Benefits of Electroplating | Uses for Electroplating | SPC

Sharretts Plating Company has been providing a wide range of industry-best metal finishing and plating solutions since . Over the years, we have developed and perfected our industrial electroplating processes that make use of various metals and metal alloys to achieve the desired result for our customers. Electroplating can offer a number of important features and benefits that can help you improve the quality of your manufacturing processes and enhance your competitive position in the marketplace.

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The process of electroplating, which in simple terms involves using an electrical charge to attach a thin metal layer or coating to an object such as an industrial part, is nothing new. For decades, many industries have benefited from the way that electroplating can increase the durability or improve the appearance of the plated piece. Sharretts Plating Company is widely recognized as a leader and innovator in the industrial use of electroplating for businesses of all types and sizes.

AUTOMOTIVE APPLICATIONS

One common industrial application of electroplating is in the automotive industry. Electroplating is frequently used to refurbish old parts such as bumpers, grills and tire rims to make them look brand new. Electroplating on plastic is also used for chrome-plating the lightweight but sturdy parts that are a staple of the modern automobile. Palladium plating is used in the manufacturing of catalytic converters due to its ability to absorb excess hydrogen. *Please note that Sharretts Plating does not plate with chrome. This content is for educational purposes only.

CORROSION PROTECTION

The industrial use of electroplating is also a popular choice in businesses when corrosion against protection is necessary to prevent the premature demise of metal materials. Nickel plating, Tin plating and their various alloys are all used for corrosion protection on nuts, bolts, housings, brackets and many other metal parts and components. Gold electroplating also provides superior corrosion and tarnish protection, although it is more expensive than other plating processes.

ELECTRICAL COMPONENTS

Industrial applications of electroplating include use on electrical parts and components. Silver electroplating, for example, is often used on copper or brass connectors due to its superior conductivity. Other precious metals such as gold and palladium plating are commonly used for switchgear in the telecommunications industry.

OUR INDUSTRIAL ELECTROPLATING CAPABILITIES ENCOMPASS A WIDE RANGE OF MATERIALS

Over the course of nine decades in business, SPC has developed and perfected cost-effective electroplating techniques for many different types of metals and metal alloys. We've also mastered the difficult process of plating on challenging materials such as titanium and plastic. We even provide electroless plating services, which involve the deposition of metals onto a substrate without the use of electricity. Each plating material has its own unique characteristics and specific user benefits. Read on to learn more about our capabilities for specific types of plating materials.

We're all familiar with copper pennies and the use of copper in electrical wiring. Copper is a soft, malleable metal that has served mankind well for thousands of years. Some of the more notable qualities of this reddish-brown metal are its ability to conduct electricity and its inherent flexibility.

Electroplating copper can be extremely valuable in applications such as the manufacturing of electronic parts and components, as well as products used in the aerospace and defense industries. Copper is also widely used for plating on plastics and other non-metallic surfaces. Key copper electroplating benefits include excellent corrosion protection, high thickness build and heat treatment stop-off.

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Nickel is a lustrous, silvery-white metal that offers many functional and decorative advantages. Types of nickel electroplating include sulfate ' which is typically used to brighten the surface of a substrate ' and sulfamate, which is used in applications where increased substrate strength and reduced stress are desired.

Key nickel plating benefits include enhanced corrosion protection, greater wear resistance and increased surface thickness. You'll find nickel plating in specific manufacturing processes such as the production of electronic and computer parts and components, as well as various telecommunications industry applications.

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The electroplating of tin, or 'tinning,' is often viewed as a cost-effective alternative to plating with more expensive materials such as gold, silver or palladium. Tin's relatively low cost and abundant supply makes it a popular choice for many different industrial applications, such as the manufacturing of electronic parts and components, hardware products, fasteners, screws, nuts and bolts.

Key tinning benefits include excellent resistance against surface corrosion, high solderability and good contact resistance. One disadvantage of the tin electroplating process is that it led to the formation of sharp microscopic protrusions known as 'tin whiskers.'

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Like tin electroplating, zinc electroplating is often chosen when cost is a primary concern. One key advantage of plating with zinc is its compatibility with just about any type of metal. Zinc can also produce a wide range of surface colors. In its natural state, zinc will provide a silvery-gray finish, although colors such as blue, yellow and black can be achieved.

Important zinc plating benefits include excellent adhesion and its resistance to hydrogen embrittlement. Because of its superior adhesive capabilities, zinc plating is sometimes used to provide a base coat prior to painting. Zinc plating is frequently used in the manufacturing of washers, bolts, nuts, transmission components, armored personnel carriers and tanks.

