Electroplating Process: Definition, How It Works & Applications
Electroplating is one finishing process that has applications in a wide range of industries. This process improves parts’ appearance and properties. Initially, metals can only be electroplated with other metals, but with the recent technological advancement, improving non-metals with this process is available too.
Besides, electroplating can combine the desirable properties of certain metals with other materials. These properties often include strength, abrasion, appearance, corrosion resistance, and electrical conductivity. Moreover, this process aims to boost or improve the material’s properties. The material could be metals, plastic, or even wood.
Aside from this information above, how does electroplating work? What metal materials are ideal for use in this process? What are the advantages and disadvantages of this plating process? Keep reading as we provide answers to these questions and other important things you need to know about the electroplating process.
What Is Electroplating?
Electroplating is a coating process that has been around since the early 19th century. Although there has been advancement in the technology used, the basic process remains the same.
Electroplating simply means coating an object or a material with a metallic layer or layers using electric current. This process also termed electrodeposition, results in the deposition of a thin layer of metal onto a material. Consequently, this process aims to alter the material’s physical properties, also called the substrate.
Additionally, due to the electroplating process, the substrate has better aesthetic appeal, corrosion protection, and increased resistance to wear and tear or increased thickness.
How Does Electroplating Work?
Electroplating works by dissolving and depositing a metal onto another surface through an electric current. There are four primary components of this process.
Anode: This is the positively charged electrode used in the circuit. The anode holds the metal used for the plating process.
Cathode: This is the negatively charged electrode used in the circuit. It holds the material you want to plate, also called the substrate.
Plating Solution: This is one of the most important metal finishing solutions. It serves as a catalyst facilitating the flow of electricity in the circuit. The plating solution usually contains copper sulfate and one or more metal salts.
Power Source: The power supply adds current to the circuit. The power source introduces electricity to the system when connected to the anode.
Electroplating Working Principle
So, how is electroplating done? Below are the steps of electroplating.
Place the anode (metal) and cathode (substrate) in the plating solution or electrolyte. Subsequently, introduce electricity to the setup through the anode.
Consequently, on the introduction of electricity to the anode, oxidation occurs. The result forms the dissolution of metal atoms in the plating solution as positive ions (cations). Furthermore, the current in the circuit causes the movement of the metal ions (positively charged ions) to the negatively charged substrate. This results in the deposition of a thin metal layer on the substrate.
Also, for the electroplating process to be successful, always remember the following points. Firstly, the electric current’s quality affects the plating process Quality here includes the voltage level and electric current application time.
Secondly, the chemical composition of the electrolyte and its temperature also determine the effectiveness of the process. Lastly, always consider the position of the anode to the cathode. This is because the distance the dissolved metal ions travel to get to the substrate also determines how effective the plating would be.
However, for plating to be optimal, engineers have to adhere to these precautions.
Precautions In The Electroplating Process
Handle the solution with great care since it contains sulfuric acid and is highly corrosive. If the solution or electrolyte gets into your eyes, rinse your eyes with a lot of water, and call a doctor immediately.
Always wear safety gadgets like goggles and gloves when carrying out this process to avoid direct contact between electrolytes and skin. Other important gear to have includes an apron and fume hood. Ensure you use the fume hood, as it prevents electrolyte fumes from reaching your face on their way out.
Also, keep the plating solutions out of the reach of animals and young children.
Avoid contact between electrolytes and household chemicals. Contact between them could trigger a reaction that could either render the electrolyte useless or release hazardous gasses into the atmosphere.
The ideal temperature for storing electrolytes is between 40 to 95 degrees Fahrenheit. Furthermore, always store it in the original container with the lid tightly sealed.
Always use a plastic funnel when transferring the electrolyte from the electroplating kit.
Follow all electrical safety precautions when attempting this process. These include rubber mats, grounding, fusing, and insulated gloves.
Do not wear rings and other jewelry during the process as they are often metallic and could cause electrocution.
