In the world of plating and anodizing operations, a reliable DC power supply is an essential component for success. Volteq adjustable DC power supplies are the go-to choice for a wide range of applications, including electro-plating, anodizing, electrolysis, hydrogen generators, electrocoagulation, and fuel cells.
Volteq power supplies stand out due to their exceptionally clean DC output, which is further enhanced by over-voltage (OVP) and reverse-voltage protection. Designed with durability and robustness in mind, Volteq power supplies are built to withstand the demands of various industrial processes. Moreover, their cost-effective nature makes them an attractive option for businesses seeking to optimize their operations without compromising on quality or performance.
Electroplating is an electrolytic machining process, and the factors of power supply will have a direct impact on the electroplating process. Electroplating power supply plays an important role in the electroplating process. The application of electroplating power supply and low ripple factor rectifier power supply in the electroplating industry allows colleagues in the electroplating industry to help in choosing a rectifier power supply, solving electroplating failures, and improving electroplating quality.
1. Switching power supply
The switching power supply has the advantages of the waveform smoothness of the silicon rectifier and the advantages of the convenient voltage regulation of the silicon-controlled rectifier. The frequency of the switching power supply has reached the audio frequency, and it is easier to achieve low ripple output through filtering. And the functions of steady current and voltage regulation are easier to realize. Therefore, switching power supply in the direction of future development.
2. Basic types of rectifiers
Silicon rectifier: Silicon rectifier has a long history of use and mature technology, and is currently the mainstream product of rectifier. All kinds of rectifier circuits obtain pulsating Direct Current, not pure direct current. In order to compare the amount of pulsating components, it is generally expressed by the ripple coefficient. The smaller the value is, the less the AC component is, and the closer it is to pure DC. The fluctuation coefficient of various rectifier circuits is different. The order from big to small is three-phase half-wave rectification, three-phase full-wave bridge rectification, or six-phase double-reverse star rectification with the balanced reactor. The thyristor uses a common thyristor rectifier that adjusts the average output DC size by changing the conduction angle of the thyristor. The thyristor outputs an intermittent pulse wave, and its ripple coefficient is controlled by the conduction angle, and the output ripple coefficient is larger than that of ordinary silicon rectifier circuits.
3. The influence of electroplating power supply on electroplating process
The DC power waveform has a prominent influence on the quality of electroplating. Among all kinds of electroplating processes, chrome plating is one of the plating species that is most affected by the power waveform. Chrome plating must use a low-ripple DC power supply, otherwise, the bright range is narrow, and the coating is prone to blooming and graying. When high-efficiency hard chrome plating additives are used, micro-cracked chrome layers are generated. When the output ripple is too large, the cracks are not fine and unevenly distributed, and the required number of cracks cannot be reached.
There is a rule for bright copper plating: from the Hull cell test piece, the higher the cathode current density, the better the brightness and leveling of the coating; the lower the current density, the worse the brightness and leveling. Try to expand the brightness range of the low current density area, while reducing the brightness of the high current density area, the best uniform brightness. In practice, using the same formula, process conditions, and the same brightener, the brightness leveling and brightness range obtained may be quite different, which has a great relationship with the output ripple coefficient of the DC power supply used.
Bright nickel plating does not require as high a rectifier output ripple factor as chrome plating and bright acid copper plating, but it is also necessary to use ordinary low ripple output DC power supplies to ensure the quality of bright nickel plating and the quality of subsequent chrome sets.
Sulfate bright acid tin plating itself is not easy to be plated. The reason is that impurities are easily introduced in large-scale production and are difficult to handle (including tetravalent tin ions), and the allowable temperature range is narrow. At present, most brighteners are not ideal. This process A low ripple factor DC power supply is also required, otherwise, failures similar to bright acid copper plating will occur.
The problem of temperature rise of plating solution: DC power supply and pulse power supply with large ripple coefficient tends to accelerate the temperature rise. The larger the ripple coefficient, the larger the harmonic component, which can generate a large amount of ohmic heat and speed up the temperature rise of the plating solution. The use of smooth DC is beneficial to lower the temperature of the plating bath. The influence of the rectifier load rate on the ripple coefficient: The closer the working current is to the rated current of the rectifier, the smoother the waveform will be. When selecting the rectifier, the rated output power supply voltage should be selected according to the process requirements to be close to the maximum demand value to ensure that the output ripple coefficient of the rectifier power supply is always maintained at a lower value.
