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Zinc-Nickel Plating

Electroplating & electroless plating · Electrolytic bath

Zinc-nickel is a sacrificial alloy electrodeposit used on steel where plain zinc is insufficient.

CNC machiningSheet metalStandard cost $$Conductive
Quote a part with Zinc-nickelCompare electroplating & electroless plating
Zinc-Nickel Plating on a machined part

What is Zinc-nickel?

Modern automotive systems target 12–15% nickel, usually at 5–15 µm plus passivate and sealer.

How it works

Parts are cathodically plated from an alkaline or acid bath containing zinc and nickel ions. Process control holds the alloy near 12–15% nickel, where corrosion resistance is strongest. A trivalent passivate and often an organic or inorganic sealer complete the system. Like all electrodeposits, current crowds at edges and weakens in recesses, so rack design, auxiliary anodes, and measurement locations matter.

Why specify it

  • Typically 720–1000 h to red rust for qualified 12–15% Ni systems
  • Only 5–15 µm metallic deposit for precision steel parts
  • Better heat and corrosion performance than plain zinc
  • Sacrificial protection remains after minor scratches

Where it falls short

  • Alloy percentage must be tightly controlled
  • Electrolytic thickness is nonuniform in deep recesses
  • Hydrogen embrittlement controls remain necessary
  • Black passivates may perform differently from clear systems

Zinc-nickel at a glance

Zinc-nickel is strongest on corrosion protection (86 of 100), at a standard cost.

Corrosion protectionExcellent86 / 100
Surface hardnessGood60 / 100
Cosmetic qualityFair48 / 100
LubricityLow28 / 100
Relative costStandard30 / 100
CorrosionHardnessCosmeticLubricityEconomy

Each score is 0–100 against every finish in this catalog. Corrosion comes from salt-spray life (ASTM B117, log scale) and hardness from the finish layer's Vickers or pencil hardness; cosmetic, lubricity and cost are FabDigit's engineering assessment. Economy on the radar is the inverse of cost.

Zinc-nickel key numbers

Typical values from the governing specifications and shop practice; bars are this finish against the highest value among electroplating & electroless plating finishes.

Thickness5–15 µm0.2–0.59 mil
Hardness350–500 HV
Salt spray720–1,000 h
Max service temp.120 °C248 °F
Thickness
8–12 µm zinc-nickel containing 12–15% nickel, plus passivate and optional sealer
Hardness
350–500 HV — Typical for 12–15% nickel zinc-alloy deposits; not normally the primary acceptance test.
Corrosion (salt spray)
720–1,000 h per ASTM B117 for a qualified zinc-nickel/passivate/sealer system — Typical red-rust targets used by automotive specifications; exact requirement is system and OEM specific.
Electrical
Conductive
Colours
  • clear
  • black
Appearance
Silver-gray or black depending on passivate and sealer.

Where Zinc-nickel sits among all finishes

Surface hardness (Vickers, log scale) against corrosion protection (salt-spray hours, log scale) for every coating FabDigit offers, one cloud per finish group. Zinc-nickel is highlighted; hover a dot for its name or open the full map.

