Zinc Nickel Plating
At SAR, we deliver advanced Zinc Nickel (Zn-Ni) electroplating from our state-of-the-art facilities in Manesar and Bawal purpose-built for the demanding quality standards of automotive OEMs and Tier 1 suppliers. As a trusted surface treatment partner in the NCR belt, SAR brings process expertise, OEM-aligned documentation, and consistent deposit quality to every Zinc Nickel job.
What is Zinc Nickel Plating?
Zinc Nickel plating is a high-performance alloy electroplating process where Zinc and Nickel are co-deposited onto a metal substrate to form a corrosion-resistant alloy layer — typically containing 12–15% Nickel. This gamma-phase alloy structure delivers corrosion resistance 5–8× superior to standard zinc plating, making it the preferred choice for critical automotive components.
Unlike conventional zinc plating, Zinc Nickel withstands temperatures up to 200°C, making it ideal for under-hood, brake system, and chassis applications. The alkaline Zn-Ni process used at SAR ensures excellent throwing power on complex geometries, low hydrogen embrittlement risk for high-tensile steel parts, and a consistent nickel content across the deposit — all critical for meeting OEM test specifications.
Why Choose SAR for Zinc Nickel Plating?
As a dedicated automotive surface treatment company embedded in the Manesar–Bawal industrial corridor, SAR brings more than just plating capacity — we bring process ownership and supply chain reliability.
- Automotive-Focused Process Control — Documented parameters, batch traceability, and inspection records aligned with IATF 16949 expectations
- Three Manufacturing Units — IMT Manesar (Units 1 & 3) and IMT Bawal (Unit 2) for capacity and supply continuity
- OEM-Ready Documentation — Process FMEA, Control Plans, and ISIR/FAIR support for PPAP submissions
- RoHS / REACH Compliant Chemistry — Trivalent passivation only; no hexavalent chromium
- Trusted by Leading OEMs — Including Maruti Suzuki India Limited, who nominated SAR as a Potential Supplier
Benefits:
- Superior Corrosion Resistance 1000+ SST
- High Temperature Stability
- Zero Hydrogen Embrittlement Risk
- Exceptional Wear & Ductility
- Versatile Finish Options
FAQ's
Zinc Nickel (Zn-Ni) plating is an alloy electroplating process where Zinc and Nickel are co-deposited onto a metal substrate through an alkaline electrolyte bath. The resulting deposit containing 12–15% Nickel forms a gamma-phase alloy structure that provides significantly superior corrosion resistance, thermal stability, and ductility compared to conventional zinc plating.
With trivalent chromate passivation, Zinc Nickel plating typically achieves 500–720 hours to white rust and 1000+ hours to red rust in Neutral Salt Spray (NSS) testing per ISO 9227 making it one of the highest-performing electroplated coatings available for automotive steel components.
Yes. The alkaline Zinc Nickel process used at SAR significantly reduces hydrogen absorption during plating making it safe for high-strength steel components above 1000 MPa / HRC 32+. A post-plate de-embrittlement bake is performed as standard practice for such components, in line with OEM and IS/DIN specifications.
Yes. SAR’s Zinc Nickel process uses trivalent chromate passivation containing no hexavalent chromium (Cr VI). The coating is fully RoHS and REACH compliant and serves as a globally accepted, cadmium-free alternative for components where cadmium plating was historically specified.
Zinc Nickel plating retains its corrosion protection properties at temperatures up to 200°C unlike standard zinc plating, which degrades significantly above 120°C. This makes it the preferred coating for under-hood fasteners, brake system components, exhaust brackets, and other thermally stressed automotive parts.
Zinc Nickel is widely specified for brake caliper brackets, ABS sensor housings, chassis fasteners, fuel line fittings, suspension clips, engine bay bolts, and EV battery tray hardware any component where high corrosion resistance, thermal stability, and hydrogen embrittlement safety are simultaneously required.
Yes. SAR offers both Clear/Blue and Black passivation finishes for Zinc Nickel plating. Black Zinc Nickel is commonly specified for fasteners, brackets, and components where a dark aesthetic finish is required alongside high corrosion performance without the need for additional painting or coating layers.
Yes. SAR supports full PPAP submissions for Zinc Nickel plating, including Process Flow Diagrams, Process FMEA, Control Plans, MSA studies, and Initial Sample Inspection Reports (ISIR / FAIR) aligned with IATF 16949 requirements and major OEM customer-specific requirements across the automotive supply chain.
SAR Coatings operates three manufacturing units two in IMT Manesar, Gurugram and one in IMT Bawal, Rewari — strategically located within the NCR automotive manufacturing belt. We serve OEMs and Tier 1 suppliers across Gurugram, Manesar, Bawal, Rewari, Delhi, and ship to customers pan-India.