Nickel plating

Nickel plating is an electrolytic process in which a thin layer of nickel is deposited on a metal surface. It can be used as a finishing process and as a base for other surface treatments such as chrome. Due to the many advantages it offers, nickel plating is used in various industries, including the electrical industry.

First, the metal components must be properly prepared – that is, cleaned and degreased using etching and pickling, which help remove oxides and rust from their surfaces. The parts are then placed in baths containing an electrolyte solution with nickel salts at the KNK zamac plant. When a direct electric current is applied, nickel ions migrate and fall on the surface of the cathode, forming a uniform layer of nickel. The thickness of the coating is controlled by the current density, the composition of the bath and the plating time. Depending on the requirements, the coatings can range from thin decorative layers to thick, highly resistant technical coatings designed for extreme operating environments.

The primary goal of nickel plating at the KNK zamac plant is to enhance the performance, functional properties and appearance of metal components. The resulting coating is characterized by high corrosion resistance, hardness and aesthetically pleasing shine. The properties of nickel plating can vary depending on the process used and the conditions of use. In many cases, nickel plating serves as an intermediate layer – for example, under decorative chrome layers to enhance appearance and wear resistance, or as a base for precious metal layers – ensuring their excellent long-term adhesion.

Nickel electroplating can be performed on a variety of materials, primarily metals. Coating a component with nickel provides better corrosion protection and improves its durability and appearance. Common applications include:

• Nickel plating of copper: to increase chemical and mechanical resistance (e.g. to abrasion) or to improve aesthetics.
• Nickel plating of aluminum: to increase corrosion and wear resistance and achieve better adhesion for subsequent plating layers.
• Nickel plating of steel: to provide greater resistance to corrosion, wear and aggressive environments. Nickel is known for its excellent resistance to oxidation and rust.
• Zinc nickel plating: offers corrosion protection and enhances the appearance of components.

Nickel plating processes at the KNK zamac plant are carried out depending on technical and aesthetic requirements. The main advantages include:

• Increased resistance to corrosion and oxidation: The nickel coating creates a protective barrier that protects the metal component not only from moisture but also from chemicals.
• Good thermal stability of nickel surfaces
• Surface hardening: Nickel has high hardness and wear resistance, making it suitable for components exposed to significant mechanical loads
• Improved aesthetics: Nickel plating gives the metal surface a sleek, shiny appearance.
• Excellent adhesive strength: Nickel plating ensures strong adhesion to coated surfaces.
• Solderability and weldability: Nickel plating significantly facilitates further processing of the component, e.g. by soldering.

All these advantages of electrolytic nickel plating are applicable in many industries such as automotive, energy, electronics, defense, jewelry, medical and even aerospace.

In the energy sector, nickel plating is widely used for components that must withstand the effects of environmental conditions, chemicals and long-term protection against oxidation. Examples of such elements include fasteners, switchgear components, structural elements, screws to increase performance and contact reliability.

Although nickel plating is versatile, it comes with some challenges. Surface preparation is critical – any contamination can lead to poor adhesion or blistering. Maintaining precise control over the electrolyte bath composition, pH and temperature is necessary to avoid problems such as internal imbalance, embrittlement or resulting uneven thickness. Nickel plating also faces environmental and health regulations as some nickel compounds can be hazardous and allergenic and require strict waste treatment and safety precautions.

Proper care is essential to maintain the protective and aesthetic properties of nickel coatings. Nickel surfaces should be cleaned regularly with mild detergents and non-abrasive cloths to prevent scratching. Exposure to strong acids, alkalis or chlorides should be minimized as they can damage the coating. For decorative items, regular polishing helps maintain the metallic luster, while industrial components may benefit from additional protective topcoats or sealants. With proper maintenance, nickel surfaces can maintain their long-term protection and appearance.

At KNK zamac, we offer electrolytic nickel plating on components manufactured in-house from the zinc alloy Zamak 5, which we cast by die casting on FRECH machines, or externally supplied metal parts, which are then, after thorough pre-treatment if they are not already copper-plated, first copper-plated in cyanide copper in a fully automated galvanic line, and if necessary, then in acid copper for a more perfect surface smoothing, and only then do we proceed through activation to nickel plating, while we can offer clients various copper thicknesses and of course nickel thicknesses – from 3 μm to 40 μm. We also make galvanic black nickel to order.