“Electro-Plating” through electrodeposition was a true “game-changer!”
So just what IS Electro-Plating? When it comes to Metal Plating— especially for performance-enhancing applications — electro-plating was a true game-changer! The discovery of the electrodeposition process (soon to be referred to as simply “Electroplating”) revolutionized the plating industry by harnessing the power of electrical current. This process allowed for the deposit of a wide variety of “coating metals” to be applied as a very thin layer onto an equally wide variety of base part metals — all with previously unobtainable thickness and location control.
Before there was Electro-plating
To truly appreciate the importance of Electro-plating, it helps to understand what options were available prior to this process. Before the advent of electrodeposition plating, there were a number of less efficient options used to adhere one metal coating onto another. Each of these methods had limitations, particularly when it came to ensuring uniform thickness, adhesion, and durability. Pre-electro-plating methods included:
Fire Gilding, a technique that involved heating the base metal and applying gold leaf or gold amalgam. The object was then heated again to burn off the mercury, leaving behind a gold coating.
Dip Coating (also referred to as Immersion Plating) involved dipping a metal object into a molten metal bath to absorb a thin layer of the molten metal. This was commonly used for coating iron with tin to create tinplate.
Tinning, a process that immersed a metal object in molten tin which then adhered to the surface to provide corrosion resistance.
Casting, a labor-intensive, less precise process that would “cast” molten metals onto objects using molds. This process was used when thin, even coatings were required.
Burnishing, involving the friction-polishing of a surface, then the forming a thin layer of precious metal onto that surface using the same burnishing action.
The first Electroplating pioneers
The invention of electroplating is credited to an English scientist George N. Stokes who, in the early 19th century, discovered the principles of electro-chemical deposition, However, it was a German scientist named Heinrich Göbel who is often credited with perfecting the first successful and “practical” electro-plating process.
The use of modern “Electroplating” in commercial applications began around 1840, thanks to process advancements of a British scientist and metallurgist John Wright. John’s advancements were so impressive that he applied for a patent to Electroplate copper onto iron. However, it was the work of Hermann von Helmholtz (a German physician, physicist, and philosopher), and Michael Faraday (an English scientist) that detailed the scientific principles behind electrolysis — opening the doors to the efficient commercial application of electroplating!
How electric current Is used in Electroplating
The core purpose of industrial plating is to bond a layer of metal to a base material in order to enhance performance properties like resistance to corrosion, appearance, and durability. Electroplating allows Plating Companies to achieve this outcome with better control. With electroplating, an electric current is used to facilitate the deposition of metal onto the surface of the object being plated, also known as the substrate.
Electroplating applies targeted electric current to facilitate electrodeposition through a chemical reaction. The object to be plated is placed in a solution containing metal ions, such as gold, silver, or nickel. When an electric current passes through this solution, the metal ions are reduced and adhere to the surface of the base material. This electrodeposition process ensures that the metal layer forms a strong, even coating with a strong bond to the substrate.
Without the use of electric current, it would be nearly impossible to control the uniformity and adhesion of the metal plating. The precision and consistency achieved by electroplating are crucial for industries such as electronics, automotive, and aerospace, where the functionality of parts depends on predictable coating performance.
Electroplating by the numbers
Electroplating involves a series of important steps to ensure a high-quality, predictable and repeatable finish:
1. Part Preparation:
The object to be electroplated is thoroughly cleaned to remove dirt, grease, and oxidation. This is an essential step, as any contamination on the surface will hinder the electroplating process and result in a poor-quality finish.
2. Creating an Electrolyte Solution:
An electrolyte solution containing metal salts and other chemicals to facilitate the plating process is carefully formulated based on the type of metal being plated and the type of coating coating being applied. This solution is what the object being plated will be immersed into.
3. Introduction of Electrical Current:
The object being plated is connected to a negatively-charged terminal or “cathode)” of a power supply, The metal to be plated (usually in the form of a metal anode) is connected to the positive terminal “anode.” When electric current is passed through the solution, the metal ions from the anode move toward the cathode (the object being plated) and are deposited onto its surface through electrodeposition. Controlling the strength of this current plays a critical role in producing desired plating results.
4. Monitoring and Controlling Plating Thickness:
The duration of the immersion process, the concentration of metal ions in the electrolyte solution, and the strength of the electric current all work to help control the thickness of the electroplated layer. The best Electroplating companies are those with proven ability to precision-coordinate all these variables.
5. Plated Part Finishing:
After electroplating is complete, the plated object is removed from the solution, rinsed, and inspected for quality. If necessary, the plated object may undergo additional processes such as polishing, coating, or heat treating to enhance appearance and performance characteristics.
Electroplating advantages of over basic metal plating
Electroplating offers several distinct advantages other electro-less plating methods, making it the preferred choice for many industries:
- Precision and Control: Electroplating allows for much greater precision in coating thickness and uniformity. This level of control ensures that even complex geometries and intricate parts can receive an even, durable coating according to performance specifications.
- Improved Bonding Strength: The use of electricity in the Electroplating process creates a stronger bond between the metal layer and the substrate. This ensures the plating petal adheres better and lasts longer, even in harsh environments where traditional metal plating might fail.
- Expanded Plating Applications: Electroplating allows for the use of a wide range of metals, including precious metals like gold, silver, and platinum, as well as semi-precious metals such as nickel and copper. This versatility makes electroplating ideal for applications that specify single and multiple coatings in order to deliver specialized function as well as aesthetic advantages.
- Enhanced Durability: Electroplated parts tend to be more resistant to corrosion, wear, and tarnishing, making them ideal for use in industries such as automotive, aerospace, and electronics (electro-less plating often lacks the durability necessary for these demanding applications).
- Cost Efficiency: Although Electroplating requires specialized equipment and expertise, the results typically justify the cost. The precision, durability, and aesthetic appeal offered by Electroplating reduces the need for frequent repairs or replacements. That’s because it reduces or eliminates the possibility of part failure due to plating malfunction.
Choosing the right Electroplating Company for your project.
To fully realize the benefits of electroplating, it’s important to work with an electroplating company that can maintain exacting precision in all stages of the electroplating process. Electroplating isn’t just about applying a metal coating— it’s about achieving the right thickness, uniformity, and adhesion for every part to meet engineering requirements. This is especially critical for parts with challenging shapes or dimensions, where the precision of the plating process can ensure or jeopardize performance of the final product.
Summit Plating has established itself as the Electroplating Company of choice for clients that rely on plating quality for program success. Our Electroplating strengths center around a unique ability to develop innovative, performance-enhancing plating solutions for even the most difficult-to-plate part shapes and sizes. We credit this ability to the attention we give to each stage of the “Electro-Plate” process. It is a difference that has positioned Summit as a world-respected Electroplating Company.
