This article will take an in-depth look at types of metal finishing.
The article will bring more detail on topics such as:
This chapter will explore metal finishing and the various processes associated with it.
Metal finishing is an all inclusive set of procedures and processes used to place a coating on the substrate of a metal part. The process includes cleaning methods, polishing methods, and other procedures that improve and enhance the surface of a metal product. It consists of electroplating and electroless plating as well as other processes that offer benefits, characteristics, and properties that prevent corrosion, rust, and add strength.
Electroplating is a finishing technique where an electrical current deposits metal ions onto a substrate. Although it might appear different, electroplating and finishing processes are often considered similar.
The plating process involves electronically applying metal to a conductive surface and is one of several finishing methods used today. The term "finishing" encompasses a variety of processes aimed at improving and enhancing the physical appearance of metal products, which are commonly found both at home and in the workplace.
Raw metal, extracted from underground, is typically crude, hard, and unappealing. To optimize its use, metal must be polished, finished, and processed through various methods. The finishing process represents the final stage of metalworking.
In this stage, the metal product undergoes various techniques to enhance its appearance and make it more attractive. Metal finishing significantly reduces wear on metal products, contributing to their durability and visual appeal.
Metal finishing enhances various properties of the metal, including its electrical conductivity, durability, chemical resistance, electrical resistance, and vulcanization. Beyond improving the metal's aesthetic appeal, finishing also benefits industrial applications, such as enhancing resistance to torque and aiding in soldering.
Corrosion resistance is a major concern for all metals. The finishing process significantly reduces the likelihood of corrosion and acts as a primer for paint application. Additionally, thorough finishing can minimize the need for cleaning by addressing defects and deformities. Metal-producing industries employ numerous finishing methods to maximize the longevity and durability of their products. The finishing process is crucial and forms an essential part of the final steps in producing high-quality metal products.
When making a manufacturing decision, it is crucial to choose a metal finishing procedure that meets the required standards for the final product. Each metal finishing method applies specific treatments to the metal surface to achieve the desired results.
Metal finishing methods also involve mechanical adjustments to the surface of the metals. It is essential to carefully consider which procedure to use, as each method offers distinct advantages.
The finishing process is the final step in achieving the desired appearance and texture of a metal product. It ensures that the product meets its design specifications, provides protection against rust and tarnishing, and enhances the metal's strength, thickness, durability, and hardness.
Choosing the appropriate finishing method is critical to the value of the end product. Cost is a primary consideration, including expenses for water, coatings, energy, consumables, labor, cleanup, and waste management.
In addition to the direct costs, it's important to consider the fixed costs associated with maintaining and operating the equipment. The type of metal being fabricated, ranging from stainless steel to various aluminum alloys, also influences the decision. Each of these factors must be carefully evaluated to ensure a profitable outcome. Additionally, the time required to complete the finishing process impacts the ability to meet delivery deadlines and affects the overall supply chain.
Electroplating can be time-consuming, whereas buffing and polishing can be completed more quickly. This stage of the finishing process is crucial for maintaining delivery schedules and has a significant impact on the supply chain.
Metal finishing is a crucial step in the production of metal products. Various types of metal finishing include metal plating, chemical coating, grinding, buffing, electroplating, and sandblasting. All these processes start with surface preparation.
Metal finishing can involve a range of techniques, from technical processes to simple buffering. The choice of method depends on the specific requirements of the end product, the structure of the metal, and the intended use of the product.
Successful metal finishing relies heavily on proper surface preparation. If the surface is not prepared correctly, coatings, platings, and other materials may not adhere properly. The initial step in surface preparation involves cleaning the metal, which can be done using various chemicals, mineral spirits, or simply wiping with a clean, dry cloth. Light sanding may also be required to remove any gloss from the surface.
Inspecting the metal surface for rust is crucial, as rust can impede the finishing process and negatively affect the final product's appearance. Rust can be eliminated through sanding, using a wire brush, or applying a rust-removal chemical.
Metal plating involves depositing a layer of metal on the substrate of a conductive metal. It is used to coat and protect metals and completed using electroplating or electroless plating. The process of metal plating enhances the properties of the base metal and improves its functionality and appearance.
Metal plating involves several steps: pretreatment and preparation, setup, the actual plating process, and post-treatment. Common metals used for plating include zinc, copper, gold, chrome, nickel, and tin, among others.
