Tin Plating of Busbars – Benefits and Advantages

This process involves applying a layer of tin, providing corrosion protection, reducing oxidation, and facilitating solderability. In the context of components such as busbars – critical elements in power systems – tin plating takes on particular significance. What specific benefits result from this process for copper or aluminum busbars? Where is it applied, and why is it considered a standard in enhancing operational parameters?

What is Electrolytic Tin Plating?

Electrolytic tin plating (galvanic tin plating)  is a process based on the application of tin layers using acidic or alkaline solutions rich in tin ions. Tin electroplating is carried out in an electrolytic bath – the metal element to be coated serves as the cathode, while tin serves as the anode. As a result of current flow, tin ions deposit evenly on the surface of the object, forming a thin layer with numerous properties. It is worth adding that proper surface preparation plays a crucial role in the entire process – the metal to be tinned must be thoroughly degreased and cleaned, as only then can the desired effect be achieved.

For clarity, it is worth saying more about the main component of the galvanic coating. What is tin? It is a chemical element with the symbol Sn and atomic number 50, characterized by corrosion resistance, ductility, good mechanical properties, and a low melting point. The important properties of tin also include low electrical resistivity and good adhesion to other metals, which is why it is widely used in industry and electrical engineering.

Benefits of Tin Plating Copper and Aluminum

The tin plating process, which is carried out on copper and aluminum elements, provides several benefits. The most important of these include:

• Corrosion Protection: Tin plating protects the metal surface against atmospheric factors (including moisture), which eliminates the risk of corrosion and element degradation.
• Solderability: Tin plating of copper and aluminum facilitates and streamlines the soldering process, which in turn contributes to increased production efficiency of electrical and electronic devices.
• Increased Resistance to Environmental Factors: This refers not only to high humidity but also to various types of pollutants, which is particularly important for metal elements exposed to extreme conditions, e.g., in the automotive, energy, and construction industries.
• Oxidation Protection: Tin is much less susceptible to oxidation than copper, which means that the resulting coating provides metal protection and allows them to maintain their original appearance for longer (this is especially important in decorative applications).

Tin Plating of Busbars and Beyond – Key Applications

All the benefits mentioned above mean that tin plating of aluminum and copper is widely used. It works well in various industries, enabling the creation of durable protective coatings on various types of elements. Tin plating of busbars (tinning busbars) is particularly popular. The technical tin coating provides this type of component with additional protection against corrosion and oxidation, which is crucial in environments where metal elements are exposed to moisture and pollutants. Additionally, tin creates a coating that reduces contact resistance between elements. Thanks to this, current can flow more efficiently, especially in joints and connections. This is especially important for various power components, where minimizing energy losses is crucial. Tin plating of element surfaces also facilitates soldering, which translates into faster and more reliable assembly. Soldered connections are more durable and resistant to mechanical damage.

It is also worth emphasizing that tin creates a durable protective barrier that protects metals against corrosion and other atmospheric factors. Thanks to this, tinned busbars and other components are more resistant to moisture, temperature changes, and chemical exposure. Thanks to the technical tin coating, individual details have a longer lifespan and stability of electrical systems and reduce their failure rate.

Tin plating of copper and aluminum busbars or other non-ferrous metals is not everything. Tin coatings are also used in:

• Power industry: minimizing energy losses and corrosion protection are key objectives in this industry. Tin plating is widely used in switchgears, transformers, and transmission lines to ensure connection reliability and durability.
• Smart grid solutions: smart grids require high precision and reliability. Tin plating of electrical components helps maintain data and energy transmission stability and efficiency.
• Data centers: continuous power supply is critical for data centers. Tin plating of busbars and connectors protects against corrosion and minimizes the risk of failure, which is essential to maintain uninterrupted server operation. Especially now, in the era of AI development, which are operated by modern server rooms, this is so important.
• Railway sector: especially in power and control systems, the tinning process of non-ferrous metal components ensures reliability and safety in difficult operating conditions, which is crucial for the efficient functioning of railway infrastructure.
• Defense and aviation sectors: in these sectors, electrical components, such as contacts and electrical connectors or structural elements, exposed to moisture and variable temperatures, must meet extreme environmental conditions. Tin plating ensures resistance to corrosion, vibration, and extreme temperatures, which is crucial for system reliability.
• Automotive and e-mobility industry: in this sector, the tin plating process is used in various connectors, small busbars, and battery components, ensuring reliability and durability in difficult operating conditions, which is crucial for electric vehicles.
• Various renewable energy (RES) solutions: in wind and solar farms, electrolytic tin plating protects components against corrosion and atmospheric factors, which is essential for the longevity of installations.

Metal Tinning at Electris Coating Systems

At Electris Coatings Systems, we specialize in electrolytic galvanization of non-ferrous metals, such as copper and aluminum, offering, among others, tin plating of busbars and other components. We apply tin coatings with a wide range of thicknesses – from 1 μm to 50 μm. We perform galvanization of elements of various geometry and size up to 2100 mm.

It is also important to emphasize that we also offer the service of combining galvanic and powder coatings on one component. This approach allows for obtaining the desired parameters in precisely defined places of a given element. We approach each order individually, implementing it based on the customer's specific requirements.

If you want to commission us to perform the tinning process of any copper or aluminum element – contact us. Write to: sales@electris.pl, and we will prepare a dedicated offer for you.