3 Types of Electroplating Methods
There are different types of electroplating methods to employ when coating a substrate. These include:
Barrel Plating
Rack Plating
Reel to Reel Plating
Let us discuss these methods in more detail.
Barrel Plating
This rotation causes the substrate within the barrel to tumble, facilitating the uniform application of the coating metal. Consequently, engineers use this type to achieve enhanced corrosion resistance and improved substrate appearance. In like manner, engineers also use barrel plating to improve a substrate’s resistance to wear and tear.
Also, since it allows the addition of more than one substrate inside the barrel, it provides a cheaper means of plating high-volume parts. This makes barrel plating ideal for plating fasteners and stampings. On the other hand, plating with this method takes more time since it requires a low electrical current.
Rack Plating
Rack plating differs from barrel plating. In this case, substrates stay in one place. This method does not allow the freedom of movement seen in barrel plating. Also, it involves using metal racks with the substrates affixed to the racks with spring fingers, wires, or screws. As a result, the substrate remains immobile on immersion into the electrolyte.
Besides, it is important to note that engineers employ rack plating when working with delicate parts. In other words, parts might find it difficult to withstand the tumbling experience of barrel plating.
Additionally, rack plating is also ideal for use when the substrate is large or complex. It is the engineer’s choice when a high-quality finish is important, giving it application in medical and electronics, automotive as well as defense and military gadgets.
On the other hand, rack plating requires a lot of labor input for success, so it is quite expensive. Nonetheless, this plating method guarantees protection against damage to substrates during the plating process.
Reel to Reel Plating
Reel to reel plating is both economical and efficient. It is a unique plating method because it allows the selective deposition of metals on a substrate. Often used for plating strips of manufactured or stamped products, reel-to-reel plating offers engineers more benefits than other plating types.
There are different types of reel-to-reel plating;
Controlled Depth Plating: Plating occurs only on both edges of the substrate. It does not occur anywhere else.
Spot Plating: Using this type of reel-to-reel plating involves using a mask. Here, metal deposit only occurs in unmasked areas in a spot pattern.
Flat Stock: This method is similar to spot plating as it involves the deposition of metal on unmasked areas of a substrate. The only difference between them is the absence of the spot pattern as seen on spot plating.
Tape Masking plating: This reel-to-reel plating method involves metal deposition on a substrate in a continuous strip. It is important to note that you should cover areas that do not require plating using masking tape.
Generally, reel-to-reel plating is ideal for use when you want to plate a particular substrate area. Furthermore, it has a high plating rate and offers increased conductivity and durability to substrates. Materials plated using this method are also durable and resistant to corrosion. Besides, this plating method, when used on high-volume jobs, also saves costs.
Metal Materials Suitable For Electroplating
The electroplating process can occur with either one metal or a combination of metals. There are many metals that engineers use for this process. However, below are the most common metals used.
Copper: Copper electroplating boosts adhesion between material layers. It also increases the heat resistance and conductivity of a substrate.
Zinc: Zinc has high corrosion resistance. Furthermore, when electroplating occurs using zinc alloyed with nickel, it improves the substrate’s resistance to atmospheric corrosion.
Nickel: This is one of the metal materials suitable for electroplating because it is wear resistant. It also has alloys that offer elemental resistance, conductivity, and hardness substrates.
Silver: Silver metal plating finishes have high ductility and malleability. It also has a pleasant appearance and resists contact wear excellently. Furthermore, silver improves a material’s electrical and thermal conductivity.
Palladium: Often used because of its corrosion resistance, palladium also improves the substrate’s hardness and resistance to corrosion.
Gold: This is a precious metal with high aesthetic appeal. Moreover, it imbues substrates with high conductivity, tarnishes, corrosion, and wear resistance when used.
Tin: This bright metal is inexpensive and environmentally friendly. It makes substrates corrosion-resistant and highly malleable when used.
