Demonstration and Validation of Brush LHE Alkaline Zn-Ni as a Brush Cadmium (Cd) Alternative

Low Hydrogen Embrittlement (LHE) Alkaline Zinc-Nickel (LHE alkaline Zn-Ni) tank plating has been studied and demonstrated as a superior alternative to Cd from a performance, environmental, and occupational health perspective.  This has resulted in widespread implementation of immersion-based LHE alkaline Zn-Ni across the US Air Force (USAF) and Navy in lieu of Cd.  This has increased corrosion protection while decreasing exposure to carcinogens and reducing environmental pollutants.  There are, however, still applications where it is more practical and sometimes necessary to perform brush plating of alkaline Zn-Ni rather than immersion.    ES3 has developed two brush Zn-Ni chemistries and an improved processing technique under USAF phase I and Phase II efforts. This NAVAIR phase II.5 SBIR effort will optimize the chemistries and the processing technique, determine their reusability limits, and down-select the top performing method utilizing typical quality, adhesion, corrosion, and hydrogen embrittlement testing.  Validation testing will then be conducted utilizing an array of testing including quality, mechanical, corrosion, durability, and demonstration/validation testing. Furthermore, this effort includes development of technical data, process specification, and training.  All of this serves to transition the brush alkaline Zn-Ni process throughout the DoD to better sustain legacy assets and protect military service men and women.