TEKNOBRITE AZ 1185 PROCESS

A HIGH PERFORMANCE CHLORIDE ZINC PLATING PROCESS

FOR BETTER BRIGHTNESS & SMOOTHNESS.

TEKNOBRITE AZ 1185 is a new generation chloride Zinc plating system specifically

formulated for vat & barrel plating. The process utilizes innovative chemical technology and
brightening agents that exhibit excellent emulsifying capability and unusual stability at higher
temperature without oiling out problems which interferes with subsequent chromating
operation. The addition agents system is extremely versatile and is equally effective in an all
Potassium chloride based Zinc plating solution and the process is ideal for either rack or barrel
plating applications, Since the process offers exceptionally bright deposits then very low to
very high current densities.

Despite its out standing performance Teknobrite AZ 1185 process is very economical; to use
and easy to control. The process produces ductile deposits and are generally easier to
Chromate without adhesion and smearing problems.

SALIENT FEATURES

 TEKNOBRITE AZ 1185 additives and brightners have unsurpassed solution,

stability and no oil-out problems even at higher temperatures.
 The process produces brilliant level ductile zinc deposits which accept subsequent
post chromate passivations readily evenness.
 Higher current densities can be used in barrel plating, less tendency to burn or white
spots, extraordinary smooth bright deposit in vat & wire plating.
 Readily plates substrates such as malleable iron, castings, heat treated and carbo-
nitrided steels.
 The process can be operated regularly under warm conditions to facilitate working at
higher current densities especially suitable for barrel plating.
 Simplified iron control of operating solution.

BATH MAKE -UP

RACK BARREL RANGE

TEKNOBRITE AZ 846 A 125 ml/ltr 100 ml/ltr. 80 - 150 ml/ltr.

TEKNOBRITE AZ 846 B SALT 250 gms/ltr. 225 gms/ltr. 200 - 280 gms/ltr.
TEKNOBRITE AZ 1185 M 40 ml/ltr 35 ml/ltr. 30 - 50 ml/ltr.
TEKNOBRITE AZ 1185 R 0.8 ml/ltr 0.4 ml/ltr. 0.4 - 1.0 ml/ltr.

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BATH OPERATING CONDITIONS

Cathode Current Density : 0.5 - 5 A/dm2. (Vat & Barrel)

Anode current density : 1 - 3 A/dm2.
Voltage : 6 - 12 (Barrel).
2 - 6 (Vat).
pH (electrometric) : 4.8 - 5.2
Filtration : Continuous.
Agitation : Air agitation recommended. If air agitation
is not available solution agitation is
recommended.
Anodes : Pure Zinc 99.99%
Special High grade.
Temperature : 20 - 45C.

CHEMICAL COMPOSITION
VAT & BARREL
ZINC METAL : 25.0 - 42 gm/ltr.
TOTAL CHLORIDE : 120 - 150 gm/ltr.
BORIC ACID : 20 - 30 gms/ltr.

FUNCTION OF SOLUTION COMPONENTS

ZINC METAL
The recommended range should be maintained in order to get desired optimum results.
Weekly analysis of zinc metal concentrations should be made and the necessary daily
additions to be done based on this analysis. Metal content can be increased by the addition of
Teknobrite 846 A liquid.

Low concentration of Zinc causes burning at high current density areas. High concentrations
of zinc will reduce the brightness in low current density areas. To overcome this Teknobrite
AZ 1185 M & R is to be added to improve the low current density range.

TOTAL CHLORIDE
The chloride content increases by adding Teknobrite AZ 846 A & 846 B salt. Routine analysis
and daily additions are necessary to maintain the total chloride within the recommended range
(Use Teknobrite AZ 846 MB for making up initial bath and also for the maintenance
Teknobrite AZ 846 B Salt to be used)

TEKNOBRIGHT AZ 1185 M (make-up)

Teknobrite AZ 1185 M is normally consumed by drag-out, the addition should be made based
upon the Hull-cell test. Low concentration of Teknobrite AZ 1185 M can cause dark film on
the plated components, dull plating in high current density areas, and may result in clouding
of the plating solution. Higher concentration of Teknobrite AZ 1185 M may reduce the overall
brightness and thus increase the consumption of Teknobrite AZ 1185 R to get the desired
results.