4. Pulse power supply equipment
The pulse power supply is mainly controlled by an embedded single-chip computer, etc. Therefore, in addition to realizing the pulse output, it generally has a variety of control functions.
1) Automatic current stabilization and voltage stabilization. The traditional silicon rectifier current or voltage cannot be automatically stabilized and fluctuates with the fluctuation of the grid voltage. The pulse power supply has a high-precision automatic adjustment function, and the output voltage of the pulse power supply can be almost unchanged. The automatic adjustment function of pulse power supply generally has two modes: one, constant current voltage limiting mode. The second is the constant voltage current limiting mode.
2) Multi-stage operation mode. When aluminum anodizing or hard chrome plating is performed, operations such as reverse electrolysis, high current impact, and stepped power transmission is often required. The pulse power supply with multi-stage operation mode only needs to be set in advance, and it can be automatically adjusted in sequence during production. This function is very useful for hard chrome plating, and the settings can be adjusted within 0 to 255 seconds per period.
3) Bidirectional pulse function. Positive and negative pulse frequency, duty cycle, positive and negative output time can be independently adjusted, flexible and convenient to use. With the hard chrome plating process, coatings with different physical properties can be obtained.
4) DC superposition function. While outputting forward and reverse pulse currents, a pure DC component is superimposed by the same power supply, which broadens the scope and application of the pulse power supply.
Summary: In summary, for electroplating, in addition to hard chrome plating, silicon-controlled rectifiers are more stable than high-frequency power supplies. Another electroplating generally uses a high-frequency pulse power supply. At this stage, chrome plating also uses high-frequency pulses. Because the conversion rate of the thyristor is too low and the power consumption is too large, it is not cost-effective to calculate. There are also some high-quality nickel-plated, and the general output also needs to be filtered. Ordinary conventional power supplies have only the output with filtering, and some even have no filtering on the input.
Electroplating lets you combine the strength, electrical conductivity, abrasion and corrosion resistance, and appearance of certain metals with different materials that boast their own benefits, such as affordable and/or lightweight metals or plastics.
In this guide, you’ll learn why many engineers, researchers, and artists use electroplating and metal plating in every stage of manufacturing—from prototyping to mass production.
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Electroplating is the process of using electrodeposition to coat an object in a layer of metal(s). Engineers use controlled electrolysis to transfer the desired metal coating from an anode (a part containing the metal that will be used as the plating) to a cathode (the part to be plated).
Diagram of copper electroplating using an electrolyte bath of copper sulfate, sulfuric acid, and chloride ions. (image source)
The anode and cathode are placed in an electrolyte chemical bath and exposed to a continuous electrical charge. Electricity causes negatively charged ions (anions) to move to the anode and positively charged ions (cations) to transfer to the cathode, covering or plating the desired part in an even metal coating. Electroplating takes a substrate material (often a lighter and/or lower-cost material) and encapsulates the substrate in a thin shell of metal, such as nickel or copper.
Electroplating is most commonly applied to other metals, because of the basic requirement that the underlying material (the substrate) is conductive. Although less common, autocatalytic pre-coatings have been developed which produce an ultra-thin conductive interface, allowing a variety of metals - most notably copper and nickel alloys - to be plated onto plastic parts.
Electroplating and electroforming are both performed using electrodeposition. The difference is that electroforming uses a mold that is removed after a part is formed. Electroforming is used to create solid metal pieces, whereas electroplating is used to cover an existing part (which is made of a different material) in metal.
You can electroplate a single metal onto an object, or a combination of metals. Many manufacturers choose to layer metals, such as copper and nickel, to maximize strength and conductivity. Materials commonly used in electroplating include:
Brass
Cadmium
Chromium
Copper
Gold
Iron
Nickel
Silver
Titanium
Zinc
Substrates can be made of almost any material, from stainless steel and other metals to plastics. Artisans have electroplated organic materials, such as flowers, as well as soft fabric ribbons.
It’s important to note that non-conductive substrates such as plastic, wood, or glass must first be made conductive before they can be electroplated. This can be done by coating a non-conductive substrate in a layer of conductive paint or spray.
