer using the science that’s similar to the electroplating process.
- Powder Coating – When powder coating you’re essentially melting a tough powder using electricity to form a layer that protects whatever it’s covering. It can be applied in many colors and offers reliable protection.
- Galvanizing – When galvanizing you’re using a physical reaction by melting metal and dipping objects in it. It results in a thick and rough layer of metal that’s often zinc.
- Ceramic Coating – Specialized ceramic compounds get sprayed using a gun to form a guarded layer. The end product is slippery and highly protective.
- Anodizing – Anodizing utilizes chemical reactions that also rely on electricity, but for aluminum mostly. When you anodize something you’re creating layers of oxide that add protection to the item while changing its appearance.
All the methods highlights serve as protection, but they’re all different than zinc plating. It’s important to realize that each alternative is only the best option in select scenarios. You must work with an expert to get the best protection for your application specifically, or you’re going to suffer from inadequate protection.
Conclusion
Metal that normally corrodes becomes much more durable when you apply some zinc. Zinc plating is an excellent enhancement for something like steel. This special protective process is amazing in specific scenarios, but not for everything. Consult with experts and use zinc plating when it offers you the greatest benefit.
