Predictive Analysis and Risk Management of Nickel-Plated Aluminum Automotive Parts Exposed to Harsh Environmental Conditions

Aluminium is widely used across various industries due to its lightweight properties, high strength-to-weight ratio, and cost-effectiveness. However, its susceptibility to corrosion, particularly in harsh environmental conditions, presents challenges to its long-term durability and performance. To mitigate these issues, nickel plating was applied as a protective measure, creating a barrier to minimize aluminums' direct exposure to corrosive environments and enhance its resistance to degradation. In this study, nickel-plated aluminum was subjected to controlled corrosion testing under simulated real-world conditions, including high humidity, saline atmospheres, and industrial pollutants. The primary objective was to evaluate the effectiveness and longevity of nickel plating as a corrosion prevention method. Periodic observations and measurements were conducted to monitor material changes, such as surface degradation and corrosion product formation. The findings highlight the critical role of plating thickness, uniformity, and environmental conditions in determining the corrosion resistance of nickel-plated aluminum. Additionally, potential galvanic interactions between the nickel layer and the aluminum substrate were also explored. Based on the study results, recommendations for improving corrosion resistance were proposed, such as optimizing the plating process and incorporating post-plating treatments like passivation or sealing. These insights contribute to advancing corrosion protection strategies, ensuring the sustainability and reliability of aluminum in exposed environments for usage in automotive field.