The metal plating process comprises several steps from pretreatment to post-treatment. There are several plating techniques; however, this aspect will focus on the basic procedures of electroplating:
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The pretreatment helps to remove all harmful contaminants on the substrate that may hinder the plating process. It may involve cleaning, rinsing, and other pretreatments that rid the plating surface of contaminants.
The requirements of your parts often decide the ideal plating process to use. Likewise, it determines how clean your substrate must be before plating occurs. For instance, some CAD plating techniques only require the removal of bulk soil and dirt, while others require the removal of oil and grease.
As electroplating is the focus here, you need materials such as an anode, a cathode, a rectifier, a tank, and a suitable plating solution to set up your plating station.
The deposition process starts as soon as you turn on the electrical current. In cases where a thicker plated finish is required, you must expose the components to the current for longer. However, you may have to consider variables such as temperature, voltage levels, immersion durations, etc.
Post-treatment cleaning is necessary after achieving the desired deposition on your product. Therefore, electrolytic polishing is an effective means of improving the corrosion resistance of manufactured components.
The metal plating finish produces heavy metals, which are usually hazardous because of their high toxicity levels. As a result, an efficient way to dispose of this waste is by pretreating the plating wastewater before its disposal.
Various standard industrial plating finishes are available for use. Here are some of them:
Zinc remains one of the most cost-effective materials that create galvanized metal on metal substrates. Manufacturers use zinc through molten bath dipping and spraying. The substrate takes the cathode position while the metallic zinc takes the place of the anode in a soluble zinc salt electrolytic bath. The zinc plating technique forms a very ductile coating on plated metal, giving you better control over thickness and uniformity.
Chrome plating or alodine finish generally involves using chromic acid and trivalent chromium baths to create an overlay on the metal components. The primary purpose of chrome plating is to enhance the aesthetics of the material.
However, chromium plating finishes increase the hardness of the material, thereby giving it a better corrosion resistance property. Chrome plating can restore tolerances on worn-out parts. These chrome-plated components are generally suitable for industrial applications.
Nickel is another common plating metal valuable in the electroless plating method. Nickel plating helps to create a protective coating on household products such as doorknobs, shower fixtures, cutleries, etc., and it helps to improve its aesthetics and wear resistance properties. This plating method is suitable for aluminum and copper. However, it works well on other metals, serving as a basic plating for chromium.
Copper is the most cost-efficient metal plating that offers high conductivity. Copper plating is standard for electronic products such as circuit boards, and it is a common choice because it provides high plating efficiency and low material cost.
Cadmium plating is a metallic silver tender coating deposited on different base metals such as aluminum, steel, copper, and iron. This process is suitable for coating bolts and screws for submarines and military parachute buckles. In addition, it has high malleability, corrosion resistance, ease of solderability, and chemical resistance.
Silver plating is identical to gold plating as it improves the aesthetic appeal of the material used. It is an excellent metal finish type when electrical conductivity is a factor you need to consider. Many manufacturers use silver plating because of its cost-effectiveness, as it is a better alternative to gold. Also, it is effective for plating parts made from copper.
This metal is famous for its resistance to oxidation and its high electrical conductivity. Gold plating is an effective means of transferring these remarkable properties to metals like copper and silver. It has an enormous application in enhancing the conductivity of electronic parts like electrical connectors.
This industrial finish involves depositing a solderable tin layer coating on a material’s surface using electrical current. Electroplating tin is a very cost-effective process because tin is readily available and costs less than metals like gold, palladium, or platinum.
Rhodium plating is another standard metal plating finish that deposits a thin coating of rhodium on the surface of a piece of jewelry. This process is the same as rhodium dip or rhodium flashing. It helps to enhance the luster, durability, and light reflection of a jewelry piece.
There are various metal plating techniques used in different industries. Here are some of them:
Electroplating is a metal plating technique that involves depositing a metal or metal alloy on the surface of a workpiece. It is a typical metal plating process involving electric currents in an electrolyte solution to dissolve charged metal particles (ions).
