Zinc Plating and Hydrogen Embrittlement

Zinc electroplated steel is widely used in rigging industry to protect rigging hardware
from corrosion. In addition, Zinc coating adds the brilliant shining look to steel
components.
The success of Zinc plating attributes to the invention of acid bath. Acid bath
technology developed in 1970s. The simplified process of application greatly lowered
the cost of Zinc plating. Zinc plating became popular since then.
However, during the process of acid pickling, a phonomenom called Hydrogen
Embrittlement could happen. Hydrogen Embrittlement could cause cracks to the
high-strength metal during or after the manufacturing. It is one of the toughest
factors affecting the performance of high-strength steel components. Therefore, Zinc
electroplating process needs to be handled extra carefully.

Hydrogen Embrittlement
Definition
When high-strength steel are being formed or finished during the heat treatment
process or zinc plating stage, hydrogen, often exists as a diffusible small atom, gets
released. Condition of high temperature can cause a rise on hydrogen solubility level.
If not treated carefully, too much hydrogen diffuses into the high-strength steel,
makes the steel to become brittle and fractured; therefore, causing cracks to the
high-strength metal during the processes. Hydrogen Embrittlement can also be
developed after the processes. As time goes by, diffused hydrogen atoms could
reassemble and form hydrogen molecules in voids of the metal matrix. With the
increases of hydrogen molecules, internal pressure (produced from the cavity where
hydrogen lives in) keeps rising as well. Once the structural balance is broken, inner
cracks will happen. If this trend continues, the whole component will break apart
over time.
Recently, hydrogen embrittlement has become one of the toughest factors affecting
the performance of high-strength steel components. People started to realize the
harmfulness of hydrogen embrittlement back from 1875. Despite a large number of
efforts done to eliminate the damage caused by hydrogen embrittlement, the
complete solution remains unknown.

How to Avoid Hydrogen Embrittlement in Zinc Plating Stage

After carefully examine how hydrogen is generated during zinc plating stage, it is
found that most hydrogen are produced in the process of acid pickling. Acid pickling
is used to chemically clean the surface of steel before electroplating. In order to
reduce the amount of hydrogen, the time of acid pickling should be kept to the
minimum.
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Electroplating solution is another major source of hydrogen. In recently years, the

most popular eletrolyte used for plating bath is cyanide which is well-known for
its affordable price and easy to apply solution. But cyanide has a major issue. The
efficiency of chemical reactivity will go down as the consumption of the plating
solutions, while hydrogen are released in proportion. Non-cyanide electrolyte was
then invented to fix this issue. The efficiency of chemical reactivity can be raised to
95% or above. This greatly reduces the generation of hydrogen.
Inevitibly, there will still be a certain amount of hydrogen accumulates inside the
metal with all the the above efforts. Fortunately, the process of invading is reversible.
Baking the rigging hardwares at an elevated temperature (around 200 ) for 4 8
hours, within 2 hours after zinc plating. Condition of elevated temperature
could cause hydrogen diffuses out from the parts. This can also help rigging
hardware getting rid of Hydrogen Embrittlement.

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