SURFACE PREPARATION OF VARIOUS METALS

AND ALLOYS BEFORE PLATING AND OTHER

FINISHING APPLICATIONS
by Stephen F. Rudy
Enequist Chemical Co,, Brooklyn, N. Y.

Regardless of the intended final finish or processing designation, the first step or series
of related treatments involve surface preparation. The quality, durability, and service life of
finished parts are directly related to the effectiveness of the initial surface preparation
conditioning. This includes cleaning, rinsing, and activation. Metal-finishing processing
cycles generally begin with these steps. Without a doubt, the first step is the most important
one. If the surface-preparation portion of the cycle is not correct the application of any plated
deposit may result in blisters, hazing, pitting, or poor adhesion. Likewise, insufficient surface
preparation results in blistering, poor adhesion, pinholes, fisheyes, and other defects related to
applying organic topcoats (paint, powder coat, lacquer). Without quality surface preparation,
chromated parts may exhibit the film sloughing, off, uneven thickness, and poor adhesion. All
of these problems hurt the finisher several ways. Among these are marginally acceptable parts,
costly rejects, failure to meet production quotas, and potential to shut down the line. Effective
surface preparation keeps the parts clean, active, and moving along in the general process
cycle. Doing it right and once makes the ultimate objective of satisfactorily finished paEts a
reality.
There are three basic considerations for selecting the right cleaning and activation
solutions: what to use, when to use, and how to use. These are supported by specific
guidelines to help us make the right choices:
• Identify the base metal (type, alloy, surface characteristics)
• Limitations (process line, chemistries, temperature, time)
• Rinsing characteristics (parts, equipment, process line)
The next set of considerations addresses the concern for sufficient, complete soil
removal. Focus on condition of the parts, soils, and existing surface coatings.
• Types of soils (oils, grease, shop dirt, buffing and polishing compounds, smuts, scales)
• Existing finishes (chromates, electroplated coatings, phosphates, rust inhibitors)
This issue of the Metal Finishing Guidebook contains additional discussions, references,
and suggestions for cleaning mad activation, as well as more detailed information regarding
filtration, rinsing, analysis, testing, and related subjects.

SOAK CLEANING

Practical soak cleaning should efficiently remove organic soils. But it should also meet F006
sludge reduction mandates, OSHA safety regulations, facilitate analysis control, and simplify
waste treatment. More chemically diverse oils in stamping, forming, eXtruding, and rest
proofing, coupled with reduction in solvent cleaning, make the soak cleaner selection more
challenging. Liquid concentrates and powder blends are formulated to meet the specific
demands of most soak-cleaning requirements. This includes cleaning ferrous and nonferrous
metals in the same solution. In some cleaning applications strong alkalis, such as sodium and
potassium hydroxide, are beneficial. Conversely, these may be detrimental for removing
certain soils, such as chlorinated paraffin oils, or chemically attack nonferrous metals. Factors
influencing soak cleaning--time, concentration, and temperature--should be determined by

191
Table I. Operating Criteria for Soak Cleaners
Cleaner Type Concentration Range Temperature Time Agitation

Liquid 4-8% v/v 120-185°F (49 85°C) 2-10 rain Solution movement
Powder 4-10 oz/gal (30-75 g/L) 120-I85°F (49-85°C) 2-10 rain Solution movement

Table II. Soak Cleaner Operating Parameters---Bath Chemistry (oz/gal)

Metal Caustic Silicate Gluconate Phosphate Borates Wetters

Steel 1.8-2.2 1.5-3.0 0.16-3.2 0.4-0.8 -- 0.40.8

Stainless steel 1.8-2.2 1.5-3.0 0.16-3.2 0.4-0.8 -- 0.4-0.8
Brass 0.0-0.8 2.0-4.0 0.16-0.32 0.8-1.6 0.0-0.8 0.4--0.8
Copper 1.6-3.2 1.2-2.4 0.16-0.32 0.8-1.6 0.0~).8 0.4-0.8
Zinc 0.0 0.8-1.6 0.16~).32 1.2-2.4 -- 0.4-0.8
White metal 0.0 0.8-1.6 0.16~0.32 1.2-2.4 -- 0.4-0.8
Multiplyoz/gal by 7.5 to convert to g/L
Wetters are usually a balancedblend of anionic and nonionicsurfactants.

