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The Zinc Electroplating guide

96K views 67 replies 20 participants last post by  p951951951t  
#1 · (Edited)
Hello everyone,
As promised, I will begin now the complete electroplating guide to help you to restore as better as possible your Alfa. Details make the difference !
I've replate now many parts of my Spider, and rather satisfied of the results.
I hope you'll be interested by the thread, and you'll be soon able to do the work without too much difficulties.

Introduction

I'm going to guide you through all the stages of plating, from setting up the tank and his chemicals and components used. The differents steps are the preparation of the electroplating bath, an explanation of the electrical needs, the preparation (degreasing and cleaning) of the items to be plated.

Why Zinc electroplating and not Nickel, Gold, Chrome or others ? First, because the Zinc plated parts are the most used in our Alfa's; there are only some chromes, many of the "chrome" parts are stainless stain made.
Next, Zinc is one of the most easy metals to plate; it gives a very good protection against the corrosion and, if applied correctly, can gives an outstanding finish, almost as shiny as chromium. You will not need hard dangerous and corrosive chemicals like industry uses (cyanide salts).
On the other hand, you will save money, many parts good for the trash will revive. You'll be proud of the result if you follow all the steps.

Tips will be in green

What will we need to electroplate ?

- the chemicals to make your electrolyte bath
- the chemicals to chromate
- some zinc to make the anode
- tanks
- electric copper wire
- a good power supply
- accessories like gloves and protection glasses


The Chemicals for the electrolyte baths :
- distilled water (5 litres > 1.32 gal), it's enough to begin.
- Ammonium Choride (hardware shop or Ebay) : 2 kilos (about 4.5 pounds)
- Zinc choride (same) : 1 kilo (about 2.25 pounds)
- Zylite 290 makeup Electrolyte chemicals and passivates : 4 x 250 mL
- Zylite 290 maintenance solution (200 mL)

The complete kit is avaible at gateros plating but it's not the best way to save money, you must add the expensive shipping, chemicals are in lower quantities, and some items not necessary.

Explanations of the quantities :

The electrolyte bath as a limited life contrary to the sellers say. The bath will be contaminated by hard metal deposits or other pollution and will go bad.
The quantities I advice are calculated to electroplate all the rusted items of a car restoration, and at lowest cost as possible.
With 2 kilos of Ammonium Chloride, 1 kg of Zinc Chloride, and the 50 cL of Zylite make-up, you'll can renew the complete bath five times, and that's enough for all the car. You can buy in lower quantities, but it will costs a little more.
So, for a tank of 4.5 litres, you will use : 4 litres of distilled water, 200 gr of Zinc Chloride, 400 gr of Ammonium Chloride and 200 mL of Zylite 290 make up. I will talk about the Zylite Maintenance later.

Total price I paid for five electrolyte baths : 100 USD
- distilled water (20 litres) : 5 USD
- Zinc Chloride (1 kg) : 40 USD (Ebay)
- Ammonium Chloride (2 kgs) : about 25 USD (hardware shop)
- Zylite Make-up (1 L) : 20 USD
- Zylite Maintenance (200 mL) : 10 USD

The chemicals for the passivate baths (chromate):
The passivate baths are avaible is several colours : white/blue, yellow/gold, olive, and black. You'll need only the white/blue and yellow/gold passivate.
It's necessary to passivate, to improve the protection against the corrosion. You can only white/blue passivate to restore some originally chromed parts, and the result will be a shiny silver colour, like chrome. But for the nuts, bolts, brackets,... it's better to yellow/gold passivate : why ? first, to keep the original look of the parts, and also to improve the protection against the corrosion. If you yellow/gold passivate, you must first white/blue passivate, if you do not, the yellow chromate will go away !

You'll need :
- white/gold passivate : about 15 USD
- yellow/gold passivate : about 15 USD
- distilled water (10 litres)

The passivate are sold in little bottles of 200 mL, and that's enough for the whole car. They will be mixed with distilled water in two plastic tanks (about 100 mL for 5 litres).