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Gold, also known by its chemical symbol 'Au,' is referred to as a precious metal because of its relative scarcity and exceptionally high value. This also makes Au electroplating more expensive than other types of plating methods. However, gold offers many important plating benefits that can make the higher cost extremely worthwhile. We're all familiar with the beauty of gold, which makes it a preferred plating option when aesthetics are important. That's why gold electroplating is commonly used to provide a gleaming finish for fine jewelry.

From a functional standpoint, gold offers superior corrosion protection and wear resistance, excellent electrical conductivity, and reliable protection from intense heat. If cost is not an object, gold is usually the best electroplating choice.

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Silver is another precious metal that can be used in a wide range of plating applications. Silver offers the advantage of being somewhat less expensive than gold or platinum, while still offering important benefits. Because of its remarkable ability to conduct electricity and heat, implementing a silver electroplating solution has gained widespread use in the manufacturing of solar panels.

Electroplating silver onto a substrate also increases its resistance to corrosion. Because of its compatibility with other types of metals such as aluminum and tin, silver is sometimes alloyed with these materials. This can also provide a cost-effective alternative to employing silver electroplating alone.

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You may be familiar with a precious metal known as platinum. Rhodium is a member of the platinum family that is relatively difficult to find. Thus, rhodium electroplating can be even more expensive than plating with gold. However, rhodium's glittery, reflective properties make it a popular choice as a finish for white gold jewelry products.

From a functional standpoint, rhodium electroplating offers remarkable protection against corrosion. It smoothes the surface of an object and improves its durability. In addition to jewelry manufacturing, rhodium electroplating is often used in the production of catalytic converters.

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Palladium is another precious metal that is sometimes used as a substitute for gold in the plating process because of its lower cost. While relatively soft in composition, palladium is still somewhat harder than gold. As with other precious metals, palladium is frequently used to provide a lustrous finish for fine jewelry.

In some instances, an additional gold coating may be plated atop the palladium layer to strengthen the surface of the substrate. Other important palladium electroplating benefits include superior protection against corrosion and reducing wear resistance. Industries that make use of palladium electroplating include electronics, jewelry, and the manufacturing of medical and dental products.

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Another commonly applied plating alloy features the combination of zinc and nickel, with zinc serving as the primary component. The addition of zinc provides increased protection against corrosion. Zinc-nickel coatings have been proven to withstand the formation of white rust for up to 500 hours and red rust up to 1,000 hours during salt spray testing.

This significantly exceeds the capabilities of either zinc or nickel alone. From a cosmetic standpoint a zinc-nickel alloy will provide a stainless steel-type appearance that is often desirable for many types of metal parts. Zinc-nickel also provides excellent surface coverage and excellent uniformity of the plate distribution.

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The desire to offer a more cost-effective substitute for gold plating led to the development of a palladium-nickel alloy. The alloying of palladium with nickel reduces the stress on the deposit and makes the palladium less susceptible to cracking.

As with gold plating, palladium plating offers superior corrosion protection, while also providing good solderabilty reduced porosity. A palladium-nickel combination is also able to withstand high temperatures, making it compatible with applications involving extreme heat. The normal ratio of palladium to nickel can range from 70/30 to 80/20.

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One disadvantage of plating with palladium is its softness. This can be rectified by creating a palladium-cobalt alloy. An offshoot of the palladium-nickel plating process, this alloy can offer another acceptable substitute to gold because it can provide similar results at a lower cost.

In fact, palladium-cobalt electroplating can result in cost savings of as much as 90 percent when compared to many gold plating processes. Another advantage is that the palladium-cobalt process is easier to control from a quality standpoint. Palladium-cobalt plating is often used in electronics and semiconductor manufacturing, as it offers better control over plating thickness.

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Plating on non-metallic substrates such as plastic is generally more challenging than plating onto metal surfaces. While difficult to master, electroplating on plastic offers many important benefits. For instance, applying a copper coating onto a plastic surface can enable the object to conduct electricity. It can also increase the aesthetic appeal ' a shiny metallic-looking object is often more attractive than a plain, dull plastic item.

This process is often used on the plastic features of electronic parts and components to increase conductivity. The fashion industry also uses plating on plastic to give certain clothing items a shiny appearance.

