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Online zinc/nickel plating bath analysis with
Maintaining a stable plating bath composition is essential for achieving consistent electroplating results. Any variation in the chemical balance of the bath can directly impact coating quality, leading to defects, rework, and increased production costs. In industries such as automotive, aerospace, and marine manufacturing, where corrosion resistance is critical, even small inconsistencies can have serious consequences for component performance and longevity.
Zinc-nickel (Zn/Ni) coatings are widely used for corrosion protection due to their superior performance compared to pure to harsh environments. However, maintaining the correct ratio of zinc to nickel in the plating bath is vital to achieving these Traditionally, plating bath analysis has relied on laboratory-based techniques such as titration, atomic absorption spectroscopy (AAS), or inductively coupled plasma optical emission spectroscopy (ICP-OES). While accurate, these methods are time-consuming and require manual sampling. This creates a delay between sampling and results, meaning operators are often making decisions based on outdated information. As a result, process adjustments may come too late to prevent defects or
To overcome these limitations, real-time analytical technologies are increasingly being adopted. One such solution is the Metrohm continuously monitor zinc and nickel concentrations directly within the plating process. This online approach provides immediate insights into bath composition, allowing operators to respond quickly to any changes.
Electroplating works by passing an electric current through a solution containing dissolved metal ions, depositing a thin metallic layer onto a substrate. In Zn/Ni plating, both alkaline and acidic bath types are used. Alkaline baths are known for producing acidic baths typically offer faster deposition rates and brighter conditions is key to consistent results. in workload. These changes can alter metal ion concentrations and affect deposition rates. Without frequent monitoring, it
The 2060 XRF Process Analyzer addresses this challenge by providing continuous, automated measurement of zinc and nickel levels. The system draws a sample from the process stream into a tungsten tube. This causes the elements in the sample to emit determine their concentrations.
The analyser is calibrated using known standards to ensure 6.5–9.5 g/L for zinc and 0.5–2.5 g/L for nickel. This calibration process ensures reliable and repeatable results, giving operators
One of the key advantages of real-time monitoring is the ability to make immediate process adjustments. Instead of waiting for laboratory results, operators can respond instantly to deviations,
Illustration of a typical zinc plating process
helping to maintain the correct bath composition at all times. This leads to improved coating consistency, reduced waste, and lower operating costs.
In addition to improving product quality, continuous analysis also sampling and handling of potentially hazardous chemicals, the time and resources.
The use of process analytical technology (PAT), such as the 2060 parameters, PAT systems enable a more proactive approach to process management, reducing variability and improving overall performance.
In summary, real-time monitoring of zinc and nickel concentrations offers clear advantages over traditional methods. manufacturers can achieve greater control, ensure consistent costs but also supports the production of high-performance components that meet the demands of modern industry.
METROHM
https://www.metrohm.com JANUARY 2021 | PROCESS & CONTROL 33 MARCH 2026 | PROCESS
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