• Polski
export@cpp-prema.pl
}
Galvanic coatings – How to protect components in demanding industries?

Galvanic coatings – How to protect components in demanding industries?

Corrosion costs the global industry over $2.5 trillion annually. How can M20 bolts in mines, turbines in power plants, or food processing equipment be protected from such losses? Galvanic coatings provide corrosion resistance, durability, and compliance with standards such as PN-EN ISO 2081, MIL-DTL-13924, or FDA 21 CFR 175.300. CPP PREMA, with 40 years of experience, delivers protective coatings for heavy industry, railways, manufacturing, and the food industry.

Why are electroplated coatings so commonly used?

Galvanic coatings are layers of metal or oxides applied electrochemically to steel, aluminum, or copper. They protect components from corrosion, abrasion, and meet hygienic requirements. In our company, we use processes compliant with ISO 9001:2015, ensuring coating thicknesses from 5 to 25 µm.

Benefits:

  • Protection of bolts and tracks in humid environments.

  • Durability of shafts at temperatures up to 500°C.

  • Hygienic surfaces for the food industry.

  • Reduction of glare in military applications.

  • Higieniczne powierzchnie dla przemysłu spożywczego.

  • Redukcja odblasków w zastosowaniach wojskowych.

Types of electroplated coatings – Standards and applications

CPP PREMA offers anti-corrosion coatings tailored to industry requirements. Here is an overview:

Technical chrome plating – High hardness

Galvanic chromium plating creates a coating with a hardness of 800–1000 HV, resistant to friction and corrosion.

  • Standards: PN-EN ISO 6158 (min. 10 µm), ASTM B650.

  • Applications: Turbine shafts (energy sector), rifle barrels (military).

  • Parameters: Baths 600x400x1500 mm, part weight up to 125 kg, thickness 10–20 µm.

Learn about galvanic chromium plating.

Galvanic zinc coating – Corrosion protection

Galvanic zinc plating protects steel with a zinc coating (8–25 µm), acting as a barrier and providing cathodic protection.

  • Standards: PN-EN ISO 2081 (5–25 µm), ASTM B633.

  • Applications: M20 bolts (mining), rails (railways).

  • Parameters: Part weight up to 25 kg, current density 1–3 A/dm².

Learn about galvanic zinc plating.

Aluminium anodising – Lightness and durability

Aluminum anodizing creates an aluminum oxide layer (10–50 µm), resistant to corrosion.

  • Standards: ISO 7599, MIL-A-8625 (min. 25 µm for hard anodizing).

  • Applications: Vehicle casings (military), train car frames (railways).

  • Parameters: Voltage 15–20 V, baths 600x400x1500 mm.

Learn about aluminum anodizing.

Steel blackening – Aesthetics and protection

Steel blackening creates a matte oxide coating (1–2 µm), reducing glare.

  • Standards: MIL-DTL-13924, PN-EN ISO 11408.

  • Applications: Gun barrels (military), dies (manufacturing industry).

  • Parameters: Bath temperature 135–145°C, part weight up to 125 kg.

Read about steel blackening.

How does the electroplating process work?

Technical galvanization is an electrochemical process of applying coatings. Stages:

  1. Part preparation: Degreasing (pH 10–12), etching, sandblasting.

  2. Immersion in electrolyte: Solution with metal ions (e.g., Cr³⁺, Zn²⁺).

  3. Coating deposition: Current 1–20 A/dm², temperature 20–60°C, time 15–60 min.

  4. Rinsing: Demineralized water (see the role of water in galvanization).

Examples of parameters:

  • Chromium plating: Chromic acid, 50–55°C, 10–20 A/dm².

  • Zinc plating: Zinc chloride, 20–30°C, 1–3 A/dm².

We use semi-automatic lines, ensuring compliance with ISO 9001:2015. We control every parameter to achieve a uniform coating.

Applications

Galvanic coatings address industry-specific challenges:

  • Mining: Zinc plating (8–25 µm) protects bolts and conveyors.

  • Energy sector: Chromium plating (10–20 µm) safeguards turbine shafts.