The Anodes :

You'll need zinc to make the anodes. It must be as good as possible, mine is 99,95 % pure.
I recommand to install at least two anodes, positionned at 180°.
The zinc sold by Gateros plating is very good but very expensive. Try to find it in a "metal shop" or a plumber.
When it is new, it's shining. Don't buy oxyded zinc !
You'll need, for a tank of 5 liters, two anodes or about 3 x 6 inches.
Here's a picture : the first is a new anode, the second an anode used two or three times, the third an anode used fifty times. You can see it melts ! but it's always good. The only condition : the area of the anodes must be equal or larger than the item to be plated.
The anodes sold have a small hole in the top, to attach the Cu wire. However, it's better to solder the wire to the anode if you have a little soldering iron.


The tanks :

You'll need, to work at ease, three plastic tanks (4-5 liters) with a cover to avoid some contamination of the electrolyse and safety when you don't use them.
The first will contain the electrolyte bath, the second, the clear/blue passivate, the third, the yellow/gold passivate.
You'll need too a 10 litres bucket filled with water to rinse the items you've plated before immersing them into the passivate baths.

Here's a picture of the plastic tanks containing the electrolyte bath (left), clear/blue passivate (middle), and yellow passivate.
The diameter of the tanks is about 8", and the height 8.5"



The copper wires

You need two sets of wires, the first to connect the power supply to the anode and the item to be plated,



and the second to hang the items into the electrolyte bath.
When you buy a kit, you only get the thin copper wire, to hang the items.
I recommand to get some big electric wire, to plate easily many bolts at the same time - imagine to have one wire for one nut ! The wire must be thick enough to support the weight of the nuts. But look at the picture to understand :



The power supply

Electroplating needs a DC current source.
First, I'm going to try to explain you what's is happening in relation of the voltage and the current.
- The voltage : it's easy, don't look at it ! The current depends of the voltage, and here, only the current is to be considered. (the voltage between the anode and the item is often below 1 DCV)
- The current : here we are ! It's one of the most important things to get right.
I can tell you what amperage is ideal, but it depends on the size of the items beeing plated (and to a lesser degree the temperature of the electrolyte).
There's no ideal voltage, but there's an ideal current. I tried many possibilities, and I found that the ideal current is 100 mA per100cm², or 65 mA per square inch.
If you don't take care of the ideal current, you can't get two problems :
- if the current is too low, the plating will take too long time and get dark and/or dull areas
- if the current is too high, the plating is too fast, and the zinc deposit is rough and grey with dark patches in the most high current density areas
- if the current is very too high you could burn the electrolyte and/or the make-up
----> so, the best way is always to set the power supply controls (voltage and/or intensity) at the minimum on starting.

The best power supply is powerfull, with both controls of the voltage and the intensity. You can adjust the voltage and the current but like I said before, only adjust the voltage, and by the same way the current will vary because I=U/R.

Here's a picture of mine : 0-30 Vots, 0 - 20 amp :



If you don't possess such a power supply, you may use a car or a car battery charger. You have to buy one big variable resistor (at least 20 - 30 watts) of 50 - 100 ohms. You'll need too a Ampere meter to know how much current is running.

On this little drawing, you can easily see how to make the connexions :



When you begin electroplating, always measure the area of the item beeing plated.Question ? do you know the surface of the front bolt of the rear trailing arm ?
I don't know too. So, let's measure approximatively. (there are some sofwares to calculate)
- The surface of the cylinder is : 2 * Π * A 2 + 2 * Π * A * B = 38 cm²
- The surface of the head is : 6 x (1.2 x 0.6) = 4,32 cm²
Total is 42 cm² or 6,5 square/inches. Did you think it was so large ?
The current needed to plate this bolt is then : 6,5 x 65 (mA)= 420 mA or 0,42 A
I did it and here it is :




Accessories :