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TEKNOBRIGHT AZ 1185 R
This is mainly responsible for getting the overall brightness and this gives the desired results
in combination with Teknobrite AZ 1185 M. Addition of brightner is normally controlled by
the Hull-cell test. Teknobrite AZ 1185 R is consumed by electrolysis and dragout. Additions
can be made based on ampere hours once a consistent routine has been established. The bath
can be maintained by adding regularly 150-300 ml of Teknobrite AZ 1185 R and 100 -200 ml
of Teknobrite AZ 1185 M.

The consumption rate given above should be taken as a rough guide for maintaining the
brightner balance in the bath. However, the consumption of the Teknobrite AZ 1185 M & R
depends upon the degree of brightness required, type of base metal and its operating conditions
such as pH, temperature, and the drag-out losses.

For example in case of rack plating 1185 M may have to added more to reduce the burning
tendency and to maintain the deposit ductility. Similarly 1185 M is to be added more as
compared to 1185 R to improve the coverage for components having deep recesses to be plated
in barrel.

OPERATING CONDITIONS

pH
The optimum pH of the bath is 4.8 and should be checked and corrected daily. After additions
of chloride, the pH should be checked, and if necessary, more hydrochloric acid (diluted)
added. Low pH, below 4.5, is usually a result of adding an excess of acid, and will result in
misplating and matte deposits. High pH causes burning and dull deposits.

TEMPERATURE
The temperature range for operating this solution is 20-45C. To maintain the temperature
within optimum range titanium cooling coils are recommended. If the temperature of the
solution in winter season falls below 18C, we recommended to install a heater to maintain
the temperature above 25C specially for rack plating.

CURRENT DENSITY
The recommended current density range for barrel plating is 0.2 to 1.5 amps/dm2. Voltage is
2 to 10 volts. For rack plating, the average current density is 2.0 amps/dm2. With rack plating,
sufficient air agitation is necessary to plate at higher current densities without burning.

AGITATION
Agitation for rack plating can be supplied with cathode rod, air, or solution circulation via
filter pump. For Rack Plating Cathode rods movement should be at a rate of 4 to 10 feet per
minute. Low pressure, clean filtered air from an air pump, not a compressor, is recommended.
Too much pressure will cause excess foaming but insufficient agitation will result in burning
at the high current density areas.

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TANKS

Acid resistant plastic lined tanks, such as polypropylene or polyethylene are suitable. Rubber
lined tanks are not suitable for bright chloride zinc solution.

FILTRATION

Filtration of this solution is necessary for both barrel and rack installations to remove iron
contamination. The filter should have the capacity to turn over the solution 2 to 3 times per
hour. The filter should not contain metal parts that will come into contact with the solution.
To remove iron hydroxide, a micron filter is recommended.

ANODES

The anodes should be 99.99% zinc. When using zinc slabs, and titanium is used for anode
hooks. Anode area of 1.5 times cathode area or greater, is recommended.

COOLING

Cooling coils of titanium or Teflon are recommended. Making the titanium coil slightly
anodic is recommended, to avoid under the influence of cathodic current.

SOLUTION MAKE UP

To make-up the 100 ltrs of operating solution using Teknobrite AZ 1185 process chemicals,
proceed as follows:

• Add 50 ltrs of warm water to the 100 ltr tank.

• Add 22.5 kgs of Teknobrite AZ 846 MB with stirring, continue the stirring till the salts
are completely dissolved.

• Add 100.0 ltrs of Teknobrite 846A liquid.

• Check the pH of the solution and adjust if necessary to 4.8 - 5.0 with CP grade
hydrochloric acid to lower the pH or potassium hydroxide to raise the pH.