appropriate trial and evaluation, adhering to any specific limitations of the cycle or process.
Displacement and emulsification mechanisms remove oils, grease, and shop dirt in this first
step of surface preparation. In recent years displacement cleaning has become more preferred
t o extend cleaner bath service life and simplify waste treatment. Automatic skimming devices,
such as belts, coalescers, ultrafiltration, tank weirs, and overflow dams, are mechanical aids
to facilitate oil and grease removal from displacement and emulsifying cleaners. Most soak
cleaners meet the operating criteria shown in Table I. A l u m i n u m requires a specialized,
different approach to cleaning, which will be dealt with separately.
Bulk parts may be soak cleaned in line or off line in basket or barrel operations. Table
II provides an example of general soak cleaner constituents and applicable concentration
ranges. Trial evaluation and testing is required to determine which specific formulation meets
the soak-cleaning requirements within the specified cycle limitations.
These are some appropriate cleanliness tests to confirm removal of soils:
° Absence of water breaks on parts rinsed after a weak post acid dip
• Flash rusting of ferrous parts
• White towel wipe cleaned surface, confirming absence of smuts, oils, and grease
• Absence of UV light fluorescence on cleaned surface previously coated with UV
fluorescing oils.
• Immersion bronze, copper, or tin deposits on the cleaned, active, appropriately reactive
substrate
• Mechanical deformation, bending of finished part or grinding of plated deposit

ELECTROCLEANING

This method uses a DC rectifier to provide current, generating gas bubbles that mechanically
scrub the part. This is a powerful cleaning method that complements the previous
soak-cleaning step. Parts are predominantly positively charged, resulting in anodic or reverse
current cleaning. To a lesser degree parts may be negatively charged, resulting in cathodic
cleaning. A third option is periodic reverse, which takes advantage of anodic and cathodic
cleaning mechanisms. Electrocleaning can be classified into four groups, meeting most
cleaning applications.
1. Anodic. If preceded by a soak cleaner the electrocleaner's main function should be
effective removal of metallic fines and oxide deposits. Oil and grease removal should

192
Table III. Electrocleaner Operating Parameters
Current Density,
A/ft 2 Voltage
Base Metal Cleaning Type Rack Barrel Rack Barrel Time (min)

Steel Anodic 50-100 10-20 4-8 8-2 i-5

Stainless steel Anodic 50-100 10-20 4-8 8-12 15
Brassa Anodic 15-30 5-10 6-9 9-13 1-3
Copper~ Anodic 20-50 5-15 6-9 9-13 1-4
Zinc Anodic 10-20 5-10 6-9 9-13 1-4
White metal Cathodic 10-20 5-10 2-4 5-7 1-2
aPolishedbrassand coppermay alsobe cathodicanycleaned as per the specificationsgivenfor whitemetal.

be secondary since an effective soak cleaner removes these soils as a primary

function. The electrocleaner concentrate can be either liquid or powder. The main
ingredient is either sodium or potassium hydroxide as the source of solution
conductivity. Desmutters, descalers, and water hardness conditioners are also present.
Buffers and inhibitors control the surface action, moderate pH, and protect the base
metal against the harmful effects of the process itself and buildup of solution bearing
contaminants. Wetters and surfactants provide secondary cleaning to remove organic
soils. They also form a light foam blanket to significantly suppress the effects of
corrosive fumes during electrolyzing. The bath may also contain reducing agents to
control certain contaminants such as hexavalent chromium.
Cathodic electrocleaning generates twice the volume of gas bubbles versus anodic
electrocleaning. The scrubbing action on parts is essentially doubled. This method is
preferred for highly buffed and polished nonferrous metals such as brass, other copper
alloys, and white metal. It prevents oxidation, tarnish, and surface attack, which
would mar or destroy the desired surface brightness, leveling, and luster.
Periodic reverse (PR) is a specialized treatment for descaling and derusting steel. This
procedure uses a switch on the rectifier (automatic or manual) that changes polarity
on the work between anodic and cathodic in specific time cycles for optimum
cleaning. Parts usually exit the process bath anodic, deplating any metallic smuts
deposited in the previous highly scrubbing cathodic mode. This oxidation/
reduction/oxidation surface treatment softens scales, rust, and oxides, permitting
chelates and complexors to dissolve them. These electrocleaners are also referred to
as alkaline descalers.
Combination soak/electrocleaners meet the requirements of soak and electrocleaning
in one step, one tank, or in separate process tanks. In many applications this provides
three advantages: simplifies product inventory, eliminates a rinse between soak and
electrocleaner, and accomplishes both cleaning steps in one tank. A disadvantage
would be shorter service life of the electrocleaner due to oil and grease buildup.

Based on the metals electrocleaned, the alkalinity level is critical relative to the caustic
(sodium or potassium hydroxide) content. Nonferrous metals, such as copper alloys, brass,
and zinc, are best suited to electrocleaning in low- to mid-range caustic solutions. These
solutions must also contain inhibitors, such as silicate in ratio with caustic, for optimum
conductivity with sufficient inhibition of the zinc surface to prevent etching; Borax buffer and
silicate inhibitor for copper alloys and brass to prevent dezincification of brass and excess
oxidation of copper alloys; high caustic for steel electrocleaning requirements such as
conductivity. The optimum caustic level also dissolves the iron hydroxide surface film that
forms, preventing splotchy brown stains and burning due to low conductivity.
Current densities are related to the base metal and whether the application is rack or
barrel. (See Table III.) Double cleaning cycles are ideally suited to cleaning and activating

194
Table IV. Eleetroeleaner Operating Parameters--Bath Chemistry (oz/gal)
Metal Caustic Silicate Gluconate Phosphate Borates Wetters