- The tank filter : some advocate to attach filter in the bottom of the tank. I tried it , and didn't get any advantage. I prefer to filter the electrolyte every five uses. The best to do it is to buy some paint filter sold in the auto paint shops. I paid mine about 3 USD for ten filters. The coffee filters block up too quickly.
- The air pump : absolutely necessary : when the part is plating, many little bubbles of hydrogen are produced; the agitation pump will chase them away from the surface of the item. With no pump, some areas could be badly plated
- The air stone : if you have one, ok, but not essential. I tried then removed it, I did'nt seen any difference.
- The gloves : it's a good idea to wear gloves, because the electrolytic is a acid mixture. But take care, many new gloves are filled with silicone and if it goes to the item, you'll got areas badly plated too. So, wear the gloves, and wash your hands with a good detergent.
- The goggles : good idea too, your eyes will not appreciate some acid projection.
- The protection mask : better to have one, but not critical for plating some screws. You will not have big fumes.
- The tank heater : if you plate outside in the snow, perhaps. If not, forget them; if the temperature of the bath is too hot, the shining will decrease...
- The PH paper : In theory, the PH balance can alter over a period of time. The PH paper can check the balnce, witch must be about 5.5 - 6. If the PH is too high, some HcL can lower it, and if the PH is too low, Potassium Hydroxyde can raise it. But normally, the PH doesn't need adjusting. I tested my electrolyte after many many uses, and never had to adjust it. So, forget it too.


Cleaning the parts before plating

One of the key factors in good plating is a good preparation, and a good preparation means a perfect cleaning.
1) Degrease perfectly the parts, to remove thick oil and grease. You can use soak, acetone, tix, and s.o.
2) Remove rust or other oxides, the easiest way is to sand them, you can too use grip paper.
If you sand, sometimes, some little pits of rust can stay, they will go on the step 4)
3) Follow with a dip in caustic soda, for a good cleaning
4) Final cleaning : dip in hydrochloric acid for 1 or 2 minutes. It should be used in a concentration of 20 % (80 % of water). Caution : always add acid to water, and never the other way round.

After every step 1 to 4, rinse in clear water.

Remember, after this, don't touch parts by hands, and don't let them exposed to the air or they will go rusty very quickly.

To be sure the part is perfectly cleaned, you can use the "water brake test". Just dip the part in clean water, if the water beads then there are still traces of oil, grease, or solvent left on it; if the water makes a "film" over the item, then it's free from any oil, grease, etc...

-----------------------------------------------------

And now, the step by step procedure !

I suppose you've read everything before, and all you need is on your bench :
- a bucket with the electroplating mixture
- a bucket with the blue passivate chemical
- a bucket with the yellow/gold passivate chemical
- a bucket with clear water
- two electrodes of pure zinc
- a power supply
- some electrical wires
- a timer
- a fish pump
- gloves, absorbing paper, googles, etc

Now, go to your garage and choose the part you want to plate.
You need as I told before, to prepare it very well, if you do not, the
plating will not work !
The very best way to have you part perfectly clean is to sandblast it. That's
I've just done now, I had two parts to restore, a jack socket and an bracket,
coming from a Vintage amplifier Sansui. Some tell to degrease the part, using
a degreaser to remove thick oil an grease, but if you sandblast it's not necessary.
When you will have finish to sandblast it, run quickly to you workbench with it
because it begins to rust again !
Some tell too to submerse the part in caustic soda, but, again, if you sandblasted
the part correctly, you may avoid this step. More than that, I tried two or three
times to pickle in a mixture of HCl, then rinse very well, but some acid always stays
on the part and pollutes the electroplating bath, so I avoid to do that now.

So, I'm here now with my littles parts, just sandblasted, and ready to be plated :



1/ As you can see on the picture, attach the part(s) with cooper wire
2/ hang the zinc electrodes into the electroplating bath with the wires, and link them
together to have a good electrical connexion (I solder mine) :



3/ connect the zinc anodes to the power supply (for these two little parts, you can see the intensity of the current I use), the positive to the zinc, the negative to the part that is to be plated. Begin with the smallest current, and increase it to the intensity required by the surface of the parts.



