TECHNICAL DATA SHEET

ZINCALUME NiZ 851 PROCESS

A unique zinc nickel alloy plating with nickel content 6-10%
Zincalume NiZ 851 process is an alkaline non-cyanide zinc-nickel plating process suitable for both rack and barrel
plating process. Zincalume NiZ 851 process produces bright zinc-nickel deposits (6-10% nickel in deposit). It has a
broad working window and excellent throwing and covering power. The deposit obtained using Zincalume NiZ can be
easily passivated by using special chromating solution to obtain blue, yellow and black colouration wherever it may be
required.

SALIENT FEATURES :
1. Low nickel ~zinc nickel alloy - Zinc: 90 to 94%., Nickel: 6-10%

2. Ductility - Much better than other contemporary process - high nickel ~ Zinc nickel alloy

3. Better chromatibility - ideal for components which undergoes dimension changes during post plating
assembly stage.

4. Corrosion ressistance - Passes automotive requirement.

5. Broad ‘operating window’ with excellent throwing and covering power - Suitably applicable in both rack and barrels
with excellent metal distribution.

A major step forward towards ‘resistance movement’ in automotive sector. It superb throwing power also improves metal
distribution which is responsible for getting good covering even on shadowed areas without using the auxiliary anode.

SOLUTION MAKE – UP :
Unit Range Optimum

*Zincalume NiZ Make Up Solution ml/l 400 – 500 450

Zincalume NiZ 851 ml/l 4–7 6

Zincalume NiZ 852 ml/l 90 – 120 100

Zincalume NiZ 853 ml/l 0.2 – 2.0 1

Zincalume NiZ 855 ml/l 0.5 – 2 1

* Solid version of the salt namely Zincalite NCZ 106 Salt is also available. Sufficient care should be taken to use this
powdered component as the reaction becomes exothermic when dissolved in DM water. Addition of 150 g/l of Zincalite
NCZ 106 Salt will provide Zn = 10 g/l and Caustic Soda = 120 g/l in the operating solution.

ZINCALUME NiZ 851 PROCESS 1 of 7

BATH PARAMETERS AND OPERATING CONDITIONS :
UNIT OPTIMUM
Rack Barrel
Zinc Metal g/l 8 - 10 10-12

Sodium Hydroxide g/l 130-160 130-160

Nickel g/l 0.5 - 0.7 0.5 - 0.7

Ratio Zinc : Nickel 12-16:1 12-16:1

*Temperature ºC 20-30 20-30

Current Density Amp/dm2 1.5 1.0

Voltage Volt 3-6 10 - 14

Current Loading Amp/l 0.7 Max. 0.7 Max.

Anode Material Nickel plated mild steel ( recommended thickness of Nickel : > 25 µm)

or electrolytic nickel.

Anode to Cathode Area 1 : 1 to 2 : 1 1 : 1 to 2 : 1

Agitation Cathode agitation of 3 – 5 m/min. Low air agitation is also possible.

Barrel rotation should be 3 – 5 rpm.

Filtration Continuous filtration is recommended.

Rate of deposition 0.15 – 0.18 µm/min at 1 Amp/dm2.

Note:
* For successful operation in barrel the temperature control is very much essential. Maintenance of correct bath
temperature is critical to keep proper nickel content in the deposit. To avoid frequent temperature build- up, it is
recommended higher volume of working bath as compared to applied coulombs. An average of 0.4 amp/l of working
solution should be ideal and helpful. Continuous solution circulation to a bigger separate tank to achieve more ‘heat loss’
would be of helpful for better maintenance of working temperature.

* Lower anode area should be preferable to control the over build up of carbonate.

SOLUTION PREPARATION FOR 100 LITRE OF WORKING BATH :

1. Take 50 lit. of D.M. water and add 45lit. of Zincalume NiZ Make Up solution with continuous stirring.
Caution : Wear Protective clothing and face shield while handling this make-up solution.

2. Add D. M water to make-up 80 % of bath volume and stir to make complete homogeneous mixture and allow to
settle for 2 to 3 hrs.

Then filter the solution through suitable cartridge filter unit, alternatively, normal filter unit with 5-10 µm
polypropylene filter cloth without using filter paper can also be used.

Note : if the temperature of the working solution exceeds > 65ºC, do not operate filter with polypropylene filter
cloth

3. Add Zincalume NiZ addition agents as follows

*Zincalume NiZ 851 ml/l 6

*Zincalume NiZ 852 ml/l 100
Zincalume NiZ 853 ml/l 1
Zincalume NiZ 855 ml/l 1

ZINCALUME NiZ 851 PROCESS 2 of 7

*Caution :
Always premix Zincalume NiZ 851 and 852 prior making addition to the working bath. Even for the
regular maintenance the required quantity of Zincalume NiZ 851 should be mixed with proportionate amount of
Zincalume NiZ 852 and the resultant mixture can be added to the working bath.