Steel 5-7 2-4 1-3 24 -- O.1-0.3

Stainless steel 5-7 2-4 1-3 2-4 -- O.1-0.3
Brass 1.5-2.5 1.2-2.4 0.2-0.4 0.8-1.6 0.8-1.6 0.1~).3
Copper 1.6-3.2 1.2-2.4 0.2-0.4 0.8-1.6 0.4-1.8 0.1-0.3
Zinc 1.2-2.4 1.6-2.4 0.08-0.16 0.4-0.8 -- 0.1-0.3
White metal 0.8-1.2 1.6-2.4 0.16-0.32 1.2-2.4 -- 0.1-0.3

Multiply oz/gal by 7.5 to convel~to g/L

Reducing sugm'sat 0.24).4 oz/gal (1.5-3.0 g/L) reduce hexavalemchromiumto the insoluble chromiumhydroxide.
Polished brass and copper may also be cathodicallycleaned as per the specifications given for white metal.The
exception is omittingcaustic in the electrocleanersolution.

welded parts, such as wire goods, or heat-treated parts. Typical operating parameters are given
in Table IV.
Sufficiently electrocleaned parts should be free of smuts, oils, and grease. Scales and rust
can be r e m o v e d or softened prior to removal in the acid.

ACID TREATMENT

A more comprehensive discussion of this subject is found in the chapter "Pickling and Acid
Dipping."
The consideration of knowing the metal or alloys processed remains a critical factor in
selecting the o p t i m u m acid solution. Sensitive metals (brass, copper alloys, and zinc) require
milder acid treatments. (See Tables V and VI.) Steels can be scaled and rusted, needing more
aggressive treatment, even cathodic action. The acids used can be grouped into inorganic
(hydrochloric or sulfuric) and organic (sulfamic, citric, gluconic, etc.). Accelerators, such as
chloride and fluoride, provide extra " b i t e " to i m p r o v e pickling. Fluorides activate brass by
dissolving lead smuts. Inhibitors prevent over pickling steel that would result in raising

Table V. Acid Dip Operating Parameters

Temperature
Base Metal °F °C Time (min) Acid Type

Steel 75-95 24-35 1-3 Hydrochloric/sulfuric

Stainless steel 75-95 24-35 I-3 Hydrochloric/sulfuric
Brass 75-85 24-29 2-4 Sulfufic/sulfamic
Copper 75-85 24-29 2-4 Sulfuric
Zinc 75-85 24-29 I-4 Sulfuric/sulfamic
White metal 75-85 24-29 1-4 Sulfuric/sulfamic

Table VI. Acid Dip Operating Parameters---Bath Chemistry (oz/gal)

% v/v (H & S)
Base Metal Acid Concentration Fluorides Chlorides Wetters" Inhibitors

Steel H(5-50), S(5-15) 0.3-0.7 0.8-1.2 0.03-0.05 0.0I-0.03

Stainless Steel H(5-50), S(5-15) 0.3-0.7 0.8 1.2 0.03-0.05 0.01-0.03
Brass S(3-5) 0.2-0.5 -- 0.03-0.05 --
Copper S(5-7) 0.2-0.5 -- 0.03-0.05 --
Zinc S(1-2), Su1(0.5-0.7) 0.3~).5 -- 0.03-0.05 --
White metal S(1-2), Sul(0.5~O.7) 0.3-0.5 -- 0.03-0.05 --
H - hydrochloricacid; S = sulfuric acid; Sul - sulfamicacid.

195
Table VII. Cathodic Acid Operating Parameters for Steel and Stainless Steel
Temperature
Cathode Current
Anode °F °C Time (min) Density (A/fi2) Voltage

Pure lead 85-120 29-49 2-7 20-60 3-6

Graphite 85-120 29-49 2-7 20-60 3-6
Use lead anodesin solutionsthat do not containany fluorides.Otherwise,~aphite anodesare required.

excessive surface smuts or detrimental hydrogen embrittlement. Pickle aids help two ways:
lower solution surface tension to improve wetting and increase contact action. Wetting agents
generate a light foam blanket to minimize corrosive sprays and mist and emulsify residual oils
on parts or dragged into the acid bath. Deflocculents prevent the redeposition of soils.
Double cleaning cycles may employ an aggressive first acid to meet pickling demands.
The second acid should be a milder type sufficient to neutralize the second electrocleaner film
while activating the surface as a last step before plating. Heavily scaled or rusted steel parts
may benefit from cathodic acid treatment. (See Table VII.) This process combines scrubbing
action with activity of the acid solution to dissolve scales and rust.
Inhibitors are special amines, substituted ureas, and glycol-based organic compounds.
Wetters may be anionic or nonionic types. Some wetters and inhibitors provide a filming
action to inhibit attack on the base metal. Good rinsing is required to remove any films, or in
a double cleaning cycle use an inhibited/wetted acid as the first acid, followed by a simple
mineral acid as the second acid.
Some modifications are made to cathodically remove heavy scales and rust.
Acid dipped or pickled parts should be free of any organic soils, rust, scale, and smuts.
This is the last process treatment bath before plating, painting, chromating, or final topcoat
application.