Aside from electroplating and electroless plating, other methods of plating are immersion, carburizing, physical vapor deposition (PVD), and plasma spray coating. Metal plating is an essential part of ensuring that products have an excellent appearance and resistance to wear and tear, corrosion, and rust.
Metal plating enhances a metal's strength and extends its lifespan. There are various options for choosing the type of metal to apply to a substrate. The selection should consider the purpose of the plating, whether for aesthetic and decorative reasons or for improved strength, durability, and solderability.
Chrome Plating - Chrome plating is an electroplating process that uses hexavalent chromium, chromium sulfate, or chromium chloride to apply a layer of chrome to the substrate.
Hard Chrome Plating - Hard chrome plating is an electroplating technique that employs a chromic acid solution to deposit a layer of chrome with a thickness ranging from 2 microns (µ) to 250 µ. Types of hard chrome include micro-cracked chromium, micro-porous chromium, porous chromium, and crack-free chromium.
Nickel Plating - Nickel plating is completed by electroless plating of a nickel phosphorus alloy with the percentage of phosphorus varying between 2% up to 14%. Higher levels of phosphorus increases the hardness and corrosion resistance of the plating.
Teflon (PTFE) Plating - Teflon plating involves an electroless process that co-deposits nickel phosphorus and polytetrafluoroethylene (PTFE) onto the metal substrate. The resulting finish has a dull silver-gray appearance, combining the properties of nickel with the lubricity of PTFE.
Tin Plating - Tin plating is achieved through electrodeposition and hot dipping, with brass or copper often added to enhance solderability. Tin coatings provide additional benefits such as non-toxicity, ductility, and corrosion resistance. It is frequently applied to copper and nickel substrates.
Zinc Plating - Zinc plating, also known as electro-galvanization, involves applying zinc through an electroplating process to provide the substrate with resistance to oxidation and corrosion. This process is commonly used to galvanize steel.
Gold Plating - Gold plating is an electroplating technique that applies a thin layer of gold onto substrates such as silver, steel, or copper. The quality of gold plating can vary based on the purity of the gold and the quality of the underlying metal.
Conversion coating is a passivation process that modifies the surface of a metal to create a protective metal oxide layer. This layer guards against corrosion, rust, and wear. The process typically involves acidic baths or electrical treatments to develop a metal oxide coating, offering protection from oxygen and corrosion. Examples include iridite on aluminum, chromate, phosphate, and black oxide. Anodizing is a specialized type of conversion coating.
In conversion coating, a chemical reaction occurs on the metal surface. Unlike plating, which adds a new metal layer, conversion coating alters the existing surface layer of the metal. It is often used as a preparatory step for further plating or painting.
Conversion coating utilizes some of the substrate metal to create the coating. As the coating forms, it integrates into the part and increases in volume compared to the original metal, providing enhanced protection.
Alodine Coating - Alodine coating is a chromate-based chemical conversion coating used to protect aluminum and other metals from corrosion. It provides a surface with enhanced adhesion and maintains electrical conductivity. The thickness of Alodine coatings ranges from 0.00001 inch to 0.00004 inch (0.25 µm to 1 μm).
Black Oxide Coating - Black oxide is a conversion coating that imparts a matte black finish to parts through an electrochemical or chemical treatment process. The coating forms when a part is immersed in an alkaline aqueous salt solution at 285°F (140°C), where a reaction between the iron in the metal and the oxide bath creates magnetite. Black oxide coatings improve the appearance of parts, reduce light reflection, and enhance dimensional stability.
Electroplating, also known as electrodeposition, involves using electric current to dissolve metal and deposit its ions onto the surface of a workpiece. The primary components of electroplating include an anode, cathode, solution, and power source. The anode is a positively charged electrode that provides the metal for plating, while the cathode is the substrate to be plated and acts as a negatively charged electrode.
The solution used in electroplating is electrolytic, containing metal salts such as copper sulfate to aid in the flow of electricity. A power source delivers electrical current to the anode. When the anode and cathode are submerged in the solution and a DC current is applied, the metal at the anode oxidizes, causing metal atoms to dissolve into the solution. Metal ions then migrate to the negatively charged substrate, where they are deposited.
