Electroplating Introduction
Electroplating is a process that uses electrolysis to deposit other metals or alloys onto the surface of a workpiece, resulting in a uniform, dense, and well-bonded metal layer. Electroplating is primarily used to enhance the surface hardness, wear resistance, and corrosion resistance of workpieces, or to improve their appearance.
Types of Electroplating Technologies
Currently, the main electroplating methods are barrel plating, rack plating, brush plating, and pulse plating.
Barrel plating uses a "barrel" as the electrolytic container. The barrel is typically made of a strong and chemically resistant material, such as polypropylene. The substrate component is immersed in the barrel, and the electrolyte and anode are added. The rotation of the barrel then ensures a uniform coating on each component. However, this may cause minor imperfections and scratches.
Barrel plating coats a large number of small components at low cost. It is particularly suitable for components made of hard materials, such as tool steel bolts, screws, bushings, etc.
In rack plating, multiple components are fixed on a large rack structure within the electrolytic tank. The rack structure can hold multiple components at once and is secured with hooks, straps, or screws. Therefore, the workpiece experiences minimal tumbling effects and complex features can be precisely coated.
Rack plating is suitable for large parts and high-volume electroplating, but it has higher initial setup and labor costs. It can plate copper, gold, nickel, etc.
Electroplating is performed using electrodes wrapped in a soft cloth (or cotton cloth). First, the cotton cloth is immersed in an electroplating solution containing metal ions, then the operator manually applies the coating to specific areas.
Unlike traditional setups, it is portable and offers high customization. Localized coatings can be achieved, suitable for selective coating or repair purposes. However, it is not suitable for parts with large and complex surfaces.
This type of electroplating process uses electrical pulses to plate the substrate. The current rapidly switches between two different levels and returns to zero during the switching, generating pulses. By controlling the pulse width and amplitude, the coating grains are finer and more uniform.
Pulse plating is suitable for parts requiring minimal surface porosity, microcracks, and roughness. However, the setup and operation are relatively more complex than other types of electroplating.
Industrial Applications of Electroplating
Aerospace: Protective sacrificial layers help improve the reliability and lifespan of aircraft components. Manufacturers coat various titanium parts with nickel to withstand thermal changes and environmental stresses. Furthermore, precise dimensions and fits are crucial in aircraft manufacturing. Plating on components resists wear and maintains the correct dimensions required for performance and safety.
Automotive: The reliability of automotive parts is critical to vehicle performance and durability. Therefore, automotive parts require hard, environmentally unaffected coatings, which chrome, zinc-nickel, or palladium plating can meet. Additionally, automakers use electroplating to customize aesthetics.
Electronics: First, coating electrical connectors, contacts, cables, and fittings with a high-quality conductive metal alters the entire electrical properties of the workpiece surface. It improves circuit performance and efficiency. Second, electroplating also contributes to the aesthetic design of housings and protects them from UV rays, corrosion, abrasion, and minor impacts. Furthermore, gold, copper, nickel, and palladium plating are most popular in the electronics industry.
Jewelry: Gold and gold alloys are most popular for jewelry electroplating, enhancing the beauty of ornaments. It can also extend the lifespan of ornaments. Furthermore, a combination of two or more metals can give it a unique appearance. You can also use other precious metals, such as silver and rhodium.
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