Zinc-nickel coatings have become more important in recent years. The deposited layers are characterized by their high corrosion resistance, even under condition with high temperatures.
When using alkaline electrolytes, decomposition products are formed which lead to a reduction in efficiency and thus in the deposition rate. This result in longer exposure times and thus higher coating costs. Membrane technologies, special anode technology or regular dilution of the electrolyte are common methods, to avoid or reduce the formation of these disruptive components.
DIPSOL’s latest development for barrel application offers the solution for the increasing demands in terms of economy and performance of modern zinc-nickel processes. A consistently high degree of efficiency is achieved without additional expenses.
The process is characterized by a significantly reduced concentration of the bath ingredients. Notable cost savings can be achieved thanks to the reduced drag-out losses and the resulting reduced waste water load.
The unique composition of the IZ-252 SIMPEX electrolyte leads to a significant reduction in the working voltage during coating. As a result, considerable savings (up to 30%) can be achieved in terms of energy use, both when coating and the corresponding cooling demand.
With the appropriate system configuration, the consistently high level of efficiency also enables short coating times or respectively additional energy savings by reducing the working current.
In addition to the economic advantages, the process also offers outstanding technical advantages comparing existing systems. Above all, the extraordinary behavior regarding the covering power of the process in the case of problematic base materials should be emphasized. Maintenance is carried out with just one additive (single shot). The nickel incorporation rates are stable even with variations in the process parameters. All ingredients can be fully analyzed.
Due to the low metal concentrations, a significantly improved throwing power and thickness distribution is achieved. The increased layer thickness in low current density ranges can be the decisive advantage, especially in the climate change test increasingly used by the automotive industry (e.g. PV 1209, ACT 2).
Furthermore, due to the low organic content, uniform deep black, highly corrosion-resistant layers can be achieved with the passivation from DIPSOL.
We would be happy to discuss your savings potential with you and look forward to hearing from you.