Validation of Low Hydrogen Embrittlement (LHE) Alkaline Zinc Nickel Electroplating for Steel and Aluminum Electrical Connectors, Back-Shells and Components

Many of the US Department of Defense (DOD) electrical connectors, back-shells and components currently contain cadmium (Cd).Cadmium is a known carcinogen.Furthermore, the cadmium is typically conversion coated with a hex-chromate which is also hazardous.Both the cadmium plating process and its subsequent conversion coating have been proven to be toxic (unlike other processes such as chromium plating, where a hazardous process yields a non-hazardous coating).Consequently, in Phase I of AF161-007 ES3 has developed a plating process utilizing LHE alkaline Zn-Ni solution with non-hex chromate conversion coating which can be utilized on electrical components made from both aluminum and steel substrates. The ES3 LHE alkaline Zn-Ni plating process is showing excellent performance results in Phase I based upon feasibility testing to date for adhesion, corrosion protection, lubricity and conductivity testing; producing a coating that performs as good as or better than cadmium plating.In Phase II, ES3 will conduct testing identified in the Phase I effort to accomplish successful development and validation required for future implementation of the LHE alkaline Zn-Ni plating process developed in Phase I of this project for replacing cadmium plating on aluminum and steel electrical connectors, back-shells and components.