Carbon steel, including mild steel, is a widely used metal alloy which primarily consists of iron and carbon. The carbon content in carbon steel can vary from as low as 0.05% to as high as 2.1% by weight. Apart from carbon, it can also contain trace amounts of other elements, such as manganese and sulphur.
Carbon steel comes in different variants, including low carbon steel, commonly referred to as mild steel, medium, and high carbon steel. Each variant has its own characteristics, such as ease of shaping, strength, ductility, and hardness.
Compared to other steel alloys like stainless steel, carbon steel has a relatively lower chromium content and relies more on its carbon content for its key properties. The alloy is widely used in various industrial applications because of its excellent strength, durability, and affordability.
Carbon steel applications
The components we plate in carbon steel vary enormously, largely because the application is driven by what each customer needs rather than by any standard list, and we would always rather talk a part through than turn it away. A good deal of the work coming through our Leigh facility does fall into a few familiar areas though, including:
- Precision machined parts
- Electronic contacts
- Automotive components
- Agricultural components
- Bolts and fasteners
If your components sit outside those, it is still worth getting in touch, and sending us a drawing is the quickest route to an accurate quotation.
Downside of carbon steel
Whilst carbon steel is a common and widely used steel, it has drawbacks that limit its applications. One major disadvantage is that increasing its carbon content for more strength makes it less flexible, decreasing weldability.
Another drawback is that the high carbon content often increases the cost of production. Moreover, carbon steel is prone to rust and oxidisation, especially in moist or humid conditions.
How plating can enhance carbon steel application
However, coating and electroplating can be applied to carbon steel to prevent rust and oxidation, making it more suitable for a wider range of applications. This is the most common reason for plating carbon steel, leading us perfectly to the benefits of plating carbon steel:
- Increase its resistance to corrosion by plating carbon steel with nickel
- Cost-effective electroless plating methods
- Enhance the visual aesthetics.
- Increase conductivity.
- Improved wear resistance of components
The most common plating methods
Zinc plating of carbon steel
Zinc plating is one of the most common ways to protect carbon steel components from corrosion, adding a sacrificial zinc layer that corrodes in preference to the steel beneath. This significantly improves corrosion resistance and extends component service life in many general purpose environments.
Depending on the specification, zinc coatings can also provide a bright, aesthetically pleasing finish. Because zinc is relatively inexpensive compared with many other metals, zinc plating offers a cost effective protection method for manufacturers. It is particularly advantageous for parts that may be scratched in service, as the zinc continues to protect exposed steel through its sacrificial action.
Transitioning to Zinc Nickel plating
Industries, particularly the automotive sector, are shifting towards zinc/nickel plating techniques to enhance resistance. According to experts, zinc-nickel plating can provide up to 5 times more protection than normal zinc plating, increasing the durability and quality of components.
Nickel plating of carbon steel
Nickel plating is a common choice on carbon steel where a component has to resist wear as well as corrosion, and it gives a harder surface than zinc will. It is also frequently specified as an undercoat beneath another finish, which is where a good deal of our dual plated work begins. If you are working to a particular thickness or to a customer specification, let us know when you enquire and our team will confirm what we can achieve on your parts.
Tin plating of carbon steel
Tin plating comes into its own on carbon steel components that carry current, which is why electronic contacts and electrical hardware make up a fair proportion of the tin work we handle. It solders well and it is a forgiving finish to work with, so it tends to be the sensible option where conductivity matters more than surface hardness.
Dual plated finishes
Some components need more than one layer, and we regularly apply dual plated finishes to carbon steel where a single coating will not do everything the part is being asked to do. These are specified case by case rather than chosen off a menu, so the best approach is to tell us what the component has to withstand in service and our team will come back to you with a recommendation.
Plating Process
Preparing carbon steel and mild steel before plating is important for great adhesions and quality finish. At Karas, we support customers with high-quality carbon steel plating with fast lead times but, most importantly, without compromising the quality and consistency of the finish. To achieve this, we offer a range of cleaning and blasting services to ensure that the metal is free from any contaminants prior to plating.
Hydrogen embrittlement relief
Carbon steel components can be vulnerable to hydrogen embrittlement during plating, particularly higher strength parts, fasteners and anything that has been hardened. We carry out a post plating de-embrittlement treatment to address it, and if your parts fall into that category it is worth flagging it at the enquiry stage so that we can build the step into the process route from the outset.
Carbon steel plating FAQs
Can you electroplate mild steel?
Yes, and mild steel is one of the most common substrates we handle. Preparation matters a great deal here, which is why we clean and blast components before plating to make sure that the coating adheres properly.
How much carbon is in carbon steel?
Anywhere between roughly 0.05% and 2.1% by weight. That range is what separates low, medium and high carbon grades, and it drives how the material behaves in terms of strength, ductility and how easily it can be worked.
Get In Touch
For professional carbon steel plating services, schedule a consultation with our team of experts. We are dedicated to delivering superior results that meet the highest industry standards.