ADDITIONAL CLEANING OPERATIONS

Electropolishing
This is an electrolytic process by which the substrate's surface can be improved using a
specific solution. Burrs, belt lines, scratches, scales, and other imperfections anywhere on the
surface that is irrlmersed and anodically charged will be polished and refined. Electropolishing
is current-density specific. In this regard surface improvement occurs more readily than by
mass finishing. A wide variety of common metals and alloys are successfully electropolished,
especially the nickel-rich 300 series stainless steels. The electrolyte is typically a mixture of
mineral acids. Parts are predominandy racked. The ranges in the operating parameters shown
in Table VIII reflect the use of more than one type of electrolyte.
The solutions are acidic, typically composed of the following inorganic acids: chromic,
fluoboric, hydrochloric, phosphoric, and sulfuric, in varying combinations and strengths.
Organic additives, such as glycols, help to condition the surface during eleetropolishing.

Table VIII. Operating Parameters for Electropolishing Different Metals and Alloys
Temperature
Anodic Current
Metal~Alloy °F °C Density (A/fie) Voltage
Aluminum 150-200 66-93 10-60 10-30
Copper 65-160 18-71 20-300 6-18
Nickel 85-125 2932 100-200 10-18
Stainless steels 110-190 43-88 50-500 6~18
Carbon steels 110-140 43-60 100-300 10-18
Titanium 60-105 16-40 80-500 3-10

196
Table IX. Liquid and Powder Spray Cleaner Operating Parameters
Temperature
Cleaner Type Concentration Range °F °C Time (min) Agitation

Liquid 2-5% v/v 100-160 38-71 0.5-3 15-35 psi

Powder 3-6 oz/gaU 100-160 38-71 0.5-3 1545 psi

a22.5~5 g/L

Table X. Spray Cleaner Operating Parameters---Bath Chemistry (oz/gal)

Metal Caustic Silicate Complexor Phosphate Glycols Wetters

Aluminum -- 0.05-0.1 0.084).12 0.10~0.17 0.10-0.i4 0.06-0.09

Steel 0.4-0.8 0.34).6 0.10~0.14 0.104).17 0.10-0.14 0.06-0.09
Stainless steel 0.4-0.8 0.34).6 0.10~0.14 0.104).17 0.10-0.14 0.06-0.09
Brass 0.04).06 0.34).6 0.124).17 0.2-0.4 0.10-0.14 0.06-0.09
Copper 0.04).17 0.154).3 0.124).17 0.2-0.4 0.1~0.14 0.06-0.09
Zinc -- 0.34).6 0.12-0.17 0.1-0.2 0.l~0.14 0.06-0.09
White metal -- 0.34).6 0.12-0.17 0.14).2 0.10-0.14 0.06-0.09
The cleanfinesscriteriaare the sameas describedin the soakcleaningsection.

Spray Cleaning
A wide variety of ferrous and nonferrous metals are cleaned in this optional procedure. Spray
cleaning can be accomplished off line, as a precleaning step, or in the process line operation.
It provides the following benefits:

• Low foaming cleaning action with displacement of soils

• Mechanical action facilitates cleaning
• Lower temperature ranges for energy savings

The alkalinity level of the spray cleaner may range from near neutral (approximately 8)
to high pH (14). This accommodates cleaning many metals (aluminum, brass, copper alloys,
steel, stainless steel, and zinc). A desired or effective chemistry lifts soils. The concentration
of surfactants and wetting agents can be low since mechanical action of spraying helps to
dislodge soils. Displacement of oils and grease allows them to be collected in a side tank and
removed by skimming or other separation device. This extends service life of the cleaner. It's
a real benefit considering the heavy oil loading some incoming parts have. Removing
displaced soils also prevents them from being sprayed on to parts that are to be cleaned. Water
hardness conditioners in the spray cleaner are invaluable to prevent nozzle pluggage. Typical
operating conditions shown in Tables IX and X.

Mass Finishing
This method helps with off-line capabilities. Cleaning, deburring, descaling, and burnishing
are surface improvements accomplished by mass finishing. The base metal is conditioned
prior to additional surface finishing. Critical areas are rounded out and burnishing can result
in low rms value or nigh luster. The process combines mechanical energy and chemical action.
The mechanical contribution is by tumbling in horizontal or oblique barrels or by using
vibratory bowls. Specially blended chemicals are added in dilute-liquid form or low-
concentration powders. They wet and react with the surface of parts, allowing other parts or
special media (e.g., plastic, ceramic, or stone) to work on the parts. (See Table XI.) Mass
finishing is especially helpful to seal porosity of aluminum and zinc before transfer to the
plating line. If parts are to be mass finished or if this is a feasible option, trial evaluations are