4. Fill up the bath to the desired volume with the amount.

5. Electrolyse the bath at 0.05 amp/l for 4 to 8 hours.
6. Use the solution for normal plating, with regular brightener replenishment.

PRE-PLATE TREATMENT :
Since the contamination tolerance of alkaline non-cyanide zinc bath is relatively poor as compared to acid chloride zinc
so cleaning cycles must be similar to those for acid chloride or bright nickel plating process. The quality of deposit
obtained depends upon the proposed pre-treatment sequence. Use of non-ionic surfactants is highly recommended
throughout the preparation sequence. Frequent checks of cleaner, acid pickle concentrations and temperature are
recommended.

An alkaline dip containing 25 to 45 g/l of sodium hydroxide is highly recommended immediately prior to the plating tank
to neutralize any acid film on the surface of the metal.

PROCESS SEQUENCE : For steel, following sequence is recommended :

Immersion clean Groclean MS / Steelex K-20 / Metaprep Act
Pickle Hydrochloric acid (50%)
Electro - clean Ginbond 808
Activation Hydrochloric Acid (5%) (only when necessary)
Pre-dip Static rinse prior to zinc plate completes the pre treatment by an alkaline
immersion, in 25-45 g/l caustic soda solution.

EQUIPMENT

All equipment must be thoroughly cleaned prior to use.

1. Tank: Mild Steel - suitably lined.

2. Anodes : Nickel plated mild steel (0.0008”/20 µm) or electrolytic nickel (99.99 % purity). Zinc is
replenished by galvanic dissolution in a steel tank that is external to the plating tank.
High purity zinc anodes (99.99% Zinc) are dissolved in nickel-plated (0.0008”/20 µm)
steel baskets in about 10% of the volume of the plating solution. It is important to
ensure a large surface area of nickel plated steel in contact with the zinc in order to
drive the dissolution of zinc. This concentrated zinc solution is pumped back into the
plating tank at a suitable rate to maintain the desired zinc concentration. Zinc should
be replenished by an out of circuit zinc generation tank.

3. Agitation : Air (oil free) agitation must be slow and regular, the tube bank must be located at the
base of the tank, the bubbles generated should pass between anode and cathode,
deposit brightness increases by air agitation. Mechanical - vertical or horizontal cathode
- rod movement (3 – 5 m/min., stoke > 5cm)

4. Filtration : Continuous at the rate of 2 - 3 tank turn overs per hour. Use Plate or cartridge filter of
porosity 10 µm optimum. Filtration is necessary to obtain full brightness, presence of
suspended particles will lead to mat deposit and risk of blistering.

5. Fume Extraction
System : Desirable. It is also recommended to have sufficient space between tank and roof of
the plant, for better maintenance of working environment. Ventilation towards opposite
side of the fume extraction system will be an ideal for ‘positive flow’.

6. Heating Coil &

Cooling : Steel or titanium (20-30ºC).
ZINCALUME NiZ 851 PROCESS 3 of 7
FUNCTIONS OF BATH CONSTITUENTS :
Zincalume NiZ Make Up Solution :
It contains suitable grade of zinc and sodium hydroxide at its optimum level. Eliminates the operational hazards of the
dissolution of salts and or creation of separate zinc dissolution tank which is very much time consuming.Addition of
450 ml/l Zincalume NiZ Make Up solution will provide zinc 10 g/l and caustic soda 130 g/l in the operating solution.

Zincalume NiZ 851 :

It maintains the nickel content in the electrolyte. In the long storage this product tends to form some ‘insoluble precipitates’.
If precipitation is formed it will be advisable to filter the same before addition, in such a situation the consumption will
increase proportionately. However to minimize, it is suggested to mix with Zincalume NiZ 852 in the ratio 4:1 (i.e. 4 lit.
of Zincalume NiZ 851 should be mixed with 1 lit. of Zincalume NiZ 852).

Zincalume NiZ 852 :

It is used to solublize nickel in the operating alkaline solution.

Zincalume NiZ 853 :

It is a brightening additive and responsible for brighter deposit.

Zincalume NiZ 855 :

Improves brightenss and also eliminates the dark deposits in low current density areas.

