By: Derek Kilgore, Mechanical Design and Project Engineer, SIFCO ASC
The short answer is yes.
The brush plating operation can be mechanized, semi-automated, or even fully automated. But first you have to ask yourself a few additional questions with your application in mind. A major consideration is practicality – does it make sense to automate your application? Can it be done? And should it be done? Typical reasons for automating a brush plating application include improving quality and consistency, increasing operator safety, and improving process throughput.
Through the mechanization of the process, the operator’s direct contact with tooling and chemicals is significantly reduced. Instead, a computer program – which can be configured by the operator – controls the volts, amps, polarity and ampere-hours required for the specific application, including preparatory and plating steps.
In practice, this removes the potential for human error and variability from the process, making the operation more reliable and consistent. By accurately controlling the level of deposits with little operator involvement, results are more consistent, driving greater levels of quality for every operation. With the introduction of data logging to the process, automated selective plating also provides full component and process traceability through constant system data monitoring.
Alongside the improvements in the operation’s results brought about by automation, the safety of operators is also elevated. Operator safety not only includes removing the operator from the chemicals, but also improved ergonomics. Reducing risk to the operator by removing them from repetitive tasks and ergonomically unfavorable positions, the capacity of skilled workers is increased to focus on other areas of the business. In turn, mechanical systems are able to replicate the application process identically every time, ensuring high levels of consistency without the need for operator intervention.
As well as improving working conditions and safety for operators, automation also leads to greater levels of efficiency and profitability. Mechanized set-ups allow for operations to run smoothly and consistently until completion, making for greater levels of productivity and the potential for reduced lead times.
Looking more closely at the operation itself, an automated approach also opens up opportunities for improving process throughput. Robotic equipment, which is capable of working around-the-clock until the completion of a particular application, also utilizes chemicals more efficiently, using only the volumes required at each stage of the selective plating process – effectively removing bottlenecks and increasing throughput.
Generally, good candidates for automation will have most or all of the following characteristics:
Once it is determined that the part is suitable for automation, then it’s a question of evaluating the current state and then understanding what the future state needs to look like. There is a significant amount of information gathering and conceptualization that needs to be done to determine options for automation.
So, in this time when industry is seeing the benefits of automating traditionally labor-intensive processes, selective plating can now be considered a state-of-the-art solution that can be semi- or fully-automated for your specific application.
To find out more, or to speak to one of the SIFCO ASC team about automated selective plating in your facility, visit www.sifcoasc.com.
With a name like blowout preventer (BOP), there is no guessing as to the critical nature of the component. A BOP is used to seal, control and monitor oil and gas wells to prevent the uncontrolled release of crude oil and/or natural gas. So, when one of the leading specialty manufacturers and suppliers of pressure control equipment approached us to apply a corrosion protection deposit to the seal pockets of their BOP, deposit quality and adhesion were main concerns.
The manufacturer required 0.030” – 0.060” of nickel for repair and to prevent any corrosion damage inside the critical seal pockets of the BOPs. Each BOP contained up to 8 seal pockets and desired turnaround time was 4-6 parts every 4-6 weeks. But the quantity and turn time were not the only challenges for this application.
The simplest approach to plating the off center seal pockets was to orient them horizontally and use an ID plater to rotate the anodes. Unfortunately, plating horizontally required flipping the part 180 degrees to prevent uneven thickness distribution and added a significant amount of time and part handling to the operation.
To improve this situation, technicians oriented the part (seal pockets) and ID plater vertically which reduced the handling of the part and provided an even plating thickness.
While this method worked to effectively plate the parts successfully, the ID plater setup required extensive masking. Further, precisely aligning the anodes with the seal pockets was difficult and time consuming. If the technician were to misalign the anode, the plating distribution would be uneven as well as causing excessive wear and plating in the cover.
But, the experts at SIFCO ASC approached the manufacturer with a state-of-the-art solution, a semi-automated machine built to increase throughput and reduce changeover time. The vertical ID plating machine uses automated PLC controlled servos and digital position readout for accurate anode alignment every time. And to cut down even further on the labor time, special masking fixtures were developed.
Now, once the BOP is in place, the technician will carry out the preparatory procedures using hand-held tools. Then, with the push of a button on an HMI, the plating process begins. The anodes will automatically align with the bores and with rectifier software controls, the technician doesn’t have to worry about setting the amps and volts during the procedure. This ensures a consistent deposit every time for every pocket. And with a carbon filter ventilation built right in, the machine can be place anywhere on the shop floor.
