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Zinc Plating vs Nickel Plating: A Complete Comparison

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Hey There, I’m Caro!

I am the author of this article and a CNC machining specialist at RICHCONN with ten years of experience, and I am happy to share my knowledge and insights with you through this blog. We provide cost-effective machining services from China, you can contact me anytime if you have any questions!

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Table of Contents

Metal plating is an important process used for increasing the aesthetics and durability of different metal products. Of all the plating options zinc and nickel plating are two of the most commonly used processes. Today we’ll compare these two plating methods and their specific properties as well as their general applications and advantages.

What is Nickel Plating?

Nickel Plating Parts

Nickel plating is the process by which a thin layer of nickel is deposited on the surface of material. There are two ways to perform this coating: through electroless plating or through electroplating. Electroplating uses electrical current and electroless plating uses chemical reactions. The result is a dull gray, smooth surface that provides outstanding corrosion protection and wear resistance.

What is Zinc Plating?

Zinc Plating Part

Zinc plating is an electrochemical process. In this process, we dip metal parts in an electrolyte solution of zinc ions. These ions are then driven to the metal surface by electric current to coat it uniformly. The zinc layer it creates doesn’t just protect your metal from oxygen and moisture; it also makes it more attractive and more durable.

Top 8 Key Differences between Zinc and Nickel Plating

1. Corrosion Resistance

Zinc Plating

A bunch of catalinized screws and nuts

Corrosion resistance of zinc plating is extraordinary in humid environments and outdoors. It works like a sacrificial coating which corrodes first, before the base metal, to provide cathodic protection. Because of this, it is best suited for parts that will endure marine conditions and rough weather.

Nickel Plating

A pile of nickel-plated metal parts

Nickel plating also gives good corrosion resistance but it does not provide sacrificial protection. Rather it shields the base metal against corrosive elements. Although very effective in most applications, nickel plating may not be as effective as zinc in the most brutal conditions or outdoors.

2. Appearance

Zinc Plating

Zinc plating produces a bright, reflective, silvery-blue finish which is semi bright or matte. The final color may be iridescent yellow green or black or blue depending on the chromate conversion coating used. Zinc looks great initially but is also prone to dulling over time due to environmental elements.

Nickel Plating

On the other hand nickel plating provides a very matte, satin finish with a slight yellow hue. It maintains its luster longer than zinc. That’s why it’s the preferred plating method for decorative applications. The final look of nickel plating can be customized. You can either polish it to high shine or leave it matte.

3. Hardness

Nickel Plating

Hardness wise, nickel far outperforms zinc plating. It has Vickers hardness between 150 and 400 HV. This extraordinary hardness produces surfaces that resist denting, scratching and general wear.

Zinc Plating

Zinc plating is much softer. It still gives some protection but is also more subject to physical damage. Its softer nature, however, can be beneficial when there is some flexibility requirement in applications.

4. Thickness

Zinc Plating

The thickness of zinc plating is dependent on usage and environmental conditions. A thickness of 5-8µm is mostly sufficient for indoor use. For outdoor or high wear environments, thicker coatings of 12 – 25µm are needed. And more thickness means more corrosion protection.

Nickel Plating

Nickel plating thickness, on the other hand, usually varies from 10 to 50µm. And you can precisely control the coating thickness of nickel coating to meet standards of specific industries. And because of this nickel plating is ideal for applications requiring tight dimensional tolerances.

5. Ductility

Zinc Plating

Zinc plating is much more ductile than nickel which makes the parts to be bent or shaped without flaking or cracking the coating. Due to its high ductility, zinc is the material of choice for components that will probably be deformed during use or assembly.

Nickel Plating

Although not as ductile as zinc, nickel plating is still formable. The coating is resistant to moderate bending and shaping. Zinc plating, however, is ideal for applications that require a great amount of deformation.

6. Cost Comparison

Zinc Plating

For metal finishing needs, zinc plating is a more economical solution. The low cost of zinc and relatively simple plating process makes zinc plating ideal for huge scale industrial use. This factor also makes it particularly enticing for low budget projects.

Nickel Plating

Because of more complicated plating process and expensive raw material, nickel plating has higher cost. However in applications where performance is very important, the initial investment can be offset by its longer service life and superior durability.

7. Effect on Environment

Zinc Plating

New zinc plating technology is more environment friendly. The cyanide free plating method produces less hazardous waste and makes the disposal process easier. And in addition to all these, zinc plating also consumes less energy than nickel.

