Corrosion pitting in service — pits become crack starters under cyclic load
Every one of these lives in the first few thousandths of the surface — exactly the layer electropolishing removes.
Compare: recast-removal methods — pickling vs. etching vs. electropolishing
Criterion
Acid pickling
Chemical etching
Electropolishing
Removes recast layer
Partial / incidental
Inconsistent
Complete, incl. microcracks
Removal control
Aggressive / uneven
Widely varying
±.0002″, precise
Fatigue impact
Neutral–negative
Neutral–negative
Improved
Pitting / intergranular risk
High
Moderate–high
Low
Leaves part passivated
✗ No
✗ No
✓ Yes
Recast microcracks are fatigue initiation sites under cyclic load. Only electropolishing removes the layer and its microcracks with bounded removal while improving finish and fatigue life. Source: Able technical evaluation, EDM Recast Removal — Process Comparison.
Where it matters most
Medical implants & stentsAerospaceAutomotiveHydraulics
The full story — problem & solution
The problem
Micro-cracks and surface imperfections act as stress concentrators. On parts that cycle — springs, flexures, stents — those defects propagate into fatigue failure long before the base material reaches its limit.
How electropolishing solves it
By dissolving the imperfection layer where cracks initiate, electropolishing removes the stress risers themselves. It greatly improves the life of components that function as springs and is standard practice on Nitinol and other cyclically-loaded medical alloys.
Fatigue life isn’t the only thing the pass buys you.
Springs, wire forms and shafts usually need passivation anyway — and the surface that resists crack initiation is the same surface that resists corrosion pitting, which becomes an initiation site of its own under cyclic load. One operation covers the crack origins, the passive layer, and the finish.
3-in-1Deburred, defect-free and passivated in one pass.
Electropolishing can eliminate the separate deburr, clean and passivation steps a part would otherwise need — outperforming passivation and pickling across the board.
● Fewer handling steps ● Shorter lead time ● Lower cost per part
Every case file we have — open any for the full story and photos.
Showing 8 of 52 case files
Send us the part. Samples are free.
Attach a print, tell us the alloy and the problem, and Able’s engineering team will process free samples — typically in 24–48 hours — with a documented recommendation before you commit a lot.
Or call (888) 868-2900 · 2001 S. Kilbourn Ave, Chicago, IL 60623
The challenge & result
Components in nickel, tantalum, Kovar, and stainless require a precise Ra value to maintain conductivity between mating parts. An inadequate surface finish can cause unwanted arcing, and where high voltage is present an improper finish interrupts the current path — leading to costly equipment damage. Electropolishing brings the finish to the specified value on every surface, including those a tool cannot reach.
Independent ASTM B-117 coupon test — all four alloys, every sample. Raw 410, 420, and Trinamet corrode by 24 hours and severely by 888; every electropolished coupon shows no rusting at either checkpoint. — Able Electropolishing · independent lab
The challenge & result
Independent-lab ASTM B-117 testing ran coupons of 304, 410, 420, and Trinamet side by side — every sample shown here, raw against electropolished, at 24 and 888 hours. The raw 410, 420, and Trinamet coupons corrode by 24 hours and severely by 888 — while every electropolished coupon, on every alloy, shows no rusting at either checkpoint.
“At SPM, we machine a lot of medical and dental components. Corrosion resistance, as well as cosmetic appearance, is of the utmost importance. Without hesitation, we turn to Able to help us with our electropolishing needs. There are times when parts come back from a process, such as heat treatment, and they are darker than the customer would like. Our solution is electropolishing — the customer gets a more corrosion resistant product, and a more aesthetically pleasing one.”
303 SS after 2,560 hours of salt spray — passivated (left) vs. electropolished (right). — Able Electropolishing
The challenge & result
With SPM, parts were passivated per all three ASTM A967 methods (citric, nitric 5, nitric 1) and a fourth group electropolished per ASTM B912, then salt-spray tested 72 hours per ASTM B117-16 at Exova. Red rust appeared on every group except the electropolished one — 303's higher phosphorus and sulfur make it prone to flash attack when passivated, and under a microscope a flash-attacked surface is rougher than the raw material it started from. A passivated/electropolished pair photographed after 2,560 hours shows the gap dramatically. Passivation is the cheaper line item; on 303 it is not always the cheaper outcome, because a batch that flash attacks is a batch of scrap.
