Nickel Electroplating

Nickel electroplating deposits controlled nickel layers for wear resistance, corrosion protection, improved solderability, and decorative finish on conductive substrates.

Overview

Nickel electroplating deposits a thin, controlled layer of nickel onto conductive parts using an electrolytic bath. It improves corrosion resistance, hardness, wear resistance, and appearance, and can also tune surface conductivity and solderability. Typical thickness ranges from ~5–50 µm (0.0002–0.002"), with tighter control possible on critical features.

This process suits steel, stainless, copper alloys, and aluminum (with proper underlayers), and handles everything from small connectors to large shafts. It works well for medium to high volumes where consistent surface performance matters. Tradeoffs: it requires good surface prep, line-of-sight coverage is better than deep recesses, internal corners may plate unevenly, and hydrogen embrittlement risk on high-strength steels must be managed. Masking, selective plating, and tight thickness control add cost and lead time.

Nickel electroplating is a strong choice when you need a hard, corrosion-resistant, and often decorative surface without changing the base material or geometry of a machined, stamped, or cast part.

Common Materials

  • Low carbon steel
  • Stainless steel 304
  • Stainless steel 316
  • Copper
  • Brass
  • Aluminum 6061

Tolerances

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Applications

  • Hydraulic piston rods
  • Injection molds and forming dies
  • Electrical and electronic connectors
  • Fasteners and hardware for corrosive environments
  • Valve and pump components
  • Decorative trim and consumer hardware

When to Choose Nickel Electroplating

Choose nickel electroplating when you need a hard, corrosion-resistant, or decorative surface on a conductive part without changing its base material or core properties. It fits best for machined, stamped, or cast parts where controlled coating thickness, improved wear performance, or enhanced solderability/conductivity are key requirements. It is efficient for small to high volumes once a plating line and fixturing are set up.

vs Anodizing

Pick nickel electroplating over anodizing when you’re working with steels, copper alloys, or mixed materials that cannot be anodized. It also makes more sense when you need high conductivity, solderable surfaces, or a bright metallic finish rather than the insulating oxide layer and color options typical of anodizing on aluminum.

vs Powder Coating

Choose nickel electroplating instead of powder coating when you need thin, tightly controlled coating thickness and preserved fine features such as threads, precision bores, or contact areas. Nickel is better when you need metallic hardness, improved wear resistance, or a conductive surface instead of a thicker, generally insulating polymer layer.

vs E-Coating

Use nickel electroplating rather than E-coating when you need a metallic, often bright finish with higher surface hardness and better wear resistance. Nickel is also a better fit when you need solderable or low-resistance electrical contact surfaces instead of a uniform organic coating primarily optimized for corrosion protection and paint adhesion.

vs Chromium Electroplating

Select nickel electroplating over chromium when you need good corrosion resistance, ductility, and easier deposit control without the regulatory and health burdens of hexavalent chrome in hard chrome applications. Nickel alone is often enough for many decorative and functional applications, and it can serve as the base for later chrome layers if required.

vs Physical Vapor Deposition (PVD)

Choose nickel electroplating instead of PVD when you need more substantial coating thickness, better edge and recess coverage, and economical processing for larger parts or higher volumes. Nickel plating is generally more forgiving on part geometry and surface prep and better suited when you don’t require ultra-thin, specialized PVD coatings for very high wear or optical functions.

Design Considerations

  • Call out required plating thickness and tolerance range on the drawing, noting whether it is total or per side
  • Identify masked and unplated areas clearly with dimensions and surface symbols to simplify fixturing and quoting
  • Avoid deep blind holes, sharp internal corners, and narrow slots where plating coverage and thickness will be difficult to control
  • Specify base material hardness and strength so the plater can manage hydrogen embrittlement risk and baking requirements
  • Provide a clear surface finish requirement before plating (Ra) and after plating so shops can plan pre-plate polishing or machining
  • Group similar parts by material, size, and thickness requirements to reduce setup variation and improve consistency across production lots