02550751000255075100Corrosion protection (0–100)Surface hardness (HV, log scale, 0–100)Plating — 19 finishesHard coatings — 17 finishesAnodize & conversion — 8 finishesPaint & powder — 7 finisheshard, low corrosion protectionhard and protectiveprotective, softsoft, little protectionType II anodize — corrosion 71, hardness 54BSA anodize — corrosion 71, hardness 52Type I anodize — corrosion 71, hardness 49Hard anodize — corrosion 71, hardness 61PTFE hard anodize — corrosion 71, hardness 61Nitriding — corrosion 55, hardness 73PEO — corrosion 70, hardness 74Sherardizing — corrosion 83, hardness 56Brass plate — corrosion 35, hardness 44Bronze plate — corrosion 40, hardness 49Cadmium plate — corrosion 70, hardness 26Copper plate — corrosion 32, hardness 39Decorative chrome — corrosion 64, hardness 71Electroless copper — corrosion 20, hardness 41Electroless nickel — corrosion 70, hardness 68Nickel plate — corrosion 51, hardness 55Gold plate — corrosion 68, hardness 39Hard chrome — corrosion 40, hardness 73Hot-dip zinc — corrosion 90, hardness 42Nickel-PTFE — corrosion 72, hardness 57Silver plate — corrosion 55, hardness 39Solder plate — corrosion 42, hardness 9Tin plate — corrosion 34, hardness 0Zinc plate — corrosion 60, hardness 30Cerakote — corrosion 83, hardness 27E-coat — corrosion 83, hardness 15Epoxy coat — corrosion 83, hardness 15Powder coat — corrosion 83, hardness 14Wet paint — corrosion 59, hardness 10AlCrN PVD — corrosion 58, hardness 93AlTiN PVD — corrosion 52, hardness 94CrN PVD — corrosion 62, hardness 83DLC — corrosion 55, hardness 93MoS2 PVD — corrosion 20, hardness 26TiAlN PVD — corrosion 50, hardness 93TiCN PVD — corrosion 40, hardness 92TiB2 PVD — corrosion 40, hardness 94TiN PVD — corrosion 45, hardness 87WC/C PVD — corrosion 48, hardness 77ZrN PVD — corrosion 52, hardness 90CVD alumina — corrosion 70, hardness 85CVD TiCN — corrosion 38, hardness 92CVD TiN — corrosion 45, hardness 87Multilayer CVD — corrosion 62, hardness 88HVOF coating — corrosion 78, hardness 77Plasma spray — corrosion 60, hardness 68Plastic chrome — corrosion 72, hardness 71Electroless plastic — corrosion 58, hardness 39Clear coat — corrosion 20, hardness 12Soft-touch — corrosion 20, hardness 5PLATINGHARD COATINGSANODIZE & CONVERSIONPAINT & POWDERZinc plateType II anodizePowder coatHard chromeDLCTiN PVDTin plateCadmium plateE-coatCerakoteWet paintHot-dip zincNitridingHVOF coatingZinc-nickel — corrosion 86, hardness 60Zinc-nickel
02550751000255075100Corrosion protection (0–100)Surface hardness (HV, log scale, 0–100)Plating — 19 finishesHard coatings — 17 finishesAnodize & conversion — 8 finishesPaint & powder — 7 finishesType II anodize — corrosion 71, hardness 54BSA anodize — corrosion 71, hardness 52Type I anodize — corrosion 71, hardness 49Hard anodize — corrosion 71, hardness 61PTFE hard anodize — corrosion 71, hardness 61Nitriding — corrosion 55, hardness 73PEO — corrosion 70, hardness 74Sherardizing — corrosion 83, hardness 56Brass plate — corrosion 35, hardness 44Bronze plate — corrosion 40, hardness 49Cadmium plate — corrosion 70, hardness 26Copper plate — corrosion 32, hardness 39Decorative chrome — corrosion 64, hardness 71Electroless copper — corrosion 20, hardness 41Electroless nickel — corrosion 70, hardness 68Nickel plate — corrosion 51, hardness 55Gold plate — corrosion 68, hardness 39Hard chrome — corrosion 40, hardness 73Hot-dip zinc — corrosion 90, hardness 42Nickel-PTFE — corrosion 72, hardness 57Silver plate — corrosion 55, hardness 39Solder plate — corrosion 42, hardness 9Tin plate — corrosion 34, hardness 0Zinc plate — corrosion 60, hardness 30Cerakote — corrosion 83, hardness 27E-coat — corrosion 83, hardness 15Epoxy coat — corrosion 83, hardness 15Powder coat — corrosion 83, hardness 14Wet paint — corrosion 59, hardness 10AlCrN PVD — corrosion 58, hardness 93AlTiN PVD — corrosion 52, hardness 94CrN PVD — corrosion 62, hardness 83DLC — corrosion 55, hardness 93MoS2 PVD — corrosion 20, hardness 26TiAlN PVD — corrosion 50, hardness 93TiCN PVD — corrosion 40, hardness 92TiB2 PVD — corrosion 40, hardness 94TiN PVD — corrosion 45, hardness 87WC/C PVD — corrosion 48, hardness 77ZrN PVD — corrosion 52, hardness 90CVD alumina — corrosion 70, hardness 85CVD TiCN — corrosion 38, hardness 92CVD TiN — corrosion 45, hardness 87Multilayer CVD — corrosion 62, hardness 88HVOF coating — corrosion 78, hardness 77Plasma spray — corrosion 60, hardness 68Plastic chrome — corrosion 72, hardness 71Electroless plastic — corrosion 58, hardness 39Clear coat — corrosion 20, hardness 12Soft-touch — corrosion 20, hardness 5PLATINGHARD COATINGSANODIZE & CONVERSIONPAINT & POWDERZinc platePowder coatZinc-nickel — corrosion 86, hardness 60Zinc-nickel
Anodize & conversionPlatingPaint & powderHard coatings

Specifications for Zinc-nickel

The documents a drawing cites to define this finish, with the Type / Class rows that apply. Each links to a page explaining the standard.

StandardType / ClassThicknessRequirement / testStatus
ASTM B841
Standard Specification for Electrodeposited Coatings of Zinc Nickel Alloy Deposits · ASTM
Class 1—Zinc-nickel deposit with 5–12 mass % nickel. · Nickel composition.Active

Test and related methods: ASTM B117 (Standard Practice for Operating Salt Spray (Fog) Apparatus), ASTM B850 (Standard Guide for Post-Coating Treatments of Steel for Reducing the Risk of Hydrogen Embrittlement).

Drawing call-out

ZINC-NICKEL PLATE PER ASTM B841, 12–15% Ni, 10 µm MIN, CLEAR TRIVALENT PASSIVATE AND SEALER; BAKE PER ASTM B850

Pattern: ZINC-NICKEL PLATE PER ASTM B841, CLASS <CLASS>, GRADE <5|8|10>, TYPE <A|B|C|D|E><HEXAVALENT STATUS>

Which materials take Zinc-nickel?