“At SPM, we machine a lot of medical and dental components. Corrosion resistance, as well as cosmetic appearance, is of the utmost importance. Without hesitation, we turn to Able to help us with our electropolishing needs. There are times when parts come back from a process, such as heat treatment, and they are darker than the customer would like. Our solution is electropolishing — the customer gets a more corrosion resistant product, and a more aesthetically pleasing one.”
430 SS auger & 304 SS wire weldment, independent ASTM B-117 salt spray — raw and passivated rust at the welds; electropolished stays clean through 144 hours. — Able Electropolishing · independent lab
The challenge & result
In independent ASTM B-117 testing, the raw and passivated augers showed advanced red corrosion after 144 hours while the electropolished part showed only light corrosion at the extremities. The raw and passivated weldments rusted at the resistance welds within 72 hours; the electropolished weldment showed no visible corrosion — EP treats the carbide precipitation in the heat-affected zone and improves the chrome-to-iron surface ratio.
“At SPM, we machine a lot of medical and dental components. Corrosion resistance, as well as cosmetic appearance, is of the utmost importance. Without hesitation, we turn to Able to help us with our electropolishing needs. There are times when parts come back from a process, such as heat treatment, and they are darker than the customer would like. Our solution is electropolishing — the customer gets a more corrosion resistant product, and a more aesthetically pleasing one.”
A customer wanted to drop to a lighter-gauge material on an automotive tube. Able electropolished candidate alloys for independent ASTM B117 testing; the electropolished stainless showed no visible rust even after 888 hours, letting the customer cut weight and cost while still hitting the corrosion requirement.
“At SPM, we machine a lot of medical and dental components. Corrosion resistance, as well as cosmetic appearance, is of the utmost importance. Without hesitation, we turn to Able to help us with our electropolishing needs. There are times when parts come back from a process, such as heat treatment, and they are darker than the customer would like. Our solution is electropolishing — the customer gets a more corrosion resistant product, and a more aesthetically pleasing one.”
For a washdown food-processing environment, 316 stainless was chosen for a hydraulic cylinder. ASTM B117 testing ran 1,000 hours: a cold-drawn part corroded at 24 hours, while the milled-and-electropolished part showed no corrosion at any point in the test.
“At SPM, we machine a lot of medical and dental components. Corrosion resistance, as well as cosmetic appearance, is of the utmost importance. Without hesitation, we turn to Able to help us with our electropolishing needs. There are times when parts come back from a process, such as heat treatment, and they are darker than the customer would like. Our solution is electropolishing — the customer gets a more corrosion resistant product, and a more aesthetically pleasing one.”
Custom 316L fittings for semiconductor chemical-distribution systems require a 10 Ra µin (or better) wetted-surface finish after electropolishing, a chromium-to-iron ratio of at least 1.5:1, and a chromium-oxide-to-iron-oxide ratio of at least 2:1 — verified by optical exam, ESCA, Auger, and SEM. Able's process meets the SEMI F19 specification.
“At SPM, we machine a lot of medical and dental components. Corrosion resistance, as well as cosmetic appearance, is of the utmost importance. Without hesitation, we turn to Able to help us with our electropolishing needs. There are times when parts come back from a process, such as heat treatment, and they are darker than the customer would like. Our solution is electropolishing — the customer gets a more corrosion resistant product, and a more aesthetically pleasing one.”
Rust had formed in a recessed area of a brazed assembly where mechanical polishing could not reach without damaging the copper braze. Electropolishing dissolved the corrosion out of the recess while leaving the braze joint intact, restoring a clean, passive sealing surface.
“At SPM, we machine a lot of medical and dental components. Corrosion resistance, as well as cosmetic appearance, is of the utmost importance. Without hesitation, we turn to Able to help us with our electropolishing needs. There are times when parts come back from a process, such as heat treatment, and they are darker than the customer would like. Our solution is electropolishing — the customer gets a more corrosion resistant product, and a more aesthetically pleasing one.”
