Electropolishing & Deburring Case Studies

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Nickel Alloy Electropolishing

Beryllium/Nickel Alloy with Surface Contamination from EDM

Alloy: Nickel

Industry: Electrical

Total Material Removed: .001”
(or half that amount per surface)

Challenge:

  • Delicate ribs showed obvious contamination, burrs, and recast materials
  • Mechanical cleaning had risk of warping or distortion

Solution:

  • All critical surfaces were completely cleaned of surface and sub-surface contamination with electropolishing
  • Removal of stress cracks improved product life

Copper Automotive Stamping with Burrs Cutting into Plastic Mating Surface

Alloy: Brass/Copper

Industry: Electronics/Communication

Challenge:

  • Edges of fingers were causing problems in assembly of the finished product
  • Could not vibra-finish the part due to the fragile nature of the fingers

Solution:

  • Electropolishing removed the burrs and made the part’s surface smoother
  • Achieved without incurring any damage to the fragile fingers

Food Service Wireform

Alloy: Stainless

Industry: Food/Beverage

Challenge:

  • Weld discoloration
  • Surfaces needed to be easily cleaned with minimal food adhesion

Solution:

  • Electropolishing removed the weld discoloration and sub-surface contamination
  • Improved corrosion resistance, achieving a smoother surface that is easier to clean

Gear Teeth Requiring Resizing

Alloy: Steel

Industry: Automotive

Total Material Removed: .0005"
(or half that amount per surface)

Challenge:

  • Heat treating caused the internal gear teeth to grow

Solution:

  • Electropolishing the steel removed varying amounts of surface material until achieving the ideal size
  • Internal gear teeth were resized uniformly, ensuring that the part fit its mate

Machined Brass Part with Burrs Around Outlet Hole

Alloy: Brass/Copper

Industry: Food/Beverage

Challenge:

  • After machining, a burr was produced around the edge of the outlet hole
  • Problem persisted after trying other methods of deburring

Solution:

  • Part was electropolished with a minimum stock removal to clean up the orifice
  • Part now has a controlled, constant stream

Stainless Steel Medical Devices

Alloy: Stainless

Industry: Medical/Dental

Challenge:

  • The teeth of this stainless steel blade had large, hanging burrs
  • Hand deburring was neither an economical nor a consistent solution

Solution:

  • Electropolishing removed the burrs while retaining the sharp blade
  • Ultraclean, exceptionally corrosion resistant surface across the entire part

Stainless Steel Medical Part with Small Holes

Alloy: Stainless

Industry: Medical/Dental

Total Material Removed: .0005"
(or half that amount per surface)

Challenge:

  • This medical part needed to be free of contaminants and burrs to improve release characteristics
  • Because the part has many small holes, hand deburring operations would be time-consuming and imperfect

Solution:

  • Electropolishing the parts removed a uniform amount of surface metal and eliminated potential initiation sites for corrosion and burrs

Titanium Part with Heat Tint

Alloy: Titanium

Industry: Medical/Dental

Total Material Removed: .0003"
(or half that amount per surface)

Challenge:

  • From heat treatment, this titanium part had a film of gray, dusty scale
  • Intricate machined features and small holes proved difficult to clean by other metal polishing techniques

Solution:

  • Electropolishing removed a uniform amount of surface metal from the titanium part, achieving a bright and uniform finish free of tint and scale while maintaining tolerance

Titanium Parts for the Medical Industry

Alloy: Titanium

Industry: Medical/Dental

Total Material Removed: .0005"
(or half that amount per surface)

Challenge:

  • Black, amorphous layer created by thread rolling on titanium parts
  • Premature corrosion due to embedded contamination from tooling

Solution:

  • Electropolishing provided a consistent finish acceptable for a part used in a medical or surgical setting and reduced the coefficient of friction, creating a better finish on the thread
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