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What to Consider before you Electroplate

Are you thinking about having parts electroplated?  Here are the most important things you need to take in to consideration before and during the process…

What should you consider Pre Electroplating?

 

  • Nesting

Electroplating involves electrical and chemical reactions on the surface of the part you are wanted to be plated, so exposure is crucial to the result of the final product.  Parts which are nesting will lack adhesion and therefore coverage on the final product.

  • Tolerance

The tolerance on vital dimensions on the part in question should be designated with the plating thickness in mind.  This is should be accounted for when the pieces are ready for assembly after the products have been through the chemical process.

  • Environment and exposure

What is your product going to be exposed to?  A high amount of friction, heat or sea spray?  This is essential for negotiating the thickness of the necessary plating required to maintain the resistance, corrosion and rust protection of the part in question.

  • Geometry

Electroplating involves using a current in order for the reaction to be initiated on the surface of a part, which means that the geometry of the parts surface will influence the distribution of electroplating across the surface.  This is called current density.  It is normal that plating builds up in parts which have sharp corners, bends and threads but it can be prevented if specialists use advanced plating processes.

  • Drainage

The preparation of the surface of a part needing plating must be correct so that the inside surfaces of a part will be sufficiently covered when the process is completed.  This is so that the plating will have the correct bond strength for plating to have been carried out correctly and for the part to have ultimate protection and increase its longevity.  This, for some parts, may mean they need to have a weep hole create during their design phase, so that this can be achieved.

  • Usage

It must be clear what your intended use is for the part you are needing plating.  Make it clear to your specialists what the use and required characteristics are of the part.  Important features include conductivity, low friction, high strength, corrosion resistance, wear, exposure to sea spray or water etc.  This will determine which metal your part is made from (eg. Copper, Nickel, Tin, etc), how your part should be finished and plated.

 

us and You

 

us are a Derbyshire based company and we are leading specialists in the plating industry.  We offer an array of well-developed, high-end techniques which are cost effective and reliable.  We have extensive experience working for industries, such as aerospace, medical, army and automotive and offer our services to the UK, France, Germany, Holland and Brazil.  If you need plating services such as electroless nickel plating, copper plating or heat treatments, then contact us today by calling our friendly and professional team on our phone number, alternatively you can click here to be taken directly to our website and view the services we offer for yourself.

 

Electroplating from the Start

Electroplating is a form of metal plating which is used by many industries in a range of capacities which include the aerospace, automotive, army, space, medical, electronic and engineering sectors, to name but a few.  It is useful due to the fact that it is so versatile and lends itself so because of its electrochemical process where metal ions in solution are bonded to metal substrates by means of electrodeposition.

Before Electroplating

Pre Electroplating, all parts must be thoroughly cleaned and then a process of chemical baths must be followed so that the parts can be prepared and activated so that the adhesion for the strong bond can take hold and become effective.  This is key in the electrodeposition process.  Many variables must be monitored closely during the electroplating bath process, such as the power supply which provides a direct flow of current to the parts in submerged.  This enables ions to be attracted to the surface of the metallic part evenly.  Every mole of electrons that are transferred to the part, allows one mole of metallic ions in the solution to adhere to the part during the bath process.  A chemical reaction can subsequently occur where the reduction and oxidation of ions takes place.

Types of Electroplating

Specialist plating facilities are able to plate a large array of different base materials to protect various surfaces.

Base materials for electroplating include:

  • Brass
  • Copper
  • Nickel
  • Stainless Steel
  • Nickel Silver

Surface finishes for electroplating include:

  • Gold
  • Silver
  • Copper
  • Electroless Nickel

About Electroless Nickel Plating

Electroless nickel plating is a high quality but cost effective coating solution which can drastically extend the life expectancy of a stainless steel component.  This is due to the metal layer deposited by the electroless nickel coating creating an even thickness across the components surface, despite its shape.  This makes electroless nickel plating very popular in sectors such as the defence, health, automotive and aerospace industries.

Happy New Year From us!