197
Table XI. Mass Finishing Media Shapes and Applications
Media Application

Triangles Reach slotted areas and reach into comers

Cones More effective on concave and convex surfaces
Pyramids Large, flat surface contact; works holes, doesn't pass through
Stars Deburrs inside diameters, blind holes, reduces lodging
Tetrahedrons Sharper points provide better penetration into remote areas
Wedges Reduces lodging. Large, flat surface maximizes contact
Angle-cut cylinders Best on concave surfaces, round areas, and holes
Tri-Cylinders Excellent for concave and convex; comers, slots, angles
Spheres Smooth rolling. Good for concave. Rolls around and through
Angle-cut triangle Better penetration into remote areas
Ellipses Good on concave surfaces
Deburring and rough cuts requireratios from 6:1 down to l:l. Burnishingand high luster require 10-12:1 or up to 20:1.

recommended to determine best suited equipment, media, and optimum: media-to-parts ratio,
flow rates, and cycle times.

SURFACE PREPARATION FOR SPECIFIC METALS & ALLOYS

The selection of specific working solutions should be determined by first evaluating candidate
baths to meet or exceed requirements while adhering to cycle and handling limitations.
Information is given for the more commonly encountered metals and alloys.

Aluminum
A l u m i n u m is in a class by itself. It requires special handling, using some unique steps and
considerations. Because of its light weight, heat capacity, durability, and corrosion resistance,
aluminum is the metal of choice for many applications. A surface preparation cycle for
electroplating or electroless plating generally consists of soak clean, etch, desmut, zincate,
optional double zincate, strike plate, and plate.
It may seem easy but aluminum demands we invest in a quality effort to obtain a quality

Table XII, Aluminum Alloy Designations

Aluminum Alloy Type Number Group

99% minimum and greater IXXX

Copper 2XXX
Manganese 3XXX
Silicon 4XXX
Magnesium 5XXX
Magnesium and silicon 6XXX
Zinc 7XXX
Other elements 8XXX
Unused series 9XXX
First digit: alloy type. Second digit: alloy modification.Third and fourth digits: aluminumpurity of alloy.

Table XIII. Aluminum Soak Cleaner Operating Parameters--Bath C h e m i s t r y (oz/gal)

Metal Caustic Silicate Gluconate Phosphate Borates Wetters

Aluminum -- -- 0.15~0.30 0.8-1.2 3.0-5.0 0.4-0.8

198
Table XIV. Alkaline Aluminum Etchant Operating Parameters--Bath Chemistry
(oz/gal)
Caustic Complexor Conditioner Wetting Agent Defoamer

6-7 3-5 2~4 0.006~.009 0.02~0.05

finish. Knowing the alloy designation is critical to selecting the optimum bath chemistries for
each step in the surface preparation cycle. (See Table XII.)
Soak cleaning denotes no etching or attack of the base metal. (See Table XIII.) The
cleaner bath pH ranges from 8 to 9.5. Ultrasonic soak cleaners also have a similar chemistry
profile. They differ in containing higher detergency levels along with selected solvents.
Etching is accomplished using acidic or highly alkaline solutions. (See Tables XIV and
XV.) This is the primary method of removing the outer, passive aluminum oxide: skin. Etching
also cleans the surface by undercutting soils and lifting them off.
Etchants and preferences:

• Alkaline--aluminum alloy extrusions, and stampings.

• Acidic---castings, polished parts, and prior to electroless nickel.

When etched, some alloys (in the 5000, 6000 series, and castings) tend to generate heavy
smuts. This can lead to incomplete desmutting, detrimentally affecting the zincate treatment.
Acidic etchants, being less aggressive, raise less smut. Typical desmutters are given in Table
XVI.
Other desmutter baths for consideration:

• 50-100% v/v nitric acid

• 15-25% v/v nitric acid + 10-20% v/v sulfuric acid
• Iron salts (ferric sulfate 3-4 oz/gal + 5-10% v/v sulfuric acid
• Universal tri-acid. Mixture of 50% v/v nitric acid + 20-25% v/v sulfuric acid + i - 2
lb/gal ammonium bifluoride, balance water to 100%.

Aluminum die cast alloys (see Table XVII) are based on six major elements: silicon,
copper, magnesium, iron, manganese, and zinc. An example of applying the preferred
desmutting bath can be illustrated by the following casting comparisons.

Table XV. Acidic Aluminum Etchant Operating Parameters Bath Chemistry (% v/v)
Sulfuric Acid Phosphoric Acid Complexor Wetting Agent

5-7 2-5 2.5~4.5a 0.0064).009

aoz/gal

Table XVI. Aluminum Desmutting Chemistry Depends on Alloying Elements

Alloy Type Sulfuric Acid Nitric Acid Fluorides
High silicon 10-25% v/v 3.0-8.0 oz/gal
High copper -- 15-25% v/v 1-3 oz/gal
Low alloys 10-25% v/v -- --
Note: Volumebalanceas water.Ammoniumbifluoridesuggestedsourceof fluorides.

199
Table XVII. Die Cast Alloy Compositions
Series 380 Series 413
Element Assay Assay

Magnesium O.tO max. O.10 max.

