Plating of Zn-Ni on Aluminum and Steel

The proposed technology addresses the U.S. Air Force need for low hydrogen embrittlement (LHE) Zn-Ni coatings as a replacement for cadmium for electrical connectors, back-shells and aircraft system components. Implementation of Zn-Ni coatings across the Department of Defense will lower processing and waste treatment costs, improve sustainability, and increase readiness. Faraday proposes to demonstrate the feasibility of applying pulse reverse electric fields to control and maintain the functional properties of the Zn-Ni coatings, to meet or exceed the performance of the established cadmium coating. The proposed Phase I effort will demonstrate the feasibility of LHE Zn-Ni alloy coatings on aluminum and steel test parts, and elucidate the advantages of pulse reverse processing on coating performance. The Phase I effort will include a detailed comparison of direct current (baseline) and pulse reverse plating parameters, focus on adhesion of the coating to the substrate, characterization of the functional properties of the coatings, and development of a preliminary technology transition plan. The Phase II effort will build upon this effort to further optimize the functional properties of the coatings, expand the technology to chrome coatings, and validate the process on simulated and full-scale landing gear components and perform a system-level validation test.