Mechanical plating
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Mechanical plating, also known as peen plating, mechanical deposition, or impact plating, is a
plating Plating is a surface covering in which a metal is deposited on a conductive surface. Plating has been done for hundreds of years; it is also critical for modern technology. Plating is used to decorate objects, for corrosion inhibition, to impro ...
process that imparts the coating by
cold welding Cold welding or contact welding is a solid-state welding process in which joining takes place without fusion or heating at the interface of the two parts to be welded. Unlike in fusion welding, no liquid or molten phase is present in the joint ...
fine metal particles to a workpiece. Mechanical galvanization is the same process, but applies to coatings that are thicker than .. It is commonly used to overcome
hydrogen embrittlement Hydrogen embrittlement (HE), also known as hydrogen-assisted cracking or hydrogen-induced cracking (HIC), is a reduction in the ductility of a metal due to absorbed hydrogen. Hydrogen atoms are small and can permeate solid metals. Once absorbed ...
problems. Commonly plated workpieces include
nail Nail or Nails may refer to: In biology * Nail (anatomy), toughened protective protein-keratin (known as alpha-keratin, also found in hair) at the end of an animal digit, such as fingernail * Nail (beak), a plate of hard horny tissue at the tip ...
s,
screw A screw and a bolt (see '' Differentiation between bolt and screw'' below) are similar types of fastener typically made of metal and characterized by a helical ridge, called a ''male thread'' (external thread). Screws and bolts are used to f ...
s,
nut Nut often refers to: * Nut (fruit), fruit composed of a hard shell and a seed, or a collective noun for dry and edible fruits or seeds * Nut (hardware), fastener used with a bolt Nut or Nuts may also refer to: Arts, entertainment, and media Co ...
s,
washer Washer most commonly refers to: *Washer (hardware), a thin usually disc-shaped plate with a hole in the middle typically used with a bolt or nut *Washing machine, for cleaning clothes Washer may also refer to: *Dishwasher, a machine for cleani ...
s, stampings, springs,
clips CLIPS is a public domain software tool for building expert systems. The name is an acronym for "C Language Integrated Production System." The syntax and name were inspired by Charles Forgy's OPS5. The first versions of CLIPS were developed st ...
, and sintered
iron Iron () is a chemical element with Symbol (chemistry), symbol Fe (from la, Wikt:ferrum, ferrum) and atomic number 26. It is a metal that belongs to the first transition series and group 8 element, group 8 of the periodic table. It is, Abundanc ...
components.. The process involves tumbling the workpieces with a mixture of water, metal powder, media, and additives. Common coating materials are
zinc Zinc is a chemical element with the symbol Zn and atomic number 30. Zinc is a slightly brittle metal at room temperature and has a shiny-greyish appearance when oxidation is removed. It is the first element in group 12 (IIB) of the periodi ...
,
cadmium Cadmium is a chemical element with the symbol Cd and atomic number 48. This soft, silvery-white metal is chemically similar to the two other stable metals in group 12, zinc and mercury. Like zinc, it demonstrates oxidation state +2 in most of ...
,
tin Tin is a chemical element with the symbol Sn (from la, stannum) and atomic number 50. Tin is a silvery-coloured metal. Tin is soft enough to be cut with little force and a bar of tin can be bent by hand with little effort. When bent, t ...
,
copper Copper is a chemical element with the symbol Cu (from la, cuprum) and atomic number 29. It is a soft, malleable, and ductile metal with very high thermal and electrical conductivity. A freshly exposed surface of pure copper has a pinkis ...
, and
aluminium Aluminium (aluminum in American and Canadian English) is a chemical element with the symbol Al and atomic number 13. Aluminium has a density lower than those of other common metals, at approximately one third that of steel. I ...
.. Invented by the Tainton Company in the 1950s, it was further developed by the 3M company.