The charged (positive) metal ions get attached to the workpiece, while the workpiece, in this case, possesses a negative charge on the circuit. The dissolved metal particles rise to the material’s surface when you put the workpiece in the chemical solution.
Electroplating enhances the chemical, mechanical, and physical properties of a workpiece. It provides a smooth, quick, and even coating on the plated metal. This thin coating forms a protective and aesthetic appearance on the metallic workpiece.
The electroless plating technique is the ideal alternative to electroplating and is a much simpler and cost-effective option. It is also known as autocatalytic or chemical plating because it does not require any external electric current.
Electroless plating deposits metals such as copper, gold, nickel, and silver on the surface of different materials using a reducing chemical bath. It produces catalytic reduction to the path because it is a chemical process that does not require machinery or electricity.
Electroless plating is suitable for hard surface components with excellent corrosion resistance. As a result, the oil and marine industries utilize this process in manufacturing their components. Some common components, such as pumps or valves, often exposed to corrosion, are created with electroless plating technology.
The immersion metal plating process involves immersing a metal into a chemical compound that contains metal ions of a noble metal. The ion present in the noble metal usually is stable.
Thus, a natural pull sets in to dislocate the metal ions from the initial metal giving it a thin layer of noble metal ions. This process is a bit slower than electroless and electroplating processes. Also, it is only suitable for noble metals like platinum, silver, and gold.
Carburizing is a metal plating process that solidifies the surface of a metal while allowing the metal beneath to remain soft. This technique is the same as carburization, surface, or case hardening, and it results in the formation of a thinner and solid layer of metal called the surface case.
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Manufacturers carburize a part after it has been machined to its final form as it helps to make element contents harder, as in pattern welding. Carburizing is an ideal metal plating technique product designers use to prevent corrosion in industries that use metals.
This type of metal plating is a thin film preparation method that physically sublimes the surface of a material source (liquid or solid) gaseous atoms, molecules, or into ionized into ions under vacuum conditions. A film with a specific function is then deposited on the surface of the substrate using a low-pressure plasma or gas.
The essential physical vapor deposition technologies are sputtering deposition, ion plating, vacuum evaporation, arc plasma plating, etc. PVD coating has rapid deposition, strong adhesion, excellent diffraction, and an extensive application range.
This metal plating is a highly flexible and effective thermal spray technique that involves spraying heat-softened or melted materials on the surface of a material to achieve the preferred coating. It uses a powerful spray coating technology that can enable the spraying of various materials such as ceramic, metal, and cermet.
Plasma spray applications include jet engine protection, restoring worn parts, and more. The plasma spraying process offers excellent resistance to wear, abrasion, electricity, heat, and oxidation.
Several industries adopt varying metal plating finishes to the best of their product specifications. These finishes are ideal options for different industries. Here are some of their primary applications:
The aerospace sector electroplates its components to achieve a sacrificial coating. Generally, it increases the path lifespan by minimizing corrosion. Adding an extra metal layer to parts can enhance functionality. This is because aircraft components are usually exposed to considerable temperature changes and several other environmental elements.
Automakers commonly use electroplating to create customized parts for concept vehicles. Various vehicle customization businesses and restoration industries utilize electroplating in applying nickel, chrome, and several other finishes for motorcycle and vehicle components. In addition, vehicle makers use black oxide coating as it is ideal for machined parts and can last longer.
The power industry electroplates solar components to enhance their electrical conductivity. Manufacturers electroplate solar cell contacts and antennas. Also, they electroplate wires using silver, nickel, and other metals.
The medical sector often uses metal plating to add toughness to the components’ surfaces in all medical and dental instruments, preventing metal deterioration. Manufacturers produce tooth inlays with gold plating making them helpful for various dental procedures.
Electroplating is one of the most widely used techniques in the jewelry sector. Manufacturers and designers often use this method to enhance the aesthetic appeal, durability, and color of bracelets, pendants, rings, and other accessories.