• Add 3 -4 ltrs of Teknobrite AZ 1185 M and 80 ml of Teknobrite AZ 1185 R with stirring.

• Add sufficient water to bring the solution to final operating level.

Now the plating bath is ready for production use.

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IMPURITIES

IRON :
Dissolve iron tends to build-up in all chloride zinc solutions during normal operation. This is
due to the slightly acidic pH of the bath, as well as drag-in of dissolved iron from the acid
pickle step in the pretreatment cycle.

Frequent iron treatment is not necessary with the Teknobrite AZ 1185 process, providing the
bath is operated within the proper pH range, and both adequate filtration and continuous air
agitation are used. These points have been discussed in previous sections on “Bath pH”,
“Agitation” and “Filtration”.

Even if these recommendations are followed, however, it’s possible occasional treatment for
iron will be necessary to maintain optimum performance. This will depend primarily upon
the amount of iron dragged-in; the amount of iron dragged-out; the normal bath pH; the level
of performance required; etc. Since these factors vary from plant, no single treatment schedule
will suffice for all installations. It’s better to observe production results and treat only as often
as is necessary.

A high iron content produces blue to black stained deposits after chromating or bright dipping.
These stains are most noticeable in higher current densities. In barrel plating, high iron can
produce dark spots, approximately the size of the barrel perforations, on processed parts.
These spots also are most apparent after chromating or bright dipping.

The preferred method for treatment of iron is to add 0.10 grams of potassium permanganate
per litre of solution. The permanganate must be predissolved in water before it is added. A
concentration of approximately 60 gms/ltr. is suggested.

NOTE : Hydrogen peroxide (35%) is not suggested to oxidize iron to the ferrous state. It is
quite slow to react at the suggested operating pH, and an excess adversely affects cathode
efficiency in low current density areas. In some cases peroxide can also necessitate extra
additions of Teknobrite AZ 1185 M Make-Up, which are not required if permanganate is used.

It is best to make additions of permanganate at the end of the plating day, and to filter the bath
during non-production hours to remove the precipitated iron. Occasionally permanganate can
be added while continuing plating without affection the quality. However, this is not
recommended, and should not be attempted without prior testing on non-critical parts.

Generally treatment for iron significantly increases the amount of solids in the bath, and
necessitates cleaning and repacking the filter. If the major source of solids within the filter
chamber is precipitated iron, it can be removed simply by continuously recirculating a small
volume of 10-15% vol. hydrochloric acid solution directly through the filter, and without
discharging solution from the filter back to the plating tank. This will rapidly dissolve the
iron and increase the filtration flow rate. After the iron is dissolved, this hydrochloric acid
solution should be discarded, and the filter put back on the plating tank.
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HEAVY METALS (Such as Copper, Cadmium, Lead etc.) :

The presence of these metals will be apparent in the low current density areas. The degree to
which performance is affected depends upon the level of contamination, and can range from
a slight dullness at a low level contamination., to black deposits, and /or skip plating, at higher
levels.

Zinc dust treatment is suggested remedy. Fresh zinc dust should be made into a water slurry
by adding approximately 120 gms. to a litre of water and then adding 0.1% vol. of this mixture
to the operating bath. It should be added with moderate agitation, and then added with
moderate agitation, and then allowed to settle after 5-15 minutes of mixing.

Zinc dust treatment should not be done in the plating tank, but rather in a separate treatment
tank. Also, once the zinc dust has settled, it should be removed from the treated solution as
soon as possible, either by filtration or decanting. Otherwise the metallic contamination which
has immersion deposited on the zinc dust will redissolve (at least partially) in the solution,
thereby reducing the effectiveness of the treatment.

CHROME :

The effect of hexavalent chrome in the operating solution is similar to the presence of heavy
metals, except that, in addition, blistered deposits generally occur in higher current density
areas. The suggested remedy is to add 0.075 - 0.15 gms. of Sodium hydrosulphite (or other
strong reducing agent) per litre of plating solution.