Rescue harness parts need an ultrasmooth finish and corrosion resistance to survive outdoor rescue work and the friction of lines running over them, and their size and shape make mechanical finishing impractical. Able runs heat treat, media blast, and electropolishing as one routed flow through its supplier network — about 100 batches a year, roughly 13,000 serialized, batch-tracked parts to date. As the customer put it, everything is serialized "since there is human life hanging off of it."
“At SPM, we machine a lot of medical and dental components. Corrosion resistance, as well as cosmetic appearance, is of the utmost importance. Without hesitation, we turn to Able to help us with our electropolishing needs. There are times when parts come back from a process, such as heat treatment, and they are darker than the customer would like. Our solution is electropolishing — the customer gets a more corrosion resistant product, and a more aesthetically pleasing one.”
Corroded production racks transferred black marks to the silicone devices they held; electropolishing restored them to production condition and stopped the scrap. (Illustration.) — Able Electropolishing · Acme case study
The challenge & result
Corrosion spots on the stainless steel racks used to produce a drug-infused urinary device were marking finished devices and driving scrap costs to $70,000 per month. On the recommendation of the customer's metallurgy SME, Able electropolished the racks back into production condition immediately — and through the Trusted Supplier Network arranged replacement racks from Acme Wire in parallel. One vendor, both problems solved.
Prototype parts arrive from every process — 3D printing, CNC, injection molding, EDM, laser cutting, stamping — and leave electropolished, ready for certification. (Illustration.) — Able Electropolishing
The challenge & result
Able finishes prototype parts produced by DMLS, 3D printing, photochemical machining, metal injection molding, EDM, laser cutting, and stamping — establishing the final surface finish early so the production spec is locked before certification, and the finished prototype is presentable to customers and investors.
Lock rods were being mechanically polished, a slow operation that filled the plant with aluminum dust. Electropolishing replaced it with a single controlled chemical step — brighter parts, lower labor, and the dust complaint gone with it.
Dual drill bit for neurosurgery — cutting edge at 230× and 300×, with the SEM locations marked on the part. Burrs removed, edge condition preserved. — Able Electropolishing · Deburring Whitepaper
The challenge & result
Grinding burrs prevented the mating bits of a dual drill assembly from rotating freely and degraded cutting — with burr flake-off posing a biohazard to the patient. Removing .0005" ±.0001" from the bit O.D. eliminated the burrs while preserving the cutting edge condition.
What electropolishing delivered here
No mechanical contactEffective on any hardnessReaches internal features
From the field
“We used to use passivation, but it was just a dull finish that didn't look very good. I don't know who found Able for us to try the electropolishing route, but it's a night and day difference.”
316 SS slotted medical fastener — large slot burr from machining, gone after electropolishing. — Able Electropolishing
The challenge & result
A medical fastener came out of machining with a large burr in the slotted head — and the manufacturer was hand-deburring lots of 10,000 and up. Electropolishing removes the slot burr consistently across the entire lot, while also removing contamination and improving corrosion resistance and microfinish in the same operation.
What electropolishing delivered here
No mechanical contactEffective on any hardnessReaches internal features
From the field
“We used to use passivation, but it was just a dull finish that didn't look very good. I don't know who found Able for us to try the electropolishing route, but it's a night and day difference.”
Titanium edge at 600× — torn, ragged machined surface before; uniform deburred edge after. — Able Electropolishing
The challenge & result
Machining leaves titanium edges torn and ragged at magnification — exactly the kind of feature mechanical deburring can't chase on delicate geometry. Electropolishing dissolves the damaged material preferentially, leaving a uniform, smooth edge with no mechanical contact and no induced stress.
What electropolishing delivered here
No mechanical contactEffective on any hardnessReaches internal features
From the field
“We used to use passivation, but it was just a dull finish that didn't look very good. I don't know who found Able for us to try the electropolishing route, but it's a night and day difference.”
Aerospace component — ragged, smeared hole edge before; clean, uniform edge after electropolishing. — Able Electropolishing
The challenge & result
Drilled and countersunk holes come off the machine with smeared, ragged edges — burrs that mechanical methods struggle to chase around a bore without damaging the surrounding surface. Electropolishing cleans the full edge uniformly, leaving a defined, burr-free hole.
