Zinc Alloy Plating Ziniloy

Transcription

1 Zinc Alloy Plating Ziniloy Ziniloy is an alkaline zinc/nickel alloy plating process offering exceptional corrosion resistance. Ziniloy produces bright deposits of a zinc/nickel alloy with exceptional distribution and covering power. Ziniloy is suitable for either rack or barrel plating. Ziniloy deposits easily accept clear, yellow or black passivates. Passivated deposits retain excellent corrosion resistance, even after 24 hours of a 250 F (120 C) temper. 1,000+ hours to red rust in salt spray Nickel alloy between 12-16% across all current density ranges Readily accepts passivates and conversion coatings Bright and ductile zinc nickel deposits Low temperature application Suitable for rack and barrel Special formulation available for high ductility application for post plate crimping or forming Pavco Inc John Crosland Jr. Dr. Charlotte, NC Zinc Alloy Plating Ziniloy Phone Fax Toll Free

2 Pavco Ziniloy Page 2 Operating Parameters Rack (12-16% Nickel Alloy) Zinc Nickel Sodium hydroxide Range oz/gal g/l oz/gal g/l oz/gal g/l Ziniloy Starter 3% - 7% 5% Optimum 2 oz/gal 15 g/l 0.27 oz/gal 2.0 g/l 17 oz/gal 128 g/l Ziniloy Brightener 0.5-2% 1.6% Ziniloy Nickel Additive % 3% Ziniloy Additive A 3-5% 4% Ziniloy Wetter % 0.01% Current Density Rack 9-28 amps/ft amps/dm 2 20 amps/ft 2 2 amps/dm 2 Operating Parameters Barrel (12-16% Nickel Alloy) Zinc Nickel Sodium hydroxide oz/gal g/l oz/gal g/l oz/gal g/l Ziniloy Starter 3% - 7% 5% 2 oz/gal 15 g/l 0.27 oz/gal 2.0 g/l 17 oz/gal 128 g/l Ziniloy Brightener 0.5-2% 1.6% Ziniloy Nickel Additive % 3% Ziniloy Additive A 3-5% 4% Current Density Barrel 2-10 amps/ft amps/dm 2 5 amps/ft amps/dm 2 RACK & BARREL Temperature: F C Anode to Cathode Area: 1:5 to 1:3 73 F 23 C

3 Pavco Ziniloy Page 3 Operating Parameters For parts requiring high ductility due to substantial post plate bending, crimping or other forming operations, use the following operating parameters: High Ductility Ziniloy Rack (12-16% Nickel Alloy) Zinc Nickel Sodium hydroxide Range oz/gal g/l oz/gal g/l oz/gal g/l Ziniloy Starter 3% - 7% 5% Optimum 2 oz/gal 15 g/l 0.27 oz/gal 2.0 g/l 17 oz/gal 128 g/l Ziniloy Nickel Additive % 2.5% Ziniloy Additive A 4-6% 5% Ziniloy Wetter % 0.02% Current Density Rack 9-23 amps/ft amps/dm 2 17 amps/ft 2 2 amps/dm 2 High Ductility Ziniloy Barrel (12-16% Nickel Alloy) Zinc Nickel Sodium hydroxide oz/gal g/l oz/gal g/l oz/gal g/l Ziniloy Starter 3% - 7% 5% 2 oz/gal 15 g/l 0.27 oz/gal 2.0 g/l 17 oz/gal 128 g/l Ziniloy Nickel Additive % 2.5% Ziniloy Additive A 4-6% 5% Current Density Barrel 2-8 amps/ft amps/dm 2 5 amps/ft amps/dm 2 RACK & BARREL Temperature: F C Anode to Cathode Area: 1:5 to 1:3 73 F 23 C