As 2019 draws to a close, we are looking back on what has been a very busy year for us in the metal plating industry. From our nomination for the Excellence in Manufacturing Award at The Sheffield Business Awards, to our new testing laboratory, 2019 has been a great year for all of us here at us.

New facilities to monitor phosphorus levels

Our new laboratory means that our lead times have been cut dramatically; we are now able to turn around standard plating jobs within 24 hours. Our new state of the art, in house facilities mean that we no longer have to outsource testing. We can now monitor phosphorus levels, perform micro-sections and hardness tests on site.

Excellence in Manufacturing Award

In November we were thrilled to discover that us had been shortlisted for The Wake Smith Excellence in Manufacturing Award at The Sheffield Business Awards. The ceremony took place in December and although we didn’t win, we were very pleased to have been nominated for such a prestigious award.

We have more than 30 years of experience specialising in the electroless nickel plating process, and a comprehensive range of metal finishing processes and techniques. We also offer a variety of surface treatments including electroless nickel plating, diffused nickel plating, copper plating, shot blasting and heat treatment. For more information, please call us or email 

UK’s Largest Electroless Nickel Plating Tanks at us

As experts in the process of electroless nickel plating, us have the largest electroless nickel plating tanks in the UK.

Pre-Treatment for Electroless Nickel Plating

Before a component can be electroless nickel plated, it must be suitably prepared for the process. Firstly, the part is cleaned in a series of pre-treatment tanks and rinsed in water. It then enters the coating tank which is heated to a critical temperature above 90C and contains the plating solution made up of the nickel-phosphorus alloy and a reducing agent.

The thickness of the coating that is deposited is dependent on the immersion time, and the phosphorus content of the solution governs its hardness and corrosion resistance.

In order to achieve the maximum thickness achievable, the part needs to be in the plating tank for approximately 9-10 hours, during which time the solution is agitated and continuously re-circulated to prevent debris being incorporated into the coating. The total contents of the tank will be filtered and re-circulated within 10 minutes.

There are three levels of phosphorus in solution that are typically used, each of them having different benefits and attributes.

 

Low Phosphorus Electroless Nickel Plating

A low phosphorus electroless nickel coating typically contains 2.5% phosphorus. This produces a very uniform porous free coating which uniformly covers the complete surface of the component, including inside recesses. It has excellent corrosion resistance in alkaline conditions, but the coating is relatively soft, below 235VPN, and is therefore not particularly wear resistant.

Medium Phosphorus Electroless Nickel Plating

Medium phosphorus solutions contain between 6 and 10% phosphorus and produce a coating which effectively combines intermediate hardness with good corrosion resistance. Medium phosphorus coatings deposit rapidly and produce a bright or semi-bright coating.

High Phosphorus Electroless Nickel Plating

High phosphorus coatings contain between 11-14% phosphorus and produce hard coatings of up to 600VPN. This level of hardness is ideal for wear resistant applications in harsh acid environments typical of the conditions experienced in oil and gas drilling or mining applications. The high phosphorus level also renders them non-ferromagnetic and hence suitable for coating, for example, austenitic stainless steels, for applications where ferro-magnetism cannot be toleration such as MRI scanners. Such hard coatings are also used on stainless steel to improve its galling resistance in wear situations.

Electroless Nickel Plating Service

Contact us today on our phone number or to talk through your electroless nickel plating requirements and see how us can provide high quality processes at a cost to suit your business.

Wheelie Fallen in Love with Copper Plating

It has recently appeared in the news that Ted Baker have teamed up with the famous bicycle producers, Quella.  Together, they are set to create three stylish bespoke models which are predicted to outdo Santander Cycles.  Each of these three new bicycle structures feature copper plating, steel frame, and will have a Brooks England leather saddle.  The bikes will be available in red, green and blue and have been named after fish due to the bikes being inspired by the ability salmon have to swim upstream – Redfinn, Bluetail and Greengill – Well, for the £1,995, you’d expect a pretty name, wouldn’t you!