What electropolishing delivered here
No mechanical contactEffective on any hardnessReaches internal features
From the field
“We used to use passivation, but it was just a dull finish that didn't look very good. I don't know who found Able for us to try the electropolishing route, but it's a night and day difference.”
420 SS vegetable peeler blades — as-ground burrs (left) vs. electropolished (right); .002″ total removal proven optimal through sampling. — Able Electropolishing · Deburring Whitepaper
The challenge & result
Ground blade edges were sharp but ragged, and the food-contact part had to be free of metal shavings. Electropolishing as the final operation removed .002″ from blade thickness — extensive sampling proved that the optimum — leaving blades burr-free, shaving-free, and measurably sharper than in the as-ground condition.
What electropolishing delivered here
No mechanical contactEffective on any hardnessReaches internal features
From the field
“We used to use passivation, but it was just a dull finish that didn't look very good. I don't know who found Able for us to try the electropolishing route, but it's a night and day difference.”
416 SS pneumatic valve sleeve — ID and OD deburred with an in-house bipolar rack, ~.0002″ removed through the bore. — Able Electropolishing
The challenge & result
A sleeve with through-holes and multiple O-ring grooves needed the ID and OD deburred; the tight clearance to its mating spool meant any burr would cause the valve to malfunction and wear early. Able built an in-house bipolar rack to run an electrode through the entire ID, removing ~.0002" from the bore.
What electropolishing delivered here
No mechanical contactEffective on any hardnessReaches internal features
From the field
“We used to use passivation, but it was just a dull finish that didn't look very good. I don't know who found Able for us to try the electropolishing route, but it's a night and day difference.”
A drawn stamping with cross-holes failed fuel-system cleanliness tests (rivaling medical-device limits) — tumbling couldn't reach the burrs. Sampling found .001" total removal optimal; hundreds of thousands of parts were processed and third-party lab analysis consistently passed the particle-count spec.
What electropolishing delivered here
No mechanical contactEffective on any hardnessReaches internal features
From the field
“We used to use passivation, but it was just a dull finish that didn't look very good. I don't know who found Able for us to try the electropolishing route, but it's a night and day difference.”
Stapler components have to be burr-free or staples jam in the track, and the parts also carried heat-treat discoloration from hardening. Electropolishing removed the burrs and the discoloration in the same operation, without touching the geometry the staple feed depends on.
What electropolishing delivered here
No mechanical contactEffective on any hardnessReaches internal features
From the field
“We used to use passivation, but it was just a dull finish that didn't look very good. I don't know who found Able for us to try the electropolishing route, but it's a night and day difference.”
A heavy-gauge stamped part was failing prematurely; fissures and cracks at the elliptical ends of its narrow slots were the root cause. Able ran test lots to dial in removal parameters, eliminated the fissures, and the part passed stringent bench testing — a key factor in the customer winning a large contract for the new design.
What electropolishing delivered here
Removes crack initiation sitesStandard for spring componentsCritical for Nitinol devices
From the field
“Phenomenal.”
Stainless spring wire at high magnification — surface tears and debris removed, leaving smooth defect-free wire. — Able Electropolishing
The challenge & result
Engine wire forms weren't meeting fatigue life under high/low psi cycling. Electropolishing removed the micro surface cracks, and the parts subsequently fatigue-tested well over 900,000 cycles. Electropolishing was added to the final design.
What electropolishing delivered here
Removes crack initiation sitesStandard for spring componentsCritical for Nitinol devices
From the field
“Phenomenal.”
Chrome-silicon valve spring at 500× — surface stress from forming and shot peening, then electropolished. — Able Electropolishing
The challenge & result
A high-cycling valve spring (1" dia. × 2") needed greater endurance, a demand that started in racing and spread to production vehicles. Shot peening plus electropolishing, with removal held to a tight tolerance lot-to-lot, lengthened spring life by 50%.
What electropolishing delivered here
Removes crack initiation sitesStandard for spring componentsCritical for Nitinol devices
From the field
“Phenomenal.”
