The Context
A global manufacturer of industrial refrigeration valves required a corrosion-resistant coating capable of withstanding demanding service environments, including exposure to moisture, temperature fluctuations, and corrosive atmospheres.
Their plating partner, a long-established Midwest job shop with deep experience in metal finishing, was responsible for delivering this performance consistently across production components.
The challenge was clear: meet elevated corrosion resistance expectations without introducing unnecessary cost or complexity into the finishing process.
The Challenge
The end user required corrosion protection approaching zinc-nickel performance levels, often associated with 800–1000+ hours of salt spray resistance.
However, this created a difficult tradeoff:
- Traditional zinc plating was cost-effective but struggled to consistently meet higher corrosion requirements
- Zinc-nickel plating could achieve the performance—but at 3–4 times the cost, along with added process complexity
- The application required not only performance, but also aesthetics, consistency, and scalability in production
For the plating provider, this meant finding a way to bridge the gap between cost and performance—without compromising either.
Acculabs’ Approach
Collaborative Development
Acculabs partnered with both the plating provider and the end user in a three-way development effort, combining field requirements with laboratory validation to engineer a practical solution.
Designing a Duplex System
Rather than moving to zinc-nickel, Acculabs developed a duplex coating system built on:
- Zinc plate (for base electrochemical protection)
- 684 trivalent passivate (thick-film, high-corrosion layer)
- 890 Integrated Corrosion Extender (I.C.E.) seal (organo-mineral topcoat for barrier enhancement)
This 684/890 system was designed to provide both electrochemical and barrier protection, addressing corrosion at multiple levels.
Testing & Validation
Extensive testing was conducted to validate performance, including:
- ASTM B-117 salt spray testing
- Cyclic corrosion testing
- Comparative analysis against zinc and zinc-nickel systems
The goal was not just to meet performance targets, but to do so consistently under production conditions.
Implementation in Production
The system was integrated into the plating line without requiring major equipment changes. Process parameters were optimized to ensure repeatability, ease of use, and compatibility with existing operations.
Impact
- Achieved up to 1,000 hours of corrosion resistance, approaching zinc-nickel performance
- Delivered required protection using a zinc-based system at a fraction of the cost of zinc-nickel plating
- Maintained aesthetic quality and coating consistency across production parts
- Eliminated the need to transition to a more complex and expensive alloy plating process
- Provided a scalable, production-ready solution for the plating provider
Most importantly, the partnership successfully bridged the gap between performance and cost—allowing the end user to meet demanding corrosion requirements without overengineering the solution.
