Surface Chemistry

&
ELECTROPLATING
 OUTLINE
▪ History
▪ Introduction
▪ Definition
▪ Components
▪ Anode and cathode
▪ Electrolyte
▪ Power source
▪ Process
▪ Factors affecting electroplating
▪ Benefits
▪ Uses
▪ Metals used
▪ Electroplating in industries
▪ Different types of electroplating
▪ Galvanization
 HISTORY

▪ Electroplating was invented in 1805 by Italian inventor Luigi V. Brugnatelli. He did this by
linking a wire between a dissolved gold solution and a battery, also known as a Voltaic pile.
A metal object was then connected to the wire, allowing the gold to become attached to it.
This caused the metal object to take on a shiny, gold coating.
▪ At this time, electroplating and metal finishing was still relatively unknown. It wasn’t until
the 1840s that Brugnatelli’s work became popular across Britain and Russia, where the
electroplating process was used for coating printing plates in copper solution. At a similar
time, a man called John Wright added knowledge to the electroplating process. He created a
brand-new electroplating solution: potassium cyanide
▪ After the widespread popularity, cousins George and Henry Elkington came to realize
that the electroplating industry and metal coating services were growing rapidly. They
bought the patent from John Wright and gained several other patents alongside this, such
as silver and gold electroplating.
 INTRODUCTION

▪ Sometimes finishes are solely decorative such as the products we use indoors or in a dry
environment where they are unlikely to suffer from corrosion. These types of products
normally have a thin layer of gold, or silver applied so that it has an attractive appeal to the
consumer.
▪ Electroplating is widely used in industries such as automobile, airplanes, electronics, jewelry,
and toys.
 DEFINATION
▪ Electroplating is a general name for processes that create a metal coating on a solid substrate
through the reduction of cations of that metal by means of a direct electric current.
▪ Electroplating is the process of plating one metal onto another by hydrolysis, most commonly
for decorative purposes or to prevent corrosion of a metal.
▪ There are also specific types of electroplating such as
✔ copper plating
✔ silver plating
✔ chromium plating.
✔ Gold plating
The electroplating process uses an electric current to dissolve metal and deposit it onto a
surface. The process works using four primary components:
▪ Anode
▪ Cathode
▪ Solution (electrolyte)
▪ Power source
The overall process of electroplating uses an electrolytic cell, which consists of putting a
negative charge on the metal and dipping it into a solution that contains metal salt (electrolytes)
which contain positively charged metal ions. Then, due to the negative and positive charges,
the two metals are attracted to each other
 ANODE AND CATHODE

▪ In electroplating practice, the current is usually introduced from an external source and the
anode is the positive electrode and cathode is a negative electrode.
▪ The cathode is the electrode where the electrochemical reduction reaction occurs. The anode is
that where the electrochemical oxidation reaction occurs.
▪ The electroplating process uses an anode and a cathode. In electroplating, the metal dissolved
from the anode can be plated onto the cathode.
▪ The anode is provided with direct current, oxidizing and dissolving its metal atoms in the
electrolyte solution.
▪ At the cathode, the dissolved metal ions are decreased and the metal is placed on the product.
 ELECTROLYTE

▪ An electrolyte is a substance that produces an electrically conducting solution when dissolved

in a polar solvent, such as water. The dissolved electrolyte separates into cations and anions,
which disperse uniformly through the solvent.
▪ Electrically, such a solution is neutral. If an electric potential is applied to such a solution, the
cations of the solution are drawn to the electrode that has an abundance of electrons, while the
anions are drawn to the electrode that has a deficit of electrons.
▪ The movement of anions and cations in opposite directions within the solution amounts to a
current. This includes most soluble salts, acids, and bases.
 POWER SOURCE