4/ Connect your little fishpump (it will improve the plating)



5/ If you everything is right, it will look like this :



6/ Every five minutes, you can change the position of the part, to improve the plating; you may also find plating is brighter if the part is near the surface of the electrolyte. Look at the part, if the current is too high the process will be quick and the zinc deposit may be rought and black, and if the current is too low, the process will be slow and the deposit can be again dull will not adhere properly to the steel.
The longer you leave the part in the electrolyte, the thicker the zinc deposit will be.
For a good plating, I leaved my little parts for fifty minutes.

7/ It time now to clear/blue passivate the parts : rince the part in the bucket of water :



You can see how the jack socket looks :



set your timer for 30 seconds,



then immediately immerse the part in the clear/blue passivate



after 30 seconds, remove the part and rinse it again - you can see on the following picture how looks the jack socket :



8/ Rinse again in the water the part, and go into the yellow passivate,
from 45 seconds if you want a light yellow color, to 75 seconds if
you want a more coloured appearance. I let my socket for 60 seconds.
Rince again the part and allow to dry for 24 hours. Your can also use a hot air gun,
but you will remark that the colour will go to dark. I don't like to use this way.



Here are my finished parts, ready to go to the Sansui !
(you can see how was the jack socket rusted !!!)





If you have still any question or remark, you can send me an email !
 
#4 ·
Thank you for this great description, tatchoune! Unfortunately, there is a problem with this statement:
I found that the ideal current is 100 mA/cm²,or 60 mA per square inch.
1 square inch = 6.45 cm² (or the inverse: 1 cm² = 0.155 square inch).

Therefore, if the current needs to increase proportional to the area, the current should be either 10 mA/cm² (if 60 mA per square inch is the correct value) or 645 mA per square inch (if 100 mA/cm² is the correct value).
 
#5 ·
1 square inch = 6.45 cm² (or the inverse: 1 cm² = 0.155 square inch).

Therefore, if the current needs to increase proportional to the area, the current should be either 10 mA/cm² (if 60 mA per square inch is the correct value) or 645 mA per square inch (if 100 mA/cm² is the correct value).
You're right, thanks, I will correct !
Some sites selling electroplating kits recommand 100 mA per square/inch but I found that value too high. It works well but when there are complex areas with edges, these are easily burnt. Decreasing to 65 mA solve the problem.
 
#7 ·
Yes, I see. But look at the price ! A 1,5 gal kit costs $ 159 (+ shipping I suppose). If you follow my instructions, the price for 1.5 gal will cost 25 USD.
You have also to buy an aquarium pump, some USD on ebay... some wires and zinc ... some passivate but we're far from the Caswell's price !
When I said 100 USD it was for 5 x 5 litres of electolyte, including the brighteners.
You can buy on Ebay 500 gr of Zinc Chloride, for ex : http://www.befr.ebay.be/itm/220721694562?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649 and Ammonium chloride in a local shop (I don't know the chemicals laws in the USA, here in Belgium we can buy Ammonium chloride but NOT zinc chloride, that's why I ordered it on Ebay).
Then just order the brighteners and the clear and yellow passivates at Gateros plating, the shipping will be low because of the low weight, and you're ready to start.
Gateros plating is a very good site, you can ask any technical question and the will reply quickly.
 
#8 ·
As much as the kits offered by our North American businesses are a little more expensive...we don't have other options. Gateros for example will only ship these goods via road transport and as such will not ship to the US or Canada. So it's becoming a bit of a task to find suppliers for these ingredients here in North America. The zinc chloride e-bay supplier you note also cannot ship to NA:(.
 
#9 ·
Great writeup tatchoune,
I'm also interested in doing some small amount of plating when I get into the next project on my car (hopefully in late 2012 if things work out), so I've previously looked at things like caswell kits. This thread is very informative for sure.