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As with plastics, plating on titanium is difficult to execute. There are only a few plating companies that currently have the expertise to perform the process effectively. With the increasingly widespread use of this lightweight yet strong metal in industries such as aerospace and medical products manufacturing, finding an effective way to plate metals onto titanium has become a necessity. Adding a nickel coating to a titanium part will make it more resistant to corrosion, while plating platinum onto titanium is often used for aesthetic purposes.

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Yet another daunting industrial electroplating challenge is the process of plating onto magnesium. As with titanium, magnesium offers an attractive combination of lightweight and superior strength that makes it amenable to a wide range of industrial and manufacturing applications.

Magnesium's primary disadvantage is that it's highly susceptible to corrosion. Plating on magnesium will limit the impact of corrosion and can also improve the appearance of the substrate. However, magnesium is a highly reactive metal, so proper pretreating is required to ensure successful plating results.

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Plating can take place without the introduction of an electrical current into the plating bath. Electroless plating is a process where metal ions are deposited onto the surface of the substrate via chemical reaction. This makes it easier to plate irregularly shaped parts and provide a more even, uniform coating.

Electroless plating can also be used to provide conductive base coating prior to electroplating a non-conductive part. Two common electroless plating processes are electroless nickel and electroless chrome plating.

• Electroless nickel plating ' Electroless nickel plating solutions can consist of a nickel-phosphorous alloy to increase a substrate's resistance to corrosion. A nickel-boron alloy is the best choice for limiting the impact of wear and tear over time. As one of the most innovative electroless nickel platers in the industry, SPC has also developed a revolutionary black electroless nickel coating known as SMITH-EN-BLACK'.
• Electroless chrome plating ' An electroless chrome plating solution actually consists of an electroless nickel bath that includes a one-percent cobalt component. The cobalt element produces a brighter, chrome-like appearance than provided by electroless nickel alone.

At SPC, our expertise is not limited to offering exceptional electro- and electroless plating services that provide maximum benefit for our customers. With the understanding that choosing the right plating process is not an easy decision, we also provide plating consulting services that can make your selection process easier. We'll evaluate your current manufacturing processes and provide a reliable recommendation that best meets your company's needs and budget requirements.

If your company performs plating in-house, we can also provide effective training. With 90 years in the metal finishing business and a staff that offers hundreds of years of combined metal finishing industry experience, you can count on us to quickly get your team up to speed on the latest plating concepts and techniques. Our goal is to be your plating resource, whether plating takes place at our facility or your plant.

CONTACT SPC TO LEARN MORE ABOUT THE MANY INDUSTRIAL USES OF ELECTROPLATING

To learn more about the industrial use of electroplating and to get help in selecting the right plating process for your business, contact the electroplating experts at SPC today. We'll be happy to provide additional details regarding plating benefits, as well as provide a no-obligation quote.

You can also learn more about the benefits of each plating service we offer by visiting our individual plating service pages. Sign up to receive our informative e-newsletter, and stay informed on the latest developments in the metal finishing industry!

Electroplating is a common surface finishing process in the manufacturing industry to coat a material (substrate) with another metal. In recent years, the process has undergone many advances, making it much more accurate and capable of working with a wider range of materials.

In this article, we will explore the modern electroplating process to understand what it is, how it works, its benefits and limitations.

What Is Electroplating?

Electroplating is a manufacturing process in which a thin layer of metal atoms is deposited to another material through electrolysis. The metal added is known as the deposition metal, and the underlying material or workpiece is known as the substrate material.

By adding a layer of the desired metal, we can improve several physical, mechanical and chemical properties of the substrate, such as its strength, heat conductivity, electrical conductivity, abrasion and corrosion resistance.

Improving these properties can allow us to combine different metals to achieve properties that perfectly suit different applications.

How Does the Electroplating Process Work?

The electroplating process works on the principle of the electrolytic cell.

In this process, two metal rods are placed in an electrolyte. The rods act as electrodes when connected to the opposite terminals of a battery or power supply to create a potential difference. The electric current causes the electrolyte bath to disintegrate into dissolved metal ions, and the positively charged metal ions deposit on the negative electrode (cathode).

These positively charged ions are part of the electrolyte. As they get deposited on the cathode, their concentration in the electrolyte reduces. By choosing a suitable element for the anode, we can replenish the concentration of the positive ions.

For instance, if we need to coat brass with copper, the brass becomes the substrate. Connecting it to the negative terminal makes it the cathode. We use an electrolyte, such as a copper sulfate solution, that gives positive copper ions upon disintegrating. On the other end, we use a copper anode to replenish the electrolyte's positive ions.

