STAUFF Zinc/Nickel Surface Coating

Corrosion protection that goes beyond the standard

With 1,200 hours of resistance to red rust, the STAUFF Zinc/Nickel Surface Coating offers reliable corrosion protection far beyond previous market standards – even after transport, processing, and assembly of the components.

This was confirmed by tests in the salt spray chamber in line with EN ISO 9227.

Across industries and applications, users can benefit from a technology which has proven successful in the highly demanding automotive industry for many years. STAUFF has been utilizing this surface coating across the product range since 2007. 

Electroplating of STAUFF products

STAUFF products are finished with the STAUFF Zinc/Nickel Surface Coating at high-capacity electroplating partners close to the STAUFF factories. 

The state-of-the-art electroplating systems exceed current technological, economic, and ecological standards, offering STAUFF reliable access to the required capacities and resources with the option of demand-based expansion.

Properties and advantages of the surface

• 1,200 hours resistance to red rust/base metal corrosion under practical conditions
• White rust only occurs as a slight gray film
• Exceeds the requirements for the highest corrosion protection class K5 (360 hours resistance to white rust / 720 hours resistance to red rust) for tube connections as defined in the VDMA standards sheet 24576
• Free from hexavalent chromium Cr(VI)
• ELV compliant as per 2000/53/EC (End of Life Vehicles Directive)
• REACH compliant as per 1907/2006/EC (Registration, Evaluation and Authorization of Chemical Substances)
• RoHS compliant as per 2002/95/EC (Restrictions of the Use of Hazardous Substances)
• High-quality look and color with light, slightly shiny surface – comparable to stainless steel
• Reduced tendency for contact corrosion in combination with other metals (e.g. aluminum or stainless steel)
• Improved wear resistance and stability due to high ductility/plastic deformability of the surface coating
• Minimal risk of allergies due to the minimal nickel release. It is below the legally defined limits for objects which come into direct contact and permanent contact with skin (independently evaluated results of the reference test procedure as per DIN EN 1811 are available on request)
• Can easily be painted over 
• Resistance to all usual pressure fluids
• Cleaning is easy with this surface coating 

Barrel Plating

• Most cost-effective method for handling sturdier components which do not exceed defined size, geometry and weight limits and can therefore be handled as bulk goods
• Components are filled into perforated round or polygonal drums which pass through the treatment tanks turning around their axis of rotation
• All treatment stages, from pre-treatment to electroplating and post-treatment to drying, are automated and centrally controlled and monitored

Rack Plating

• For components which cannot or should not be electroplated as bulk goods (i.e. in a barrel) on account of their size, geometry or sensitivity
• Use of individually designed frames and product carriers with suspension brackets designed for the specific products, which transport the components to the various treatment tanks (pre-treatment, electroplating, post-treatment)
• Fully automatic electroplating system, where the entire process (monitoring and check of electrolyte composition, metering of additives, monitoring and control of separation temperature and coating duration) is centrally controlled and monitored

Quality Assurance

• Consistent results are achieved in production, processing, and handling, by following detailed and regularly tested procedures that can be adjusted for better efficiency
• Ongoing quality monitoring integrated in the production process with state-of-the-art inspection methods and systems in electroplating and at the STAUFF Technology Center:
  • Layer thickness tests
  • Corrosion tests (in-house salt spray and climate chambers)
  • Raw depth measurements
• Option for complete traceability by issuing 3.1 acceptance test certificates in accordance with DIN 10204