Other benefits of the automating the plating operation have also been realized, including increased throughput by plating two areas at the same time, improved productivity by decreasing setup and masking time, reduced labor costs, process control and consistency, optimized deposit properties with standardized plating processes, data logging, and reduced lead time – from 25 days per part to 8!
Through the ingenuity of the SIFCO ASC team and the willingness of the manufacturer, meeting the requirement of 4-6 parts every 4-6 weeks has not only been met, but has been surpassed with superior quality and consistency.
The oil and gas market is making a strong comeback after the downturn starting in 2014. After the restrictions were lifted on the four-decades long ban on oil exports in the beginning of 2016, the US witnessed a substantial increase in the demand for exported oil.
And with a positive outlook for the oil and gas market comes investment in new capital equipment, as well as refurbishment of old equipment to ensure the maximum lifetime value. With rigs operating sometimes 24 hours a day, 7 days a week, the constant wear and fatigue on the equipment causes corrosion, galling threads, ineffective seals, or worse.
As we discussed in the last blog, one critical component that experiences wear is the blow out preventor (BOP). And within the BOP is a hydraulic cylinder containing an o-ring. This o-ring provides fundamental corrosion protection when it maintains proper dimension.
But what do you do when the groove in your o-ring is out of dimension, corroded or damaged? Reaching these unique areas is not practical for your typical surface finishing techniques such as tank plating. With selective plating with the SIFCO Process, custom anodes and workstations can be developed to plate your groove to size.
Watch the video below
Depending on the purpose of your o-ring, multiple deposits can be plated. Corrosion protection, interference fits, anti-galling, or re-sizing from over- or mis-machining can all be plated to your required dimensions without the need for disassembly or post-machining.
Contact our Technical Department to discuss your specific requirements today, 800-765-4131.
When it comes to maintaining turbines and generators within the power generation sector, selective plating has long been the plating solution of choice. As a flexible, portable and highly efficient process, selective plating has proven a worthwhile investment for original equipment manufacturers and repair specialists, making it possible to create a robust finish which delivers optimum performance requirements for critical components.
Here, Mark Meyer explores how selective plating – the preferred method for industry leaders such as Siemens, GE and MHPS – can help to improve asset availability and return on assets.
Producing less waste and significantly reducing the volume of chemicals required (when compared to tank plating), selective plating is a highly mobile, incredibly flexible process which allows repairs to be carried out on-site. This improves the cost and time effectiveness of making repairs to critical components. It enables facilities to remain operational and improve their return on assets and asset availability.
Fast and effective when time matters
Selective plating allows operators to accurately focus the plating onto specific areas of a component, enabling parts to be plated on-site. This can drastically reduce downtime and minimize production and maintenance delays, which is especially beneficial for applications where turbines or generators need to be returned to service in a time-critical fashion.
In contrast to tank plating, selective plating does not require extensive masking or special fixtures to plate the component. The length of time a plating operation will take is determined by the size of the part and the thickness requirement. In market-leading selective plating systems, deposits can be plated at rates that are 30-60x faster than conventional tank plating. Selective plating also allows for plating of areas on parts that are too large to fit in a tank.
The performance and cost differences that these factors can make to maintaining, enhancing or repairing critical components can be significant.
One process, multiple coatings
The selective plating process is suitable for repairing a variety of critical turbine or generator components and can be used for an extensive range of applications, including improved corrosion protection, wear resistance, electrical conductivity, and enhanced lubricity, while increasing performance and in-service life. Deposits include zinc-nickel, nickel, nickel-tungsten, cobalt chromium carbide, silver, gold, platinum and more.
Eliminating error through automation
Did you know, while selective plating can be carried out manually, through advancements in automation technology, repair facilities and manufacturers can now achieve even greater quality and consistency by eliminating operator error and optimizing the deposit properties? With the use of programmable power packs operators can use standardized plating parameters that include volts, amps and ampere-hours for consistent deposits from component to component. This data can also be captured and stored for seamless quality control.
A proven alternative
In the power generation industry, technicians and engineers have multiple repair options that can be used depending on the component’s size, location, and damage. Yet each process has its disadvantages when compared with selective plating. For example, one budget-conscious customer needed to resize the bearing diameter of a 42.5 inch thrust block. Sleeving and flame spray were considered, however, sleeving has inherent limitations on a bore with keyways and flame spray was considered too hazardous.