The only thing that I'm personally concerned about is the safety aspect. You did mention fumes, and I looked up zinc chloride in a few places, e.g. on CDC.org and it would *appear* that fumes from a solution are similar to fumes from welding zinc, i.e. quite toxic.
CDC - NIOSH Pocket Guide to Chemical Hazards - Zinc chloride fume

I can't be sure about this however, as I'm hardly expert in this - but I wanted to add this aspect to the thread in case it's useful.
/Neil
 
#10 ·
The only thing that I'm personally concerned about is the safety aspect. You did mention fumes, and I looked up zinc chloride in a few places, e.g. on CDC.org and it would *appear* that fumes from a solution are similar to fumes from welding zinc, i.e. quite toxic.
I'm a technician in electronics, and I can assure you that welding zinc with an iron solder makes much more fumes than the little electroplating I do.
Don't forget, the area of the electroplating zinc is rather small, and I can't see any fumes while plating. Also, I've never had any trouble with the fumes if there are.
I got also many times electroplating bath contact with my skin, it's not a terrific acide, (the Ph is 5.5), less than vinegar or lemon. Of course, I rinced my hands if acid touched them. It's a good idea to have a bucket full of water near the place you're working.
If you're still afraid, you can electroplate for example in you garage, with the door wide open.
I can say also there's no smell in the room while doing the job.
I will try to insert soon a video showing the "fumes". I think you will see (or not see) the fumes easily if I run the beam of my big Maglite in the dark just over the bath.
 
#11 ·
Absolutely, I don't think the quantity is comparable to welding galvanized steel, for example, but the risk appears to still be there to some amount. I am more concerned about long-term effects of things I breathe than I used to be - but that's just me.

By the way, I lived in Aachen from 97 to 05, not too far away.
Cheers
Neil
 
#13 ·
Excellent and inspiring thread.If I can get the chemicals to Georgia,I'm definitly going to try Tatchounes' system.BUT,I have had success using a chemical bath made up of 1lb.Epsom salts,1lb.white sugar,and 1gallon of white vinegar!eek:I stumbled across this on the Honda 305 forum.This is a creative group. For power,they're using flashlight or car batteries,chargers,train transformers,and anything else that creates direct current.I'm lucky enough to have a plating machine.I'd like to add that zinc roofing strip(in my case,Z-Stop,but there are others)works well for anodes.I found mine at an Ace hardware,3lb.strip,2 1/2"x50',99.2%zinc,for $28.00.Also,2lb.Zinc bar is available on ebay for around $8.00.Here are a few crappy pictures of the strip and a couple of parts I did.If intrested,I'll try to send better pictures.Phil
 

Attachments

#14 ·
Z-stop looks an easy way to get the pure zinc you need for the plating !
Could you describe with some details your procedure to plate with your ingredients ? I tried myself with home made zinc chloride (zinc + hcl), but the result was not very beautiful, nothing to see with the complete method I've described.
 
#15 ·
To use this solution for zinc plating,the Epsom salts and sugar are disolved in the vinegar,this takes a few minutes.It may help to heat the vinegar,but I haven't done this.This solution needs to be saturated with zinc,so the zinc is cut into strips and placed around the plating tank/bucket,and left overnight.Now the plates can simply be connected to each other with copper wire and used as the anode.That is what many of the Honda 305 guys did.For the spare tire bracket,I used two new zinc strips,one on each side,shaped to the contour of the part.Shaping the anode/s to the part helps the plating go on evenly,as this is a "line of sight"procedure.(parts closer to the anode will plate heavier,had I used only one anode,the other side of the bracket may not plate at all).I didn't use bubbles,agitation or heat.That's about it.Everything else was done the same way you did,ie,degrease,derust,clean,clean,clean....1/10amp per square inch for 20-30min..This setting/solution did make the part a little dark,but this polished out easily.Passivate would no doubt help,and if I can get it,I'll try it and decide from there if the results are good enough using my solution.I should add that this solution "is" safe to use(except for the small amount of hydrogen bubbles while plating).You could probably drink some,and certainly put your hands in it,but it gets very sticky!Please don't take the last sentence too seriously.I still feel that your system will be easier to use with better results.Regards,Phil
 
#16 ·
An easy way to obtain the zinc chloride is to put 10 cl of HCL into a little bottle, then cut zinc in strips, fit the zinc into the HCL until the HCL is "dead" (until there's no more reaction).
You must do that outside, because of the Hydrogen, and the bad smell of the HCL.