Nitinol arterial clips — R&D validation established the optimal stock removal for the implant. — Able Electropolishing
The challenge & result
The maker of a tiny Nitinol arterial clip needed the precise stock-removal level that gives the best microfinish. Able brought the client into the Chicago plant for a day of real-time testing with micrometer, profilometer, and microscope — establishing exact specs and keeping their FDA timeline on track.
What electropolishing delivered here
Removes crack initiation sitesStandard for spring componentsCritical for Nitinol devices
T-head, oval-neck, and square-neck track bolts from ⅜" up to 4" diameter came out of forging and shot blasting with discoloration and surface defects hurting durability and corrosion resistance. Electropolishing smooths the fasteners — a critical advantage for water works customers — and Birmingham now direct-ships finished parts from Able without inbound re-inspection.
What electropolishing delivered here
Full thread deburringBulk processing availableImproved fit & function
From the field
“It's been fantastic… You can send parts over there and everything gets taken care of.”
Sharp burr edges on the threads of a 48" ball screw that raises and lowers recreational vehicles caused the assembly to gall and seize. After a three-year evaluation, electropolishing eliminated the burr edges; the assembly ran far past the client's 5,000-cycle standard test with no lockup, and EP became a standard part of their design.
What electropolishing delivered here
Full thread deburringBulk processing availableImproved fit & function
From the field
“It's been fantastic… You can send parts over there and everything gets taken care of.”
Gear teeth — directional grinding marks and micro-tears blended into a uniform low-Ra flank surface. — Able Electropolishing
The challenge & result
Ground cutting teeth on a heat-treated 410 stainless part needed both microfinish improvement and cleanup of heat-treat discoloration and light scale. At 45X the grinding marks and clinging debris were clearly visible; at 300X the ground edge showed hanging burrs at roughly 16 µin. Removing .0007″ blended the majority of the grinding marks while retaining most of the cutting edge, and because removal concentrates on the leading edge the burrs came off completely — finishing near 8 µin, clean and free of scale and oxides.
What electropolishing delivered here
50% Ra reduction (16 → 8 µin typical)Max benefit at ~.0005" removal/surfaceNo induced stress
Knurled surface before and after microfinishing — grinding texture leveled into uniform, bright flanks. — Able Electropolishing
The challenge & result
Microfinish improvement tracks stock removal on a steep-then-flattening curve: a roughly 16 µin as-ground surface improves to about 12 µin with just .0002" total removal, 10 µin at .0004", and about 8 µin at .001" — beyond which additional removal yields no further surface improvement. That curve is why Able samples each part to find the optimal removal rather than defaulting to more.
What electropolishing delivered here
50% Ra reduction (16 → 8 µin typical)Max benefit at ~.0005" removal/surfaceNo induced stress
A delicate Electrical Discharge Machined contact for a ceramic substrate had a rough recast surface that risked damaging the pad and arcing. Removing approximately .0005" total eliminated the recast layer and produced a smoother, application-ready finish.
What electropolishing delivered here
50% Ra reduction (16 → 8 µin typical)Max benefit at ~.0005" removal/surfaceNo induced stress
Alex Wifler with the recurve-bow plunger Able electropolished — components tested by Olympic archers. — Able Electropolishing
The challenge & result
A competitive archer’s magnet-based plunger — one of only two parts the arrow touches on release — needed a smoother, better-looking finish. Electropolishing was “night and day… just way smoother,” and the part drew raves for “unparalleled consistency” from Olympic test archers.
What electropolishing delivered here
50% Ra reduction (16 → 8 µin typical)Max benefit at ~.0005" removal/surfaceNo induced stress
A fail-safe fire-detection system uses a 316 stainless ring to continuously reflect UV light, requiring a flawless, uniform reflective surface that mechanical polishing couldn't achieve. Able's electropolishing produced the imperfection-free reflective finish — and has run the part continuously for more than 10 years.
What electropolishing delivered here
50% Ra reduction (16 → 8 µin typical)Max benefit at ~.0005" removal/surfaceNo induced stress
Drive gears were running noisier than spec allowed, and the tooth form left no room for a mechanical finishing pass. Removing .0005" smoothed the tooth flanks enough to quiet the motor while holding the tooth size inside its dimensional window.