4 Pavco Ziniloy Page 4 Equipment Tank: Generator tank: Polypropylene, polyethylene, PVC, or alkaline resistant rubber lined steel. Do not use fiberglass. Plumbing must not be glued, it must be welded or threaded Consult Pavco for design parameters. Steel tank preferred. Sized 10-20% of bath volume. Use carbon steel baskets for anodes Anodes: Thin nickel anodes 4-6 inches (10-15cm) width and inch (0.64cm) thick are recommended. Do not use bright nickel plated steel Anode Hooks: Anode Bars: Filtration: Agitation: Rectifier: Temperature Control: Titanium hooks bolted to anodes, hung or bolted to anode rail Use copper anode bars, preferably shielded with plastic. Use 5-15 micron polypropylene disks or cartridges. Filtration speed should be 1-2 tank turnovers per hour Cathode rod agitation in a direction parallel to anode rails is recommended at a linear speed of ft/min. ( dm/min) Additional circulation using eductor systems is recommended. Uniformity of agitation is important Up to 12 volts A temperature of 73ºF (23ºC) with a range of +/- 2º F (1ºC) is necessary in order to maintain a constant rate of alloy codeposition in the deposit. A cooling/heating system is necessary to maintain a constant bath temperature. Titanium or PTFE coils are recommended Ziniloy Rack Bath Makeup per 1000 gallons (3785 l) 1. Prepare a tank by leaching it with 1% sodium hydroxide for hours. 2. Rinse the tank 3. Fill the lined tank with 500 gallons (2000 liters) of water. 4. Add 581 pounds (264 kg) of sodium hydroxide and mix well to dissolve. 5. Add 100 gallons (379 liters) of Pavco Zincate and mix well to dissolve. 6. Add 30 gallons (114 liters) of Ziniloy Nickel Additive to 50 gallons (189 liters) of Ziniloy Starter, mix well and then add the solution to the bath. 7. Add 16 gallon ( 61 liters) of Ziniloy Brightener 8. Add 40 gallon ( 151 liters) of Ziniloy Additive A 9. Add 13 fluid ounces ( 380 milliliters) of Ziniloy Wetter 10. Add water to the 1000 gallon (3785 l) level 11. Electrolyze at 5ASF for 2 A-hrs/liter 12. Allow solution to sit hrs before production IMPORTANT NOTE: It is best to prepare new solutions and allow them to sit idle for hrs. This allows the bath time to equilibrate and form the proper complexes. This will reduce the concentration of additives Ziniloy Additive A and Ziniloy Brightener required to obtain full brightness by 30-50%.

5 Pavco Ziniloy Page 5 Ziniloy Barrel Bath Makeup per 1000 gallons (3785 l) 1. Prepare a tank by leaching it with 1% sodium hydroxide for hours. 2. Rinse the tank 3. Fill the lined tank with 500 gallons (2000 liters) of water. 4. Add 581 pounds (264 kg) of sodium hydroxide and mix well to dissolve. 5. Add 100 gallons (379 liters) of Pavco Zincate and mix well to dissolve. 6. Add 30 gallons (114 liters) of Ziniloy Nickel Additive to 50 gallons (189 liters) of Ziniloy Starter, mix well and then add the solution to the bath. 7. Add 16 gallon ( 61 liters) of Ziniloy Brightener 8. Add 40 gallon ( 151 liters) of Ziniloy Additive A 9. Add water to the 1000 gallon (3785 l) level. 10. Electrolyze at 5ASF for 2 A-hrs/liter 11. Allow solution to sit hrs before production Maintenance Mix Mix 700 mls of Ziniloy Additive A, 1.75 liters of Ziniloy Brightener, and 9.1 liters of Ziniloy Nickel Additive in a container. The above maintenance mix should be fed into the bath at the rate of 3 gallons (11.4 liters) per 10,000 amp-hours Maintain the zinc level with a generator tank. Maintain the sodium hydroxide by analysis.

