Electropolishing: Ultracleaning and Decorative Finishes

Electropolishing for Ultracleaning and Decorative Finishes

Perhaps the best known application for electropolishing is decorative finishing. This is only a small part of the story. While the bright finish is the trademark of electropolishing, the key benefits of surface cleansing are much more than a shiny appearance. Since the process removes surface metal, virtually all surface impurities are removed as well. Ultraclean parts are completely free of residual dust, embedded scale, foreign debris, oils, grinding compounds, and other materials.

Electropolishing is capable of removing heat tint from welding and heat treating operations. Removing heat tint and the embedded oxides from machining and polishing compounds is achieved by removing controlled amounts of material. After electropolishing, the part is clean, passive, in tolerance and ready for assembly.

 

An electropolished part has the following characteristics:

Non-Coating

Unlike paints, plating or Teflon coatings, an electropolished surface does not peel or abrade. This is especially important where particles from coating abrasion can cause equipment malfunction or other hazards. Typical areas include food or pharmaceutical processing, high vacuum assemblies, pure gas/water systems and critical switch assemblies.

Non-Distorting

Electropolishing can provide a uniform on complex or fragile parts that do not lend themselves to conventional finishing methods. There is no effect on surface hardness and no stresses are introduced to the part.

Stain/Corrosion Resistant

Since electropolishing removes embedded impurities and smoothes a metal surface, the resulting finish is more resistant to corrosion, tarnish or oxidation. These properties are especially evident on stainless steel, but also found on carbon steel, brass, aluminum and copper. While all these alloys are more resistant, we do not routinely recommend electropolishing as a substitute for coatings designed to protect a metal part in harsh environments.

Improve Weldability

In critical spot weldments, electropolished components are more conductive. The improved conductivity allows better, stronger welds at lower voltage. In other welding or brazing operations, electropolished surfaces generally weld more readily with less weld splatter and surface damage.

Ultracleaning Case Study: Deburring, Decontamination and More

This part is fabricated from a beryllium/nickel alloy, used in a switch application. The ribs are cut by wire EDM, formed to shape, followed by heat treat. The customer was looking to remove surface and embedded contamination from both the EDM process and subsequent handling.

Ultracleaning Case Study -1

Under 100x and then 500x magnification, the delicate ribs show obvious contamination, burrs, and recast materials on all sides and edges. Because of the soft alloy and very critical shaping, this part did not lend itself to mechanical cleaning for fear of warping or distortion. Additionally, critical dimensions eliminated the possibility of chemical etching, which often has widely varying stock removals. The part required deburring and the removal of surface and sub-surface contamination sites.

Ultracleaning Case Study - 2

By carefully controlling material removal, all critical surfaces were completely cleaned of surface and sub-surface contamination. The amorphous layer was removed as well, exposing the true base metal. In this and similar cases, electropolished parts will pass strict clean room standards. Additionally, in high stress/high cycle switching applications, the removal of stress cracks extends product life (see case histories in de-stressing).

Contact us to learn more about electropolishing and ultracleaning

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Medical Device Manufacturing

Medical Device Manufacturing

From implantable devices to surgical instruments, electropolishing is a single-process treatment that results in biocompatible, safe and ultra clean parts.

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Aerospace

Aerospace

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.

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Pharmaceutical

Pharmaceutical

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.

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Automotive

Automotive

Corrosion resistance and microfinish improvement are essential for critical automotive parts, making electropolishing an increasingly beneficial option for automakers.

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Consumer Appliance

Consumer Appliance

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.

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Food & Beverage

Food & Beverage

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.

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Hydraulics & Pneumatics

Hydraulics & Pneumatics

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.

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Electronics

Electronics

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.

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Electropolishing Blog

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If you’re manufacturing parts with 440C stainless steel and relying on passivation to get the finish you need, you may be overlooking an opportunity to dramatically improve the corrosion resistance of your parts.

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While electropolishing is best known for the results it achieves as the last step in the process for finishing critical metal parts, it can also be an interim step for improving the results of parts that will undergo plating.

Biocompatibility and Electropolishing for Medical Manufacturing

The biocompatibility of medical devices, implants and instruments to ensure that every part that comes into contact with the human body poses no risk of irritation or harm is a fundamental requirement for medical manufacturers.

Electropolishing Process with the Highest Standards of Quality Control

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.