electropolishing

Since the 1950s, scientists have commercially used the combination of electricity and chemicals to improve the surface finish of metals. It is a common finishing procedure across a wide variety of industries, including the following:

Surgeons and dentists use electropolishing to keep their tools clean and functioning well.
Food, beverage and pharmaceutical processors benefit from the sterilizing features of electropolishing.
Appliance manufacturers use electropolishing in appliances like refrigerators and washing machines to make parts last longer and look better.
Aerospace manufacturers use electropolishing on flight-critical parts to reduce friction and ensure top performance.
Semiconductor manufacturers use electropolishing with fragile, irregularly-shaped products.
Automakers and the racing industry electropolish gears and fuel lines to reduce friction, boost performance and ensure long life of parts.

Examples of metal parts commonly electropolished:

Piping and tubing
Fasteners
Springs
Wire racks
Blades
Automotive parts such as alloy and stainless wheels, even engine blocks

Metals compatible with electropolishing include:

Aluminum
Brass
Carbon steels
Cobalt-chrome
Copper
Nickel alloys

The amount of material that is removed by electropolish systems is directly proportional to the run time / cycle time and the amp-minutes that pass through the surface area of the part. All of these variables can be controlled to create a consistent, reliably controlled surface finish. Material removal is commonly only 0.0003″ to 0.0007″ for most deburring and polishing applications after machining. With precise monitoring, electropolishing can remove as little as 0.0001″. For an electropolishing process with longer cycle time and amp-minutes, as much as 0.003″ to 0.005″ of material may be removed.

Benefits of Electropolishing

Benefit

Description

Decorative appearance

The bright and shiny finish, often highly reflective, is aesthetically pleasing and has a uniform luster, without the fine lines that occur with abrasive polishing.

Microscopic smoothness

Levels peaks and valleys and provides up to 50% improvement in surface roughness (Ra). Unlike mechanical finishing, electropolishing does not smear, bend, stress or fracture the crystalline metal surface.

Deburring

On a microscopic level, electropolishing removes small pieces of displaced surface material that can snag and break.

Ultra-clean finish

Creates a clean surface that is easier to sterilize. Removes embedded contaminants that can lead to corrosion.

Removes surface defects

Increases operational life by removing fissures and cracks from the surface, thus eliminating sites where corrosion can take hold. Helps parts that need to flex and bend to last longer.

Reduces friction

Prolongs life of parts in constant motion. Reduces galling on threaded parts, improving sealing.

Eliminates oxide scale

Removes discoloration from heat tint and oxide scale.

Good for fragile parts

Works on delicate parts that might be damaged in a tumbling process. Can replace some mechanical finishing techniques such as grinding, buffing, milling and blasting.

Good for complex parts

Can polish areas that are inaccessible by other polishing methods without causing damage. Effectively treats tiny surfaces on complex components.

Size control

Can be used to slightly reduce size of parts if necessary.

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