ORGANIC CONTAMINATION :

Organic contamination generally detracts from overall deposit brilliance and levelling, and
can also reduce chromateability. Additionally, it can cause brittle and / or burned deposits in
high current density areas.

Some method of carbon treatment will generally eliminate the effect of organic contamination.
With low levels of contamination, recirculating the solution through a carbon packed filter
frequently removes the inferring organic. In more severe cases a batch treatment may be
needed.

Hull cell, or other small scale, plating tests are a convenient way of determining the
effectiveness of various treatment methods in removing detrimental contamination.

ANALYSIS

FOR ZINC METAL

Apparatus Needed
2 ml Pipette.
25 ml Graduated cylinder .
50 ml Burette.
250 ml Erlenmeyer Flask.
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Reagents Needed

i] Eriochrome Black T Indicator :

This is prepared by mixing 1.0gm. Eriochrome Black T Indicator with 100 gms. AR
grade Sodium Chloride.

ii] 0.1 M EDTA Solution :

This is prepared by dissolving 40.0gms. EDTA Di-sodium salt and make-up the
level to one litre and standardize against 0.1M Magnesium Sulphate Solution.

iii] Ammonium Chloride Buffer Solution:

Dissolve 40 gms of NH4Cl and 200 ml. Ammonia and make-up the level to one
litre.

iv] Formaldehyde solution:

Dilute 100 ml of Conc. Formaldehyde to one litre.

PROCEDURE

a} Pipette out 2 ml of sample into 250 ml of Conical flask.

b} Add Ammonium Chloride buffer solution.
c} Add a pinch of Eriochrome Black T Indicator.
d} Add formaldehyde (2 - 4 drops)
e} Titrate immediately against 0.1M EDTA solution to blue colour end pt.

CALCULATION

Burette reading x 3.269 = g/l of Zinc Metal.

ANALYSIS

FOR TOTAL CHLORIDE

Apparatus Needed:
1 ml pipette, Conical Flask , 50 ml. Burette.
Reagents needed:

i] 0.1N Silver Nitrate

Dissolve 17.5 gms. of Silver Nitrate in a sufficient amount of distilled water to
make one litre of solution. Store in brown glass bottle. Standardize with 0.1N NaCl
solution.

ii) Chromate Indicator

Dissolve 25.95 gms. of Potassium Chromate in 1 litre distilled water.

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PROCEDURE

a] Pipette 1 ml sample solution into a conical flask.

b] Add a pinch of Potassium Chromate Indicator
c] Titrate it against silver nitrate solution till permanent reddish brown ppt.is formed.

CALCULATION

Burette reading x 3.5 = gm/l Total chloride.

ANALYSIS

FOR BORIC ACID :

Reagent Needed :

1. 0.1 N Sodium Hydroxide :

Dissolve 4.0 gms of AR grade NaOH in sufficient amount of (distilled water), make
it to one litre, standardize against Sulphuric acid of known normality.

2. Bromocresol purple indicator :

Dissolve 0.1 gm of Bromocresol purple powder in 18 ml of 0.01N Sodium
Hydroxide and dilute it to 250 ml with distilled water.

3. Mannitol AR grade.

Procedure

1. Pipette 1 ml sample of the plating bath into conical flask and add a spatula a
mannitol and stir well.

2. Add several drops of bromocresol purple and titrate it against 0.1 N NaOH with
continuous stirring
End point - purple.

CALCULATION

Burette Reading X 6.184 = gms /ltr. boric acid

NOTE :

Our recommendations are made in good faith and are based on our skill and experience.
However, since the conditions of use of these products are beyond our control, this information
is given on the express condition and agreement that Artek Surfin Chemicals Ltd., will not
be liable to any person by reason thereof. Nothing herein shall be deemed to be a
recommendation to use any product in violation of any existing patent rights.