There are many different types of metal plating and in its simplest definition, metal plating is a thin covering of metal on top of another metal. This type of metal plating has been used for hundreds of years and is a critical part of modern technology. The reasons for metal plating are as varied as the types of metals used and the processes of plating:
There are many metals used in plating:
There are many different types of metal plating and the process of electroplating is probably the most well known. It involves passing an electric current through an electrolyte solution. Two terminals called electrodes are dipped into the electrolyte solution, which connects them into a powered circuit.
The electrodes are the Cathode (the object being coated) and the Anode (the metal being used as the coating. When the electricity flows through the circuit the electrolyte splits some of the metal atoms from the anode, which are then deposited in a thin layer on top of one of the cathode.
Many types of metals can be electroplated in this process; gold, silver, tin, zinc, copper, chrome, nickel, platinum, and lead.
In the diagram below; copper (the anode) is being used to coat another metal (the cathode). The electrolyte being used is copper sulfate.
When choosing a process for metal plating, one would opt for electroplating. However, in certain cases, there is an alternative; Electroless Plating. Electroless plating is a simpler, more cost-effective alternative to electroplating. Also known as autocatalytic plating, this method is a way of plating without using an external power source.
The process itself involves plating the part in an aqueous solution and depositing nicking. This creates a catalytic reduction of nickel ions to plate the part, as this is a purely chemical process it does not require electricity or extra machinery.
Electroless plating is suited to parts for which a very hard surface, better resistant to corrosion is required. This makes this process best suited to the oil or marine industries. Parts such as pumps or valves that are subject to corrosive agents will typically be best suited to being electroless plated.
This is the process of applying adhering layers of nobler metals to another metal’s surface by dipping the part into a solution of nobler metal ions. So when metal parts made from a material such as copper are put into the electrolyte, the nobler metal ions will coat the parts the copper releases it’s electrons.
Also known as metal replacement or dip plating. Just like electroless plating, there is no external current, it is a chemical process. Unlike electroless plating; once the part is completely coated, the deposition of metals is halted. Immersion coating alters the metal’s surface to improve wear and corrosion electrical resistance and electrical conductivity. It can also alter the appearance and reflectivity and bonding capabilities of the coated part.
Also known as case hardening, carburizing is a heat-treating process that produces a wear-resistant surface whilst maintaining the strength of the core. Usually applied to low carbon steel after machining, as well as high, allow gears, bearings, etc. Carburizing is suited to complex shapes of lower-cost materials that can be machined easily to give a very hard surface. The process involves heating the part in either a pit furnace or a sealed atmosphere furnace.
Then carburizing gases (usually carbon monoxide but also sodium cyanide and barium carbonate) are introduced at temperature, with the heat and temperature affecting the depth of carbon diffusion. The part is then either slow-cooled for quenching later or quenched directly in oil.
PVD is a family of coating processes in which thin films are deposited on the substrate. In the physical vapor deposition process, the solid coating material such as titanium, chromium or aluminum is evaporated by heat or by bombardment with ions. During the process, a reactive gas such as nitrogen is introduced, forming a compound with the metal vapor and depositing on the metal’s surface as a very thin coating. This results in an extremely strong bond between the coating and the metal part.
Some of the advantages of PVD are; a very hard and corrosion-resistant surface, high-temperature resistance, and good impact strength.
Ideal for a wide range of applications:
Plasma spray coating is one of the lesser-known types of metal plating. In this plating process, also known as thermal spraying, molten or heat-softened material is sprayed onto a surface to provide the coating. The coating material is injected into a very high-temperature plasma flame (up to 10,000 K in heat), it is rapidly heated and then accelerated to a high velocity onto the surface of the part and rapidly cools to form a coating on the part’s surface.
The process produces a coating, usually to structural materials, to protect against very high temperatures, for example in exhaust heat management. It also provides resistance to corrosion, erosion, and wear. The coating can also change the appearance and electrical properties of the part.
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