Zinc 3.0 max. 0.50 max.
Manganese 0.50 max. 0.35 max.
Silicon 7.5-9.5 11.0-13.0
Copper 3.0-4.0 0.60 max.
Iron 1.0 max. 0.8~1.1
Nickel 0.50 max. 0.50 max.
Titanium
Chromium 0.35 max. 0.35 max.
Tin -- 0.15 max.
Lead -- --
Cadmium
Other 0.50 max. 0.20 max.

Tips:
• The universal tri-acid is best suited to desmut both of these castings; however, the
formula containing 2 lb/gal of a m m o n i u m bifluoride is recommended for the series
413 casting. That's because of its greater silicon content (41% more).
• Usually, the aluminum part will exit the desmut bath white and smut free. Close
inspection may also indicate a very fine surface etch, which is actually beneficial for
zincating or chromating. If the part fails a white paper towel wipe (smutty) chances are
slim that subsequent processing will be successful.
• If the part gasses while immersed in the zincate there is a good possibility it hasn't
been properly desmutted.
• If the desmut bath contains nitric acid be certain that good operating, compliant
exhaust is in use to safely vent off nitric oxide fumes.

Zincating
This is an immersion treatment where a coating of zinc or zinc alloy is deposited over cleaned
and activated aluminum. It is over this tightly surface-adherent film that plating can occur.
There are three common zincating solutions:
1. Conventional zincate. This solution contains one metal, zinc, which is immersion
deposited over aluminum. It also contains an oxidizer, such as sodium nitrate,
conditioning the aluminum surface by mildly etching it. Tartrates are included as
complexors. The viscous working solution is concentrated in sodium hydroxide
(forming the chemical zincate). Baths prepared from powdered concentrates must be
cooled for several hours before they can be used.
11-13 oz/gal sodium hydroxide, 2-3 oz/gal zinc oxide, 0.6-0.8 oz/gal sodium nitrate,
7 5 - 8 5 ° F (24-29°C), 0.5-2 minutes.
2. Conventional alloy zincate. Similar to the conventional zincate but differs as follows:
contains iron, which forms an Fe-Zn alloy immersion deposit. Chemistry and
operation as previous plus 0.2-0.4 oz/gal ferric chloride
3. Modified alloy zincate. Similar to conventional alloy zincate but differing as follows:
contains several metals (commonly from among copper, iron, nickel and zinc,
forming a unique alloy immersion deposit. Copper and nickel control rate of zincate
formation and enhance its tight, cross-linked structure. Gluconate eomplexors (small
amounts of cyanide are optional) used in place of tartrates, and much less sodium
hydroxide. The working solution is much less viscous, providing improved rinsing
characteristics.

200
 In each zincate described, the type and concentration of complexors are critical to
maintain solubility of the alloying metals.
Which zincate to use? The conventional zincate is a good process when applied to
high-purity aluminum alloys. But, it doesn't provide as strong adhesion over 5000 and 6000
series alloys as do conventional alloy and modified alloy zincates. The latter provide a far
stronger bonding to a wider range of aluminum alloys. This is due to formation of less porous,
denser, uniform films. They also protect sharpened comers and edges of zincated parts from
being worn and abraded in barrel plating.
Tips on zincating include:

• Rinse well before the zincate bath to prevent drag in of desmut acid solution. For
example, fluorides will detrimentally affect the zincate film.
• The zincate should be an even gray or blue-gray color. Splotchiness may indicate
zincate solution components are out of balance.
• Poor adhesion of zincate to basis aluminum may be due to bath temperature out of
range or poor cleaning and surface preparation.
• Spongy zincate (thickened) is usually a result of excess immersion time or too high
bath temperature.
• A good, adherent zincate film will pass a Scotch tape pull.

Strikes

Copper
This bath is designed to coat the zincated surface with a strong bond, while not attacking it
in the process. (See Table XVIII.) The deposit serves as an active site for reception of
subsequent electrodeposits, some of which might be highly aggressive toward the unprotected
zincate.
Both formulas operate at 4 A/ft2 for 5 minutes or at 25 A/ft2 for 10 seconds, 110-125°F
(43-52°C). pH of first bath at 10-10.5. pH of second bath at 11.5-12.0. A proprietary grain
refiner and anode corroder may also be added.

