What are the Advantages and Disadvantages of Electroplating?

A common method for improving and polishing metals that are utilized across many different sectors and for a variety of purposes is electroplating. Although electroplating is widely used, relatively few people outside of the business are aware of the procedure, what it is, and how it operates. You need to understand how electroplating functions as well as your alternatives for material and procedure if you're thinking about using it in your next production process.

Electroplating: What is it?

Electrodeposition is another name for electroplating. The procedure includes depositing materials using an electric current, as the name would imply. The substrate, a workpiece, is coated with a thin coating of metal as a consequence of this procedure. The main purpose of electroplating is to modify an object's physical characteristics. Along with increasing thickness, this procedure can boost an object's wear resistance, corrosion protection, or aesthetic appeal.

Although electroplating appears to be a cutting-edge technique, it has been practiced for many years. One of the earliest electroplating experiments took place in the early eighteenth century, and in the first part of the 19th century, Brugnatelli codified the procedure. Following Brugnatelli's research, the electroplating technique spread throughout Europe. The electroplating method changed during the following two centuries to keep up with demand as manufacturing techniques expanded during the industrial revolution and two world wars, giving rise to the procedure that the Sharretts Plating Company uses today.

Electroplating Procedure

An electric current is used in the electroplating process to break down the metal and deposit it on a surface. The four main parts of the procedure are as follows:

1. Anode: The metal used for plating will be the anode, or positively charged electrode, in the circuit.
2. Cathode: The component that has to be electroplated is the cathode in the electroplating circuit. Additionally known as the substrate. This component serves as the circuit's negatively charged anode.
3. Solution: In an electrolytic solution, the electrodepositing process occurs. To aid in the passage of electricity, this sample contains one or even more metal salts, most frequently copper sulphate.
4. Power supply: Using a power source, electricity is introduced into the circuit. This power source injects electricity into the system by passing a current through the anode.

The power supply delivers a direct current (DC) to the anode once the anode and cathode have been inserted into the solution and connected. The metal oxidizes as a result of this current, permitting metal atoms to dissolve as positive ions in the electrolyte solution. The metal ions are subsequently moved by the current to the negatively charged substrates and deposit a small coating of metal onto the object. Take the use of gold plating on metal jewelry as an example.

The anode of the circuit is gold-plated metal, and the cathode is the metal jewelry. Both are dissolved in solution, and the gold is given DC electricity to dissolve it. The gold atoms that have been dissolved then stick to the jewelry's base metal surface to form a gold coating.

These elements include the following:

1. Bath conditions: The efficiency of the electrolytic process is influenced by both the bath's temperature and its chemical makeup.
2. Part placement: The location of the anode about the cathode is crucial because it determines how far the dissolved metal must travel to plate the substrate.
3. Electrical current: The effectiveness of the electroplating method depends on both the operating voltage and the duration of the electrical current's application.

What Metals are Utilized in the Process of Electroplating?

Individual metals or different alloy combinations (which can add value to the electroplating process) can be plated. The following metals are some of the most often used for electroplating:

Copper: Due to its heat resistance and conductivity resistance, copper is frequently utilized. It is frequently employed to strengthen the bond between materials.

Zinc: Zinc is very resistant to corrosion. To improve this quality, zinc is frequently alloyed with other metals. Zinc, for instance, is highly resistant to air corrosion when alloyed with nickel.

Tin: This shiny, matte metal is very solderable, corrosion-resistant, and safe for the environment. Additionally, it is less costly than other metals.

Nickel: Heat treatment can increase nickel's already high wear resistance. Because they provide elemental resistance, hardness, and conductivity, their alloys are also extremely important. Additionally prized are electroless nickel plating's hardness, magnetism, reduced friction, and corrosion resistance.

Gold: This priceless metal is highly conductive and aesthetically pleasing, with high corrosion, tarnish, and wear resistance.

Silver: Silver is extremely malleable and ductile. It has remarkable resistance to contact wear and has outstanding aesthetic value. However, it is not as weathering resistant as gold. In situations where both electrical and thermal conductivity is required, it also serves as a substitute for gold.

