Milling Nickel plated Aluminum

Machinerer · Nov 1, 2021

I've got a rather large part that is going to have to be machined AFTER nickel plating on some faces, due to issues with masking. Does anyone have experiences with this? Best way to avoid chipping where nickel meets aluminum? Am I better off leaving a large or small amount of stock? What about tooling? Will tooling designed for aluminum stand up to the 12µm nickel plating?

Any advice is appreciated.

metalmadness · Nov 1, 2021

barbter said:
Hmmm....this can turn into a complete nightmare.
Nickel is a high tension plating - think of it wrapped tight around the aluminium.
Depending upon adhesion levels, I've seen it scratched, and the nickel plate overnight lift and curl back like a roll back lid on a can of spam!

While I have no direct experience with this, just the idea of it is giving me nightmares. I would exhaust all possible solutions in getting the masking done properly before tryng to mess with machining it.

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