According to archaeological research, chemical chrome plating technology was already used on bronze weapons in China 2,200 years ago. The electrolytic chrome plating technology was first reported by German scholar Gerther in his doctoral dissertation in 1856. In the 1920s, Sargent and Fink further developed the hexavalent chromium plating technology using chromate as the electrolyte, which subsequently industrialized the chrome plating process. To date, this technology has a development history of nearly 100 years.
Today, the metal components of many household products and industrial goods are chrome-plated on the surface. This is because the chrome-plated layer not only serves an aesthetic purpose but, more importantly, enhances surface hardness and reduces corrosion of the base metal. Although there are currently various surface decoration and anti-corrosion technologies, chrome plating still occupies an important position. There are numerous chrome plating factories worldwide, and the demand for chrome plating remains strong.
Based on the type of electrolyte used, chrome plating processes are divided into hexavalent chromium processes and trivalent chromium processes. The hexavalent chromium (Cr(Ⅵ)) process, which has been developed to the present day, uses chromic anhydride (CrO₃) as the electrolyte, and concentrated chromic acid solution (CrO₃ + H₂SO₄) is prepared by adding sulfuric acid. The bath solution has extremely high acidity; chromium in chromic acid is reduced from Cr(Ⅵ) to Cr(Ⅲ), and finally to Cr(0). The electrode reaction equations at the cathode and anode during the chrome plating process are shown in Figure 1.
In the Cr(Ⅵ) electroplating process, since the cathode current efficiency is only 10% to 15% and the anode uses an insoluble lead alloy, a large amount of hydrogen gas is generated at the cathode and a large amount of oxygen gas is generated at the anode. When these gases rise to the liquid surface in the form of bubbles and are released into the air, they carry a large number of chromium-containing droplets, forming fog-like pollutants, as shown in Figure 2, commonly known as "chromium fog".
The chromic acid discharged along with the chromium mist accounts for 20% to 40% of the chromic acid used in chrome plating, depending on the working conditions. The generation of chromium mist not only leads to a large loss of chromic anhydride, but the strong corrosiveness of chromic acid also seriously affects the health of workshop workers, and its emission into the atmospheric environment will cause heavy metal pollution. Trivalent chromium uses chromium salts such as chromium chloride (CrCl3) or chromium sulfate [Cr2(SO4)3] as electrolytes. Although the Cr(Ⅲ) process has the characteristics of low plating solution concentration, wide current density range, and low toxicity, due to problems such as poor tolerance to impurities in the process, easy occurrence of pinholes and cracks on plated parts, and the possibility of Cr(Ⅲ) being oxidized to Cr(Ⅵ) during the electroplating process which pollutes the electrolyte, the trivalent chromium Cr(Ⅲ) process did not achieve industrial application until the 1970s. At present, although the trivalent chromium Cr(Ⅲ) process is developing rapidly, the mature hexavalent chromium Cr(Ⅵ) process is still mainly chosen for industrial chrome plating.
References: Application of fluorinated surfactants as chromium mist inhibitors. Organic Fluorine Industry, Issue 4, 2020.