PRODUCTS & PROCESSES
again , encapsulated plating offers increased process control versus other surface plating methods . The ability to manage speed , temperature , flow rate and the amps used as part of the plating process provides a high level of control , while the design of the system makes it possible to track and trace the plating process parameters for every part plated .
For FAMAT , the move to encapsulated plating offered a repeatability rate of over 99 %. Crucially , once the process parameters were set - including deposit thickness , deposition rate etc . - the process remained the same . In this case , the repeatability and level of process control reduced the variability of the thickness by 80 %, allowing the customer to optimize the finish while also reducing costs . The customer also benefits from the complete traceability of the process from start to finish .
Speed , efficiency and ROI
For both customers , the incumbent process - tank plating - was time-consuming . The encapsulated plating process eliminates the need for masking and other time-consuming pre-plating procedures which would usually slow down the plating process . For FAMAT , the use of tank plating meant that each part had to be transported off-site for plating , with a three to four-week turnaround per unit .
By installing an encapsulated plating cell within the FAMAT facility , the company managed to dramatically increase throughput - decreasing downtime from three-plus weeks to just three hours per casing . With no large tanks required and no need for a full plating line , the small footprint of the process meant that it could be carried out in-house and incorporated into the existing production layout .
Safety and sustainability
For both companies , the new process also offered improved EHS benefits . In comparison to tank plating , which uses vast quantities of chemicals , encapsulated plating uses significantly less solution and creates less effluent waste , posing minimal risk to the environment .
With the component and plating solution enclosed within the custom tooling , operator safety is also improved by limiting exposure to chemicals . With no need to ship products off-site to be plated , companies can further reduce the carbon footprint , cost and downtime associated with off-site repairs .
Right process , right time , right place
Encapsulated plating provides an ideal alternative when the volume of parts to be plated is too high for brush plating , but - as was the case with these two customers - too low or too complex for tank plating . While the main advantages mirror those of brush plating , including minimized masking and waste generation , and a fast plating rate , the nature of the process means that it can be used to plate parts with non-line of sight areas and dimensions .
As well as being used to plate new parts to alter and enhance their properties and improve their service lifespan , encapsulated plating can be used to improve and extend
the life of worn-out components . This has a direct impact on scrap rates , reducing downtime , component failure and production costs by extending the life of the part .
Having a fast and efficient way to plate parts with recessed areas , sharp corners , or axi-symmetric geometries such as pipes or couplings stands to hugely increase process efficiency across a range of industries .
For more information on selecting the right plating method for your application , visit http :// www . sifcoasc . com /
76 JUNE 2021 read online : www . surfaceworld . com