Verdict per material family, with the grades that behave differently. Each family links to its datasheets in the material library.

Material familyVerdictNotes
Steel
YesPrimary substrate.
  • High-strength fasteners need embrittlement controls.
DMLS / SLM
With careSteel AM parts after porosity review; apply ASTM B850 baking when strength requires it.
Aluminum
LimitedNot a standard aluminum finish; the steel fastener is usually the plated member.
Brass
LimitedRarely specified on brass.
Copper Alloy
LimitedPossible but uncommon versus nickel or tin systems.
Stainless Steel
LimitedRequires activation and is rarely the preferred system.
Zinc Alloy
LimitedPossible on some die castings after a strike.
FDM
NoFused-filament polymers are incompatible with this process.
Magnesium Alloy
NoIncompatible.
MJF
NoPolymer powder-bed prints are incompatible with this process.
Polymer
NoOrganic polymers cannot take this inorganic metal-finishing process.
SLA
NoPhotopolymer prints are incompatible with this process.
SLS
NoPolymer powder-bed prints are incompatible with this process.
Titanium
NoTitanium is not zinc-nickel plated.

How Zinc-nickel is applied, and what it does to the part

  1. 1Clean
  2. 2Pickle or activate
  3. 3Electroplate zinc-nickel
  4. 4Rinse
  5. 5Trivalent passivate
  6. 6Seal
  7. 7Embrittlement-relief bake when required
  8. 8Test alloy and thickness
DimensionsAllow 5–15 µm per plated side and identify low-current-density measurement locations.
Build-up per side5–15 µm — Local buildup follows current density; edges are thicker than recesses.
MaskingUsually needed. Mask precision threads, bores, and contact areas; define torque-tension requirements for fasteners.
ElectricalConductive
Temperature limit120 °C (248 °F) continuous
AppearanceSilver-gray or black depending on passivate and sealer.
Added lead time3–7 working days on top of the bare part

Design rules for Zinc-nickel

What to decide on the drawing before the part goes to the finisher.

  1. Specify 12–15% nickel.Corrosion performance depends on alloy composition.
  2. Name the passivate and sealer.The metallic layer alone does not define salt-spray performance.
  3. Control fastener friction.Sealers change torque-tension behavior.
  4. Apply ASTM B850 controls to susceptible steel.The electrolytic process can charge hydrogen.

Zinc-nickel versus the alternatives

Finishes engineers weigh against Zinc-nickel, and when each wins.

FinishCorrosionHardnessCosmeticCostThicknessChoose it when
Zinc-nickel
this page
866048$$5–15 µm—
Zinc Plating
Zinc-nickel vs Zinc Plating →
603055$5–25 µmwhen moderate corrosion performance and lowest cost govern
Zinc-Flake Dip-Spin Coating
Zinc-nickel vs Zinc-Flake Dip-Spin Coating →
85—35$$$6–15 µmwhen avoiding electrolytic hydrogen charging is critical
CorrosionHardnessCosmeticLubricityEconomy
Zinc-nickelZinc Plating

The radar overlays Zinc-nickel with Zinc Plating, its most common alternative — chosen when moderate corrosion performance and lowest cost govern. Scores in the table are 0–100 across every finish in the catalog.

Cost, lead time and compliance

Relative cost

Zinc-Nickel Plating is a standard-cost finish ($$): cheaper than about 67 % of the finishes FabDigit quotes.

Finishing is priced per part with a lot minimum, from FabDigit's own China-side rates cross-checked against US job-shop pricing. The exact figure appears on the instant quote once the part is uploaded.

Lead time and compliance

Added lead time3–7 working days
RoHSCompliant
NotesSpecify trivalent passivation; nickel-containing wastewater and worker exposure require controls.

What Zinc-nickel is used for

  • Brake components
  • Underbody fasteners
  • Marine fasteners
  • Hydraulic fittings

Zinc-nickel — frequently asked

zinc nickel plating vs zinc plating

Zinc-nickel at 12–15% Ni and 5–15 µm commonly reaches 720–1000 h system targets to red rust. Plain zinc is cheaper but usually provides substantially shorter protection at comparable thickness.

how thick is zinc nickel plating

A common engineering range is 5–15 µm, with 8–12 µm frequently specified. Passivate and sealer are additional thin layers and must be named separately.

what percent nickel is zinc nickel plating

High-performance alkaline zinc-nickel systems are normally controlled at 12–15% nickel by mass. Lower alloy contents do not provide the same corrosion behavior.

does zinc nickel plating cause hydrogen embrittlement

Yes, cleaning and electrodeposition can introduce hydrogen into susceptible high-strength steel. Specify prompt relief baking and process controls under ASTM B850 or the product specification.

can zinc nickel plating be black

Yes, a black trivalent passivate can follow the 12–15% nickel deposit. Validate corrosion and coefficient-of-friction requirements because black and clear post-treatments are not automatically equivalent.