About Copper Plating

Copper plating is used for both functional and decorative reasons.  Traditionally, it is used for electroforming but can also be used for Electro Magnetic Interference (EMI) and Radio Frequency Interference (RFI) shielding purposes.  The reasons for this are because copper is a brilliant conductor and its deposits from copper plating are very bright.  It also has excellent levelling properties and naturally kills bacteria which is why it is used so frequently in laboratories to plate medical equipment.  The aesthetics of copper plating are used due to its bright, highly polished copper-pink appearance which can be lacquered in order to prevent the copper plating from becoming tarnished if it is intended only for decorative purposes.

Electroless Nickel Coatings Can Increase the Lifespan of Steam Turbines

 

Here at us, we have a wealth of experience electroless nickel plating components for large multinational companies and a wide variety of industries and applications.

As a leading provider of worldwide metal plating services, we have recently worked with Elliott Turbo-Steam Turbines. Elliot steam turbines are specially built to be able to perform for years, and they have an excellent reputation as being the best in the industry.

Elliot steam turbines are very reliable and hard wearing, and by adding an electroless nickel coating, their life span can be further increased. As the addition of an electroless nickel coating is very hard, it can reduce the wear of the part when friction is an issue.

Elliot steam turbines are used in power generation and food processing,  chemical and petrochemical, pulp and paper, and the oil and gas industry.

For more information on how electroless nickel coatings can be used to increase the lifespan of components and reduce wear through friction, contact us by visiting our website, speak to a member of our specialist team on 0845 224 357, or email 

Replace Stainless Steel with Electroless Nickel for Large Components

Stainless steel can be very expensive, especially when it is used on very large components. It can also be hard to find a source to cast large stainless steel components. A cost effective alternative to stainless steel is electroless nickel, therefore it is often used as a replacement on large parts. It is much more cost effective and time saving to make large components out of cast iron and then electroless nickel plate them to provide extra corrosion resistance.

Alternative to stainless steel

Electroless nickel is perfect for plating large machined parts that need to be resistant to corrosion. With electroless nickel, once the component has been plated, no more needs to be done to it.

But with conventional electro-deposit such as hard chrome or electrolytic nickel, they need to be machined after plating to hold dimensional accuracy. This re-machining on large, electroplated parts can cost hundreds to thousands of pounds.

Electroless nickel properties and characteristics often give it a significant advantage over conventional materials and methods. Here at us, the equipment and methods we use mean that even the most difficult large part can be plated correctly and consistently.

Hardness and corrosion resistance

When designing large parts, electroless nickel should be considered if hardness, corrosion resistance and wear are a concern. As leading specialists in the electroless nickel plating field, we have the facilities to plate large components, unlike small firms.

If you would like to find out how you can save money by using electroless nickel plating instead of stainless steel for large parts call the us team , email  or get in touch via our contact page.

New Aerospace Project Could Revolutionise the Design and Manufacture of Aircraft Wings

A group of 13 partners have been chosen to take part in a new £30 million research programme which could revolutionise the design and manufacture of aircraft wings.

Aerospace Technology Institute Backing

Backed by the UK’s Aerospace Technology Institute (ATI), the VIEWS (Validation and Integration of Manufacturing Enablers for Future Wing Structures) programme will develop wing design, manufacture and assembly technologies so that they are near to being ready for use in the aerospace market.

In addition, they will select some other novel technologies that may be suitable for further development in the future.

Partners of the VIEWS Programme

Partners of the VIEWS programme include the Universities of Nottingham, Bath, Bristol and Sheffield Hallam; as well as five of the UK’s high value manufacturing catapult centres: the National Composites Centre, the Manufacturing Technology Centre, the Advanced Manufacturing Research Centre (the University of Sheffield),the Warwick Manufacturing Group (the University of Warwick) and the Advanced Forming Research Centre (the University of Strathclyde). The four industrial partners involved are as follows: GKN Aerospace, Bombardier Aerospace, Spirit AeroSystems, and GE Aviation.

Aircraft Wing Architecture

The programme will be based on technologies emerged from the structures technology maturity (STeM) research programme and will indentify tools and other manufacturing requirements to produce wing architectures and improve the process design and flow of production. It will also study inspection and repair tools and progress various composite and metallic manufacturing and assembly processes.