We can control the plate thickness, rate of metal deposition, surface finish, colour and many other factors by manipulating the process parameters. For example, using pure copper plates will give a better appearance than regular copper rods available in the market.

Using this process, the material can be coated with one or more metals.

Are you interested in learning more about electro plating power supply? Contact us today to secure an expert consultation!

Types of Electroplating Methods

Over the years, the electroplating process setup has evolved to suit different applications. By choosing a method in line with the application, the efficiency of the operation can be increased significantly.

To choose the right one, we must first understand the different types. Overall, electroplating methods can be divided into four major types. These are:

1. Mass plating

2. Rack plating

3. Continuous plating

4. In-line plating

Mass Plating

Barrel plating

As the name suggests, mass plating is used for mass-production applications. The method can handle a large volume of products that require thin coatings of metal.

A common type of mass plating method is known as barrel plating. In this method, the material to be coated (substrate) is dipped in a barrel containing the metal salt (electrolyte) and the anode of the coating metal.

The barrel plating setup is highly economical for small parts that need a uniform coating. As the barrel rotates, all the parts are cleaned, descaled and uniformly coated to a greater extent compared to rack plating.

This method is not recommended for parts that require a detailed finish without scratches and entanglement.

Mass plating is generally used for small but robust parts such as nuts, bolts and screws.

Rack plating

Rack plating

When the parts are larger than those suitable for mass plating, the rack plating method is used. In rack plating, the parts are mounted on racks and immersed in the chemical electroplating bath.

The rack plating process reduces the damage to delicate or fragile parts and coats the interior contours and deep crevices of parts, unlike mass plating.

This process is, however, more expensive than mass plating. But it makes up for it by providing a plated layer of much higher quality than a mass-plated product.

Rack plating is typically best for large, fragile and complex parts that require a plating of gold, silver, tin, copper or nickel.

Continuous plating

The continuous plating process is performed on exceptionally long parts, such as metal tubes, wires and strips.

In the case of thin strips, this process is also known as the reel-to-reel plating process. In this process, a long product is passed through the chemical bath at a specified rate. The end product's quality is controlled by manipulating the process parameters and the time spent in the bath.

The reel of the product to be coated is uncoiled at the initial station, and once it passes the electrolyte/anode and gets coated, it is recoiled for easier storage and transport. Then further operations can be performed to stamp it into the required shapes.

In-line plating

The in-line plating method uses an assembly line for the metal plating operation. The metal passes through the various stations and automated machinery facilitates the chemical reaction.

Line plating is generally used for coating copper, zinc, chromium and cadmium. A variety of substrates can be coated with these metals through line plating. This method is relatively cheaper than other methods because a lower amount of chemicals is needed per piece.

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Suitable Materials

Electroplating is a versatile process owing to the fact that it requires only one property in the substrate: electrical conductivity.

Since this property is exclusively available with metals (barring a few exceptions), we could initially use electroplating only for metals. But with the advent of conductive sprays and coatings, it is now possible to coat non-conducting materials such as plastic and wood too.

As a result, today, there are many more materials that can be electroplated. The substrate material can greatly vary depending on the application.

Silver or gold plating is often used to improve the appearance. To improve properties such as bacterial resistance and conductivity, copper plating is a favourite. Copper electroplating also offers increased malleability, lubricity and corrosion resistance.

Similarly, when we need to improve corrosion and wear resistance simultaneously, we go for nickel plating. Nickel also improves the appearance of the product.

Some other metals that are normally used for coating in electroplating are chromium, cadmium, zinc, iron and titanium.

But the substrate and the coating must be chosen carefully. Not all materials combine with each other. For example, steel cannot be plated with silver right away. It must first be plated with copper or nickel before silver plating.

Benefits

The first modern electroplating plant was set up in Hamburg in the late 19th century. The intention was to improve the appearance. But as science understood the mechanism and benefits of electroplating, its applications for non-decorative purposes became common.

Today, we understand the true breadth of electroplating benefits. Let's list them down for a better overall understanding.

Improved physical properties (colour, lustre, conductivity, low weight)

Electroplating improves physical properties such as colour, lustre and conductivity.

Colour and lustre provide cosmetic upgrades that are necessary for many day-to-day products as well as art applications.

Everyday appliances and kitchen products such as utensils, pans, cutlery, taps, kettles and other gadgets become much more attractive when coated with shinier metals such as copper, gold or silver. It also improves their functionality, as electroplated products are often easier to clean.