Electropolishing utilizes electrical current and chemicals to polish metal parts, similar to electroplating. This process removes material from the metal surface with precision up to 0.0002 inches. Electropolishing enhances the surface finish, eliminates tiny imperfections, and thoroughly cleans and deburrs metal surfaces to a microscopic level.
During electropolishing, parts are submerged in a tank containing an electrolyte solution made of phosphoric and sulfuric acid. Metal plates lining the tank act as cathodes, and a positive DC current is passed through the solution to dissolve a thin layer of metal from the pieces. The treated parts emerge with a clean, smooth, passivated surface and are rinsed multiple times to eliminate any remaining electrolyte solution.
As a passivation method, electropolishing removes free iron from the metal surface, reaching beneath the surface layer to level out peaks and valleys. It is considered a more effective passivation process compared to traditional methods.
Hot-dip galvanizing involves coating steel by immersing it in a molten zinc bath. The process consists of three main steps: surface preparation, galvanizing, and inspection. Surface preparation is critical and includes degreasing, pickling, and fluxing. Pickling involves an acidic bath, while fluxing removes oxides and coatings. Proper surface preparation is essential for the zinc to adhere to the steel surface effectively.
After preparation, the steel is dipped into a molten zinc bath, which contains approximately 98% zinc heated to about 830°F (443°C). The steel is immersed in the bath to ensure that the coating covers all parts of the steel uniformly.
Metalized sprayed coatings, also known as thermal spray coatings, are used to provide corrosion protection. This method involves spraying heated metals, which are heated either electrically or with a flame, onto various surfaces such as concrete or steel. Metalized coatings can be applied in a range of environmental conditions and cure instantly upon application.
Metalized sprayed coatings are often preferred over other methods, such as epoxy, due to their durability and extended service life. Structures treated with metalized coatings exhibit resistance to impacts and ultraviolet rays. Common metals used in metalized sprayed coatings include zinc, aluminum, and their alloys.
Anodizing refers to the conversion coating process applied specifically to aluminum, though it can also be used for magnesium, titanium, niobium, or tantalum. Unlike general conversion coatings, anodizing involves both an electric current and a chemical conversion at the metal surface to create the coating.
The application of current accelerates the anodizing process, allowing the layer to form thicker and faster compared to a purely chemical reaction. Additionally, anodizing creates tiny microscopic pores in the coating, which can be filled with dyes to produce a range of colors for the parts.
The painting process involves applying a liquid organic coating to various substrates, which can include wood, plastic, metal, ceramic, paper, or foam. The types of paint used can vary from solvent-based to solid paints, including UV-curing liquids.
As a result, paint can be in the form of a liquid due to various carriers, such as water or solvents, or it can be a two-part epoxy paint that cures through cross-linking rather than simply drying by the evaporation of the carrier. Several spraying methods can be used to apply the paint, with a few described briefly below:
The E-coat painting process is a hybrid method combining elements of plating and painting. In this process, a metal part is dipped into a water-based solution containing a paint emulsion. An electric voltage is then applied to the part, causing the paint emulsion to deposit onto the surface through electrophoretic deposition.
Wherever the liquid can access the metal surface, the part can be coated both inside and out. The voltage applied controls the coating thickness, with areas experiencing higher voltage becoming insulated as the coating builds up, while areas with lower voltage accumulate more coating. This ensures that even the interior surfaces, which are fully insulated by the coating, receive coverage. After coating, the part is rinsed to remove any residual emulsion, which is then recycled back to the paint tank through ultrafiltration.
The process of powder coating is similar to painting, except that the coating used is a dry powder rather than a liquid. The powder adheres to the parts due to electrostatic charging of the powder and the grounding of the parts.
Substrates that can withstand the heat required for powder curing and that can be electrically grounded to improve the adhesion of the charged particles can be used. During the heating process, the powder melts and cures. Powder coating offers several advantages over traditional paints, including:
Despite its advantages, powder coating has some limitations when compared to traditional paints. One issue is that it tends to exhibit less evenness in the final finish. Additionally, the curing process for powder coatings requires significantly more energy due to the higher temperatures involved.