What electropolishing delivered here
50% Ra reduction (16 → 8 µin typical)Max benefit at ~.0005" removal/surfaceNo induced stress
Metal-injection-molded injector bodies needed recessed internal sealing lips brought to an 8 Ra finish — surfaces no abrasive tool can reach. Roughly .002" of removal hit the finish, and the removal was held to ±.0002" across hundreds of thousands of parts.
What electropolishing delivered here
50% Ra reduction (16 → 8 µin typical)Max benefit at ~.0005" removal/surfaceNo induced stress
Nitinol wire at 600× — drawn-wire striations and surface defects removed, leaving smooth, uniform wire. — Able Electropolishing
The challenge & result
Electropolished surfaces are highly resistant to biofilm production — surface leveling eliminates the nooks where bacteria harbor. Fatigue testing on Nitinol rotary endodontic instruments showed electropolished instruments last significantly longer, and on orthodontic arch wires EP strengthens the titanium dioxide passive layer, improving corrosion resistance and reducing toxicity exposure to the patient. Processed per ASTM F86.
USDA Agricultural Research Service studies on stainless used in meat and poultry found electropolishing the most effective finish at repelling bacterial adhesion and biofilm organization (salmonella, E. coli, listeria). Electropolishing was the most resistant surface of eleven finishes tested.
A blasted 304 hopper suffered severe product buildup and cleaning problems with powdered foods. Electropolishing smoothed the blasting impingement and eliminated the microscopic peaks and valleys, so powder flowed freely and cleaning times dropped.
Worn tooling left burrs and rollover on every edge of the run; controlled electropolishing dissolved them uniformly with no mechanical contact, returning the full production quantity to print spec. (Illustration.) — Able Electropolishing
The challenge & result
A stamper ran hundreds of thousands of components for textile machinery on tooling that had gone bad, leaving burrs across the entire production run. Hand-deburring a lot that size was not realistic and scrapping it was expensive. Able electropolished the parts instead — the burrs dissolved uniformly, every part in the run came back to spec, and the customer shipped the full quantity.
What electropolishing delivered here
Removal control to ±.0001"Scrap recovery on hardened partsOrder standard stock, EP to size
Surgical tube end view at 75× — standard .025″ wall stock electropolished to final .0235″ sizing; cutting burrs and debris removed in the same pass, tubes ready for clean-room purifying. — Able Electropolishing · 7 Solutions Tech Guide
The challenge & result
Tubes previously required special-order .0235" wall material — expensive and hard to get, with cutting burrs complicating sizing. Switching to standard .025" stock and electropolishing off .0015" delivered final wall dimension while removing all burrs and debris, leaving tubes ready for clean-room purifying and assembly.
What electropolishing delivered here
Removal control to ±.0001"Scrap recovery on hardened partsOrder standard stock, EP to size
Standard-gauge stock electropolished to final thickness — .0500″ down to .0499″ at ±.0001″ control per surface — then stamped to print, with no special-order material. (Illustration.) — Able Electropolishing · 7 Solutions Tech Guide
The challenge & result
A close-tolerance titanium stamping needed a material thickness that wasn't readily available. Coupons were electropolished to the required tolerance before stamping, letting the customer hit print specs while avoiding special material orders entirely.
What electropolishing delivered here
Removal control to ±.0001"Scrap recovery on hardened partsOrder standard stock, EP to size
Internal gear teeth on a carbon-steel yoke grew during heat treat and finished oversize, and the teeth were unreachable for conventional sizing once hardened. Electropolishing took the growth back out to bring the teeth into print, recovering a lot that was otherwise scrap.
What electropolishing delivered here
Removal control to ±.0001"Scrap recovery on hardened partsOrder standard stock, EP to size
Impeller under fluorescent penetrant — uniform pre-cleaning (±.0002″) opens true indications to the dye; tight-tolerance bores masked. (Illustration.) — Able Electropolishing · case: Aerospace Tech Guide
The challenge & result
Various-sized impellers in 17-4 PH stainless, aluminum, and Inconel needed uniform pre-cleaning before fluorescent penetrant inspection to avoid masking critical defects. Able developed a process removing a specific amount of material ±.0002" from all outside surfaces, masking extremely tight-tolerance bores at the customer's request.