GKN Aerospace technical director Rich Oldfield said: “STeM saw us make valuable progress and VIEWS will work from that base, taking us nearer to market readiness with a new generation of automated processes and technologies that will extend what we in the UK are able to manufacture, at the same time as increasing the quality, consistency and speed of production.”

Metal Finishing Services for the Aerospace Industry

Here at us, our metal plating services are widely used in the aerospace industry for everything from aircraft engine mounts to aircraft control systems. For more information, please call us or email

Beat Friction and Wear with Slippery Nickel PTFE

The problems of friction and wear on metal components can inhibit their efficiency and reduce their lifespan. Conventional lubricants can be harmful to some components, so unfortunately they are not always an option. However, the composite coating of electroless nickel PTFE can solve this problem, as the coating is actually slicker than the best self lubricating materials!

Durable Dry Lubrication with Anti-galling Requirements

Ni-PTFE has fantastic qualities of low friction wear and self lubrication, which make it the perfect choice for sliding wear applications where friction and wear on parts can be a problem.

The hardness of electroless nickel coupled with the low friction release properties of PTFE make it an ideal composite coating for components and assemblies where conventional lubricants are a problem.

The coating of electroless nickel PTFE is created by adding sub micron particles of PTFE to the plating solution, which are then co-deposited with the electroless nickel. This method ensures that an even distribution of the PTFE particles are deposited throughout the plated layer, and can be varied in the solution to give the performance characteristics required depending on what the final plated component will be used for.

Applications of Electroless Nickel PTFE

Electroless nickel PTFE can be used for a wide variety of applications in a range of industries. The coating is often used in the automotive industry, for example, where components including piston rings, valves, injection nozzles, carburetors, and oil pumps benefit from it. When treated with electroless nickel PTFE coatings, these parts contribute to increased fuel management for vehicles, and also demonstrate corrosion resistance, wear resistance, and tribological properties.

Electroless nickel PTFE is often used to coat pistons in the hydraulics industry, as its properties of corrosion and wear resistance are incredibly useful. It is also commonly used in the aerospace industry to coat connectors, again, improving their corrosion resistance and wear properties. When coated with electroless nickel PTFE, cutting tools and guides used in the textile industry show reduced noise and a longer lifespan.

Electroless Nickel with Polytetrafluoreothylene

If you want to beat friction and wear on metal components, electroless nickel PTFE is the perfect solution. Call us , email us at  or visit the contact page on our website to make an inquiry.

The Future’s Bright, The Future’s us

2008 saw the beginning of the EU process which took four years to put in to place, preventing incandescent light bulbs from being sold.  This was because they performed inadequately and were not eco-friendly due to the high amount of electricity they consumed.  The LED has therefore taken its place on our supermarket shelves, as they are proven to be much more efficient.

Plating Industries

The electronic and automotive industries, as well as most British households and road engineers for road lighting applications, are using LED lights.  The LED substrate can be silver plated either conventionally by rack or less conventionally by reel-to-reel plating procedures.  Plating differs depending on the thickness, and ranges from 20 to 150 A/dm², normally.

Bright Lights

How are LED lights so bright?  This is due to a low free-cyanide silver process which contains brightener additives.  This creates high luminosity.  These LEDs are much more eco-friendly, cost effective and use a fraction of the amount of electricity of an incandescent light bulb.

Heat Treatment gets the Deep Treatment

The silver deposits used to plate the LEDs were initially heated for 60 minutes at 200° and then for 120 minutes at the lower temperature of 170°C but it was quickly identified that significant reflectivity was lost during this.  So it was decided that a post-dip was going to be used in order to prevent the reflectivity loss, in the form of an aqueous treatment post heat treatment.  This seems to have worked, having been tested on multiple different types of nickel, at higher temperatures and with the nickel being treated for shorter lengths of time (up to 1 minute), as the GAM measurements do not diminish dramatically at all.  Thus, proving the effectiveness of the combination of plating, heat treatment and the post-dip aqueous treatment as a trio.