Curing and drying operations are very energy intensive operations in the powder coating process. The drying and curing operations are bonded with convection ovens. Using convection heating is costly and very slow if the parts are heavy and large. This is because the evaporation or curing will be greatly dependent on the part temperature. The part must be hot enough for the part surface to dry or for curing of the powder coat. Large amounts of air volumes need to be exhausted and heated from the convection oven to dry or cure the parts effectively.
Heating with infrared has notable benefits for powder coating curing. This method provides consistent and rapid heating of the surface, enhancing the flow of the powder and reducing the likelihood of defects caused by dirt or dust. The minimal airflow associated with infrared heating helps to prevent particle deposition and issues related to convection heating.
Additionally, infrared curing proves advantageous for liquid paints as well. Unlike convection curing, which heats the paint and can lead to trapped solvents or uneven drying, infrared light warms the part surface directly. This approach facilitates drying from the inside out, preventing the paint from forming a skin or trapping moisture beneath the surface.
Grinding metal is used to refine surfaces by removing rough edges, smoothing welds, deburring, and producing sharp edges or distinctive finishes. Grinding is typically carried out using either stationary machines or handheld tools equipped with industrial grinding wheels.
Grinding primarily relies on techniques such as attrition, friction, or compression to refine the metal surface. The degree of smoothness achieved is typically influenced by the type of grinding machine used. Various grinding techniques can be employed to achieve the desired shape, size, and characteristics of the final product.
Grinding methods include electrochemical, centerless, cylindrical, and surface grinding, among others. Choosing the appropriate method is essential based on the type of metal and the specifications of the final product.
Tumbling finishing, also known as barrel tumbling, involves loading parts, abrasive media, and various compounds into a rotating barrel. This process smooths corners, deburrs, grinds, descares, burnishes, and polishes parts in bulk. Friction generated between the parts, media, and compounds drives the tumbling action. Tumbling methods are categorized as wet or dry, with wet tumbling designed for removing excess material and dry tumbling suited for a range of finishing tasks.
The specific requirements of different parts and metals determine the choice of tumbling method for achieving the best finish. Vibratory tumbling is ideal for creating smooth and polished surfaces on delicate components. It utilizes the combined action of abrasive media and water in a machine that vibrates rapidly.
Dry tumbling involves a vibratory bowl equipped with an electric motor and media. As the bowl vibrates, the parts are agitated against the media, each other, and the bowl's interior. Common media used in dry tumbling include corn cob and walnut shells. Corn cob media, which is also employed in sandblasting, delivers a high-gloss finish but requires longer processing time. Walnut shell media is more abrasive and results in a satin-like finish.
Alkaline cleaning is another important finishing technique. The process begins with the setup of alkaline cleaning tanks, which are then used to tackle the majority of contaminants. These tanks are designed to eliminate wax, grease, oils, particulates, and light oxides from the surfaces of parts.
Detergent additives in the tanks can lead to the accumulation of oil emulsions, surface oils, suspended solids, and sludge at the bottom of the tank. Acids used in cleaning help to remove these contaminants and prevent their redeposition during the process.
Initially, it's important to implement a method or procedure to assess the effectiveness of the alkaline cleaning bath. This can range from complex chemical analysis of samples to simple pH measurements. The chemical supplier may either test various methods to monitor the bath or provide test kits, and they can adjust the cleaning chemistry as it deteriorates over time.
To eliminate surface oils, a combination of surface sparging and the use of various oil skimmers can be employed to extract accumulated oil from the weir. It's important to address potential dead zones on the tank surface to ensure effective removal.
This is where oils can accumulate and redeposit as the parts exit the tank. An effective sparger will push a layer of surface water across the tank and over the weir. Several methods can then be employed, such as disk skimmers, belt skimmers, and concentrator vanes.
Heavy particles settling at the bottom of the tank can be removed using bag filtration or other basic filtration methods. This step is crucial, particularly when ultrasonic transducers are present on the tank bottom, as a layer of dirt can significantly reduce their cleaning efficiency. For parts with substantial soil, a dual filter system may be necessary. This system allows for switching between filters as one becomes loaded, enabling filter replacements without interrupting the process.
Emulsified oils and suspended solids present additional challenges, as they are difficult to remove with standard filtration techniques. Ultrafiltration is a method that effectively breaks down oil emulsions and separates suspended solids without disturbing the active cleaning chemistry. The effectiveness of ultrafiltration depends on the cleaning chemistry's pH level and the bath temperature. Some ultrafiltration systems are designed to handle a wide pH range from 0 to 14 and temperatures up to 158°F, making them suitable for various industrial applications.
