Electrical connectors are not immune to the effects of corrosion, and they are responsible for providing power, signal and data to military systems and heavy industrial vehicles. As a result, a great deal of research has gone into making them more corrosion resistant.
So how does Tin Zinc J plating provide military-grade corrosion resistance while adhering to environmental regulations?
Both military ground vehicles deployed in desert operations and heavy, off-road and construction vehicles face extreme environmental challenges, including scorching daytime temperatures, cold nights and abrasive sand that can degrade their components.
Shifting to coastal areas introduces high humidity and salt air, accelerating corrosion, especially on electrical connectors that are critical for operation.
For decades the defence and heavy industrial sectors have relied on connector plating technologies to ensure the durability and reliability of electronic and communication devices in harsh environments.
Historically, olive drab cadmium plating has been the standard for the military, prized for its corrosion resistance and electrical conductivity.
However, cadmium's environmental and potential health risks have prompted a search for safer, yet equally effective alternatives.
According to the scientific paper Electrodeposition, characterisation and corrosion investigations of galvanic tin-zinc layers from pyrophosphate baths, Tin Zinc alloy deposits are now recognised as suitable alternatives to cadmium coatings due to their outstanding corrosion resistance.
These coatings combine the barrier protection of tin with the galvanic protection of zinc.
High environmental yet low electrical resistance
Tin Zinc J plating can withstand harsh environmental conditions, being rated with a corrosion resistance of over 500 hours of static/5 days of cyclic salt spray endurance as per VG test standards. This resilience ensures that connectors can endure the rigours of extreme weather, exposure to corrosive substances and the wear and tear of rugged terrain, extending the lifespan of military equipment and heavy machinery, while reducing maintenance needs.
The plating also offers high conductivity with a resistance of < 5m ohm. This low resistance ensures a reliable flow of electric current, an essential attribute for maintaining operational integrity in critical communication, navigation and weapon systems.
Military-approved
ITT Cannon’s Tin Zinc J plating is an ultra-harsh environment formulation that exceeds the VG (German Military) performance requirements of cadmium. In fact, Tin Zinc J plating is the official VG approved 1-to-1 replacement for cadmium.
VG standards, set by the German military, are detailed specifications defining requirements for defence industry products and processes. These standards cover aspects such as environmental resistance, durability and electrical performance, including requirements for connectors used in military applications.
ITT Cannon provides Tin Zinc plated connectors on their VG and commercial equivalent lines.
Another benefit of using Tin Zinc J plating over cadmium is that it complies with Restriction of Hazardous Substances (RoHS) and Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) regulations, meaning that it complies to current environmental standards.
The connector for tough environments
Military equipment needs to be designed with durability and quick deployment in mind. Patrols cannot afford equipment failure when in dangerous areas and lives are at stake. Similarly, heavy, off-road and construction vehicles come into daily contact with dust, sand and water.
With this in mind, what would be a reliable connector to use in something like a ground vehicle?
Bayonet connectors are highly valued in military operations for their quick and secure locking mechanism, ensuring a reliable connection with a simple twist-and-lock action. This design minimises the risk of disconnection due to vibrations or impacts and is highly resistant to sand and dust, crucial in dynamic and harsh environments.
Consequently, a Tin Zinc plated bayonet connector would provide a highly conductive, corrosion resistant, environmentally safe, secure and quick connection for a ground vehicle, adding to its operational readiness.
Author details: Achim Raad, Product Manager at defence and industrial connector manufacturer ITT Cannon, whose products are distributed by PEI-Genesis
