Nickel Electroplating

Nickel electroplating deposits a controlled nickel layer on metal parts to improve corrosion and wear resistance, solderability, and appearance with uniform coverage on conductive surfaces.

Overview

Nickel electroplating applies a metallic nickel layer to a conductive part using an electrolytic bath and DC current. It’s commonly used for corrosion protection, wear resistance, improved solderability, and a bright decorative finish. Plating thickness is selectable to meet performance requirements, and the coating can act as a barrier layer under other finishes.

Choose nickel electroplating when you need a durable metallic surface without changing the base material, especially on steel and copper alloys. Expect tradeoffs: thickness varies with current density (edges build faster than recesses), deep blind features may plate poorly, and surface finish follows the substrate (plating won’t hide machining marks or pits). Hydrogen embrittlement risk exists on high-strength steels, so baking after plating may be required. Masking and racking drive cost and can leave contact marks that must be placed on non-critical surfaces.

Common Materials

  • Steel 1018
  • Stainless steel 304
  • Copper C110
  • Brass C360
  • Beryllium copper
  • Aluminum 6061

Tolerances

±0.0002" to ±0.001" on plated thickness (process-dependent)

Applications

  • Wear-resistant shafts and pins
  • Connector and terminal plating
  • Fasteners and springs (with embrittlement relief bake)
  • Valve and pump components
  • Tooling and mold components for corrosion protection
  • Underplate for decorative chrome finishes

When to Choose Nickel Electroplating

Use nickel electroplating when you need a controllable metallic coating for corrosion and wear protection on conductive parts, with thickness matched to functional needs. It fits prototypes through production as long as racking/masking is repeatable and contact marks are acceptable. Best results come from parts with accessible surfaces and clear definitions of plated vs masked areas.

vs Anodizing

Choose nickel electroplating when the substrate is steel, copper alloys, or stainless and you need a true metallic deposit rather than an oxide conversion layer. It’s also a better fit when you need solderable surfaces or a nickel underplate for later decorative stacks.

vs Powder Coating

Choose nickel electroplating when you need a thin, conductive, dimensionally controlled coating with better edge detail and minimal build. It’s preferred for functional wear surfaces or electrical contact areas where polymer coatings are too thick or insulating.

vs E-Coating

Choose nickel electroplating when you need a metallic surface with wear resistance, solderability, or electrical conductivity. E-coat is typically a paint-like barrier; nickel plating is used where metal-to-metal contact or sliding wear matters.

vs Chromium Electroplating

Choose nickel electroplating when you need good corrosion resistance and moderate hardness without the higher hardness/brittleness emphasis of chrome. Nickel is commonly used as an underplate or standalone finish when extreme wear performance isn’t required.

vs Zinc Electroplating

Choose nickel electroplating when the environment or duty cycle needs higher wear resistance and a more durable barrier layer than typical zinc coatings. Nickel is also used when a brighter cosmetic metallic finish is required and sacrificial protection isn’t the main goal.

Design Considerations

  • Call out plating thickness range and measurement location (e.g., local vs average) on the drawing to avoid overplating critical fits
  • Avoid deep blind holes, tight recesses, and sharp internal corners where current density is low and coverage is inconsistent
  • Define mask/no-plate areas clearly and provide generous mask lands to reduce labor and leak-through
  • Locate rack/contact points on non-functional surfaces and specify acceptable contact-mark zones
  • Specify post-plate hydrogen embrittlement relief bake requirements for high-strength steels (include hardness/strength on the print)
  • Control base metal finish before plating; plating will replicate scratches, pits, and tool marks rather than hide them