One of the key factors that determine the performance and longevity of connectors is the type of plating used. Plating bolsters the durability and functionality of connectors while also providing protection against environmental factors such as corrosion, extreme temperatures, and mechanical wear.
At Amphenol Aerospace, we offer a range of plating options designed to meet the rigorous demands of various operational environments. Our plating solutions are tailored to enhance connector performance, ensure compliance with industry standards, and meet specific application needs. What type of plating to opt for on your connectors is going to depend on your application and what you’re seeking to accomplish with your interconnect solution.
Choosing the Right Plating
Selecting the appropriate plating option depends on several factors, including environmental conditions, mechanical requirements, and regulatory compliance. For applications in harsh environments with high corrosion risk, Amphenol Aerospace Durmalon or Black Zinc Nickel plating are excellent choices due to their superior resistance properties. For connectors subject to high wear and frequent mating cycles, Electroless Nickel offers enhanced durability and wear resistance.
Many of our popular plating options meet RoHS compliance, which restricts the use of multiple harmful substances in electrical and electronics equipment, including cadmium. In projects requiring RoHS compliance, both Durmalon and Black Zinc Nickel provide environmentally friendly alternatives without compromising on performance. For the most demanding environments, AP-93 plating provides exceptional corrosion resistance and durability, while passivated stainless steel is an excellent choice for applications that require superior resistance to corrosion and tarnishing, especially in naval and aerospace environments.
See below for further details on some of our most popular plating options.
Durmalon Plating
Durmalon is a plating option designed as an environmentally friendly alternative to traditional cadmium (Cd) as the military and aerospace markets continue to move away from restricted materials such as cadmium and Hexavalent Chromium (Cr(VI)). It is RoHS compliant and offers outstanding protection against corrosion. Durmalon, like Olive-Drab Cadmium plating (Class W), meets 500 hours of dynamic salt spray, combined with 500 mating cycles and meets specified millivolt drop shell-to-shell conductivity. Durmalon also meets a 392 °F (200° C) temperature rating. Durmalon plating is particularly suitable for applications in rugged environments where both environmental compliance and superior performance are required.
Black Zinc Nickel Plating
Black Zinc Nickel is an advanced plating option that combines the protective qualities of zinc and nickel with an attractive black finish. It offers excellent corrosion resistance and is a RoHS-compliant alternative to traditional cadmium and other hazardous coatings. Black Zinc Nickel can withstand 500 hours of salt spray and performs excellent against corrosion, with 500 mating cycles and a temperature rating of 347 °F (175° C). Black Zinc Nikel is commonly used with commercial aerospace and military applications that are increasingly opting for RoHS compliant plating over Cadmium.
AP-93 Plating
AP-93 plating is a high-performance, RoHS-compliant tri-nickel alloy used for aluminum connectors, designed as an alternative to cadmium. This plating offers superior corrosion resistance, capable of withstanding 1000 hours of salt spray exposure. It meets the shell-to-shell conductivity requirements of MIL-DTL-38999 Class F and is compatible with existing cadmium finishes, making it a suitable drop-in replacement. AP-93 plating also supports up to 500 mating cycles and is rated for operating temperatures up to 200°C. Additionally, it passes 336 hours of sulfur dioxide (SO2) exposure, ensuring reliability in harsh environments. This plating is particularly beneficial in applications requiring extreme durability and corrosion resistance, such as military, aerospace, and industrial sectors.
Electroless Nickel Plating
Amphenol Aerospace's Electroless Nickel plating provides a uniform layer of nickel-phosphorus alloy on connectors, providing exceptional corrosion resistance and withstanding up to 1000 hours of salt spray in high-resistance formulations depending on shell or composite application. It offers excellent wear resistance and maintains strong shell-to-shell conductivity crucial for effective EMI shielding. This RoHS-compliant plating can operate at temperatures up to 392°F (200°C), ensuring reliability in high-temperature environments. The uniform deposition characteristic of Electroless Nickel plating ensures consistent coverage even on complex geometries.
Passivated Stainless Steel
Passivated stainless steel plating offers excellent resistance to corrosion and tarnishing, making it ideal for applications exposed to harsh environmental conditions. This plating involves treating the stainless-steel surface to remove contaminants and enhance the natural protective oxide layer, resulting in improved performance and longevity. Passivated stainless steel provides excellent protection against rust and corrosion, enhancing the strength and durability of connectors and ensuring long-lasting performance. It is non-toxic and safe for use in environments where toxic materials are a concern. This makes it ideal for marine and aerospace applications where connectors are exposed to moisture and corrosive elements. Additionally, it is suitable for high-temperature applications capable of withstanding extreme temperatures, making it perfect for use in harsh environments.
Plating Options for Any Harsh Environment Application
At Amphenol Aerospace, we understand the critical role that plating options play in the performance and longevity of connectors. By offering a range of high-quality, specialized platings, we ensure that our connectors meet the various challenges that military and aerospace applications face when operating in harsh environments.
For more detailed information and information on more plating options, or to discuss your specific needs, our team of experts is always available. Contact us today for more information.