NB ; this ZnCl2 solution is also very useful to help soldering on stainless stain, iron, and so, except aluminium with a solder iron.
 
#17 ·
An easy way to obtain the zinc chloride is to put 10 cl of HCL into a little bottle, then cut zinc in strips, fit the zinc into the HCL until the HCL is "dead" ...
Ok..I'll start with the dumb questions first. I assume the resultant mixture here is a solution yes? If so, how does the formulation differ if one uses powder zinc chloride vs. the liquid ZnCl solution?
 
#18 ·
Ok..I'll start with the dumb questions first. I assume the resultant mixture here is a solution yes? If so, how does the formulation differ if one uses powder zinc chloride vs. the liquid ZnCl solution?
I think it's to modify the Ph, to have a more conductive electrolyte. I tried with only Zn and the result is not smooth. On the edges, there too much Zn, and the item is grey and not shining.
 
#19 ·
Sorry...but I don't think I made myself clear with my question. Your formula requires zinc chloride...and I assumed it was in powder form. But in post#16 you're talking about making up a liquid solution of zinc chloride. So would you replace the powder zinc chloride in your formula with the solution of zinc chloride?
 
#20 · (Edited)
I tested the "do it yourself" zinc chloride, but without the ammonium chloride. As I said, the result was rather bad. I must say I have not added the Zylite (brightener).
-------------
I think this week I will have the time to continue the topic. I will add a real time electroplating guide with the differents steps and many pictures. Sorry for the delay.
-------------
If anyone interested, I could help by shipping Zinc Chloride at the costing price. But I do not know if I can ship this chemical to NA.
Prices of the zinc chloride are rather high on ebay. I asked for zinc chloride in France, and I find a shop which can sells me 50 kgs for a much lower price. If there are many interested on this forum, I could ship the chemical for the lowest price. I don't want to make any money, I just want to thank for the help I get on this nice forum.
 
#22 ·
...If anyone interested, I could help by shipping Zinc Chloride at the costing price. But I do not know if I can ship this chemical to NA....
Well that would be a huge offer on your part....I'd be interested in the 2kg/1kg Ammonium Cl/ZnCl for sure. I fear however that this material may be Hazmat classified and not qualify as air freightable material. Could you investigate this at some point soon before we get our hopes up too much?
 
#23 · (Edited)
Yes I can investigate, but before, can you look if any of these chemicals can be bought in NA ? For example, ammonium chloride is sold in Belgium, zinc chloride not, but it can be bought in France (and shipped to Belgium !!!!!.... 20 or 50 kgs is not a little quantity). Otherwise, the owner told me "some times ago, I still had zinc chloride, and I could sell it to you. But now, I have no more, and I can't order it". That's to say he could sell this chemical if he had still.

Less weight will cost less in shipping, that's why I ask the question.

This is a link of the shipping costs to the USA : (just click on "tarifs") bpost - Kilopost Standard
 
#25 · (Edited)
Interesting possibilities Brad. I'll contact them to find out if they sell in small quantities (1 kg of the zinc chloride). For the ammonium chloride I'll investigate a local producer of industrial zinc chloride used in the plating industry.....http://www.khchems.com/Inorganic.asp see if they too sell in small quantities (2 kgs)...they seem to have 25kg bags of the stuff only listed on their site.

Cheers gents...
 
#28 ·
So far,I've found ammonium chloride 10lb.for $15.00 +$11.00 shipping,(26-0-0 whats' this?)99% on ebay from alphachem08,auction #370467918571. Also zinc chloride crystals 3Kg(6.6lb.?)for $99.95+$24.95 shipping from billythec,auction #390367239929.One other ammonium chloride 99% powder,2lb.@$14.00,free shipping from pmproducts1,auction #160665310575.Hope this helps
 
#30 · (Edited)
Yes it does thanks. So for the folks in the States it likes you're set to go! However, for those of us in Canada I haven't yet found a source for the zinc chloride (billythec won't ship outside the US) and EU supplier won't either (although am I wrong?....I'll check as well by contacting pure-domestic-chemistry).