Process

The process begins with a
descaling A descaling agent or chemical descaler is a liquid chemical substance used to remove limescale from metal surfaces in contact with hot water, such as in boilers, water heaters, and kettles. Limescale is either white or brown in colour due to ...
and removing soil from the workpiece. This can be done in the tumbler or in a separate cleaning system. After cleaning, the parts are prepared by combining them with water, medium, and a surface conditioner. The surface conditioner lightly coats the workpiece in
copper Copper is a chemical element with the symbol Cu (from la, cuprum) and atomic number 29. It is a soft, malleable, and ductile metal with very high thermal and electrical conductivity. A freshly exposed surface of pure copper has a pinkis ...
, while the medium removes any residual
mill scale Mill scale, often shortened to just scale, is the flaky surface of hot rolled steel, consisting of the mixed iron oxides iron(II) oxide (FeO), iron(III) oxide (), and iron(II,III) oxide (, magnetite). Mill scale is formed on the outer surfaces ...
or oxides. Finally, accelerators, promoters and metal powder are added to the mix. The accelerators and promoters provide the proper chemical environment for the plating to occur, such as the maintenance of a pH level of 1 to 2 to prevent oxidation and promote adhesion. The medium that is already in the mixture cold welds the metal powder to the workpiece through
impact Impact may refer to: * Impact (mechanics), a high force or shock (mechanics) over a short time period * Impact, Texas, a town in Taylor County, Texas, US Science and technology * Impact crater, a meteor crater caused by an impact event * Impac ...
s that are induced by the tumbling action of the tumbler. At this point the surface finish is typically
matte Matte may refer to: Art * paint with a non-glossy finish. See diffuse reflection. * a framing element surrounding a painting or watercolor within the outer frame Film * Matte (filmmaking), filmmaking and video production technology * Matte p ...
to a semi-bright finish, however the finish can be improved with a water
polish Polish may refer to: * Anything from or related to Poland, a country in Europe * Polish language * Poles Poles,, ; singular masculine: ''Polak'', singular feminine: ''Polka'' or Polish people, are a West Slavic nation and ethnic group, w ...
. The time required for the above process is approximately 50 minutes. For some thinly coated workpieces a chromate passivation is necessary. Finally, the workpiece, whether passivated or not, is dried. The medium material is usually
soda lime glass Soda or SODA may refer to: Chemistry * Some chemical compounds containing sodium ** Sodium carbonate, washing soda or soda ash ** Sodium bicarbonate, baking soda ** Sodium hydroxide, caustic soda ** Sodium oxide, an alkali metal oxide * ...
or a
ceramic A ceramic is any of the various hard, brittle, heat-resistant and corrosion-resistant materials made by shaping and then firing an inorganic, nonmetallic material, such as clay, at a high temperature. Common examples are earthenware, porcelain ...
. It is usually
spherical A sphere () is a geometrical object that is a three-dimensional analogue to a two-dimensional circle. A sphere is the set of points that are all at the same distance from a given point in three-dimensional space.. That given point is the ce ...
in form, but angular shapes are also used. For plating, medium usage is usually 1 part medium for every workpiece, but for galvanization the ratio is 2:1. However, various sized media are used in each batch with a typical batch consisting of 50% sized beads, 25% sized beads, and 25% sized beads. The smaller media are omitted when the workpiece has a cavity that the medium can get caught in, such as a fastener's recessed head. Note that the medium is reused many times. This process works better if the workpieces' surface finish is slightly rough.


Equipment

The most important piece of equipment in the process is the ''tumbler''. It is constructed of steel or stainless steel and lined with an acid and abrasion resistant material, such as neoprene,
polypropylene Polypropylene (PP), also known as polypropene, is a thermoplastic polymer used in a wide variety of applications. It is produced via chain-growth polymerization from the monomer propylene. Polypropylene belongs to the group of polyolefins a ...
, and
polybutylene Polybutylene (polybutene-1, poly(1-butene), PB-1) is a polyolefin or saturated polymer with the chemical formula (CH2CH(Et))n. Not be confused with polybutene, PB-1 is mainly used in piping. Production Polybutylene is produced by polymerisatio ...
. The barrel sizes range from , however the working volume is only 25 to 35% of the total volume. For most plating applications the tumbler is rotated at 60 RPM, however it can vary. If the speed is too fast then lumpy deposits will form on the workpieces, but if the speed is too slow then the metal powder will not deposit onto the workpiece. The ''separator'' separates the coated workpieces from the medium after coating. It can be as simple as a screen with water nozzles or as complicated as a vibratory system with magnetic separators. A ''medium handling machine'' then takes the separated medium and transports it to a storage tank for reuse. The separated workpieces are then taken to a ''dryer'' to remove any moisture. Usually centrifugal dryers are used, however oven are used for larger parts or loads.


Advantages and disadvantages

The greatest advantage of the process is its ability to overcome hydrogen embrittlement problems, which is important for workpieces that have a hardness greater than HRC 40. Note that there still is some embrittlement of the workpiece. While this process does not cause problems with hydrogen embrittlement, and electroplating does, it still offers equivalent
corrosion Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engi ...
protection. There is a great cost savings in using mechanical plating over electroplating on hardened workpieces, because the electroplating processes requires a pre- and post-plating operation to overcome hydrogen embrittlement problems. Moreover, because mechanical plating occurs at room temperature there is no tempering of hardened workpieces. Another advantage is that mechanical plating evenly coats all surfaces and features, unlike electroplating which has issues plating recesses. Mechanical plating can evenly coat up to 75 μm thick. For thicker plating mechanical plating is especially cost advantageous versus electroplating, because the cycle time does not increase much for the thicker plating, unlike electroplating. One of the disadvantages is the processes size limitations. Workpieces heavier than can be damaged by the process, while flat lightweight workpieces tend to stick together so they are not properly plated.


References


Bibliography

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