Welded 304 SS wire rack — weld discoloration removed across the assembly in one operation. — Able Electropolishing
The challenge & result
Weld discoloration marks the heat-affected zone where chromium has been pulled from the surface — a weak point for corrosion and a variable no downstream process wants. Electropolishing removes the oxide and restores a uniform, chromium-rich surface across every joint in one operation, with no hand-finishing of individual welds.
The wire surface was too rough and too contaminated from forming and lubrication to hold a plated finish, and the part was showing adhesion problems and flaking of the plated material. Electropolishing removed the contaminated outer layer left behind by the manufacturing and lubrication processes, smoothing the wire underneath so the plating had clean base metal to bond to. The same removal improved the spring’s cycle longevity.
A manufacturer of beryllium copper contacts for two-way radios was chasing conductivity problems. The cause was a die break around the part edges that was still there when the contacts went out for plating. Electropolishing eliminated the die break ahead of the plating step and the conductivity problem was resolved.
304 SS wire weldment — weld discoloration and heat-affected-zone oxide removed across every joint. — Able Electropolishing
The challenge & result
Welding leaves heat tint and oxide across the heat-affected zone — discoloration that isn't just cosmetic, since the depleted chromium layer beneath it corrodes first. Electropolishing removes the discolored layer across every joint in one operation, restoring a uniform chromium-rich surface without hand-finishing each weld.
What electropolishing delivered here
Removes alpha case & EDM recastRemoves heat tint & scaleMore conductive — better spot weldsNot a coating — can't peel
From the field
“We use Able to electropolish and passivate some of our surgical instruments. Their customer service is very helpful.”
Beryllium-nickel comb with EDM wire-cut slots — recast, heat-treat discoloration, and embedded contamination removed. — Able Electropolishing
The challenge & result
A beryllium-nickel alloy part with EDM wire-cut slots, followed by heat treating, carried embedded contamination from both processes — recast layer, heat-treat discoloration, and debris lodged in the slots. Electropolishing removed all three in one operation, reaching every slot without mechanical contact.
What electropolishing delivered here
Removes alpha case & EDM recastRemoves heat tint & scaleMore conductive — better spot weldsNot a coating — can't peel
From the field
“We use Able to electropolish and passivate some of our surgical instruments. Their customer service is very helpful.”
Friction and heat from thread rolling left a black amorphous layer that solvents and ultrasonic cleaning could not touch. Removing roughly .0005" from the diameter (.00025" per surface) cleaned and passivated the threads in one step — and the lower coefficient of friction reduced galling risk.
What electropolishing delivered here
Removes alpha case & EDM recastRemoves heat tint & scaleMore conductive — better spot weldsNot a coating — can't peel
From the field
“We use Able to electropolish and passivate some of our surgical instruments. Their customer service is very helpful.”
Glass-fusing a critical aerospace battery component in an oven left a green oxide layer that had to come off entirely. Electropolishing removed it, leaving a uniform oxide-free surface, and the assemblies passed stringent leakage testing.
What electropolishing delivered here
Removes alpha case & EDM recastRemoves heat tint & scaleMore conductive — better spot weldsNot a coating — can't peel
From the field
“We use Able to electropolish and passivate some of our surgical instruments. Their customer service is very helpful.”
17-4 PH cutting wheel — heat-treat discoloration removed; bright uniform surface with tooth edges preserved. — Able Electropolishing
The challenge & result
A splined 17-4 stainless gear came out of heat treat with heavy discoloration across the rim, the tooth form, and the hub. Electropolishing dissolved the discolored outer layer instead of blending it mechanically, reaching into the spline roots and the recesses between teeth where abrasive methods cannot work evenly. The part came back bright and uniform with the tooth geometry intact.
What electropolishing delivered here
Removes alpha case & EDM recastRemoves heat tint & scaleMore conductive — better spot weldsNot a coating — can't peel
From the field
“We use Able to electropolish and passivate some of our surgical instruments. Their customer service is very helpful.”