  • Military: Blackening (1–2 µm) reduces glare on gun barrels, anodizing strengthens casings.

  • Railways: Zinc plating and anodizing protect rails and train car frames.

  • Manufacturing industry: Nickel plating (10–20 µm) extends the lifespan of shafts.

  • Food industry: Tin plating (3–15 µm) ensures hygiene for mixers.

How to choose a galvanic coating?

The choice of protective coating depends on:

  • Material: Steel (zinc plating), aluminum (anodizing).

  • Environment: Humidity, temperature 500°C, food contact.

  • Standards: MIL-DTL-13924 (military), FDA 21 CFR 175.300 (food industry).

  • Function: Protection, durability, hygiene.

Coating Standard Application Thickness (µm)
Chromium plating PN-EN ISO 6158, ASTM B650 Energy sector, military 10–20
Zinc plating PN-EN ISO 2081, ASTM B633 Mining, railways 8–25
Anodizing ISO 7599, MIL-A-8625 Military, railways 10–50
Blackening MIL-DTL-13924, PN-EN ISO 11408 Military, manufacturing industry 1–2
Nickel plating PN-EN ISO 4526 Food industry, manufacturing 5–20
Tin plating PN-EN ISO 2093, FDA 21 CFR 175.300 Food industry 3–15

Examples:

  • Corrosion in mines: Zinc plating (8–25 µm) protects bolts for 5–10 years.

  • Turbine wear: Chromium plating (10–20 µm) reduces maintenance costs by 30–50%.

  • Food hygiene: Tin plating (3–15 µm) complies with FDA standards.

Preparation of details for galvanisation

The quality of the coating depends on preparation:

  1. Degreasing: Alkaline baths (pH 10–12).

  2. Etching: Sulfuric acid for steel, alkaline solutions for aluminum.

  3. Sandblasting: Surface roughness Ra < 1.6 µm.

Benefits: Better adhesion, fewer defects, lower costs.

Quality control of security measures at CPP PREMA

CPP PREMA conducts tests:

  • Thickness: X-ray spectrometer (ISO 3497, ±0.1 µm).

  • Corrosion: Salt spray chamber (PN-EN ISO 9227, 96–240 h for zinc).

  • Adhesion: Bend tests (ISO 2819, no delamination).

  • Hardness: Microhardness tester (800–1000 HV for chromium).

Compliance with ISO 9001:2015 and standards (e.g., FDA 21 CFR 175.300) ensures reliability. Tests confirm that coatings meet industry requirements.

FAQ – Answers to questions about electroplated coatings

  1. What standards do coatings for the military meet? Blackening (MIL-DTL-13924, 1–2 µm) and anodizing (MIL-A-8625, 25–50 µm) provide protection for weapons and vehicles.

  2. Why zinc plating in mining? Zinc plating (PN-EN ISO 2081, 8–25 µm) protects M20 bolts for 5–10 years in humid conditions.

  3. How to prepare parts for galvanization? Degreasing (pH 10–12) and sandblasting (Ra < 1.6 µm) improve adhesion.

  4. How do coatings support the food industry? Tin plating (FDA 21 CFR 175.300, 3–15 µm) ensures hygiene for mixers.

  5. What tests confirm coating quality? Thickness tests (ISO 3497, ±0.1 µm) and corrosion tests (96–240 h) guarantee reliability.

  6. Is anodizing suitable for railways? Anodizing (ISO 7599, 10–50 µm) protects train car frames from corrosion.

  7. How to choose a galvanic coating? Consider the material, environment, and standards (e.g., FDA).

  8. How do coatings reduce machine costs? Chromium plating (10–20 µm) reduces shaft wear by 30–50%.

  9. Does CPP PREMA offer custom quotes? Yes, we provide quotes tailored to the project.

  10. How long does galvanization take? From 2–12 h (e.g., zinc plating 15–30 min).

Summary

Galvanic coatings protect components in mining, energy, military, railways, manufacturing, and food industries, meeting ISO, MIL, and FDA standards. Our company offers anti-corrosion coatings tailored to your needs. Contact us through galvanic services to protect your products and machines.