Zinc Plating System is a field-proven chloride zinc electroplating system that will increase production up to 50% when compared to conventional systems. is characterized by ease of control, consistent day-to-day operation, high temperature tolerance and excellent passivate receptivity. Mirror bright finish Unmatched zinc distribution Increased productivity Excellent passivate receptivity Ease of control Excellent adhesion and ductility Reduced solution build-up Temperature tolerance up to 150 F (65 C), reducing cooling costs Reduced power consumption as heated bath requires less voltage to push required amperage PAVCO, Inc. 1935 John Crosland Jr Drive Charlotte, NC 28208 Phone: 704-496-6800 Toll-free: 1-800-321-7735 or 1-877-PAVCO INC (728-2646) Fax: 704-496-6810 Order Fax (for orders only) 704-496-6851 www.pavco.com
Operating Parameters: Barrel Operation Range Optimum Zinc: Potassium chloride: Ammonium chloride: 2.5-6 oz/gal 20-45 g/l 15-20 oz/gal 110-150 g/l 4-8 oz/gal 30-60 g/l 3 oz/gal 22.5 g/l 18 oz/gal 130 g/l 6 oz/gal 45 g/l Current Density: 1-15 amps/ft 2 Rack Operation Zinc: Potassium chloride: Ammonium chloride: 0.1-1.5 amps/dm 2 3-6 oz/gal 22.5-45 g/l 15-20 oz/gal 110-150 g/l 4-8 oz/gal 30-60 g/l 3.5 oz/gal 26 g/l 18 oz/gal 130 g/l 6 oz/gal 45 g/l Current Density: 1-80 amps/ft 2 0.1-8 amps/dm 2 Carrier 2-6% 4 % Premier Toner 0.1-0.3% 0.2% ph: 5.5 6.0 5.8 Temperature: 65-120 F 18-49 C 115 F 46 C Anode to Cathode Area: 1:1 minimum 2:1 Equipment: Tank: A polypropylene, PVC, or Koroseal lined tank is required. Anodes: Use Special High Grade (SHG 99.99% pure) zinc balls or slabs. Anode Baskets: Titanium baskets are required. Always keep the baskets filled with zinc anodes and do not exceed 9 volts on the rectifier. Anode Bags: Nylon or polypropylene bags are required for rack operations. Anode S-Hooks: Nickel-plated S-hooks. Anode Bars: Use copper anode bars, preferably shielded with plastic. Filtration: Use a 5-15 micron cartridge packed with a filter aid or activated carbon. Filtration rate should be at least one tank turnover per hour. Sand filters have been found to work quite satisfactorily. Rectifier: Up to 12 volts Temperature Control: The is tolerant to temperatures ranging from 65-150 F (18 65 C). A titanium heat exchanger is recommended for heating. Ventilation: Recommended Agitation: Air agitation is mandatory for rack operations. Optional Equipment: Automatic ph controller, brightener feeder, and temperature control 2
Maintenance of the Solution: Zinc Potassium Chloride Ammonium Chloride Carrier Premier Toner By analysis By drag-out & analysis By drag-out & analysis By drag-out & analysis 1.5 gal / 20,000 30,000 amp hrs (1.5 l / 5,000 8,000 amp hrs) Bath Makeup per 1,000 gallons (3,785 L): 1. Prepare a lined tank by leaching it with 5% hydrochloric acid for 12-24 hours. 2. Rinse the tank. 3. Fill the lined tank with 500 gallons (2,000 liters) of water. 4. Add 45 gallons (170 liters) of 62.5% liquid zinc chloride and mix well to dissolve. 5. Add 375 pounds (170 kg) of ammonium chloride and mix well to dissolve. 6. Add 1125 pounds (510 kg) of potassium chloride and mix well to dissolve. 7. Hang slab anodes or zinc filled titanium anode baskets in the bath. 8. Add 40 gallons of Carrier. 9. Add 0.5 gallons of Premier Toner. 10. Add warm water to the 1,000-gallon (3785 L) level. Analytical Procedures: Zinc Reagents Acetate Buffer - to make this, dissolve 180 grams of sodium acetate, 30 ml of acetic acid and add deionized water to make one liter. Xylenol Orange Indicator - to make this, dissolve one gram of Xylenol Orange in 1 liter of deionized water. 0.1 M EDTA Solution Procedure 1. Pipette a 5-mL bath sample Into a 400 ml beaker. 2. Add 150 ml of deionized water. 3. Add 50 ml of 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 3