Advantages and Disadvantages of Electroplating
Now that we know more about electroplating and why it is important to engineers and manufacturers, let’s discuss its merits and demerits.
Advantages of Electroplating
Offers Substrate material protection: Protecting objects from corrosion and tarnishing is one of the major advantages. Furthermore, it also improves object shock protection and heat resistance.
Reduces friction: Electroplating objects minimizes the friction on metals when rubbed together. Hence, reducing scraping and heat generated. Moreover, less friction also translates to less wear and tear, allowing you to use objects for a long period.
Improving object properties: this process imbues objects with extra properties such as thickness, magnetism, and conductivity. This gives the process application in producing electronics and other products that require materials with such properties.
Improved adhesion: In some cases, the electroplated surface is not the final coat but just an intermediate step. The surface acts as a glue, holding the base material and the outer coating together, improving adhesion.
Disadvantages of Electroplating
Environmental Pollution: When not properly done, this process can produce hazardous waste that is detrimental to the environment. However, you can avoid this with proper waste management.
Expensive to set up: A complete setup for this process is quite expensive as you would have to get metals, chemicals, and other expensive equipment before it is up and running.
Takes time: Metal deposition occurs very slowly, which takes a lot of time. It even consumes more time when the material requires more than one layer.
Applications of Electroplated Parts
Electroplating has applications in a wide range of industries. Let’s examine a few of them.
Aerospace
Aircraft components are often subject to a wide variation in temperature, so plating them helps increase their lifespan. Besides, it improves base metal’s resistance to wear and tear.
Automotive
To achieve an aesthetic finish, automotive companies apply electroplating metals such as chrome and nickel to various car and motorcycle parts.
Medical and Dental
Medical and dental tools such as forceps and implants, including replacement joints, screws, and plates, come with electroplated parts. This layer makes them more corrosion-resistant.
Prototyping
Since producing a prototype of custom or low-volume metal parts traditionally is quite expensive, manufacturers now combine the process with 3D printing when prototyping. That way, saving cost and time.
Power
Electroplating objects for electrical or solar power transmission helps improve their conductivity greatly. Besides, it improves their durability.
Jewelry
This is probably the industry with the highest application of this process. Manufacturers rely on this process to improve jewelry’s appearance and durability, such as bracelets, rings, pendants, etc.
Specific Examples of Electroplating Applications
Use of chromium and zinc-nickel in electroplating bolts and fasteners used in the aerospace industry
Chrome bumpers and other metal parts in the automotive industry
Tooth inlays that aid dental procedures
Silver and nickel plating of wires for improved conductivity
Turning biodegradable items like flowers and bugs into works of art by artisans
RapidDirect’s Electroplating Services for Metal Parts
Every electroplating process requires electrolysis as its base. However, what differentiates one electroplating process from another is the solution employed during the process as well as the expertise of the professional. If need metal parts with electroplating finishing, RapidDirect is your best bet.
To ensure your product stands out among competitors, RapidDirect applies a top-quality surface finish with exquisite materials meeting your requirements. Besides, we use high texturization standards to ensure a quality finish for metallic parts. Also, since we consider time an important factor in production, we shorten the production process using our self-owned factory and its established networks.
At RapidDirect, our manufacturing ability is versatile and aids in the production of high precision and top-notch metal parts, ranging from CNC machining machines to sheet metal fabrication services. Our sheet metal fabrication aids in the production of high precision and top-notch metal parts.
Besides, our strict quality assurance ensures you get high-quality metal parts with outstanding finishing and aesthetics. What’s more, you can get a quote for your electroplating, and other manufacturing needs easily by visiting our online platform.
Conclusion
The electroplating process is one technology that has been around for a long time. It aids in the production of parts that have improved properties and are durable and aesthetically pleasing. For electroplating to be successful, it requires an anode, cathode, electrolyte, and power source.
Are you looking to electroplate an object? Doing so without proper guidance or training is a risky affair. So, it is best you visit RapidDirect for your electroplating needs.