▪ Current is added to the circuit using a power source. This power source applies a current to
the anode, introducing electricity to the system.
▪ Once the anode and cathode are placed in solution and connected, the power supply supplies a
direct current (DC) to the anode. This current causes the metal to oxidize, allowing metal
atoms to dissolve in the electrolyte solution as positive ions.
▪ The current then causes the metal ions to move to the negatively charged substrate and deposit
onto the piece in a thin layer of metal.
 PROCESS
▪ The electrolyte should contain positive ions (cations) of the metal to be deposited. These
cations are reduced at the cathode to the metal in the zero valence state. For example, the
electrolyte for copper plating can be a solution of copper(II) sulphate, which dissociates into
Cu 2+ cations and SO2 −4 anions. At the cathode, the Cu 2+ is reduced to metallic copper by
gaining two electrons.
▪ When the anode is made of the coating metal, the opposite reaction may occur there, turning it
into dissolved cations. copper would be oxidized at the anode to Cu 2+ by losing two electrons.
In this case, the rate at which the anode is dissolved will be equal to the rate at which the
cathode is plated and thus the ions in the electrolyte bath are continuously replenished by the
anode. The net result is the effective transfer of metal from the anode source to the cathode.
▪ The anode may instead be made of a material that resists electrochemical oxidation, such as

lead or carbon. Oxygen, hydrogen peroxide, or some other byproducts are then produced at

the anode instead. In this case, ions of the metal to be plated must be periodically replenished

in the bath as they are drawn out of the solution.

▪ The plating is most commonly a single metallic element, not an alloy. However, some alloys

can be electrodeposited, notably brass and solder. Plated "alloys" are not true alloys, i.e. solid

solutions, but rather discrete tiny crystals of the metals being plated.
 FACTORS AFFECTING
ELECTROPLATING
While this process is constant, three factors can impact the quality of the plating. These factors
are the following:
▪ Bath conditions: Both the temperature and the chemical composition of the bath impact how
effective the electroplating process is.
▪ Part placement: The distance the dissolved metal needs to travel will affect how effectively
the substrate is plated, so the placement of the anode relative to the cathode is important.
▪ Electrical current: Both the voltage level and the application time of the electrical current
plays a role in the efficacy of the electroplating process.
 BENIFITS:

The major application is to optimize a material’s resistance towards corrosion. The plated layer
often serves as a sacrificial coating which reveals that it dissolves before the base substance. Some
of the other common applications of electroplating involve:
▪ Improving wear resistance.
▪ Improving the thickness of the metal surface.
▪ Enhancing the electrical conductivity like plating a copper layer on an electrical component.
▪ Minimizing Friction.
▪ Improving surface uniformity.
 USES

▪ Copperplating is used extensively to prevent case hardening of steel on specified parts.