Total Chloride - Free Chloride Reagents Buffer to make this, mix dextrin and calcium carbonate in a 1:1 ratio. Chloride Indicator to make this, dissolve 0.2 g of Dichlorofluorescein and 70 ml of methyl alcohol and add deionized water to make 100 ml 0.153N silver nitrate solution Procedure 1. Pipette a 1 ml sample of zinc chloride plating bath into a 250 ml Erlenmeyer Flask. 2. Add 100 ml of deionized water. 3. Add one scoop, approximately 2g of buffer. 4. Add 1 ml of indicator. 5. Titrate with 0.153N silver nitrate until the color changes from yellow to pink. Calculation ml of Silver Nitrate x 0.724 = oz/gal total chloride (A) A x 7.49 = g/l total chloride (Am) Zinc in oz/gal x 1.083 = oz/gal chloride associated with the zinc metal (B) B x 7.49 = g/l chloride associated with the zinc metal (Bm) A - B = oz/gal free chloride (C) Am - Bm = g/l free chloride (Cm) C x 2.1= oz/gal of potassium chloride Cm x 2.1 = g/l of potassium chloride Iron Test and Treatment per 1,000 gallons (3,785 l): Procedure 1. Into a 100 ml beaker add 30 ml of clear bath sample (if the sample is not clear, filter it). 2. Add 1 ml of 3.5% hydrogen peroxide 3. Determine the concentration of the iron in the bath by the intensity of the color change. No change - no iron Slight precipitate - moderate iron Heavy precipitate - high iron 4. If the test indicates moderate or high iron, or if barrel spots are present, treat the bath for iron as follows: Dilute one pint (500 ml) of 35% or 50% hydrogen peroxide to 1 gallon (3.785 L) with water. Mix this diluted peroxide throughout the plating bath. Repeat steps 1 to 4 until the majority of the iron is precipitated. Filter out the precipitated iron. 4
Blister Frost Gray Gray Zinc Plating System Hull Cell Trouble Shooting: 267 ml Hull Cell: Agitation Mechanical or Air Temperature 90 F, 32 C Current & Time 2 amps/5 minutes Normal Panel Control Panel 1 2 3 Normal Low Current Density Problem Hull Cell Panel Observe From Left to Right Area 1 High Current Density Area 2 Mid Current Density Area 3 Low Current Density Metal Contamination Problem High ph Low Total Chloride Low Premier Toner High Current Density Problem Blackish Discoloration Metallic contamination, copper or cadmium, of the plating bath or the bright dip ener Problem Black Burn Semi- Low Zinc, Low Ammonium chloride, High ph, Low Carrier, Low temperature Chromium Contamination Low Premier Toner High & Low Current Density Problem Skip Chromium Contamination Low Smart Zinc Carrier Low Smart Zinc Premier Toner 5
Black Discoloration Zinc Plating System Iron Problem High Iron (Black color shows up after the bright dip or chromate) Pavco Inc s Hull Cell Scale: 1 AMP 2 AMPS. 3 AMPS. 5 AMPS. TOTAL CURRENT PANEL EDGE 40 30 25 20 15 12 10 8 6 4 3 2 1 0.5 80 60 50 40 30 24 20 16 12 8 6 4 2 1 120 90 75 60 45 36 30 24 18 12 12 6 3 1.5 200 150 125 100 75 60 50 40 30 20 15 10 5 2.5 7.5 GM./1000 ML. 7.8 ML./1000 ML. AMPS./SQ. FT. 267 ML. OR 534 ML. HULL CELL OR 2 GM/267 ML. HULL CELL = 1 OZ./GAL. = 6.25 LBS./100 GAL. 2 ML./267 ML. HULL CELL = 0.96 FL. OZ./GAL. = 6 PTS./100 GAL. 4 GM. 534 ML. HULL CELL = 1 OZ./GAL. = 6.25 LBS./100 GAL. 4 ML./534 ML. HULL CELL = 0.96 FL. OZ./GAL. = 6 PTS./100 GAL. CU. FT. X 7.48 = GAL. GM/L X 0.134 = OZ./GAL. OZ./GAL. X 7.5 = GM/LITER GAL. X 3785 = ML. A/SQ. FT. X 0.108 = A/SQ. DM. AMPS./SQ. FT. 1000 ML. HULL CELL 3 AMPS 5 AMPS PANEL 90 60 45 36 30 24 18 15 12 9 6 3 0.6 EDGE 150 100 75 60 50 40 30 25 20 15 10 5 Trouble Shooting Chart: Problem Cause Solution High current density (HCD) burn Poor agitation Improve air uniformity in rack or adjust rotation speed in barrel Low zinc level Add zinc chloride High current Reduce current Low ammonium chloride Add ammonium chloride Low temperature Raise temperature Low Carrier Add Carrier HCD bright-dips black, or barrel work exhibits hole pattern defects High iron Treat for iron with diluted hydrogen peroxide 6