Table XVIII. Suggested Copper Strike Formulations

Component Concentration (oz/gal)
Copper cyanide 3.50
Sodium cyanide 4.25
Sodium carbonate 4.00
Rochelle salts 4.00

Copper cyanide 1.5 3.0

Free sodium cyanide 0.2-0.4 x Copper cyanide conc.
Potassium hydroxide 0.1~).5

Table XIX. Suggested Watts Nickel Strike Formulation

Component Concentration (oz/gal)
Nickel metal 10-12
Nickel chloride 8-10
Nickel sulfate. 3~37
Boric acid 5-6

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Table XX. Wood's Nickel Strike Bath Composition
Component Concentration

Nickel chloride 30-34 oz/gal (225-255 g/L)

Hydrochloric acid, 22°B6 10-12% v/v
Nickel anodes Sulfur free

Electrolytic Nickel
The purpose is the same as the copper strike, protect and seal the zincate film, preparing
the part for reception of additional deposits. (See Table XIX.)
The bath is operated at the same current density as Watts nickel barrel and rack plating
solutions. Time is just sufficient to cover the zincate. Bath pH should be maintained at 4.4 to
4.6 to minimize attack of solution on the zincate. Proprietary wetting agent and zinc tolerant
Class I brightener (carrier) are normally added. Routine low current density (LCD) dummying
at 5 to 10 A/ft 2 is recommended to plate out zinc contaminant.
Where possible, live entry into any of the described strike baths is recommended. This
can be accomplished by using an auxiliary cable, while parts are in transit "live" to the strike
bath. Plating begins as soon as the parts contact the solution, significantly minimizing attack
on the zincate.

Alkaline Electroless Nickel

The benefit of this bath is total, even nickel thickness of all exposed surfaces since this
is an immersion process. The zincate itself is catalytic toward the electroless nickel solution.
For a 10-rain immersion the deposit thickness may range from 20 to 30 millionths of an inch,
at ll0°F (43°C). Bath pH is 8.5 to 10.0.

Low Carbon Steels (e.g., stampings and extrusions)

Standard soak clean, electroclean, and acid dip, as described in process bath descriptions.

High Carbon Steels (e.g., springs, fasteners, lock parts)

Classified as above 0.35% carbon. Base metal has higher smutting tendency. Preferred acid
dip consists of 25 to 40% v/v hydrochloric acid with additions of a pickle aid and wetting
agent. The pickle aid minimizes attack on the base metal, greatly reducing tendency for
hydrogen embrittlement. Stress due to hydrogen embrittlement can be relieved by baking at
350 to 400°F (177-204°C) for i/2 to 3 hours.

Cast Iron
Standard alkaline soak clean, followed by alternate hot and cold rinsing to push solutions out
of pores. Anodically electroclean in alkaline descaler. Parts exiting the electrocleaner should
have a uniform light yellow cast. Dip in 15 to 20% v/v hydrochloric acid or 5 to 10% v/v
sulfuric acid, to dissolve oxides, desmut, and form an active surface for plating.

High Strength Alloy Steels

These materials retain a Rockwell C hardness of 38 or higher. Hydrogen embrittlement can
be avoided by using the acid dip as mentioned previously. Baking at 50 to 75°F (10-24°C)
below the tempering temperature, 800°F maximum (427°C) is recommended.

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Table XXI. Wood's Nickel Strike Operating Parameters
Operating Parameter Range

Temperature 75-90°F (24-32°C)

Anodic Treatment 10-20 A/ft2, 1-2 nfin (optional)
Cathodic Treatment 40-120 A/fta, 2-3 rain

Stainless Steel
Standard soak and electrocleaning followed by acid dip or pickle is not sufficient if the
material is to be plated. Surface passivity must be overcome. This is accomplished by a
treatment in the Wood's nickel strike solution. (See Tables XX and XXI.)

Beryllium Copper
This copper alloy typically contains 2% beryllium with 0.25% cobalt and 0.36% nickel.
Surface preparation cycle:
1. Alkaline soak clean to remove organic soils. Mild tarnish is acceptable.
2. Electroclean in a specially buffered blend (refer to suggested formula for copper),
having moderate caustic at 20-40 A/ft 2, anodic.
3. Activate in a mildly etching solution composed of peroxy derivatives, persulfates, or
sulfuric acid with fluoride. Ex. 2% v/v of sulfuric acid and 4 oz/gal ammonium
persulfate.
4. Rinse well, proceed to plating bath.

Cobalt
Surface preparation similar to stainless steel. The Wood's nickel strike is very important to
develop a sufficiently active surface to accept subsequent plated deposits.

Leaded Brass (0.35-4.00% Lead)

Red and Yellow Brasses Commercial Bronzes

Surface preparation cycle:
I. Soak or ultrasonically clean to remove buffing and polishing compounds. 20-40
KHz/gal. Highly wetted, with solvents, soap optional.
2. Secondary soak clean. Moderate alkalinity, containing surfactants, some inhibition
preferred.
3. Electroclean at 10-30 A/ft 2, anodic. Buffered blend similar to application on copper
alloys.
4. Activate. Sulfuric acid type containing fluorides, essential to dissolve lead smuts.
5. Rinse well, proceed to plating bath.

Bright Dipping Brass

1. Mild to moderately alkaline soak cleaner.
2. 5% v/v sulfuric acid dip. Neutralizes and conditions the surface.
3. Chemically polish in either a peroxide-type or sulfuric acid/iron salts blend. Both
solutions are wetted and specially inhibited.
4. Tarnish inhibit in dip application using either a soap (mechanical tarnish inhibit film)
or a benzotriazole (active surface antioxidant).