▪ The entire article may be copperplated and the plate ground off on the areas to be hardened.
▪ Silver plating is used on tableware and electrical contacts; it has also been used on engine
bearings.
▪ The most extensive use of gold plating is on jewelry and watch cases. Zinc coatings prevent
the corrosion of steel articles,
▪ while nickel and chromium plate are used on automobiles and household appliances.
 METALS USED IN THE ELECTROPLATING PROCESS
Plating can occur with individual metals or in various combinations (alloys) that can provide
additional value to the electroplating process. Some of the most commonly used metals for
electroplating include:
▪ Copper: Copper is often used for its conductivity and heat resistance. It is also commonly
used to improve adhesion between layers of material.
▪ Zinc: Zinc is highly corrosion-resistant. Often, zinc is alloyed with other metals to enhance
this property. For example, when alloyed with nickel, zinc is particularly resistant to
atmospheric corrosion.
▪ Tin: This matte, bright metal is highly solderable and corrosion resistant as well as
environmentally friendly. It is also inexpensive compared to other metals.
▪ Nickel: Nickel offers excellent wear resistance, which can be improved through heat
treatment. Its alloys are also very valuable, offering elemental resistance, hardness and
conductivity. Electroless nickel plating is also valued for its corrosion resistance,
magnetism, low friction and hardness.
▪ Gold: This precious metal offers high corrosion, tarnish and wear resistance and is coveted
for its conductivity and aesthetic appeal.
▪ Silver: Silver is not as corrosion resistant as gold, but it is highly ductile and malleable, has
excellent resistance to contact wear and offers excellent aesthetics. It is also an alternative
to gold in applications where thermal and electrical conductivity is needed.
 INDUSTRIES THAT USE ELECTROPLATING
Listed below are some of the industries and how they apply electroplating:
▪ Automotive industry: Plating is commonly used in the automotive industry to prevent
corrosion in harsh environmental conditions. Zinc-nickel plating solutions help prevent rust
formation, while electroless nickel plating serves as a great alternative for chrome on
catalytic converters and plastic parts.
▪ Electronics industry: Electronics companies often use gold plating for its conductivity,
applying it to semiconductors and connectors. Gold is also coveted for its corrosion
resistance in this industry. Copper plating is another commonly used metal in this industry,
used as an alternative to gold when the focus is on conductivity. Palladium alloys are also
commonly used as protective coatings on electronic equipment and components.
▪ Medical industry: The medical equipment industry often uses metal electroplating to
improve the biocompatibility of components, especially implants. Gold, silver and
titanium are commonly used in this industry for their biocompatibility, corrosion
resistance, hardness and wear resistance, all of which are essential for implants and joint
replacements.
▪ Aerospace industry: The aerospace industry frequently uses titanium for aircraft
manufacturing due to its high strength-to-weight ratio. Nickel plating is also commonly
used in this industry to protect against corrosion and wear, while copper is used to
improve heat resistance.
 GOLD PLATING
▪ The Ancient Greeks used to mechanically attach gold to other metals through heating metals
and placing them together then rapidly cooling the combination. This was hammered into
shape for statues, books and many other artifacts.
▪ Modern gold plating, called gold electroplating, relies on a chemical process to combine
various layers of metal into a solid piece with a layer of gold resting on the surface.
Electroplating has been in use commercially since the 1840s and was heavily refined during
the two World Wars.
▪ In all gold plating, the part is polished and cleaned as thoroughly as possible before the
electroplating process starts. Gold plating will look uneven and smudged if the surface is
dirty, oily, scratched or otherwise damaged.
▪ Modern electroplating begins with the creation of a metal salt using the plating metal,
typically gold or silver. These salts are formed when an acid and a base combine and create
a neutralization reaction. Metal salts are formed when positively charged ions of a metal
are combined with an acid or with a non-metal. This salt is then placed in water and mixed
together to form the “bath” for your component.
▪ The component you’re plating is immersed in this bath and an electric current is applied to
it. The current is directed to the component and dissolves the metal salts as it moves
through the bath. Gold molecules ride the current and are deposited onto your component.
▪ How long the component is left in its bath typically determines the thickness of the plating.
When you get gold plating done, there are decades of clean and refined practices behind
you.
 ELECTROPLATING EXAMPLES
There are many specific examples of electroplating applications across various industries.
Some of these are detailed below:
▪ Copper plating of semiconductors: Various metal plating options are used in the
electronics industry. Copper plating is commonly used to increase the ability of
semiconductors and circuits to conduct electricity.
▪ Nickel plating of hard drives: Nickel is a magnetic metal, which is an essential property
for hard drives. Hard drives require magnetism to improve disc reading, so hard drives are
commonly electroplated with nickel during the manufacturing process.
▪ Palladium plating of catalytic converters: Palladium plating is commonly used in the
automotive industry, specifically on catalytic converters. Palladium absorbs excess
hydrogen during the manufacturing process, an element that negatively impacts the
functionality of catalytic converters. Plating with palladium absorbs this excess hydrogen,
improving catalytic converter performance.
▪ Electroless nickel plating of aerospace components: Black electroless nickel plating is
capable of absorbing light and energy. This is an essential quality in the manufacturing of
various types of defense vehicles. Many defense and aerospace industry manufacturers
choose to use this plating option to ensure compliance with industry standards, including
the Department of Defense guidelines.
 GALVANIZATION
Galvanization or galvanization (or galvanizing as it is most commonly called) is the process of
applying a protective zinc coating to iron or steel, to prevent rusting. The most common method is
hot dip galvanizing, in which steel sections are submerged in a bath of molten zinc.
Galvanizing protects from rust in a number of ways:
▪ It forms a barrier that prevents corrosive substances from reaching the underlying steel or
iron.
▪ The zinc serves as a sacrificial anode so that even if the coating is scratched, the exposed steel
will still be protected by the remaining zinc.
▪ The zinc protects its base metal by corroding before iron.
▪ The zinc surface reacts with the atmosphere to form a compact, adherent patina that is
insoluble in rainwater.
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