Media blasting utilizes various materials to clean and remove debris, dirt, and particles from metal surfaces. While often called sand blasting, sand is just one of many materials that can be used. Choosing the right media for the specific conditions and metal type is essential for effective cleaning.
Frequently, media blasting eliminates the need for additional finishing steps, thus saving both time and cost. Among finishing methods, media blasting is one of the quickest, which enhances both efficiency and productivity.
The media blasting process employs various abrasive materials such as aluminum oxide, silica sand, crushed glass, nut shells, silicon carbide, corn cob grit, plastic abrasives, and glass beads.
The process of micro sand blasting is used for areas as small as 1.3 mm by 2 mm (0.051 in by 0.08 in) and is widely used for cleaning small workpieces such as medical instruments. Small minute imperfections on an instrument can radically affect an instrument’s performance. Blasting it with a soft abrasive removes built up residue without damaging the instrument.
Wet media blasting, also referred to as vapor blasting or vapor honing, utilizes a combination of abrasive material, liquid, and compressed air to achieve a refined surface finish. Water is used as the liquid to ensure a smoother and more consistent result. The choice of blasting media in wet media blasting significantly affects the effectiveness of the process.
The primary goal of wet media blasting is to enhance the safety of both the material being processed and the operator. Water helps to mitigate dust generated during blasting and adds weight to the particles, making them more efficient in achieving the desired finish.
Brushed metal treatment involves using friction to smooth out imperfections while creating a textured grain pattern on the surface. This process typically employs fine bristle brushes or abrasive belts, resulting in a non-reflective, matte finish.
The orientation and pattern of the grain are influenced by the type and placement of the abrasive used. Brushing metal not only reduces its shine but also imparts a unique appearance. Various finishes can be achieved using power-driven stainless steel brushes, wire wheels, back sander heads, nylon discs, and various abrasive cloths.
The phosphating process is typically classified as a conversion coating process. This is because the process includes the removal of metal as part of the reaction. It differentiates from processes such as black oxide or anodizing in that the phosphate coating reaction is a precipitation reaction. The last or final surface is a layer of crystals of phosphate sticking to the metal surface.
Phosphates play a crucial role in both paint and powder coatings, serving two main purposes. First, they enhance the adhesion of the coating by providing anchoring sites through the organic nature of phosphate crystals. Second, the phosphate layer acts as a protective barrier against corrosion, especially in areas where the coating might be scratched. When evaluating rust resistance, the presence of a phosphate layer significantly reduces rust creep compared to scenarios where no conversion layer is used beneath the organic coating.
Phosphate coatings can be applied independently to enhance properties such as lubrication in manufacturing components. Common types of phosphating include zinc phosphate, iron phosphate, and manganese phosphate. Unlike traditional methods, some phosphating processes, such as plaforizing, use a single-step approach and are classified as organo-phosphates. These treatments are unique because they interact with both metal surfaces and organic contaminants.
Passivation is primarily used for stainless steel and involves treating the metal to enhance its resistance to corrosion by making it less reactive to its environment. This process creates a passive oxide layer through the reaction between the metal and oxygen. This oxide layer forms a protective barrier that helps to prevent corrosion from penetrating beyond the surface of the steel or stainless steel.
The protective bond formed between the metal and the corrosion layer acts as a seal, stopping corrosion from spreading deeper into the metal. In passivated metals, if the surface is scratched or otherwise damaged, the treatment helps to naturally repair itself using molecules from underlying layers.
The success of passivation relies on the type of oxides used, as not all oxides offer effective protection. Porous oxides, for instance, may allow oxygen to pass through and fail to create a proper seal, leading to potential corrosion of the underlying metal.
The various processes under part drying are:
To prevent water spotting, using deionized water for the final rinse is an effective solution. Water spots typically occur due to minerals present in regular tap water, which can be eliminated by using water free of these minerals. Another approach to minimizing water spots is to use an air blow-off technique to expel water droplets before they have a chance to dry. The success of this method depends on the orientation and arrangement of the parts on the racks. If the air stream cannot reach certain areas due to the parts' geometry or because parts are obstructing each other, spotting may still occur in those locations.
