Aluminum is used more and more today due to the reasonable cost, ease of machining and light weight. The only negative issue that arises with aluminum is the limited metal finishing options. Unlike stainless steels, you cannot passivate aluminum in order to remove the contaminants on the surface. In addition, there are few options for improving microfinish after machining. Electropolishing is an effective means for providing a part that has an enhanced surface finish and clean surface. Many companies use the electropolishing for parts that are assembled in a clean room, such as laser components.
Aluminum is generally separated two main categories: casting and wrought alloys. Casting alloys are comprised of high amounts of silicon. This lends the casting alloys their low melting points and decent fluidity. But at the same time, lessens their desirable smooth finish.
Wrought alloys have significantly different compositions and microstructures from casting alloys. A wrought aluminum part that has been electropolished will exhibit an improved surface and will be contaminant-free. The surface will also display a shiny finish.
Common aluminum alloys and the results that can be achieved through electropolishing:
| ALUMINUM | COMMENT |
|---|---|
| 1008 | Good Bright Finish After Electropolishing |
| 1100 | Excellent Mirror Type Finish After Electropolishing |
| 2014 | Satin-Pitted Finish – Not Suited for Electropolishing |
| 2024 | Bright Finish After Electropolislhing (Slight Pitting) |
| 3003 | Good Reflective Finish After Electropolishing |
| 4032 | Gray Finish – May Come Out Better With More S/R |
| 5052 | Good Reflective Finish After Electropolishing |
| 5086 | Good Bright Finish After Electropolishing |
| 5350 (Cast) | Bright Finish After Electropolishing (Pitted) |
| 5657 | Good Bright Finish After Electropolishing |
| 6061 | Good Bright Finish After Electropolishing |
| 6082 | Good Bright Finish After Electropolishing |
| 6105-T5 | Excellent Finish After Electropolishing |
| 6463 | Bright Finish After Electropolishing (Some Pitting) |
| 7050 | Good Bright Finish After Electropolishing |
| 7073 | Good Bright Finish After Electropolishing |
| 7075 | Good Bright Finish After Electropolishing |
| Al Cu 31 | Bright Finish After Electropolishing (Pitted & Rough) |
| Al EA70-2 | Very Bright Finish After Electropolishing |
| ALUZINC | Good Finish After Electropolishing (Some Pitting) |
| 2011 | (Bright Finish After Electropolishing (Slight Pitting) |
Why electropolish aluminum? Corrosion always begins on or near the metal’s surface. Unfortunately, all handling and fabricating procedures will eventually degrade the surface integrity and properties. Surface contaminants, including metallic particles, iron, dirt, and grease are a fundamental part of welding, machining, and other fabrication procedures. Mechanical polishing, cutting, handling, and polishing tend to result in extraneous iron and other abrasive particles that are embedded within the surface of the material. These surface contaminants break down the aluminums’ naturally occurring corrosion resistant oxide layer and are often the site where corrosion begins. The electropolishing process dissolves a minute layer of surface material and contaminants, thus freeing embedded particles and increasing the part’s lifespan.
Ultimately, electropolished aluminum will increase the part’s resistance to pitting, localized galvanic corrosion, surface corrosion, crevice corrosion, cracking, stress corrosion, and microbiological corrosion.
At Able Electropolishing, we perform our signature electropolishing treatment on a variety of metal alloys, including aluminum. Following our treatment, parts have an enhanced corrosion resistance, improved microfinish, and are clean and free of harmful contaminants. Along with the commonly used 6061 aluminum, our process is suitable with other alloys such as 1100, 3003, 5002 and 7075.
Contact us to see how we can utilize our metal finishing capabilities for your aluminum parts.
Join the experts at Able Electropolishing via Microsoft Teams to ramp up your knowledge of metal finishing processes and have lunch (or breakfast, if you prefer) on us.
Send us your parts/prototypes and we’ll electropolish them for free – we’ll even pay for the shipping! Samples are processed in 24-48 hours.
From implantable devices to surgical instruments, electropolishing is a single-process treatment that results in biocompatible, safe and ultra clean parts.
We offer aerospace vendors and original equipment manufacturers our signature metal finishing services to increase fatigue-resistance for their metal parts, rendering them capable of withstanding the stress and corrosion that comes with long-term use.
Our strict adherence to industry standards ensures that pharmaceutical components are electropolished in accordance with ASTM B912 and ASME BPE specifications. These products are clean and smooth, corrosion resistant and contaminant free.
Corrosion resistance and microfinish improvement are essential for critical automotive parts, making electropolishing an increasingly beneficial option for automakers.
Our metal finishing services help increase corrosion resistance for these parts, and by removing the outermost layer of metal withelectropolishing the durability and longevity of these appliance components is increased.
Electropolishing materials for this industry eliminates the buildup of bacterial biofilms, as well as keeping the equipment free of contaminants like Salmonella. Electropolishing delivers the level of sanitation required by a number of regulatory agencies.
From robotics to mobile equipment, the uses of electropolishing in the hydraulics and pneumatics industry are many. By helping prevent premature part failure, electropolishing reduces downtime and increases the life cycle of these components.
Improving conductivity and performance is just one benefit electropolishing offers for electronics parts. The surface finish is improved by as much as 50%, removing imperfections from the material without material removal.
For every successful project at Able Electropolishing, there is a meticulous, high-quality process at work behind the scenes. Our clients rely on us for precise and consistent results, customized to the demanding needs of industries like medical device manufacturing, food and beverage production – and industries like yours.
Electropolishing provides an ultrasmooth, ultraclean surface, and improves corrosion resistance for metal fasteners.
Read Able Electropolishing’s guide on passivation, pickling, and electropolishing to learn about the benefits and drawbacks of each for your metal parts.
Across industries, electropolishing is the go-to metal finishing method for parts with no room for error. From aerospace to medical manufacturing, engineers rely on electropolishing to eliminate surface defects and create a hygienic, passive and ultra-smooth finish with improved fit, function and durability.
