We are considering switching from a zinc plating to electroless nickel for a leaf spring clip, .020" thick 1050 steel. In the past we have seen cracking/breakage when the spring was press fit into a housing. Our tests to date showed that nickel-plated parts show no cracking during assembly, whereas the zinc plated parts cracked. Hydrogen embrittlement was not found in any parts we tested, but we can't rule it out as a potential problem. Furthermore, both the zinc and nickel plating specs call for an embrittlement bakeout. Is there any theoretical advantage to using a nickel plating over zinc for this application? Corrosion is not a significant factor to us in our decision, but consistent as-plated appearance is important.