Nickel Plating

Nickel plating is more harmful to the environment. The process produces hazardous by-products that require very careful handling and is also energy-intensive. In addition, manufacturers have to implement very strict environmental controls to treat this waste. All of these things combine to make nickel plating a less environmentally friendly option overall.

8. Applications

Zinc Plating

Application of Zinc Plating

Automotive sector is the most primary market for zinc plating. Manufacturers typically apply it to different types of fasteners, vehicle parts and different small components. Outdoor equipment and construction hardware also benefit greatly from the protective properties of zinc plating. Its good performance even in harsh weather conditions makes it a valuable option for structural steel parts.

Nickel Plating

Application of nickel plating

Nickel plating finds its place in high precision industries. Aerospace sector depends on nickel-plated parts due to their light weight and strength. Also electronics manufacturers use nickel plating for precision parts, connectors etc. The medical field also relies on this finish particularly where abrasion resistance and hardness are important. In addition, nickel plating is also used for cosmetic purposes in many areas.

Pros and Cons of Nickel vs Zinc Plating

Nickel Plating

There are a number of advantages of nickel plating but there are also some shortcomings. Now let’s look at some of the pluses and minuses of this popular metal finishing process.

Pros

  • Nickel plating provides good protection against corrosion and rust.
  • The hard nickel coating increases the wear resistance and therefore increases the life of nickel plated metal components.
  • Nickel plating gives a very attractive, bright finish which improves the looks of products.
  • Because of the high conductivity of nickel, it is a good material to plate electrical appliances and devices.
  • Nickel plated parts can resist high temperatures; therefore they are appropriate for aerospace and automobile applications.

Cons

  • Nickel plating process may be more costly than others finishing processes because of expensive raw materials.
  • If you are allergic to nickel, contact with nickel-plated surfaces can irritate your skin.
  • Nickel plating is an energy intensive process and the process can be environmentally damaging if not controlled.

Zinc Plating

Pros

Zinc plating also has many advantages. Some of which are:

  • Zinc plating forms a protective barrier which slows rusting down and increases the lifetime of metal parts.
  • Zinc coating is less costly and is broadly applied for corrosion protection of metal components and appearance improvement.
  • You can zinc plate different shapes (both simple and complex) and many different metals.
  • The zinc layer enhances the material’s service life and strength particularly in difficult environments.
  • Another advantage of zinc is that it’s very easy to recycle so it’s an environment friendly metal to use for metal finishing.

Cons

Like any other process, zinc plating also has some drawbacks:

  • The coating produced by zinc plating is usually thinner than that produced by other processes, such as hot dip galvanization, which may reduce its long term durability.
  • Electroplating of some metals results in hydrogen embrittlement which causes loss of structural integrity of that metal.
  • Zinc plated components may corrode more quickly in the presence of dissimilar metals in wet environments.

Which One is Best? Zinc Plating or Nickel Plating

Which one is best Zinc Plating or Nickel Plating

The decision between zinc and nickel plating is dependent on your application’s specific requirements. Zinc plating has sacrificial properties and thus gives outstanding corrosion protection in harsh environments. However, nickel plating is best suited to applications that demand wear resistance, hardness and good appearance.

Budget is another very important factor. The zinc plating is a low cost solution for general use and mass production. But if your application requires a premium finish or involves high wear conditions, then nickel plating’s durability makes it worth the extra cost.

At the end of the day, choice between the two depends on what you really need. Decide after taking into account desired finish quality, environment and budget.

To Sum Up

Zinc and nickel plating have distinct advantages as metal protectors. Cost effectiveness and extraordinary corrosion protection are the best attributes of zinc whereas good appearance and hardness are the best attributes of nickel. The choice should be made on the basis of requirements of the specific application, budgetary constraint and environmental conditions. If you need any CNC machining or plating services, contact Richconn.

Common Questions

Is zinc plating rust proof?

Sacrificial corrosion makes zinc plating provide extraordinary rust protection. But it’s not fully rustproof. Zinc plating gives full protection as long as it remains on a surface completely intact.

Can zinc or nickel plating be applied on all metals?

No. Nickel plating is generally applied on brass, steel, aluminum, copper and some plastics (when treated), whereas zinc plating is largely restricted to steel, iron and a few non ferrous alloys.

How can I strip zinc plating?

You can use hot caustic solution and hydrochloric acid to remove zinc plating.

In what way can nickel plating be cleaned?

Clean nickel plating with soapy warm water and a soft cloth. But for tougher stains, use a mixture of vinegar and water.

Can nickel plated surface be painted?

Yes, but you will need to do proper preparation. First clean the surface, then use metal etching primer on it and then apply paint.

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