Selective brush plating was used as a cost and time efficient alternative, surpassing expectations throughout the process.
Many in the power generation industry prefer on-site brush plating as a way of avoiding rack marks from tank plating. These inevitably require additional ‘touch up’ work after the tank process – a time intensive and inefficient two-pronged method of repair, which can be avoided with the use of selective plating.
Learn more with SIFCO ASC’s webinar
On January 29, 2020 we will be delivering a webinar – Conducting Business: Maximizing Profits by Reducing Turbine Downtime. Created specifically for project managers, process or repair engineers, plus generator specialists and those involved in the maintenance, treatment and resurfacing of critical components for the power generation sector. This webinar will support you in:
Understanding the basics of the selective plating process
Learning about which industry and commercial specifications the SIFCO Process® meets
Exploring real examples of critical component repairs and enhancements
Understanding the benefits of selective plating over alternative surface finishing processes
Taking place on the 1st to 31st of March every year, Women’s History Month sets to recognize and celebrate the achievements of females all over the world. While it’s important to acknowledge the accolades of all women, we’re focusing on those working in STEM (science, technology, engineering and math) and we’ve shone the spotlight on Danijela Milosevic-Popovich, our Research and Development Manager.
From talking about how to remove the glass ceiling for women in engineering, to changing the future of electroplating, we found out what inspires Danijela, and how she strives to create a better future for herself and other females in STEM.
Science and math – the foundations of STEM
Danijela knew she wanted to work in a STEM field since she was young – her passion for science and math started in grade school. She loved the challenge of figuring out equations, learning theories, and knew from very early on that having a background in science would provide her with a strong foundation no matter what career path she followed.
Her father – her biggest cheerleader and inspiration – always motivated her to advance her education and strive for independence. Growing up in the Balkans, it wasn’t common for girls to go to college and while his support of her continued studying was considered a taboo, he never let the criticism distract her.
Danijela realizes just how much her childhood and education shaped her career. Science and math helps Danijela to think more critically. She approaches every problem knowing that there is a logical process to follow. She also questions any critical factors associated with resolution. She said:
“I believe a strong STEM background helps train the brain to think more critically. Intuition and critical thinking together create the perfect storm of problem solving and I believe math and science are key building blocks to perfect this process.”
When asked about her day-to-day role at SIFCO ASC, Danijela lights up as she talks about all of the areas she’s involved in.
“Everyday brings something new to the table. My role encompasses so much more than the traditional R&D activities – it’s multifaceted, and keeps me on my toes. My department and I are the repository for technical know-how, which ultimately leads to growing the knowledge base capabilities of our existing product lines and the development of new applications, plating solutions, and technology.”
Through this research and knowledge base, Danijela and her team are slowly changing the perception of brush plating. Advancements such as programmable power packs and process automation have not only revolutionized the way electroplating is done, but has given repair engineers even more control.
“As we’ve developed various plating applications, we’ve been able to introduce more controls to the processing phases. As a result, we’ve refined the plating process parameters to provide repeatable and controllable deposit characteristics for a process that is traditionally manually performed by an operator. This level of control has propelled us to further develop semi and fully automated plating applications and equipment along with going away from traditional brush plating by developing encapsulated plating technologies.”
Creating a safer and more sustainable future
It’s not just the electroplating process that’s feeling the impact – this research and development is paving the way towards a much safer and sustainable future for repair mechanics and the environment. Working with a team of engineers, Danjiela develops REACH compliant brush plating alternatives.
For example, cadmium and hard chrome are commonly used by maintenance repair engineers who are undertaking component repairs for a wide range of industries due to their increased wear resistance, surface hardness and durability. However, exposure to both metals in their compound state can be incredibly harmful for both plating technicians and the general public.
Danijela and her team’s actions are beginning to have profound consequences on the plating industry and the planet. Through exploration, analysis and development, SIFCO ASC has developed brush plating solutions that aim to replace cadmium and chrome in the future.
“Right now, there is no ‘one size fits all’ solution for drop-in replacement of cadmium or chrome, so we’re focusing on making solutions such as ZnNi (Zinc-Nickel) as cadmium plating alternatives, and MMC (metal matrix composite) solutions for chrome alternatives.”