6 Pavco Ziniloy Page 6 High Ductility Ziniloy Rack Bath Makeup per 1000 gallons (3785 l) 1. Prepare a tank by leaching it with 1% sodium hydroxide for hours. 2. Rinse the tank 3. Fill the lined tank with 500 gallons (2000 liters) of water. 4. Add 581 pounds (264 kg) of sodium hydroxide and mix well to dissolve. 5. Add 100 gallons (379 liters) of Pavco Zincate and mix well to dissolve. 6. Add 25 gallons (95 liters) of Ziniloy Nickel Additive to 50 gallons (189 liters) of Ziniloy Starter, mix well and then add the solution to the bath. 7. Add 50 gallons (189 liters) of Ziniloy Additive A 8. Add 26 fluid ounces ( 760 milliliters) of Ziniloy Wetter 9. Add water to the 1000 gallon (3785 l) level 10. Electrolyze at 5ASF for 2 A-hrs/liter 11. Allow solution to sit hrs before production High Ductility Ziniloy Barrel Bath Makeup per 1000 gallons (3785 l) 1. Prepare a tank by leaching it with 1% sodium hydroxide for hours. 2. Rinse the tank 3. Fill the lined tank with 500 gallons (2000 liters) of water. 4. Add 581 pounds (264 kg) of sodium hydroxide and mix well to dissolve. 5. Add 100 gallons (379 liters) of Pavco Zincate and mix well to dissolve. 6. Add 25 gallons (95 liters) of Ziniloy Nickel Additive to 50 gallons (189 liters) of Ziniloy Starter, mix well and then add the solution to the bath. 7. Add 50 gallons (189 liters) of Ziniloy Additive A 8. Add 26 fluid ounces ( 760 milliliters) of Ziniloy Wetter 9. Add water to the 1000 gallon (3785 l) level 10. Electrolyze at 5ASF for 2 A-hrs/liter 11. Allow solution to sit hrs before production Maintenance Mix (High Ductility) Mix 1.2 liters of Ziniloy Additive A and 9.1 liters of Ziniloy Nickel Additive in a container. The above maintenance mix should be fed into the bath at the rate of 2.7 gallons (10.3 liters) per 10,000 amp-hours Maintain the zinc level with a generator tank. Maintain the sodium hydroxide by analysis.

7 Pavco Ziniloy Page 7 Function of Additives Ziniloy Starter (used only in makeup) Operates as a nickel complexing agent and stabilizes the nickel ions in the zincnickel bath; guarantees a uniform nickel co-deposition over the whole current density; used only for makeup. Ziniloy Additive A Operates as a low current density brightening agent in the bath. Ziniloy Additive B Operates first as a nickel complexing agent and also as a zinc complexing agent; provides a uniform nickel co-deposition. Used if alloy range is excessive. Ziniloy Brightener Operates as a brightener in the mid to high current density and improves the metal distribution at low current densities. Excess can lead to pitting, reduced efficiency or loss of ductility. Ziniloy Nickel Additive Used for makeup and to maintain the nickel content of bath. Ziniloy Wetter Low foaming agent. Reduces surface tension, prevents pitting in rack applications. Operating Tips The zinc concentration must be maintained in exact required limits. A zinc generator is necessary. Large variations of zinc concentration are not acceptable The plating bath must be analyzed daily The concentration of nickel is adjusted using Ziniloy Nickel Additive 42.5 ml/gal (11 ml/l) Ziniloy Ni Additive will increase the nickel concentration by 0.1 oz/gal (0.75g/l) All additives should be maintained by a metering pump. Carbonates will build up in Ziniloy, as with every alkaline solution. The accumulation of carbonates decreases the efficiency of the working solution. If the sodium carbonate concentration reaches 10 oz/gal. (75 g/l) the carbonates should be frozen out X Ray Fluorescence must be in place in order to operate this process. Numerous operating parameters can impact the alloy %, so this must be monitored regularly Uniform temperature and adequate cooling capacity are critical to maintaining consistent nickel alloy %

8 Pavco Ziniloy Page 8 Analytical Procedures Zinc Reagents 1. Acetate Buffer -To makeup, dissolve: a)180 grams of sodium acetate b) 30 ml of acetic acid c) Add de-ionized water to make one liter 2. Xylenol Orange Indicator-To make this indicator liquid: a) One gram of Xylenol Orange b) Dissolved in 1 liter of de-ionized water M EDTA Solution Procedure 1. Into a 400 ml beaker pipette a 5 ml bath sample. 2. Add 150 mls de-ionized water and 5 mls 50% (v/v) HCl 3. Add 50 ml acetate buffer. 4. Add indicator 5. Titrate with 0.1 M EDTA until the color changes from red to yellow Calculation: ml of titration.176 = zinc in oz/gal ml of titration 1.32 = zinc in g/l Sodium hydroxide analysis Reagents 1. Indigo Carmine Indicator 2. 1N acid Procedure 1. Pipette a 5 ml bath sample into a 125 ml Erlenmeyer flask 2. Add 10 mls de-ionized water. 3. Add 5 drops of Indigo Carmine indicator 5. Titrate with 1N acid until the color changes from yellow to blue Calculation: ml of titration + oz/gal zinc = sodium hydroxide in oz/gal Nickel analysis Measure nickel using atomic absorption (AA)