Electroless Nickel Plating a Vacuum Chamber

Here at us, we are often approached by companies with specific plating needs for bespoke applications. We were approached by Rutherford Appleton Laboratories, who had manufactured a large vacuum chamber that they wanted plating with a thin layer of electroless nickel.

Without plating, the iron from the walls of the chamber would compromise and possible affect the results of the tests carried out inside it. Lasers used during testing would also cause damage to the chamber walls without a layer of electroless nickel.

The facilities at Rutherford Appleton Laboratories are used by scientists and engineers in order to advance their research into materials and structures, light sources, astronomy and particle physics. Every year about 10,000 scientists and engineers use the Laboratory’s facilities to advance their research. Many are academics and post-graduate students working on projects funded by the Science and Technology Facilities Council.

Electroless nickel plated layer for protection

Rutherford Appleton Laboratories had manufactured the large vacuum chamber for tests that involved lasers travelling down the centre of the chamber. This area needed to be plated with a layer of electroless nickel so that the layers did not burn through the paint during testing.

The vacuum chamber came in a number of large sections, some which weighed more than 20 tonnes. The team at us manufactured tanks to fit each part of the chamber that needed to be plated. The main body of the chamber weighed 150 tonnes and was built like a small room, containing many windows, portals and doors.

Blanking plates were manufactured for each of the chamber components, and the chamber was then sheeted over and manually and internally shot blasted. Originally, the chamber was going to be used as the plating tank and filled with electroless nickel plating solution. But the portals and windows contained recesses which were identified as gas traps and to overcome this and ensure complete coverage of the electroless nickel plating, all of the blanking plates were fitted with small air pipes. These fed up the outside of the chamber and back into the top, removing gas and solution and ensuring complete coverage.

Electroless Nickel Plating for an Oil Rig Vortoil Pipe for Marine Corrosion Resistance

Electroless nickel plating is perfect for applications in the oil and gas industries due to its excellent corrosion resistance properties. When used as a barrier layer, electroless nickel provides the highest levels of corrosion and wear resistance, and the thickness of the coating can be adjusted to suit the application.

Corrosion and wear protection

A recent project of us’s involved the nickel plating of a vortoil pipe for use on an oil rig. Vortoil pipes are used for separating crude oil from seawater, and are therefore exposed to harsh marine environments and susceptible to corrosion and wear due to their surroundings.

The tolerance of the vortoil pipe had to be less than 3 microns over the length of the component, with an overall deposit thickness of 100 microns.

Electroless nickel is an excellent plating method to ensure uniform levels of thickness over a deposit, but when the competent is a large as a vortoil pipe, there may be slight variations in the thickness of the deposit due to localised changes in temperature and activity.

Because of the size of the component, us manufactured a jig with a motor which was attached to either end of the pipe. The pipe was then electroless nickel plated horizontally, while it was turned very slowly to make sure all of the surface area was covered by the electroless nickel deposit.

Accurate deposit thickness of the nickel coating

The pipe was approximately 4m in length, and needed to be electroless nickel plated internally and externally, including all the attached pipes, holes and fins. The staff at us were able to work to the tight distribution tolerances using our monitoring system, which enabled us to ensure the accurate deposit thickness of the nickel coating onto the component.

If you are looking for a metal coating that provides high levels of corrosion resistance for use in the oil or gas industries, call the us team , email  or get in touch via our contact page.

Common Applications of Electroless Nickel Coatings

Here at us, we have an impressive total of 7 nickel plating lines, making us one of the largest nickel plating providers in Europe. As experts in the process of electroless nickel plating, we’ve put an article together describing the common applications of this unique metal plating service, illustrating its versatility and wide reaching advantages.

Aerospace Components

Electroless nickel plating is commonly used for aerospace components due to its excellent wear resistance, corrosion protection, chemical resistivity and lubricity. These fantastic qualities are perfect for use on valves, pistons, engine shafts, engine mounts, compressor blades and other flight-critical components.