A copper can holding the oxygen-producing chemicals for commercial-airliner emergency breathing masks had to be completely contaminant-free and resist oxidation through years of storage. Electropolishing removed the outermost metal layer and the contaminants with it in a single step; the part met or exceeded all design and testing specifications.
What electropolishing delivered here
Removes alpha case & EDM recastRemoves heat tint & scaleMore conductive — better spot weldsNot a coating — can't peel
From the field
“We use Able to electropolish and passivate some of our surgical instruments. Their customer service is very helpful.”
Cockpit control parts in 15-5 stainless carried an EDM recast layer the customer worried would interfere with mating, moving parts — and the parts were also falling outside the size tolerances called out on the print. Electropolishing solved both in one operation: the remolten layer came off, the surface smoothed, and a pre-determined amount of stock brought the parts back inside the tolerance band.
What electropolishing delivered here
Removes alpha case & EDM recastRemoves heat tint & scaleMore conductive — better spot weldsNot a coating — can't peel
From the field
“We use Able to electropolish and passivate some of our surgical instruments. Their customer service is very helpful.”
A tray fabricated from multiple stainless alloys, perforated and spot welded, sits constantly immersed in cooking oil and in contact with food, leaving numerous points of surface contamination. Electropolishing cleaned every weld area and perforation in one pass, leaving a smooth, easy-to-clean surface with a visibly brighter finish.
What electropolishing delivered here
Removes alpha case & EDM recastRemoves heat tint & scaleMore conductive — better spot weldsNot a coating — can't peel
From the field
“We use Able to electropolish and passivate some of our surgical instruments. Their customer service is very helpful.”
Learn everything you need to know about electropolishing as part of a private, interactive webinar. Let us know your availability and your part issues and our electropolishing experts can get you on our schedule.
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.
Electropolishing, Passivation and Metal Surface Analytics Blog
Precise & Effective Deburring for Critical Parts
They may be microscopic, but the tiny jagged microburrs left behind on metal parts that have undergone machining processes can be big problems for manufacturers.
Improve the Finish, Fit & Function of Refractory Metal Parts
The extreme heat resistance and resilience characteristic of refractory metals like niobium, molybdenum, tungsten, tantalum and TZM make them useful in applications like aerospace components, small modular reactor components and other parts that must withstand extreme environments.
Electropolishing for More Durable, Corrosion-Resistant Springs
A wide array of modern assemblies for everything from aerospace parts to medical devices depend on high-quality springs that must perform to incredibly precise specifications, often in very tiny spaces.
Electropolishing for Small Modular Reactor Component Performance
Small modular reactors are entering component fabrication under tight schedule pressure. Across every coolant technology, surface integrity is becoming a qualification gate — not an afterthought.
What are the maximum part sizes that can be processed for electropolishing, passivation, and vapor degreasing?
Electropolishing:
300 & 400 series stainless steel: 108” Length x 41” Width x 42” Height
Copper, brass, aluminum, steel, and nickel alloys: 72” Length x 14” Width x 17” Height (best results are achieved on parts that are no larger than 12” square)
Titanium, Nitinol, tungsten, and niobium, etc. (refractory metals): 26” Length x 8-3/4” Width x 9-3/4” Height
Passivation:
Standard nitric acid passivation: 72” Length x 30” Width x 30” Height
Nitric acid/sodium dichromate: 20” Length, 20” Width x 20” Height
Citric acid: 26” Length x 18” Width x 15” Height
Vapor degrease:
Vapor degrease (vacuum): 23” Length x 16” Width x 10” Height
Note: If there is a question regarding our capabilities, please email a print for review to sales@ableelectropolishing.com.
What information do you require in order to receive a quotation?
We need a copy of the drawing, service needed, lot and annual quantities, process specification and packaging requirements.
What is your standard lead-time?
Standard delivery is 3 to 5 working days after receipt of order. Next day and same day services are offered at an additional cost. Please contact our sales department for further details.
What is the difference between passivation and electropolishing?
Passivation is a chemical process designed to remove free iron and other contaminants from the part surface. Electropolishing is an electro-chemical process that removes surface metal which improves micro finish, provides deburring and adds to the aesthetics of your part.