9 Pavco Ziniloy Page 9 Trouble Shooting Chart Problem Cause Solution High current density burn Low nickel level Check and adjust zinc and nickel levels. Adjust as needed High current Low Brightener Low Additive A Low temperature Reduce current Add increments of 0.4% Ziniloy Brightener Add increments of 1% Ziniloy Additive A Adjust to F (21-25 C) Pitting in Deposit Low Ziniloy Wetter Add 0.01% increments Ziniloy Wetter Low Ziniloy Brightener Organic contaminants Low Additive A Add increments of 0.4% Ziniloy Brightener Carbon filter with g/l activated carbon Add increments of 1% Ziniloy Additive A Slow Plating Rate Low Zinc Analyze and adjust metals High Carbonates Excess Complexors Excess Ziniloy Brightener Freeze out carbonates Raise metal levels by 10-15% or cut solution Electrolyze bath at 20 ASF Incorrect alloy Chemistry is out of range Check and adjust Zinc and nickel content High temperature Adjust to F (21-25 C) Wide alloy range (>3%) Metals out of range Low complexor Check and adjust zinc and nickel levels Add 1-2 % Ziniloy Additive B LCD Dullness Low Additive A Add 1% Ziniloy Additive A Low Nickel Analyze and adjust with Ziniloy Nickel Additive

10 Pavco Ziniloy Page 10 Waste Treatment Dispose of the concentrates or solutions thereof according to local waste treatment regulations. Safety Handling Pavco mandates that the following safety equipment be used when handling chemicals in an electroplating environment: safety glasses, face shield, plastic or rubber apron, rubber gloves and safety shoes. Chemicals should only be handled by trained and experienced personnel. Storage Store Pavco products in a clean, well ventilated room which temperature remains above 45 F (7 C). Pavco products should remain in their original container with the lid or cap tightened. Drum pumps or pails must be clean prior to dispensing Pavco products to prevent contamination. If any Ziniloy product freezes during shipment or storage, warm the product and mix it well before use. Emergency Procedures Refer to the MSDS for detailed emergency procedures Eye Contact Seek immediate medical attention. Flush the eyes with water for 15 m minutes. Skin Contact Remove all contaminated clothing. Wash the skin with soap and water. Seek medical attention Inhalation Remove the person to an area with fresh air. Seek medical attention if necessary Product Description & Shipping Ziniloy Starter (ZN 200) is a clear colorless liquid. The specific gravity is between 1 and1.1 with a ph greater than 11 Ziniloy Nickel Additive (ZN 222) is a purple liquid. The specific gravity is between 1.1 and 1.2 with a ph greater than 7 Ziniloy Brightener (ZN 205) is a pale yellow liquid. The specific gravity is between 0.97 and 1.1 with a ph less than 7 Ziniloy Additive A (ZN 215) is a clear pale yellow liquid. The specific gravity is between 1 and 1.1 with a ph greater than 9 Ziniloy Additive B (ZN 210) is a pale yellow liquid. The specific gravity is between 1.0 and 1.1 with a ph greater than 8 Ziniloy Wetter (ZN223) is a clear liquid. The specific gravity is between 0.99 and 1.05 with a ph less than 7 All Ziniloy products are available in 5 gallon containers or 55 gallon drums. Revision Date: 12/6/10 WARRANTY AND DISCLAIMER Technical information and recommendations contained herein are believed to be reliable, however, the accuracy or completeness thereof is not guaranteed. No statement or recommendation shall constitute a representation unless set forth in an agreement in writing by the seller and manufacturer. NO WARRANTY OR MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS MADE. The following warranty is made in lieu of any other warranties, express, implied, or statutory. Products are warranted to be free from defects on material and workmanship at the time sold. The sole obligation of the seller and manufacturer under this warranty shall be to replace any product defective at the time sold. Under no circumstances shall the manufacturer or seller be liable for any loss, damage, expense, direct or consequential, arising out of the use of or inability to use the product. Materials shall not be returned to the seller or manufacturer without express written permission. No information or suggestions given by us shall be deemed to be a recommendation to use any product in conflict with any existing patent rights. Zinc Alloy Plating Ziniloy