Palladium: Due to its hardness, resistance to corrosion, and lovely polish, this brilliant metal is frequently employed in place of gold or platinum. This metal acquires outstanding rigidity and plating quality when alloyed with nickel.

The most suitable electroplating substance for your application depends on several parameters, including cost, substrate composition, and desired results.

Several Plating Methods

There are several plating methods available, and each one has a variety of uses. Below are some of these electroplating kinds in further detail:

1. Barrel plating

Large groupings of tiny components can be plated using the barrel plating technique. In this procedure, components are put within a barrel that has an electrolyte solution inside of it. The barrel is spun while the electroplating process is taking place, agitating the pieces to provide consistently equal finishes. Barrel plating is an inexpensive, effective, and adaptable option that works well on tiny, robust items.

2. Rack electroplating

When electroplating large groupings of components, rack plating, also known as wire plating, is a viable choice. This technique puts each component in immediate communication with the power supply by arranging it on a wire rack. This choice is ideal for more sensitive items that really can undergo barrel plating, albeit being more costly. It is crucial to remember that rack plating is much more challenging for objects that are electrically conductive or have irregular shapes.

3. Electroless plating

Electroless plating also referred to as autocatalytic plating, is a method similar to electroplating but does not subject the component to electricity. Instead, a chemical process is used instead of an electric one to dissolve and deposit the plating metal. Despite being beneficial for parts that cannot be operated by electrical currents, this approach is more expensive and less effective than others.

Although these techniques achieve electrodeposition in various ways, they all share the same fundamental ideas.

Electroplating Applications

While electroplating is frequently employed in a variety of sectors to enhance the visual appeal of a base material, it also serves other functions. Among them are the following:

1. Build thickness: Plating is frequently used to gradually add thin layers to a substrate's thickness.
2. Protect substrate: Electroplated layers act as disposable metal coatings to shield the substrate. This implies that the plated layer degrades before the underlying material does when a part is exposed to a hazardous environment, safeguarding the substrate from injury.
3. Surface attributes are added: Substrates can gain from the qualities of the metallic materials they are electroplated with. Some metals, for instance, can minimize friction, enhance electrical conductivity, guard against corrosion, or prepare a surface for improved paint adherence. Different metals provide various characteristics.
4. Enhance aesthetic appeal: In addition, electroplating is frequently used to make a substrate seem better. This might entail electroplating the base with a decorative metal or just adding a layer to enhance the quality and uniformity of the surface.

Electroplating-User Related Industries

Electroplating provides options for businesses seeking corrosion protection, better durability, or improved electrical conductivity. Because of this, electroplating is often employed in many different sectors. Below are a few of the sectors that SPC supports and how they use electroplating.

1. Automotive sector: To stop corrosion in challenging environmental conditions, plating is frequently employed in the automotive sector. Electroless nickel plating is an excellent substitute for chromium on catalytic converters and plastics components, while zinc-nickel plating treatments prevent the formation of rust.
   
2. Industry of electronics: Due to gold plating's conductivity, electronic industries frequently utilize it to cover connections and semiconductors. In this business, gold is highly prized for its ability to resist corrosion. When the emphasis is on conductivity, copper plating is employed as a substitute for gold in this business. Palladium alloys are frequently utilized on electronic components and equipment as protective coatings.
3. Medical industry: Metal electroplating is frequently used in the medical equipment sector to increase the biocompatibility of parts, particularly implants. Because of their biocompatibility, resistance to corrosion, hardness, and wear resistance?all of which are necessary for implantation and joint replacements?gold, silver, and titanium are frequently utilized in this business.
4. Aerospace industry: Titanium is commonly used in the aerospace industry to build airplanes because of its excellent strength-to-weight ratio. In this business, copper is frequently utilized to increase heat resistance while nickel plating is frequently used to defend against corrosion and wear.
5. Oil and gas sector: Because of the nature of petrochemicals, corrosion prevention is a major problem for the oil and gas sector. In this business, electroless nickel coating is frequently used to prevent corrosion on pipes and other components, extending the life of the parts.

