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Caused by a number of beneficial properties inherently from the zinc-nickel material, this electrodeposited alloy is used more and more for cathodically protecting layers on ferrous components like cast iron brake calipers. Direct plating from acidic solutions is the state-of-the-art solution for zinc-nickel surface finishing of these components. To contribute to the continuous improvement of the final component and reduce the finishing cost, areas for improvement have been scrutinized in a current finishing system. Areas for improvement have been identified in the uniformity of the nickel distribution within different current densities and in the handling and economy of the metallic zinc anodes used for zinc metal replenishment. While today’s acidic zinc-nickel electrolytes suit and usually exceed the requirements for an alloy containing 10-15% nickel, nickel incorporation may drop just below 12% incorporation rate in areas which are plated at high current densities.

Cast-iron is a well suited material for manufacturing automotive brake components due to excellent mechanical and thermic properties. The application of a well chosen cathodically protecting coating adds durable appearance and preservation of the functional properties of the components. The selection of the right coating is driven by multiple factors of which economic considerations will always rank within the highest priorities next to protection performance and the appearance of the coating. Aiming for the highest possible performance in cathodic corrosion protection coatings leads directly to zinc-nickel coatings. Zinc-nickel coatings are already state-of-the-art in the finishing of mild steel and carburized steel materials in the automotive industry, mostly being plated from alkaline plating solutions.