Oil & Gas Components

Nickel plating is used primarily for corrosion protection in the oil and gas industry. It is incredibly effective at protecting parts used in harsh undersea and underground environments, for example on parts such as valves, pumps, and pipe fittings.

Automotive Components

Electroless nickel plating is commonly used for the purpose of wear protection and corrosion resistance on components such as pistons, cylinders, gears, differential pinon ball shafts, fuel injectors, ball studs, transmission thrust washers, knuckle pins, hose couplings, heat sinks and others.

Food Service Equipment

With its superior corrosion and wear resistance, attractive finish and cleanliness, electroless nickel coatings are perfect for food service equipment.

Electrical Equipment

Electroless nickel is often used for electrical equipment due to its solderability and conductivity properties.

Packaging and Handling Machinery

Electroless nickel is commonly used to plate components used in the packaging and handling machinery due to wear resistance, cleanliness and attractive finish.

Chemical Manufacturing and Transport Equipment

The chemical resistance of electroless nickel coatings makes them ideal for chemical manufacturing and transport equipment.

Molds and Dies

Electroless nickel coatings provide corrosion protection on molds and dies, and also help to minimise erosion and abrasion. Also, their low coefficient of friction improves release.

Plastics Manufacturing Equipment

Nickel plating is a common choice of plating of plastics manufacturing equipment due to its durability and release properties on injection molds and extrusion dies.

Printing Industry Equipment

It is often used for plating components and equipment used in the printing industry due to its excellent abrasion resistance on conveyance and chemical resistance on printer cylinders.

Salvage

Electroless nickel plating is commonly used to salvage old parts. It naturally deposits a very even layer of electroless nickel, therefore is often used to restore parts to their original dimensions, or bring mis-machined parts into tolerance.

Support for Offshore Oil and Gas Industry with New Tax Reform

The offshore oil and gas industry is facing a radical reform with regard to the way that the industry is taxed.

The UK government plan to move away from their previous focus of maximising revenue for the Treasury, admitting that the new burden of maximising extraction will mean a lower tax burden.

 Economic Benefits “For Years to Come”

The treasury minister announced on Thursday 4th December that this new support for the industry will provide economic benefits for years to come.

These radical reforms will mean that the tax burden on the oil and gas industry will be lower, encouraging investment in the North Sea, and providing significant economic benefits for the UK for the future. The reforms include the implementation of a basin-wide investment allowance, designed to reduce the tax rate for companies investing in the future of the UK Continental Shelf.

Offshore Exploration in the North Sea

This will be in addition to tax concessions announced in the chancellor’s Autumn Statement, which included an immediate cut in the supplementary charge element of offshore tax, from 32% to 30%. There will also be more flexibility in tax allowances for companies that haven’t yet seen an income from their investments. Furthermore, the government has committed to boosting offshore exploration through supporting seismic surveys in under-explored areas of the North Sea.

Reducing the Tax Burden on the Oil and Gas Industry

“The government is demonstrating its long term commitment to supporting the North Sea oil and gas industry with a package of measures expected to drive around £7bn of additional investment,” said MP, Priti Patel. “These measures will reduce the tax burden on the industry, driving investment in the North Sea that will provide economic benefits to the UK for many years to come.”

The changes to the tax regime follow the recent review of the sector by Sir Ian Wood. The review recommended a new regulator, and a requirement that the industry, government and that regulator should be co-operating more closely.

Chief executive of industry body Oil and Gas UK, Malcolm Webb, said: “We are encouraged to note that fiscal policy will now be framed in the context of the sector’s wider economic benefits and will also take account of the global competitiveness of the industry in terms of commodity prices and costs.”

Metal Finishing Services for oil and Gas Applications

Here at us, we provide a range of metal finishing and metal plating services for both onshore and offshore oil and gas applications. Our revolutionary metal coating SeaTEC100 is a solution to increase the longevity of components used in subsea conditions that protects mild steel from salt spray corrosion and marine corrosion for an extensive period of time. For more information about corrosion resistant coatings, please call us or email