Electroplating is used in several different areas, including the military, defense, and gun sectors. Electroplating is preferred by all of these sectors because of its practical qualities, cheap cost, and adaptability of use.

Example of Electroplating

Applications for electroplating may be found in several distinct sectors and fields. Here are a few of these in more detail:

1. Plating semiconductors in copper: The electronics sector employs several metal plating techniques. Copper plating is frequently used to improve the electrical conductivity of semiconductors and circuits.
2. Hard drive nickel plating: Magnetic metal nickel is a crucial component of hard drives. Hard drives are frequently electroplated with nickel during manufacturing because magnetism is necessary for hard drives to improve disc reading.
3. Palladium plating of catalytic converters: Catalytic converters are frequently plated in palladium in the automobile sector, particularly for those components. During production, extra hydrogen is absorbed by palladium, which has a detrimental effect on the efficiency of catalytic converters.
4. Aeronautical parts electroless nickel plated: Electroless nickel plating in the colour black can absorb light and energy. This is a crucial characteristic in the creation of many kinds of military vehicles. To assure adherence to industry standards, especially the Defense Department regulations, many firms in the defense and aerospace sectors elect to adopt this plating option.

Advantages of Electroplating

There are several advantages to electroplating for components. The following are some unique advantages of electroplating:

1. Protection measure: The substrate is given a barrier during electroplating, which shields it from the elements. This barrier may occasionally be able to prevent corrosion brought on by the atmosphere. This characteristic notably helps components since they can withstand harsher environments for longer, requiring less frequent replacement.
2. An improved appearance: To make exterior objects more glossy and visually appealing, tiny coatings of precious metals are frequently plated onto them. Because this plating adds visual appeal without incurring expensive expenditures, beautiful parts may be offered for less money. Additionally, electroplating is frequently used to stop silverware from tarnishing, enhancing durability and aesthetic beauty over time.
   
3. Electrical conductivity: Silver and copper plating contribute to improved electrical properties in parts, providing a practical, affordable alternative for enhancing conductivity in electrical and electronic components.
4. Heat resistance: Several metals, such as gold and zinc-nickel, are heat-resistant, enhancing the substrate's capacity to withstand heat damage. This in turn may lengthen the lifespan of items that are plated.
5. Enhancement of hardness: Electroplating is frequently used to strengthen substrate materials, reducing their susceptibility to damage from stress or harsh usage. This characteristic can lengthen the life of plated components and decrease the amount of replacement.

Some advantages provided are unique to metals. For instance, nickel plating can aid to lower friction, which lowers wear & tear and increases the longevity of the item. On the other hand, sharp protrusions during production that might cause component damage are avoided by using zinc-nickel alloys. In many applications, copper is also employed expressly as an undercoating because it makes it easier for other metal coatings to adhere to, improving the finished product's top quality.

Disadvantages of Electroplating

The many benefits of electroplating have been examined, but it would only be fair to consider the drawbacks of this crucial process as well. Let's look at the drawbacks of electroplating:

1. Pollution is the primary and most significant drawback of electroplating. The electroplating process generates various hazardous waste products, which. However, this may be prevented with effective waste management.
2. Costs are another drawback that is frequently mentioned about electroplating. As you may expect, an entire electroplating system is rather expensive! Before you can begin, you'll need to acquire a lot of metals, reagents, and other pricey pieces of equipment. Fortunately, the price of plating equipment is getting cheaper with time.
3. The electroplating process's final drawback has to do with time. Electroplating may be a lengthy procedure that requires a lot of tolerance since the metal layer is placed very slowly. Even when components require numerous layers, perseverance will ultimately pay off.
4. Since it offers a health danger, the waste produced during the electrodeposition is challenging to get rid of in the environment.
5. It takes a lot of time to cover the metal with multiple layers.
6. Equipment that costs a lot is needed for electroplating.