FAQs
Is it Possible to Electroplate Plastics?
Yes, it is possible to electroplate plastics. However, you cannot achieve this by immersing the plastic material in an electrolyte. This is because it requires a special plating technique.
What’s the Difference Between Electroplating and Electroforming?
The main difference between them is that electroforming results in the creation of a new object while electroplating deposits a layer on an existing object called the substrate.
How does a Metal Get Deposited over Others During electroplating?
It occurs through a process called electrodeposition. The plating metal is the anode, while the other metal or substrate is the cathode. Introducing electric charge through the anode results in the oxidation of the plating metal. The electric current in the setup carries and deposits this oxidized metal into the cathode.
What is electroplating?
Electroplating is the process of coating the surface of a conducting material (a material that allows electrical currents to pass through) with a thin layer of another metal through means of electrolysis. Electroplating is used because it helps protect the conducting material from wear, corrosion, and rust.
What are electroplating masking products?
Also known as anodize masking, electroplating masking products are used to cover specific areas which will be exposed in the electroplating process. This essentially means that when the metal is being covered, the electroplating masking products will protect the covered area of the item from being electroplated. Plugs, caps, dots, and masking lacquer for electroplating can all be used when electroplating. These can withstand the temperatures and conditions in an electrolytic bath. It’s important to note that electroplating masking products are not always required to be used in every case of electroplating
How does electroplating work?
Electroplating works by submerging the metal area required to be coated, known as cathode or anode, in an electrolytic bath. The electrolytic bath usually consists of a mixture of salts, as well as the metal used in the plating process. An electric current, which is unidirectional, is passed directly through the solution in the electrolytic bath. This then results in a change in the transfer of metals onto the cathode surface side of the metal, and subsequently plates metal onto the object. The cathode is the side of an electrode which electricity flows out of, whereas the anode is an electrode which electricity flows into. Therefore, cathode is generally the negative side and the anode the positive side.
What many people aren’t aware of is that electroplated products are part of our daily lives. An example of a day to day product which is electroplated is tableware. Items are electroplated to be protected against premature tarnishing or damage, hence why silverware items that haven’t been electroplated tend to rust.
What electroplating masking products are there?
Masking & Stop Off Lacquer: we have a variety of thinners and masking lacquer for electroplating which are able to perform high resistance to acidic and difficult solutions. Some of these products are also suitable for electroplating different types of materials. Alternatively, you will find two types of wax masking electroplating options: petroleum-based low-temperature waxes and chlorinated synthetic high-temperature waxes.
High Temperature Masking Tape: electroplating masking tape varies from adhesive to non-adhesive options (sticky and non-sticky), and tapes for powder coating or stove enamelling.
Masking Tape Dots: these are used to mask off circles of a specific size (1mm increments). Masking tape dots are suitable for electroplaters, powder coaters, and stove enamellers.
Silicone & Vinyl Caps: whilst the silicone caps can operate to a temperature of 260°C, the vinyl caps operate to a lower maximum temperature of 170°C.
Tapered Plugs: our tapered silicone and rubber plugs can withstand temperatures of up to 260 °C.
Electroplating: The Process & Uses in Liquid Analysis Explained
Electroplating is a process that occurs when the surface layer of one type of metal is added to another kind of metal. Also known as electrodeposition, this process is used to ensure that the metal base isn’t subjected to rust and corrosion. The thin layer of metal that’s positioned on top of another metal can alter the base metal’s physical properties, improve wear resistance, and increase material thickness. Electroplating is also commonly used to make a product more visually appealing.
There is a range of metals that can be used during the electroplating process, which include everything from copper and zinc to silver and gold. Even though modern advancements to electroplating have made this technique more popular than ever, the process was invented back in the 18th century. At the time, electroplating only existed as a basic experiment. It wasn’t until 1805 that Luigi Brugnatelli formalized the process, after which it was quickly adopted throughout most European countries. Since that time, advancements have continued to be made that allow electroplating to offer many distinct benefits.