Problem Cause Solution Low current density (LCD) is High ph Reduce ph dull or hazy Low total chloride Add potassium or ammonium chloride Low Carrier Add Carrier Metallic or organic contamination Treat with zinc dust or carbon Poor LCD coverage High ph Reduce ph Low chloride Low Carrier Low/High Premier Toner Metallic contamination High zinc level (>6oz/gal or 45 g/l) Excess peroxide added Organic contamination Add potassium or ammonium chloride Add Carrier Check Premier Toner level in hull cell Treat with zinc dust Dilute the bath to 3-4 opg (22-30 g/l) for optimal LCD performance Electrolyze bath Treat with carbon LCD area bright dips black Metallic contamination Treat with zinc dust Overall Haze Low Carrier Add Carrier Low Premier Toner Add Premier Toner Inadequate agitation Increase agitation Poor cleaning Improve cleaning Work rusting before plating Acidify rinses Poor bright dip Remake bright dip or try HCl instead of nitric acid Blue bright chromate out of Remake chromate balance or contaminated Temperature too high Decrease temperature Overall Dullness Low Carrier Add Carrier Low Premier Toner Add Premier Toner Metallic contamination Treat with zinc dust Temperature too high Decrease temperature ph too low Raise ph Organic contamination Treat with carbon Slow Plating Speed Low zinc level Add zinc chloride Low chloride level Add potassium or ammonium chloride Low Carrier Add Carrier Weak pickle or pickling problem Add more hydrochloric acid to the pickle or make a new pickle Low temperature Raise temperature Low current Increase current Smut formation in pickling Add PavPrep LF to the pickle Roughness Inadequate filtration Improve filtration Low Carrier Add Carrier Low anode area Increase anode area Particles from anodes Bag the anodes Current too high Lower the current 7
Problem Cause Solution Blistering Poor cleaning &/or pickling Improve pretreatment Organic contamination Treat with carbon Metallic contamination Treat with zinc dust Chromium contamination Treat with peroxide High current Lower current High Premier Toner Hold Premier Toner Low Carrier Add Carrier Flaking or star dusting High Premier Toner Hold Premier Toner Low Carrier Add Carrier Current interruption Check all contacts High current Lower current High ph Reduce ph 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 in which temperatures remain 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 Smart Zinc Carrier or Premier Toner freezes during shipment or storage, warm the product to 120 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 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. Ingestion Seek immediate medical attention. Spill Dike the area to contain the spill. Refer to the MSDS for clean-up. Notify the proper authorities if required. *NOTE: Refer to the MSDS for detailed emergency medical procedures. Product Description & Shipping: Carrier (ZB 705) is a light amber liquid. The specific gravity is between 1.0 and 1.1 with a ph greater than 6.0 Premier Toner (ZB 716) is a colorless to pale yellow liquid. The specific gravity is between 1.0 and 1.1 with a ph less than 6.0. Both products are available in 55 gallon drums and 275 gallon totes. Revision Date: 01/15/2018 Revision number: 3 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. 8