Electroplating and Corrosion Protection

A Handbook of Surface Finishing, Anodizing, and Metal-Plating Techniques for Engineers and Small WorkshopsBy Viktor Zagorsky

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Length13h 27m

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Plating is arithmetic wrapped around chemistry: amp-hours in, micrometres out—provided the surface was clean and the current went where you wanted it. This handbook teaches both halves of that equation. You will calculate deposit thickness from Faraday's laws, understand why a recess plates thin and how anode placement, thieves, and shields correct it, and prepare surfaces properly so nothing blisters a week later. Nickel, copper, chromium, zinc, tin, precious metals, and electroless nickel each get bath conditions, operating ranges, and their characteristic defects. Anodising and conversion coatings are covered for aluminium and steel. Hull cell work, contamination analysis, and a defect-to-cause troubleshooting chapter follow, closing with corrosion mechanisms, coating selection, and cathodic protection. Written for engineers, finishers, and small workshops, the book moves from first principles to bench practice without skipping the arithmetic or the chemistry. Whether you are setting up a plating line, diagnosing a blistering deposit, or specifying a coating for a corrosive environment, the chapters give you the calculations, the operating windows, and the diagnostic logic to get repeatable results. What you will learn: • Electrochemical principles of deposition and how to calculate deposit thickness from current density and time • Current distribution and throwing power—why recesses plate thin and how anodes, thieves, and shields fix it • Setting up a plating area safely, including tank layout, ventilation, and electrical requirements • Surface preparation and adhesion, from degreasing and pickling to the causes of blistering and peeling • Bath conditions and operating ranges for nickel, copper, brass, chromium, zinc, tin, silver, gold, and electroless nickel • Anodising and conversion coatings on aluminium, plus sacrificial coatings for steel • Bath control and analysis, including Hull cell testing and contamination diagnosis • Defect-to-cause troubleshooting for pits, roughness, poor adhesion, and uneven deposits • Corrosion mechanisms, coating selection strategy, and cathodic protection Who it is for: This book is for engineers, plating technicians, and small workshop operators who need practical, calculation-based guidance on electroplating, anodising, and corrosion protection. It assumes no prior plating experience but does not shy away from the formulas and chemistry required for professional results.

Audiobook details

GenreTechnology

Length13 hrs 27 mins

Narrated byListen with 1,000+ voices

FormateBook with Audio

Publish dateSep 27, 2026

LanguageEnglish

1Electroplating and Corrosion Protection

2Foreword

3Preface

4About This Book

5Important Safety Notice

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6Chapter 1: Electrochemical Principles of Deposition

71.1 Ions, Electrodes and the Plating Cell

81.2 Faraday’s Laws and Deposit Thickness

91.3 Electrode Potentials and the Nernst Equation

101.4 Current Efficiency and Hydrogen Evolution

111.5 Polarization, Overpotential and Bath Conductivity

121.6 Bench Procedure: Measuring Efficiency and Deposit Mass

13Chapter 2: Current Distribution and Throwing Power

142.1 Primary and Secondary Current Distribution

152.2 Throwing Power and the Haring-Blum Concept

162.3 Anode Placement, Thieves and Shields

172.4 Plating into Recesses, Blind Holes and Internal Surfaces

182.5 Bench Procedure: Mapping Distribution with a Coupon Array

19Chapter 3: Setting Up a Plating Area

203.1 Tanks, Linings and Materials of Construction

213.2 Anodes, Bags and Anode Maintenance

223.3 Rectifiers, Ripple and Electrical Practice

233.4 Agitation, Filtration and Heating

243.5 Racking, Contacts and Jigging

253.6 Ventilation and Personal Protection

263.7 Effluent Handling at Small Scale

27Chapter 4: Surface Preparation and Adhesion

284.1 The Case for Preparation and the Nature of Adhesion

294.2 Solvent and Alkaline Degreasing

304.3 Electrocleaning, Pickling and Descaling

314.4 Activation and Strike Layers

324.5 Adhesion Testing and Failure Diagnosis

33Chapter 5: Nickel Plating

345.1 Watts Bath Composition and Operating Conditions

355.2 Brighteners, Levellers and Their Control

365.3 Internal Stress and Its Measurement

375.4 Sulphamate and Other Nickel Baths

385.5 Multilayer Nickel for Corrosion Performance

395.6 Bench Procedure and Defect-to-Cause Table for Nickel

40Chapter 6: Copper and Brass Plating

416.1 Acid Copper Sulphate Baths

426.2 Alkaline and Cyanide-Free Copper Baths

436.3 Brass Plating and Alloy Deposition

446.4 Throwing Power Comparison and Undercoat Strategy

456.5 Bench Procedure and Defect-to-Cause Table for Copper

46Chapter 7: Chromium, Zinc and Sacrificial Coatings

477.1 Decorative Chromium Plating

487.2 Hard Chromium and Trivalent Alternatives

497.3 Zinc Plating from Acid and Alkaline Baths

507.4 Chromate and Passivate Conversion Coatings

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Electroplating and Corrosion Protection

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