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Able Electropolishing ELECTROPOLISHING THE FINAL STEP IN PROTOTYPING ENHANCING YOUR METAL PARTS FOR ACCELERATED SPEED TO MARKET CONTENTS 01 TECHNICAL SUMMARY 03 DIRECT METAL LASER SINTERING 05 INVESTMENT CASTING 07 PHOTOCHEMICAL MACHINING 09 METAL INJECTION MOLDING 11 ELECTRICAL DISCHARGE MACHINING 14 3D PRINTING 15 LASER CUTTING 17 METAL STAMPING 19 ABOUT ABLE ELECTROPOLISHING WHAT IS ELECTROPOLISHING? // WHAT IT DOES TECHNICAL SUMMARY While the process is best known for the bright polish left on a surface, there are some important, often overlooked, benefits of this metal finishing method. These benefits include deburr- ing, size control, microfinish improvement, ultraclean finishing, corrosion resistance and others. These metal improvement Electropolishing is often referred to as a “reverse plating” process. Electrochemical in nature, benefits are highly desirable to design and production engi- electropolishing uses a combination of rectified current and a blended chemical electrolyte neers for cost savings and product lifespan improvement. bath to remove flaws from the surface of a metal part. When speed to market is critical, electropolishing offers the necessary // HOW IT WORKS part enhancements needed in the final step of production. Figure 1 The typical electropolishing installation is deceptively Since the development of electropolishing in the 1950s, substantial refinements have taken similar to a plating line. A power source converts AC current place. Able has many electrolytes to allow for electropolishing on a broad range of metals. to DC at low voltages. A rubber-lined tank, usually fabricated These newer electrolytes, combined with advanced parts handling techniques, have improved from steel, is used to hold the chemical bath. production yields on a wide range of metal products. A series of copper or stainless steel cathode plates are TECH SUMMARY | PAGE 02 PAGE | TECH SUMMARY More recently, electropolishing has been utilized in many prototyping methods, including lowered into the bath and installed to the negative (-) side investment casting, photochemical machining, injection molding, laser cutting, metal stamping, of the power source. A part or group of parts is fixed to a 3D printing, direct metal laser sintering and electrical discharge machining. Following the rack made of titanium, copper or bronze. That rack in turn electropolishing process, metal parts have improved microfinish value, an ultraclean surface is fixed to the positive (+) side of the power source. and enhanced corrosion resistance. As the adjoining illustration depicts, the metal part is charged positive (anodic) and immersed into the chemical bath. // ALLOYS WE ELECTROPOLISH When current is applied, the electrolyte acts as a conductor THE BENEFITS OF ELECTROPOLISHING FOR PROTOTYPING | PAGE 01 PAGE | FOR PROTOTYPING OF ELECTROPOLISHING THE BENEFITS Able specializes in providing electropolishing services for a variety of common and specialty to allow metal ions to be removed from the part. While the metal alloys. Here is a partial list of alloys we can electropolish: ions are drawn toward the cathode, the electrolyte maintains the dissolved metals in solution. Figure 2 200-300 Series Stainless Steels Specialty Alloys Tool Steels Gassing in the form of oxygen occurs at the metal surface, 400 Series Stainless Steels Nickel Alloys Aluminum furthering the cleansing process. ABLE ELECTROPOLISHING: Precipitating Hardening Grades Specialty Steels Titanium Once the process is completed, the part is run through a series of cleaning and drying steps to remove clinging Unusual Stainless Steels Carbon Steels Nitinol electrolytes. The resulting surface is ultraclean and bright. Copper Alloys In fact, the bright surface is the most identifiable trait and is what helped coin the process name: electropolishing. Figure 3 DIRECT METAL LASER SINTERING Direct metal laser sintering (DMLS) is an additive rapid manufacturing prototyping method used to create production tools for the automotive, aerospace, dental and medical industries. Sintered Part Using CAD models, metal powder builds up in layers and is fused into a solid part without tooling, creating THE BENEFITS CASE STUDY products with speed and accuracy, 04 PAGE | LASER SINTERING METAL DIRECT even in a matter of hours. These parts // ULTRACLEANING are ideal for small prototypes used in functional tests. Electropolishing can be used in conjunction with other traditional mechanical finishing methods to leave the part clean and free of surface Stainless steel and cobalt contamination. Most notably, electropolished parts have an ultraclean chrome alloys are used for finish free of lingering surface impurities, such as oils, embedded scale, DMLS parts and often have a debris and more. raw finish that is very