The challenge of being a woman in STEM
When asked the question “what are the challenges of being a woman in STEM?”, Danijela says they are the same stereotypical barriers that have been internalized over several decades. She talks about the unconscious bias where both men and women are conditioned to think that men are more inquisitive, motivated and in charge. As a result, women have to work harder.
However, she muses that if we change the narrative, we may be able to remove the glass ceiling for both women and minorities in STEM, if we start to celebrate their accomplishments, rather than the challenges they face. She says:
“Every woman in a STEM field has a unique set of challenges ahead of her that no man will ever have to experience. I’d like to shine a spotlight on the accomplishments of women in STEM historically so that we can lay a framework for continued recognition of our girls as they turn into women and change the world alongside their male colleagues.”
For any female looking to advance a career in STEM, whether younger or older, Danijela says that believing in yourself and finding a mentor who will advise you and push you out of your comfort zone is the best thing you can do.
“There was one high-level meeting where there were four levels of managers in attendance, quite overwhelming for a young woman especially when most of the crowd was male. I ran through my presentation with my boss beforehand, and he told me he’d meet me there. Only, he didn’t show up. I survived the meeting, walked over to his office and asked why he didn’t show up. He told me he ‘didn’t want to take the spotlight away from me,’ he ‘didn’t want the rest of the room to see a MAN standing behind me.’ He taught me that I was capable of standing on my own two feet and that I shouldn’t ever feel inferior, regardless of who is in my company.”
Find out more about Danijela’s research and SIFCO ASC’s plating solutions at https://www.sifcoasc.com/
Gears are a crucial part of many machines, and if they wear and corrode beyond repair then it can be a costly expense to replace them.
Repairs can be needed at 2 different stages: manufacturing and MRO.
During the manufacturing stage, despite all the modern machining centers, parts can end up mismachined, whether that’s in the bore, the teeth or the shaft. The extent of these dimensional defects is usually small, but the cost of remanufacturing the entire part would be prohibitive.
When in operation, gears are often subjected to harsh environments, with wear and tear from corrosion or day-to-day running in dusty conditions in being common problems.
With small gears, the capital cost of replacing these components in many cases will be tolerable. However, in larger equipment, such as in earth moving, industrial, or marine machinery, it is not just the capital outlay that maintenance engineers must factor in. Not only is the capital cost of larger gears much higher, but there is also the downtime from taking machines out of service that can make the true cost of replacing these components extraordinarily high.
Indeed, downtime is one of the biggest costs that any business can face. In Britain, the impact of machine downtime is costing manufacturers more than £180bn every year (The Manufacturer). The study, conducted by Oneserve, found that 3% of all working days are lost annually in manufacturing due to faulty machinery. 83% of those surveyed also said that they replace machines at least once a year, no doubt carrying huge financial implications and operational costs to do so.
With that said, it is crucial that maintenance costs are kept down, machinery components like gears can be kept in service as long as possible, and if needed, they can be repaired quickly and effectively.
Brush plating, or selective electroplating, is one proven cost-effective way of building gears back to their original specification and help extend their life.
Brush plating, or selective electroplating, is one proven cost-effective way of building gears back to their original specification and help extend their life.
Plating can serve a variety of purposes such as a localized defect repair or bringing an inside diameter (ID) or outside diameter (OD) back to size. Plating can also enhance wear or corrosion resistance exactly where it is needed, even on new parts where it would be prohibitive to make the entire part from a more resistant material.
When assessing parts for repair, it is always important to consider the size and location of repair required, and how much material needs to be plated, as this will determine whether selective plating is appropriate or not.
Repairing a damaged pinion gear with Selective Electroplating
Working with large gear manufacture and repair specialists Horsburgh & Scott Co., SIFCO ASC’s brush plating solutions were used to repair two defects on the 16” diameter by 5” long bearing journal of this gear. They were caused by a seized bearing which damaged the seat and also created a gouge during the removal of the bearing.
The first defect was a 0.030” deep gouge measuring 0.75″ wide and 12″ long, while the bearing seat was 0.012″ undersized after clean-up.
This was considered a good selective plating application because the groove was relatively shallow and could be quickly filled with copper using a 100% tool contact. The undersized condition required only 0.006” thickness of nickel.
Welding to fill the defect was rejected as an option due to the heat and associated structural changes in the metal associated with the welding process. Meanwhile machining the entire diameter to remove the defect would have made the diameter 0.060” undersize, and so this was ruled out as well, as it would have made the journal too impractical for plating at such a high thickness.
