Cadmium plating is currently employed in the corrosion protection of electrical connectors used on civil and military aircraft. It has been the preferred protective treatment for this application since it provides an effective level of corrosion protection, whilst offering galvanic compatibility with structural aluminium alloys. On environmental grounds, the replacement of cadmium plating has been identified as a major priority within the aerospace industry. Cadmium compounds are highly toxic and the use of cadmium plating for many general engineering applications is now prohibited within the European Union. This paper reviews the coating requirements for electrical connectors in terms of corrosion resistance, galvanic compatibility and physical properties. A range of possible alternatives to cadmium plating is considered and data obtained for zinc alloy and aluminium based coatings are presented. Recent research into aluminium alloy and zinc-nickel-manganese electrodeposited coatings is also outlined. It is concluded that several protective schemes may eventually provide suitable alternatives to cadmium plating for connector applications.


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