SOLUTION MAINTENANCE AND OPERATION

Operating electrolyte should be maintained by periodic analysis for bath constituents – Zinc, Sodium Hydroxide and
Nickel. It is also recommended to carry out regular Hull Cell Test which will give an indication of proper maintenance of
Zincalume NiZ 851, 852, 853 and 855. Lower maintenance of zinc would change the alloy composition at different
current density area. It affects the proper adherance towards post plating chemicals, whereas excess would facilitate
burning / dull deposition at high current density. Similarly, lower concentration of caustic soda would affect the low
current density performance whereas, higher concentration will cause excessive gassing which may sometime becomes
root cause for blister formation.

Zinc metal should be maintained by connecting out of the circuit zinc generation tank. In this case a separate tank is
kept out side the plating line wherein concentrated caustic soda solution is used (120 – 140 g/l). Zinc slabs / balls
(Purity : 99.99% Min., free from lead and copper) should be kept in steel basket and necessary precautions should be
taken to ensure that zinc slabs / balls must be in constant contact with the steel basket and these are fully immersed in
the caustic soda solution. Mild air agitation or preferably, solution movement is recommended to circulate this Zincate
solution uniformly through out the tank. In absence of this solution movement, a hard crust of Zinc Oxides / Hydroxides
is formed on the zinc slabs / balls which inhibits further zinc dissolution. In this separate bath the Zincate solution will be
produced and the proportionate quantities of the same can be added to maintain the zinc metal content in the operating
electrolyte. It is also possible to maintain the constant flow of operating solution into this zinc generation tank (in this
case the volume of this tank should be approx 20 – 30% of the operating tank.). Flow rate and other accessories should
be designed in such a way so that the solution level and bath constituents are maintained uniformly.

Caustic Soda should also be maintained to obtain desired performance.It is always recommended to dissolve the
Caustic Soda separately prior making addition to the tank and also, it should be added at small installments (preferably
once a day at the end of the shift rather than making large addition at a time).

Nickel content should also be analysed by suitable atomic absorption spectrophotometer or following the process given
herewith. This should be maintained in the working bath by adding requisite quantities of Zincalume NiZ 851 in premixed
with Zincalume NiZ 852. Large excess of nickel solution may lead to the blisters in the deposit and hence, the nickel
content in the solution should be maintained to its optimum limit.

BRIGHTENER REPLENISHER:

CHEMICALSMAINTENANCE
Zincalume NiZ 851 350 – 550 ml/KAH Both products should be premixed in desired proportion & then,
it should be added to the working solution
Zincalume NiZ 852 250 – 350 ml/KAH
Zincalume NiZ 853 100 – 300 ml/KAH
Zincalume NiZ 855 100-300 ml/KAH
However the above addition may vary depending upon the work requirement and so also on the plant layout.

ZINCALUME NiZ 851 PROCESS 4 of 7

CAUTION :
Non cyanide alkaline zinc-nickel plating process using Zincalume NiZ 851 system is having less cathode efficiency
(approx. 50 – 70%), so gas evolution may takes place.

POST PLATE TREATMENT

Chromate conversion coatings ranging from clear-blue to yellow to black may be applied to the zinc nickel deposit
obtained with the Zincalume NiZ 851 process. It is definitely advised to have a dilute nitric acid dip prior to all
chromating process.

Recommended Chromate passivation processes are as follows :

Ginthox NiZ Blue - Trivalent chromium based chromating process - produces blue finish.
Ginthox NiZ Yellow - Hexavalent chromium based chromating process - produces yellow finish.
Ginthox NiZ Black - Hexavalent chromium based silver free chromating process - produces black
finish.
Ginthox NiZ Triblack A & B - Twin additive Trivalent chrome based black passivation process.
Trichrome HB 2200/2202/2203 C- Trivalent chrome based irridescent passivation process.

Process Sequence :
1. Zinc Nickel Plate
2. Cold Water Rinse
3. Neutralization dip - Trichrome NiZ Activation salt (conc. - 50 gm/l) instead of mineral acid e.g. Hydrochloric Acid
4. Cold Water Rinse (optional)
5. Chromate - Dip
6. Cold Water Rinse
7. Zincoseal 605 M: 200- 300 ml/l at 50-60 ºC for 1 min
Aquaguard 401/ 305/500 : 200- 300 ml/l at 28-35 ºC for 1 min
8. Dry

SOLUTION CONTROL

Maintenance additions of Zincalume NiZ 851 brighteners are best determined by conventional hull cell analysis and
visual observation of the work. Regular solution control through hull cell test (2 Amp, 10 min) with solution movement or
cathode rod movement and followed by yellow passivation in Ginthox NiZ Yellow is highly desired to maintain the
optimum concentration of the bath constituents along with its additives. It is however advisable to check the alloy
compositon on different current density range on the passivated hull cell panels by XRF technique. This observation
would help to decide the optimum condition of the additive. Maintain the zinc metal, sodium hydroxide and nickel
contents using the analytical procedures listed follows :