Finishing processes require the use of water and various compounds to achieve the desired surface quality. To prevent issues in subsequent manufacturing steps, it's crucial to ensure that parts are thoroughly dried before moving them on for additional processing. Although drying is less complex than finishing, selecting the appropriate drying method is essential to guarantee that the workpiece is completely dry.
Drying equipment can be categorized based on the drying medium or the application of hot air. Simple workpieces with straightforward shapes can be dried rapidly at lower temperatures. Conversely, complex parts with intricate features like undercuts and internal passages need extended drying times and higher temperatures to ensure thorough drying.
After finishing, a variety of dryers can be employed, including rotary vibratory, belt, drum, and centrifugal types. Common drying media include maizorb, which is derived from crushed corn cobs and typically comes in granule sizes ranging from 0.002 inches to 0.2 inches (0.5 mm to 5 mm). This media may need replacement every few days if it becomes contaminated with residual substances like oil.
Rotary vibratory and drum dryers are suitable for drying small to medium-sized parts using a drying media. Belt dryers and drying centrifuges, on the other hand, use hot air. Very small parts that cannot be processed with other methods are typically dried in drying centrifuges. Belt dryers are particularly effective for large, complex components to prevent media from becoming trapped in intricate features.
Rinsing, like other metal finishing processes, is essential and requires meticulous planning to achieve optimal results. Its main role is to remove and dilute surface residues and contaminants, thereby reducing the risk of part failure. Rinsing involves using a medium to clean the surface, preparing the part for subsequent processes.
Water is typically employed in the rinsing process, and efficiency is crucial to optimize water usage. Key factors to consider in a rinsing process include water purity, the mechanical action of the rinse, the duration of the rinsing, and the water temperature.
Common sources of water for rinsing include city water and well water. While these are readily available, they may contain chlorides or sulfates that can contribute to corrosion. Deionized (DI) water or water filtered through reverse osmosis (RO) are preferred as they have fewer impurities. Agitation during rinsing improves the effectiveness by increasing water contact with the part. Additionally, heating the water to between 75°F and 85°F (24°C to 29°C) enhances the rinsing process.
Air drying methods fall into two main categories, which can be used alone or together for optimal results.
High Velocity Air: This method focuses on swiftly removing water from parts rather than fully drying them.
Heated Air: This technique uses blowers that blow heated air to assist in the drying process.
This chapter will explore the various applications and advantages of metal finishing.
Metal finishing has a wide range of applications across various industries. In manufacturing, finished metals are employed to protect materials that are highly susceptible to oxidation. The coatings used in this process help prevent unwanted chemical reactions.
In the automotive sector, metal finishing is crucial for safeguarding components of the combustion engine from extreme temperatures. Similarly, in the aerospace industry, finished metals are essential for preventing corrosion and wear within engine blocks.
For industrial purposes, finished metals play a significant role in maintaining machinery. They help protect against corrosion, wear and tear, and other factors that can lead to rapid deformation.
In household settings, metal finishing is valued for its aesthetic and decorative applications. The process not only enhances appearance but also contributes to the longevity of metal products.
Finished metals offer several key advantages, including enhanced resistance to wear and tear. Metal finishing can also improve mechanical properties, making products less prone to corrosion. Additionally, it helps preserve the aesthetic qualities of the metal.
Finished metals can accommodate a range of microstructures and perform well under both low and high atmospheric pressures. They may feature varying levels of porosity throughout their thickness and can be both decorative and resistant to high temperatures. The finishing processes used are generally cost-effective, and these metals are also suitable for biomedical applications. Moreover, they offer high adhesion properties and can be manufactured into complex geometries.
Despite their advantages, metal finished products also have some limitations. Each product has a specific operational range due to the varying mechanical properties of the coatings or finishes used. Consequently, performance can vary between different metal products depending on the pressure and temperature conditions. In industrial applications, there is often a need for metals that offer exceptional vacuum or corrosion resistance, high melting points, and substantial tensile strength.
The metal finishing products come in different shapes and sizes. They have impacted the industrial sector where much corrosion, wear and tear of metals do happen. Metal finishing applications are so broad with the available technology. Machines can operate smoothly for quite a long period of time because of these finishing techniques.
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