The electroplating process always involves two different types of metals. In order for this process to occur, one of the two metals will need to be positively charged while the other is negatively charged. When an electrical current begins to flow from one metal to another, the negatively charged metal will take some molecules from the positively charged one.
For this process to work as intended, the layer of metal that you want to add to the surface of another metal must accommodate an electrical charge. This requirement means that it can be difficult to plate materials like wood and plastic that are unable to conduct electrical charges. You can bypass this issue altogether by thoroughly cleaning the material and applying a very thin layer of metal to the base material. Once you’ve found a material that can hold an electrical charge, the electroplating process can begin in earnest. This article offers you a detailed guide on the process and many uses of electroplating.
Electroplating Uses
Because of how versatile electroplating is, it has several different uses, which means that it can be applied in many industries. The four main uses of the electroplating process include:
Lend various surface properties – Once applied, the substrate can benefit substantially from the characteristics and properties of the metal that it is plated with. The plating metal you select can increase the electrical conductivity of the substrate or reduce material friction. Each plating material provides its own distinct benefits.
Improve an item’s appearance – The electroplating technique is commonly performed to enhance the appearance of the substrate in question. Silver and gold are two popular plating metals that can improve the substrate’s appearance.
Protect the substrate – If you want to protect the substrate surface from damage or corrosion, the plating metal can serve as protection for the substrate below. When the finished item is exposed to harmful conditions, the plating metal will be damaged first, which ensures that the substrate has more protection than it otherwise would have.
Improve material thickness – It’s possible to add several layers of plating metals, which can help you improve substrate thickness.
Industries That Use Electroplating
Because of the many uses that electroplating has, there is a range of different industries that benefit from the electroplating process. The five primary industries that use electroplating are:
Medical industry – It’s common for the medical industry to use electroplating to enhance component biocompatibility. Metals like titanium, gold, and silver are used in the medical industry for their wear resistance, corrosion resistance, and biocompatibility. In fact, this process is integral for the creation of joint replacements and implants.
Automotive industry – The main purpose of using plating in the automotive industry is to keep corrosion at bay when the substrate is exposed to harsh environmental conditions. While zinc-nickel plating assists with rust prevention, nickel plating is commonly paired with plastic parts and catalytic converters as opposed to chrome.
Aerospace industry – Titanium is commonly used in aircraft manufacturing because of its fantastic strength-to-weight ratio. Two other plating metals that are popular in the aerospace industry include copper for heat resistance and nickel to protect against wear and corrosion.
Oil and gas industry – Because of the composition and volatility of petrochemicals, corrosion protection is essential. To ensure that piping is properly protected, nickel plating is applied via the electroplating process. Performing the electroplating process in this situation ensures that the parts can last longer.
Electronics industry – Electroplating is also commonly used in the electronics industry for several applications. For one, gold plating is applied to connectors and semiconductors to ensure that the item is conductive. Gold is highly resistant to corrosion, which makes it perfect for the electronics industry. It’s possible for copper plating to provide the same benefits. Another type of metal that can be useful as a protective coating for electronic components and equipment is palladium alloy.
While these five industries use electroplating the most, this process is also used for several applications throughout the military and firearms industries. Along with the functional capabilities that electroplating provides, it’s also a flexible and affordable process.
Electroplating Process Explained
The electroplating process works by directly dissolving a metal with an electric current. The dissolved metal is then placed on the substrate metal. There are four primary components that must work together if you want the electroplating process to be effective. These components include:
Cathode – The cathode is the substrate material that must be plated with another metal. This is a negatively charged material.
Anode – This is the metal that forms the plating and is positively charged.
Power source – An electric current is sent to a circuit with a power source of some kind. The power source will apply the current directly to the anode, which allows electricity to be introduced to the item.
Solution – The reaction that takes place during the electroplating process occurs within an electrolytic solution. The solution consists of at least one metal salt that helps with the flow of electricity. It’s common for one of these salts to be copper sulfate.