Analysis for Zinc Metal

Apparatus Needed :
2 ml Pipette
50 ml Burette
500 ml Erlenmeyer flask
Reagents Needed :
Buffer solution : 65.5 g/l Ammonium chloride + 142.5 ml/lt Ammonia solution
10% Potassium cyanide
E.B.T. Indicator
0.1 M EDTA
8% Formaldehyde

ZINCALUME NiZ 851 PROCESS 5 of 7

Procedure :
1. Pipette 2 ml sample of the plating bath into a 500 ml Erlenmeyer Flask.
2. Add 150 ml of distilled water and 20 ml of buffer solution (pH 10).
3. Add 5 ml of 10% Potassium cyanide and 20 ml of 8% Formaldehyde.
4. Add a pinch of E.B.T. indicator and titrate against 0.1 M EDTA.
5. Colour changes to rose violet or clear blue.

Calculation :
ml of EDTA titrated × 3.269 × M EDTA
—————————————————— = gm/lit. of Zinc Metal
0.1

Analysis for Sodium Hydroxide

Apparatus Needed :
5 ml Pipette
50 ml burette
100 ml Beaker
pH meter
Flat top magnetic stirrer
Bar magnet
Reagents Needed :
1.0 (N) sulphuric acid (H2SO4) - Carefully add 26.5 ml of AR grade concentrated sulphuric acid to 500 ml of
de-ionized or distilled water. Cool and dilute to 1 litre.

Procedure :
1. Pipette a 5 ml sample of the plating bath into a 100 ml beaker.
2. Add 10 ml 10 percent sodium cyanide solution.
3. Insert properly calibrated pH electrode in the testing solution and keep this beaker on
magnetic stirrer with a magnet.
4. Switch on the magnetic stirrer to start uniform stirring.
5. Switch on the pH read knob and check the pH of the solution.
6. Titrate with 1.0 (N) H2SO4 from burrette untill the pH meter indicates the pH value of 11.0.

Calculation :
No. of ml 1.0 (N) H2SO4 titrated x 8.0 = g/l Sodium Hydroxide.

Analysis for Nickel

Nickel concentration should be measured by Atomic Absorption Spectrophotometer or UV - visible Spectrophotometer.

Reagents Needed :
Saturated bromine water
Ammonia 1:10 (1 part Ammonia : 10 parts DM water)
1% dimethylglyoxime in 1% sodium hydroxide solution.
Procedure :
1. Pipette 5 ml of the operating solution into a 100 ml measuring flask and add distilled water to the level, and then
mix thoroughly.
2. Pipette 1 ml of this diluted plating solution into a 100 ml measuring flask.
3. Pipette 0.1ml of saturated bromine water into the solution and leave it as it is for about 3 minutes. Add another
0.5 ml if yellow color disappears.

ZINCALUME NiZ 851 PROCESS 6 of 7

 4. Drop diluted ammonia and mix until yellow color disappears.
5. Add 2 ml of 1% dimethylglyoxime and stir.
6. Add water to volume and mix thoroughly.
Leave it as it is for more than 30 minute.
Measure absorbance at 450 nm
The concentration of the sample solution is calculated by measuring a standard solution with a known concentration
at the same time.

Calculation :
Absorbance of sample
———————————————— x gm/l of nickel metal standard solution
Absorbance of the standard

= gm/l of nickel metal in sample

CAUTION

Zincalume NiZ Make Up and Maintenance solution, the operating solution of Zincalume NiZ process are strongly
alkaline. Contact with the skin or eyes should be avoided. Proper safety equipment such as rubber gloves and chemical
safety glasses should be used when handling this brightener or the operating solution and essentially while preparing
the solution. In case of contact with the skin or eyes, flush immediately with plenty of cool, clean water for 15 minutes.
For eyes, obtain immediate medical attention.

For more details refer MSD

DISCLAIMER :
Our recommendations are made in good faith and are based on our skills. However, since the conditions of use of these products are beyond our
control, this information is given on the express condition and agreement that
Grauer & Weil (India) Limited, will not be liable to any person by reason thereof. Nothing herein shall be deemed to be a recommendation to use
any product in violation of any existing patent rights.

Issued on : 14.10.14
Supersedes all earlier

ZINCALUME NiZ 851 PROCESS 7 of 7