Electroplating of Aircraft Parts

Electroplating is a surface treatment process used in the aerospace industry to enhance corrosion resistance, wear resistance, conductivity, and aesthetic appeal of aircraft components. It involves depositing a thin metallic layer onto a substrate using an electrochemical process, improving the performance and lifespan of critical parts.

How Electroplating Works

1. Surface Preparation – The metal part is cleaned and pre-treated to remove contaminants and ensure proper adhesion.
2. Electrolyte Bath Immersion – The part (cathode) is submerged in an electrolytic solution containing metal ions.
3. Electrochemical Deposition – A direct current (DC) is applied, causing metal ions from an anode or solution to deposit onto the part’s surface.
4. Rinsing & Finishing – The part is rinsed, dried, and post-treated for additional protection or functionality.

Common Electroplating Metals in Aerospace

1. Nickel Plating

• Purpose: Corrosion resistance, wear resistance, and adhesion for other coatings.
• Applications: Engine components, landing gear, and fasteners.

2. Chromium Plating (Hard Chrome & Decorative Chrome)

• Purpose: High hardness, wear resistance, and low friction.
• Applications: Landing gear struts, hydraulic pistons, and turbine blades.
• Standard: MIL-STD-1501 (Hard Chrome Plating).

3. Cadmium Plating (Being Phased Out for Environmental Reasons)

• Purpose: Corrosion protection and excellent lubricity.
• Applications: Aircraft fasteners, landing gear components.
• Alternatives: Zinc-nickel plating or aluminum coatings (due to cadmium’s toxicity).

4. Zinc-Nickel Plating (Cadmium Alternative)

• Purpose: Corrosion resistance similar to cadmium, environmentally friendly.
• Applications: Fasteners, brackets, and connectors.

5. Silver Plating

• Purpose: High electrical conductivity, heat resistance, and anti-galling properties.
• Applications: Electrical connectors, bearings, and aerospace engine components.

6. Gold Plating

• Purpose: High conductivity, corrosion resistance, and solderability.
• Applications: Avionics, circuit boards, and satellite components.

7. Copper Plating

• Purpose: Conductivity and adhesion layer for multi-layer coatings.
• Applications: Electrical grounding components, aircraft wiring.

Aerospace Applications of Electroplating

✔ Landing Gear & Hydraulic Components – Hard chrome or nickel plating enhances durability. ✔ Aircraft Fasteners & Bolts – Zinc-nickel or cadmium plating prevents corrosion. ✔ Turbine Blades & Engine Parts – Nickel-based coatings improve heat resistance. ✔ Avionics & Electrical Systems – Gold and silver plating ensure conductivity. ✔ Structural Components – Electroplated coatings prevent oxidation in harsh environments.

Advantages of Electroplating in Aerospace

✅ Enhanced Corrosion & Wear Resistance – Protects against oxidation, friction, and environmental stress. ✅ Improved Conductivity – Essential for avionics and electrical systems. ✅ Low Friction & Lubricity – Reduces wear in high-load components. ✅ High Temperature Resistance – Critical for jet engine parts and thermal protection. ✅ Aesthetic & Reflectivity – Used for branding and component identification.

Challenges & Environmental Considerations

• Toxicity Concerns: Cadmium and hexavalent chromium plating are being phased out due to environmental regulations (RoHS, REACH).
• Alternative Coatings: Zinc-nickel plating, PVD coatings, and advanced ceramic coatings are replacing hazardous materials.
• Cost & Processing Time: Electroplating requires precise control of bath chemistry and current for uniform coatings.

Industry Standards

• AMS 2403 – Nickel Plating for Aerospace.
• AMS 2406 – Hard Chrome Plating Specification.
• MIL-STD-870 – Electroplating of Aerospace Components.
• RoHS & REACH Compliance – Phasing out hazardous plating processes.