similar to a fine investment casting. // DECORATIVE FINISH These parts can benefit from ultra- Many DMLS parts have complex shapes that are difficult to polish. Elec- THE BENEFITS OF ELECTROPOLISHING FOR PROTOTYPING | PAGE 03 PAGE | FOR PROTOTYPING OF ELECTROPOLISHING THE BENEFITS cleaning and improved corrosion tropolishing can provide a clean, bright finish in difficult to access areas resistance, as well as the decorative of complex, customized geometries. After undergoing electropolishing finish, electropolishing provides. treatments, metal parts have a noticeably bright, shiny appearance that Before Electropolishing After Electropolishing cannot be achieved using traditional metal finishing methods. // THE PROBLEM // THE SOLUTION ABLE ELECTROPOLISHING: // CORROSION RESISTANCE The customer was looking for a way to improve the finish Electropolishing was able to clean the Surfaces with heavy contamination often do not respond well to and provide an ultraclean surface for DMLS-created parts passivation treatments alone. These parts require more aggressive used in a medical application. surface of the DMLS part and minimize metal finishing methods, like electropolishing, to enhance their corrosion the mechanical finishing required without resistance. They needed a finishing method that would not adversely affect the porous surfaces that are suitable for better damaging the textured surface. By eliminating embedded contaminants and surface imperfections, osteointegration. Following electropolishing treatment, the part had a clear, shiny electropolishing provides 30 times greater corrosion resistance than and ultracleaned surface with improved oxidation resistance. passivation alone. Electropolishing can also be performed on almost any metal alloy, making it a desired method for DMLS prototyped parts. INVESTMENT CASTING Investment casting is a prototyping method that uses a CASE STUDY THE BENEFITS wax mold to create metal parts. // THE PROBLEM // THE SOLUTION Investment casting is typically used for // ULTRACLEANING metal parts that require complex and thin The customer had a 17-4 PH stainless steel investment The parts were electropolished to remove .0008” total material. casting used in the marine industry. The parts, as cast, After the electropolishing process was completed, the parts Investment casting, along with other prototyping wall castings, as well as for parts with highly methods, can create metal parts that have impu- were not passing stringent salt spray testing for corrosion were cleaned of all embedded scale, oxides and abrasives. rities left behind. Electropolishing can be used to customized shapes and edges that cannot resistance. The resultant surface was free of impurities, remove contaminants, creating a surface that is be achieved using conventional methods. The parts were sent through various blasting and passiva- more resistant to corrosion. and all surface cracks and fissures were Because investment casting can produce parts with highly tion operations with no positive results. Ultimately, the client unique and intricate characteristics, many industries, decided to have electropolishing performed on the parts. eliminated or reduced, effectively extending // DECORATIVE FINISH 06 PAGE | CASTING INVESTMENT including aerospace, medical and others, rely on this the parts’ lifespan. After investment casting has been completed, method to develop new parts. The parts exceeded salt spray requirements by 210%. prototyped parts exhibit a dull finish. Following electropolishing, investment-cast Electropolishing can enhance parts for a bright, clean parts have a smoother, ultra clean surface finish that is long-lasting. These parts also have a with a decorative finish, as well as enhanced smooth surface that combats against oxidation, corrosion resistance. even in harsh conditions. // CORROSION RESISTANCE THE BENEFITS OF ELECTROPOLISHING FOR PROTOTYPING | PAGE 05 PAGE | FOR PROTOTYPING OF ELECTROPOLISHING THE BENEFITS For prototypes with custom shapes, such as those created through investment casting, corrosion resistance is the utmost importance. Electropolishing is an effective way Before Electropolishing After Electropolishing ABLE ELECTROPOLISHING: to prevent corrosion, whereas, other methods, like passivation, provide a lesser level of protection. Electropolishing removes embedded impurities for increased part protection and longevity. PHOTOCHEMICAL MACHINING Photochemical machining is a prototyping process used to create detailed parts. This CASE STUDY process is ideal for manufacturing parts created from extremely thin metal, as they can be machined without distorting the material. // THE PROBLEM The customer was looking to improve the finish of stainless Many companies use photochemical discs with critical
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