ELECTROPLATING PRACTICE MARKED ASSIGNMENT 1

CORROSION AND HARDNESS ASSESSMENT OF COMMON COATINGS USED ON FASTENERS

BEN BATESON

Contents
1 2 3 4 Method Observations before exposure Observations during and after exposure Analysis and potential applications

Method A variety of metallic samples were exposed to a saturated sodium-chloride environment designed to encourage and accelerate corrosion for a period of three weeks. The physical jigging was carried out by cotton thread in a closed 1l glass beaker containing ~300ml of saturated sodium chloride solution. Prior to exposure, samples were ad hoc tested for hardness, first by scratching with a length of hardened steel wire (an unbent paperclip!) and then by a hardened steel scalpel blade. Visual inspection was made of the samples before and after exposure with particular reference to hardness and the extent of corrosion. A magnified inspection was also possible at 20x magnification. Samples used: Steel (exact composition unknown probably stainless) Nickel-plated Zinc-plated Japanned Aluminium Galvanised Brass

Observations before exposure

Under magnification

Item

Appearance (applied scratch marks highlighted)

Light scratch test

Heavy scratch test

Steel

Semi-smooth finish. No obvious defects or inclusions

No mark left on surface.

Light marks seen after pressure applied

NickelPlated

Very smooth and uniform finish

Possible to scratch with pressure.

Deep marks evident.

Zinc-Plated

Reflective but uneven finish, particularly around screw threads

No scratches apparent.

Very light markings even after pressure.

Japanned

Matt, dark appearance. Uneven throughout.

Impossible to mark

Impossible to mark

Aluminium

Reflective and even finish

Significant scratching even with light pressure

Very deep scratch: base metal distorted around the indentation.

Galvanised

Mottled greywhite. Edges not always clearly defined

No markings

Extremely faint indentation

Brass

Yellow colour, reflective, even finish

Light markings

Quite deep scratch. Brass appears to be continuous no paler substrate metal revealed.

Observations during and after exposure Item

Steel Nickel-Plated Zinc-Plated Japanned Aluminium Galvanised Brass

Observations of corrosion
Some small red rust patches under magnification easily removed. Metal beneath has some pitting. Some formation of green nickel chloride on outer surface easily removed. Red rust forming at base of scratch Heavy pitting of zinc. Scratched area appears to be unchanged. No visible corrosion, even under magnification. Colour change appears to be paler (whiter) than sample before exposure. No pitting or damage to scratched area. No visible corrosion, even under magnification. Minor pitting, particularly in region of scratches.

4
Steel

Analysis and potential applications

Mild steel would be extensively rusted in this time frame, so we can assume these are a lowalloy stainless where there would still be enough homogeneous iron for corrosion to start. Steel screws such as this would demonstrably not be used in marine environments or areas with ongoing weather exposure. However, they are cheap and mass-produced for a range of building applications. Nickel-plated The nickel has largely demonstrated corrosion resistance: it is suspected that the formation of green nickel chloride is due to a galvanic reaction as the nickel sample was inadvertently allowed to rest against another. The importance of good nickel coverage is emphasised by the rust forming where it has been scratched away. As a fairly expensive coating, it is likely to be used in engineering applications which require lasting corrosion-resistance (in contrast to the zinc coatings). Zinc-plated A classic sample of sacrificial protection. The bimetallic formed between the iron substrate and zinc plate creates a galvanic cell and the zinc corrodes in preference to the iron. Likely to be used in cheaper outdoor applications such as wooden fencing where long life is second preference to cheapness and wear resistance. Japanned The japanning lacquer coating provides a hard and completely impermeable barrier. The surface is very poor, though, so this coating couldnt be used in precise or moving work. The high cost makes this suitable for low-volume work with aesthetic considerations (decorative ironwork and the like).

Aluminium Very soft and lightweight, but it has passivated under a corrosive environment: the additional oxide providing lasting protection. The expense of aluminium means this is more likely to find applications in precise scientific equipment. It is also ideal for fastening aluminium materials (window frames, notably) because there is no galvanic cell created. Galvanised The very coarse and imprecise finish means galvanisation is a poor choice for precise screws, and it tends to be a mass treatment for nails and pins designed for outdoor use. Again, scratches are not a problem: firstly because the quenched zinc is very hard, and secondly because it will corrode in preference to the iron. Brass A good combination of corrosion resistance and finish makes brass suitable for a range of applications; it is also the best electrical conductor of any on this list, making it suited for electrical terminals and the like.