Thanks to scientific advances in materials and plastic manufacturing, lightweight and low cost plastic parts have replaced more expensive metal parts in a wide variety of applications serving various industries, from automobiles to plumbing pipes.
Although plastic boasts an array of advantages over metal, there are many applications where metal still reigns supreme. Try as you might, you’ll never get plastic to have the same opulent finish as copper. And while plastic might be more flexible material than the majority of metals, it’s not nearly as strong. This is where metal plating comes in.
3D printing offers unique advantages when combined with electroplating. Engineers often choose to 3D print substrates because of additive manufacturing’s design freedom. It is often cheaper to electroplate 3D printed parts than to cast, machine, or use other manufacturing methods, especially when it comes to prototyping.
Stereolithography (SLA) 3D printing is ideal for electroplating because it creates 3D printed parts with very smooth or finely textured surfaces that make the transition between the two materials—plastics and metals—seamless. It also creates watertight parts that won’t get damaged when submerged in the chemical bath required during the electroplating process.
From an engineering standpoint, the combination of 3D printing and electroplating offers unique tensile strength options for finished designs. As you can see in the chart above, the combination of these two manufacturing processes bridges the gap in tensile strength between the two material groups.
Metal plating can have a major impact on the mechanical performance of (3D printed) plastic parts. With a structural metal skin and a lightweight plastic core, parts can be produced with surprisingly high flexural strength characteristics.
In addition to improving mechanical behavior, electroplating can be used to protect plastic parts from environmental degradation. In applications where plastic parts are exposed to chemical attack or ultraviolet light, metal plating provides a permanent barrier that can extend the life of your parts from months to years.
When used as an aesthetic treatment, plating offers an easy way to create prototypes that both look and feel like metal. Depending on the plate thickness, electroplated plastic can be thin and light, or add noticeable weight to a part. Thicker electroplated coatings can even be texturized or polished to achieve a variety of metal finishes, from cast aluminum to mirrored chrome. More complex textures can be achieved by 3D printing a textured resin substrate.
Given the potential combinations of 3D printable materials, a variety of plating metals, and plate thickness ratios, it’s easy to see how electroplating gives engineers a new field of design options to consider.
Electroplating offers many benefits, including increased strength, lifespan, and conductivity of parts. Engineers, manufacturers, and artists capitalize on these benefits in a variety of ways.
Engineers often use electroplating to increase the strength and durability of various designs. You can increase the tensile strength of various parts by coating them in metals such as copper and nickel. Place a metallic skin on parts and you can improve their resistance to environmental factors like chemical exposure and UV light for outdoor or corrosive applications.
Artists often use electroplating to preserve natural elements prone to decay, such as leaves, and turn them into more durable works of art. In the medical community, electroplating is used to make medical implants that are corrosion-resistant and can be properly sterilized.
Electroplating is an effective way to add cosmetic metal finishes to customer products, sculptures, figurines, and art pieces. Many manufacturers also choose to electroplate a substrate to create more lightweight parts that are easier and cheaper to move and ship.
Electroplating also offers the benefit of conductivity. Because metals are inherently conductive, electroplating is a great way to increase the conductivity of a part. Antennas, electrical components, and other parts can be electroplated to increase performance.
Though electroplating boasts plenty of benefits, its limitations lie in the complexity and hazardous nature of the process itself. Workers performing electroplating can suffer from hexavalent chromium exposure if they don’t take proper precautions. It is essential for workers to have a properly ventilated workspace. The U.S. Department of Labor Occupational Safety and Health Administration has published numerous documents outlining the risks involved in electroplating.
Although it is possible to electroplate resin parts yourself, amateur users may run into difficulty. The main reason is quality and capability. Laminate adhesion strength using DIY electroplating methods is usually lower than what is achieved by a professional plating service. Structural plating, which requires long plate times, multiple baths, and compatibility between metals, is quite difficult to execute reliably. Successful applications of in-house plating are typically simple and small, such as jewelry prototyping, and thin (single layer) RF copper coatings.
Because of the expertise required and the dangers involved, many engineers and designers choose to hire a third-party electroplating manufacturer specializing in this process. Luckily, several companies, such as RePliForm and Sharretts Plating, specialize in custom electroplating projects. Download our white paper for a list of electroplating services by region and job size.