The appearance of artistic installations such as sculptures and figurines can also be improved by using electroplating. As a result, electroplating also finds use in art restoration and preservation projects besides new art creation.

Functionality can also receive a boost in technical applications involving electrical components such as antennas and integrated circuits. Although metals are already conductive, coating them with a better conductor improves the overall conductivity of the part while keeping costs low.

Costs are also reduced by the fact that non-metals can be used for electrical applications after electroplating. Besides having lower costs, non-metals also weigh less, which reduces the cost and difficulty related to the transport and storage of products.

Improved mechanical properties (tensile strength, bending strength, abrasion resistance, surface finish)

Electroplating also improves mechanical properties such as tensile strength, wear resistance and durability, depending on the application.

The small increase in tensile strength is enough to bridge the gap between the SLA resins of 3D printing (plastics) and metal alloys. The distinct strength characteristics allow the use of electroplated materials in applications where previously metals would have had to be used.

The metal skin on a plastic product, besides making the product lighter, also imparts excellent flexural strength characteristics.

We can also improve the surface finish using electroplating. This makes the products easier to handle and reduces friction.

All these improvements increase the short-term performance while also lengthening the lifespan of the products.

Improved Chemical Properties (Corrosion, Chemical, UV and Radiation Resistance)

The chemical properties of a material can also be enhanced by using electroplating. Properties such as corrosion resistance, resistance to chemicals and UV light are crucial in certain applications such as medical implants.

Typically, medical implants depend on precious metal coatings of gold, silver, platinum and copper for their corrosion protection, electrical conductivity, heat dissipation, non-toxic and antibacterial nature.

Chemical and corrosion-resistant products are also required for harsh service environments where the product is exposed to chemicals, moisture and seawater.

Limitations

Electroplating has certain disadvantages that prevent its use in some cases. Let's evaluate these to get a complete picture.

Complex process

The process is far from simple and can be difficult to carry out reliably. A process would have to be set with predetermined parameters to obtain parts of a consistent quality. Mistakes in preparation and pretreatment can lead to defects, poor quality and capability of finished parts.

Electroplating cannot be used for all material combinations, as they may not combine well with the plating solution.

Long plating time

The plating time can be excessively long in some cases. The metal deposition rate can be increased by either increasing the power supply or the concentration of the electrolyte or both. But this will cause uneven deposition, which can be a dealbreaker in some cases.

The benefits are limited to the surface

By its nature, electroplating is only limited to the surface. Once the surface layer is scratched off, the product can lose some or all of the benefits provided by the process.

Hazardous nature

The process releases gases due to the reduction at the cathode. If these gases are of a hazardous nature, they pose considerable risks for personnel in the vicinity.

Hexavalent chromium exposure from chrome plating is an apt example of how hazardous the electroplating process can be.

Wrapping It Up

Electroplating is nothing short of an engineering wonder. In the past, we could only use it on metals, but that is no longer the case. Today, we can electroplate plastics, ceramics and even organic materials such as leaves and flowers.

However, it still remains a very difficult process to execute consistently. This is why engineers and designers should turn to electroplating service providers for their expertise. Fractory's sales engineers have plenty of experience in planning and executing custom projects, so don't hesitate to get in touch.

FAQ

How do I identify the positive and negative terminals of the power supply in the electroplating solution?

It is very important to maintain the right polarity during electroplating. If for some reason you are not able to identify the anode (positive electrode) from the cathode (negative electrode), remember that the bubbles are generated on the cathode during the reaction.

This tells us that the electrode with the bubble formation is connected to the negative terminal of the power supply.

What is the difference between electroplating and electropolishing?

Electropolishing is basically the reverse operation of plating. Instead of adding material, electrochemical polishing removes it. In the electropolishing process, the workpiece is the anode, contrary to electroplating, where the workpiece is the cathode. Thus, electropolishing is also known as the reverse plating process.

What is electroless plating?

Electroless plating works on the principle of an electrochemical cell. A chemical reaction causes the deposition of one material on another without the need for an electric current. The coating metal is usually a metal or a metal alloy and the substrate could be either a metal or non-metal such as plastic, ceramic, glass, etc.

What is electroforming?

The electroforming process refers to the use of electric current across a chemical bath to form solid models with intricate cavities. The process is similar to electroplating except that instead of a surface, we are building a solid article with a complex cavity.

It uses a template known as the mandrel. The mandrel is dipped in the electrolyte and the electrolytic reaction forms a layer of the deposition metal on the mandrel in the negative shape of the mandrel.

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