For the resize deposit, the part required a deposit of approximately 30 Rockwell hardness. Nickel was chosen to meet that requirement.
First, the gouge was selectively filled with copper to bring it back to the overall OD. The bearing journal was first plated with 0.001″ thickness of copper and then masked for the defect repair. A plating anode was used to cover the full length of the gouge which shortened the plating time. The defect was filled with three layers of copper and hand finished between layers. The final layer was dressed flush with the OD.
Once the gouge defect was repaired, the entire OD was brought back to size by plating with 0.006” thickness of nickel. After the repair of the two defects, the journal was as good as new and ready to receive a new bearing, making the excavator ready for action once again.
Building layers without compromising gear strength, durability and specification
Gears used in large applications are expensive to replace if damaged or worn.
In many cases, brush plating can return the gear components back to their nominal specification, and in some cases, even exceed the performance of the original material.
With brush plating, a frequently used plating material for repairs is nickel. Other materials such as cobalt are also popular, while certain alloys like nickel tungsten alloys or nickel cobalt alloys can provide their own unique properties. With proper selection of deposition parameters, the grain structure of the nickel can be influenced to yield the desired properties such as hardness and corrosion resistance, thus enabling it to withstand the day-to-day operation that gears are subjected to.
For gears the most common repairs are shafts, bearing journals, and bores. In the right circumstances, localized damage to teeth may also be considered. For gears that will see corrosive environment, the bores and outside machined surfaces that cannot be painted are also plated when new to provide corrosion resistance.
On Site Selective Plating Brings Down Costs
Another consideration that engineers face with repairing gears is how the maintenance can be achieved while incurring the least cost. These can start rising through directly associated expenses like the shipping the gear to a job shop, disassembly and reassembly of the gear, and the repair itself. Then there are indirect costs to factor in, such as disruption, downtime and loss of productivity.
Often, the gears that are too large to simply replace are also too large to easily disassemble and too impractical and costly to ship to off-site job shops for repair. Downtime is also prolonged, due to the need to take the gear and machinery apart, and wait for it to be repaired, sent back and re-assembled.
Brush plating overcomes these obstacles. In many cases, technicians can assess the damage to the gears and make the repairs on-site.
This was the case for the pinion gear repair on the dragline excavator. Of the repair, Dave Niederhelman, Chief Metallurgist, Horsburgh & Scott Co. said: “SIFCO ASC is a well-established partner of Horsburgh & Scott and their ability to work on-site is highly attractive. Over the years they have helped us to find the most efficient ways to repair and maintain our customers’ equipment and this has added up to thousands of dollars, hours of downtime, and manpower time saved.
“In this application the SIFCO Process® has extended the working life of the gear and improved the failure rate due to the nature of the nickel coating on the journal. The cost of manufacturing and material to replace the gear would have been extortionate in comparison, as well as causing weeks of downtime.”
While simple on the surface, gears are complex components and once they start to wear and tear while in service, it can be an even more complex job to repair them.
Repairs must be well considered and executed correctly, and the gear must remain strong enough to handle the day-to-day operation or setting that it is in. Otherwise, it can cost even more than the initial cost of refurbishment, when factoring in downtime and lost productivity costs.
This is where brush plating offers a versatile, flexible solution for many gear repair jobs. Along with being able to make repairs on-site, the SIFCO Process® of selective electroplating is highly effective. The precise nature of selective electroplating means it can apply the plating material accurately and requires very little time to set up. Unlike with alternative repair methods, post-machining or treatment of the gears frequently are not required because plating can be done to size. Due to the low temperature of the process there is no risk of changing the structure of the base material and with that its properties.
A portable, high speed process allows molders to make minor surface defect repairs in mold cavities without removing molds from the press.
Plastics molders, operating both captive and job shops, are frequently plagued with downtime due to repairs that must be made on damaged or worn molds. Conventional machine shop practices commonly employed to repair plastics molds share a serious drawback – they all require that the mold be removed to carry out the needed repair. SIFCO Process® of selective plating will allow the repair of plastics molds in-situ. This process reduces downtime substantially. Typical repairs include damaged cavities, worn gate areas, and parting lines that cause flashing of molded parts.
High-Speed Selective Plating The process deposits metals with excellent adhesion to all classes of steel, aluminum, and beryllium-copper molds, as well as to chrome or electroless-nickel plated mold cavities.
In the following series of blogs, you’ll learn the various applications that selective plating is suitable for, including:
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