Electroplating is a process by which a metal is electroplated onto another metal. Copper, nickel, and chromium are popular choice materials as they are more reactive than zinc and other materials. Gold and silver are also used in electroplating because they are highly effective conductors of electricity. They are also less reactive than copper and zinc, making them an attractive option for electronic consumer products. This process involves two metals: one of which is positively charged, and the other is negatively charged. An electrical current passing through the solution causes objects at the cathode to be coated by the metal in the solution. The metals’ molecules transfer from one to the other. The process results in a protective layer. The metallic layer is then applied to the object. In most cases, electroplating is done on metal, and the final result is a beautiful, durable product. Further, it has added advantages for the industry, such as corrosion protection.
“According To Coherent Market Insights, the rising demand for electroplating from aerospace and defense application for providing proper finishing to the machinery is expected to foster the market growth of electroplating. The global electroplating market was estimated to account for US$ 15.8 billion in terms of revenue in 2018 and is predicted to grow at a CAGR of 3.7% during the forecast period (2019 to 2027).”
An important application for electroplating is in the field of construction. The process is essential for many building structures, especially bridges. The structure will rust and break down without proper protection, so it is critical to make sure that it is electroplated. In addition to this, it helps make materials stronger. Depending on the type of material, electroplating can increase the durability and aesthetic appeal of your project. It is also a valuable investment that saves you money in the long run.
A good example of electroplating in everyday life is coins. Despite the fact that coins are not in constant use, they are often passed from person to person. Hence, they need to be durable. During the electroplating process, a thin layer of metal is deposited onto the brittle surface, which makes the coin strong. In the long run, the coin will remain useful and won’t lose its value.
Electroplating is a surface finishing method where a pre-plated metal is electrolytically deposited on a base metal surface using a plating layer as a cathode.
Equipment containing the plating bath is known as a plating bath.
Due to the requirements of the electroplating process, the solution in the electroplating tank must reach a certain temperature for proper plating. Therefore, the electroplating tank must be heated, i.e., the solution in the plating tank needs to be heated.
The methods of electric heating include steam heating, electric heating, circulating water heating, etc. Usually, steam heating is used in this case.
Steam heating is fast and has good results. It is best suited for large copper-nickel-chrome automatic lines or large liquid volumes
Electrochemical Deposition
The first steps in electrochemical deposition begin with a catalyst. The precursor consists of a metal solution containing a number of different metal ions. These ions are subsequently deposited onto the substrate in a process known as vapor deposition. The substrate is then cured with an alkali to form the desired material. After the catalyst dries, the substrate is then subjected to a second treatment. The final step involves the removal of the supporting media and the formation of a final layer of deposited metal.
The electrode in the electrochemical process is a specially designed chemical solution. In this solution, the desired metal is dissolved into submicroscopic metallic particles, which are positively charged ions. The mixture contains various substances to create a bright, smooth deposit. The object to be plated is then submerged into the electrolyte, acting as a negatively charged cathode. The positively charged anode(s) complete the electrical circuit. In electroplating, the anode(s) may be at opposite edges of the plating tank. The plating process will result in a film deposit on both sides of the cathode.
Pulse Electroplating
Pulse electroplating involves the application of an electrical current to a surface in a periodic manner. The frequency of the pulses is varied. The frequency can be varied by varying the duty cycle. The resulting current density is used to smooth the surface and yield geometric leveling of protrusions relative to the thickness of the plating. The technique is characterized by its high current density and short cycle time.
Pulse electroplating has some advantages over conventional electroplating. The process is highly efficient, requiring fewer additives and simpler solutions. Due to its short pulse duration, it is a cost-effective option. It also allows users to reduce their environmental impact as compared to traditional electroplating methods. It has many variations and is capable of overcoming common limitations of standard plating processes. To maximize the efficiency of electroplating, different processes should be employed.
One of the main advantages of pulse electroplating is that it allows the user to control the rate of the reaction by selecting the driving force. This capability has been greatly enhanced by modern electronics. The ability to control the amount of current or voltage that flows through a device is an added benefit. These parameters can be changed to suit the application requirements. It is important to keep in mind that pulse shape alone cannot accurately predict the properties of a deposit.
Brush Electroplating
Brush electroplating is a common process that uses direct current to coat metal parts. The process starts with a portable power pack that supplies the brush with direct current. The tool itself consists of a handle and an electrode, covered with a protective cover. The operator dips the brush tip into the plating solution and then paints the material onto the part. The current flowing through the tool bonds the plate to the part.
The brush-based application process offers several advantages over tank plating. It can plate items that are difficult to tank plate. It requires fewer steps and a smaller volume of plating solution, making it more convenient and cost-effective. However, it requires more attention from the operator. It also allows for greater plate thickness.
The brush-based application process is less expensive and more environmentally friendly than other methods. It also consumes less power and chemicals because it exposes only specific patches of material to the coating metal or alloy. Since it involves fewer components, it saves both energy and money. The benefits of brush plating are numerous, and it is a cost-effective process for many companies. With brush-based electroplating, you can achieve a superior finish in a fraction of the time it takes to do traditional electroplating.
Reel-To-Reel Electroplating
Reel-to-reel electroplating is the most common and cost-effective method of plating. Reel-to-reel plating involves loading the material onto the de-reeling station. The material then feeds through the electroplating process using a capstan system. When the desired metal finish is achieved, the material is respooled and fed back into the de-reeling station.
Advantages and Disadvantages
As with all electroplating processes, proper care should be taken to protect the surface of the part being plated. Clean electrodes are essential for a successful electroplating process. The surface of the part must be completely free of dirt or oil. A dirty electrode will not allow the metal atoms to bond effectively with it. This process requires the electrode to be cleaned before electroplating. A clean electrode is important for the final product.
Electroplating has several advantages over other processes. It allows for pre-design of surface and whole-part properties. In addition, it can produce new materials with very thin layers. This is why it is an excellent choice for coatings for electronic devices. There are a number of advantages to electroplating. However, there are some drawbacks to this process. It is not ideal for large-scale productions, which is why it’s important to understand how the process works.
While electroplating is a highly efficient process for many applications, it is a complex and potentially hazardous process. Workers must be provided with proper ventilation and protective gear while working. According to the U.S. Department of Labor, electroplating can lead to workplace injuries and serious health issues. For this reason, many engineers outsource the electroplating process. Fortunately, there are a number of third-party companies specializing in custom projects.