When the cathode and anode have been properly placed in the solution, a power supply will send an electric current to the anode. The current ensures that the metals oxidize, which dissolves metal atoms into positive ions. The ions will then move over to the negatively charged metal to create a thin metallic layer. The three factors that play a part in the plating quality include:
Electric current – The success of this process is determined by the application time and voltage level of the electric current.
Bath conditions – The chemical composition and temperature of the solution dictates what the results of the electroplating process will be.
Part placement – The effectiveness of the plating can be determined by how close the anode is in comparison to the cathode.
If you want a real-life example of how the electroplating process works, consider what happens when gold is plated onto metal jewelry. While the jewelry exists as the cathode, the gold plating acts as the anode. These metals are then positioned in a solution, after which an electric current is sent to the gold.
The gold will dissolve within the solution, which creates dissolved gold atoms. These atoms will be attracted to the negatively charged metal, which is the jewelry. If performed correctly, the gold atoms will stick to the metallic surface to create a gold coating.
Different Plating Techniques
There are three primary plating techniques that can be used with the electroplating process, which include:
Rack electroplating – This technique is ideal for plating sizable groups of parts. When using this method, the parts will be placed directly on a wire rack, which ensures that every part comes into contact with the power source. While this process is similar to barrel plating, it’s better for delicate parts that wouldn’t be able to withstand the barrel-plating process.
Electroless plating – This plating technique is the only one that doesn’t require the parts to come into contact with an electric current. To bypass this requirement, the plating material of your choice is dissolved with a chemical reaction. This particular technique is best used on parts that don’t accommodate electric currents.
Barrel plating – This plating technique is ideal when large amounts of smaller parts need to be plated. These parts will be positioned inside a barrel that’s filled with the electrolyte solution of your choice. From here, the barrel is rotated, which helps to agitate the parts and apply an even coating.
Metals Used Throughout the Electroplating Process
As touched upon previously, there are many different metals that can be used in the electroplating process. The metal that you choose depends on the substrate composition and your preferred price. The main metals used in the electroplating process include:
Nickel – This metal provides fantastic wear resistance. The different nickel alloys can also provide the substrate with better conductivity and elemental resistance. As for electroless nickel plating, it can help provide low friction, corrosion resistance, and magnetism.
Silver – This metal is malleable, ductile, and highly wear-resistant. It’s a more affordable alternative to silver.
Gold – This metal provides high wear and corrosion resistance as well as fantastic conductivity.
Palladium – This metal offers a sleek finish, hardness, and corrosion resistance. When you combine palladium with nickel, the plating quality is superb.
Zinc – This specific metal has great corrosion resistance and can be enhanced when alloyed with other metals.
Copper – Along with improving material adhesion, copper is ideal when used for its heat-resistant and conductive properties.
Tin – This metal is environmentally friendly, inexpensive, and resistant to corrosion.
Benefits of Electroplating
The electroplating process comes with many benefits the primary of which include:
Heat resistance – When metals with high heat resistance are used in the electroplating process, the substrate materials can withstand heat damage. By keeping heat damage at a minimum, plated parts should last longer.
Added protection – As an added layer of protection, plated metals can protect the substrate from harsh environmental conditions.
Better hardness – Plated materials will invariably be stronger and more durable, which keeps stress damage at a minimum.
Electrical conductivity – Plating metals like copper and silver can enhance the conductivity of substrate materials. This cost-effective solution is very popular in the electronics industry.
Improved appearance – Plating metals like silver and gold improve the appearance of base metals that may inherently have worse appearances.
Keep in mind that these benefits are dependent on the metal you use in the electroplating process. For instance, nickel plating keeps wear and tear at bay, which bolsters part longevity. Because of its flexibility and the many applications, it can be used for, electroplating is a highly important process across numerous industries. If you want to strengthen a substrate or improve its appearance, electroplating offers a cost-effective solution.
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