Numerous industries use electroplating to make everything from engagement rings to electrical antennas. Here are some common examples:
Many airplane components are electroplated to add a “sacrificial coating,” which increases the lifespan of parts by slowing down corrosion. Because aircraft components are subject to extreme temperature changes and environmental factors, an additional metal layer is added to a metal substrate so that the functionality of a part isn’t compromised by normal wear and tear.
Many steel bolts and fasteners designed for the aerospace industry are electroplated in chromium (or, more recently, zinc-nickel, due to changing restrictions).
Type the word “electroplated” into Etsy, and you’ll be presented with a vast array of electroplated home decor and one-of-a-kind keepsakes. Artisans often turn biodegradable items, including flowers, branches, and even bugs, into durable and long-lasting pieces of art with this process. You can employ electroplating to show off and preserve fine details in items that would otherwise quickly decompose.
Electroplating is often used to create art, such as this copper-plated beetle and honeycomb. (image source)
Digital designers sometimes use electroplating to produce sculptures. Designers can 3D print a substrate using a desktop 3D printer and then electroplate the design in copper, silver, gold, or any metal of choice to achieve their desired finish. Combining 3D printing with electroplating in this manner produces pieces that are easier (and cheaper) to manufacture, while still having the same look and finish as a sculpture that is solid cast metal.
Electroplating is very common in the automotive industry. Many major automotive companies use electroplating to create chrome bumpers and other metal parts.
Electroplating can also be used to create custom parts for concept vehicles as well. For example, VW teamed up with Autodesk to create hubcaps for their “Type 20” concept vehicle. The prototype hubcaps were 3D-printed and then electroplated.
Restoration companies and vehicle customization businesses also use electroplating to apply nickel, chrome, and other finishes to various car and motorcycle parts.
Electroplating is perhaps most commonly associated with the jewelry industry and precious metals. Jewelry designers and manufacturers rely on this process to enhance the color, durability, and aesthetic appeal of rings, bracelets, pendants, and a wide range of other items.
When you see jewelry that is described as being “gold plated” or “silver plated,” there’s a high chance the piece you’re looking at was electroplated. Combinations of various metals are used to achieve uniquely hued finishes. For example, gold is often combined with copper and silver to create rose gold.
Electroplating is used to add resilient exteriors to all sorts of medical and dental elements. Gold plating is often employed to create tooth inlays and aid in various dental procedures. Implanted parts such as replacement joints, screws, and plates are frequently electroplated to make parts more corrosion-resistant and compatible with pre-insertion sterilization. Medical and surgical tools, including forceps and radiological parts, are also commonly electroplated.
Numerous electrical and solar components are electroplated to increase conductivity. Solar cell contacts and various types of antennas are routinely manufactured using electroplating. Wires can be electroplated in silver, nickel, and many other types of metal. Gold plating is often used (in conjunction with other metals) to increase durability. Gold is also frequently used to increase the lifespan of parts because it is conductive, very ductile, and doesn’t interact with oxygen.
Producing custom or low-volume metal parts for prototyping can be very costly and time-consuming with traditional manufacturing processes. As a result, engineers often combine electroplating with 3D printing for a low-cost and time-saving solution.
For example, Andreas Osterwalder of the Swiss Federal Institute of Technology in Lausanne (EPFL) has been able to speed up the prototyping process and reduce costs of advanced experimental setups by 3D printing new designs himself on his Formlabs resin 3D printer and working with Galvotec to have those parts electroplated.
Andreas Osterwalder used 3D printing and electroplating to manufacture this beam splitter.
Antennas need to have electrical conductivity to propagate radio waves. While plastic 3D printed parts don’t conduct electricity, they offer almost infinite design freedom and materials with good mechanical and thermal properties. These benefits can be combined with electroplating to achieve the desired conductivity, resulting in a great solution for custom antennas for research and development in the automotive, defense, medicine, and education.
Electroplating plastic parts creates conductive parts that enable high performance RF applications.
Electroplated composites are a means to a wide variety of ends. Because of its versatility, electroplating opens up countless possibilities across different industries. Want to learn more about electroplating 3D printed parts?
Download our white paper to learn how engineers are adding metal to resin 3D prints, and why hybrid metal parts can open doors to a surprising range of applications, including (but not limited to) enduse strength and durability. By the end of the white paper, you will learn new ways to apply electroplating, as well as design considerations and practical tips on using metal electroplating to amplify the performance of your SLA parts.
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