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Table XXlI. Zinc Alloy Compositions
Alloy % Zinc % Aluminum % Magnesium % Copper % Lead

Pure 99.9+ -- -- --
Zamak 3 Balance 4.0 0.04 -- --
Zamak 5 Balance 4.0 0.04 1.0 --
Zamak 2 Balance 4.0 0.03 3.0 --
Slush Balance 4.75 -- 0.25
Slush Balance 5.5 -- --
Drawn Balance -- -- -- 0.08

5. Optionally lacquer (dip or electrolytic) or apply electrolytic chromate.

Inconel
This alloy constituent typically contains 13.5% nickel and 6.0% chromium. (Note: one alloy
type may contain 2% silicon.)
Surface preparation cycle:
1. Alkaline soak clean. Mild to moderate alkalinity with sufficient detergency.
2. Acid dip. 2 0 - 3 0 % v/v hydrochloric acid for primary oxide removal.
3. Anodically etch. Wood's nickel strike, 100-120°F (38-49°C), 50 A/ft 2, 2 0 - 3 0 sec.
4. Strike plate cathodic. Woods' nickel strike, 100-120°F (38-49°C), 50 A/ft 2, 2-3 min.
5. Rinse well, proceed to plating bath.
The above cycle is sufficient for Inconel X and Hastelloy C.

Nickel and Nickel Alloys

Require similar treatment as stainless steels. Anodically etch at 15 to 25 A/ft 2 for 1 to 3
minutes in a 25% v/v sulfuric acid solution. Next, cathodically condition at 150 to 225 A/ft 2
in the Woods' strike, or at 40 to 60 A/ft 2 in a sulfuric acid/fluoride/chloride solution. Parts not
long aged may also be activated in an immersion dip consisting of 5 tp 10% v/v sulfuric acid
and 2 to 4 oz/gal of potassium iodide at 75 to 90°F (2d-32°C). These treatments also apply
for replating aged nickel plated parts and rejects.

Powdered Metal
Same recommended surface preparation steps as for cast iron. Rinsing is very important, to
facilitate drainage and removal of previous contaminating solutions.

Silver
The metal and its alloys tarnish readily, forming a blackish oxide film. After soak cleaning in
an appropriate caustic containing cleaner, dip in 5 to 10% v/v sulfuric acid to neutralize
surface. Next, chemically polish in a solution consisting of 20 to 25% v/v hydrogen peroxide,
at 85 to 100°F (29-38°C).

Titanium
Activation is the critical factor. The following cycle may be appropriate with sufficient testing
beforehand.
Surface preparation cycle:
1. Alkaline soak clean.

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 2. Activate and pickle in a solution consisting of 20-25% v/v hydrofluoric acid 75-80%
v/v nitric acid.
3. Etch in solution of sodium dichromate at 30-35 oz/gal (225-263 g/L) and 4-5% v/v
hydrofluoric acid for 15-30 minutes.
Thorough rinsing between each step.

Zinc and Zinc Alloy Die Castings

Zinc is molten and cast into many shapes and forms, comprising a wide variety of consumer
and industry relegated parts. Just like aluminum, zinc is available in different alloys. (See
Table XXII.) The casting operation does result in surface defects, which must be corrected in
an appropriate manner either before shipment to the plater or in the surface preparation cycle.
Pores, cracks, "cold shut," and roughness are some of these common problems. Mechanical
operations, such as buffing and polishing, refine, and smooth the surface but leave
accumulated buildup of related soils, grease, compounds, and rouges. The exceptionally high
temperature of these mechanical finishing techniques will burn, harden, and drive contami-
nants into the metal surface. The sooner parts are cleaned the easier the surface preparation
cycle becomes.
Surface preparation:
(refer to specific cleaner baths and operating parameters, as previously given)
1. Soak or ultrasonically clean. Removing buffing and polishing compounds. The
cleaner may be wetted with glycol and cyclic pyrollidone type solvents. A combina-
tion of high HLB and low HLB surfactants are helpful. Soaps are also an option. The
cleaner should be buffered to prevent tarnish and etching of the zinc surface. Many
buffing and polishing compounds are effectively softened in the soak cleaner at
175-190°F (79-88°C). Ultrasonic conditioning uses 2 5 4 3 KHz/gal of power in the
solution to maintain effective standing waves, resulting in bubbles imploding on the
surface for cleaning action. Temperature of the ultrasonic cleaner should be in the
range of 160-180°F (71-82°C). Somewhat cooler to avoid higher temperatures,
which distort the standing waves.
2. Secondary soak clean. Removes residual organic contaminants and any inhibiting
films that may have formed on the surface during the step #1 soak cleaning.
3. Electroclean. Moderate alkalinity, inhibited.
4. Acid dip.
Thorough rinsing is understood between steps.
Copper strike as per formulas given for zincated aluminum. Castings should be sealed
with at least 0.03 to 0.05 mil. Additional copper as plated to 0.08 to 0.14 mil before
application of nickel plating.

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