The plating process plays a very important part across a range of industries, from aerospace to oil and gas and power generation. It’s easy to presume that selective plating or tank plating should be able to plate every component and complex part possible. However, there are instances where both of these processes are unsuitable due to intricate component design, plating requirements or production volumes.
To plate complex components and non-line of sight parts such as sharp corners, pipes, wiring and coupling stands, SIFCO ASC developed encapsulated plating.
What is encapsulated plating?
Encapsulated plating is a sustainable way to plate axi-symmetric parts and complex components with deep bores and recessed areas. This method combines the best of tank plating and selective plating.
The encapsulated plating process
Using custom tooling, the engineer directs the plating solution through a gap in the tooling, which allows the composite to flow over the part at high velocity. This then creates electrodeposition, which happens when the electric current is passed through the chemistry as it flows over the area.
Engineers are able to plate intricate components and parts using state-of-the-art, customized electrodes that are designed to match the complex geometry of the selected area. Custom-fit seals encapsulate the area, allowing for a defined gap between the anode and the component.
Custom tooling enables the solution to flow and is confined to the surface to be plated. This tooling keeps better management of flow in order to avoid cavitation risk at the anode / cathode interface. The optimized high solution flow velocity aids in removing hydrogen gas bubbles at the surface. It also efficiently replenishes the metal ions at the surface of the workpiece providing for a smooth and uniform finish.
The benefits of encapsulated plating
While the main benefit of encapsulated plating is that it enables engineers to plate non-line of sight applications, this unique method of plating comes with many other advantages:
Improved process control
Process control, repeatability and traceability plays a key role in ensuring that manufacturers meet exacting industry specifications, and this method of plating ensures this.
The one-piece flow treatment uses the same tooling and parameters time and time again, meaning it has increased process control in comparison to other surface plating methods.
As engineers can manage temperature, flow rate, speed and amps, they have a high level of control. Additionally, the design of the system makes it possible to track and trace the plating process parameters for every part plated.
Speed, efficiency and ROI
Faster cycle times, fewer costly reworks and factory footprint efficiencies are other benefits that come with this method of plating.
The custom all-in-one tooling quickly deposits, eliminating the need for masking and other time-consuming pre-plating procedures which usually slow down the plating process.
As no large tanks are required and there’s no need for a full plating line, the small footprint of the process means that it can be carried out in-situ and incorporated into the current production layout.
A safer, sustainable way of plating
Encapsulated plating helps engineers decrease their carbon footprint and meet EHS standards, because the custom-designed tooling offers improved health and safety credentials in comparison to other plating methods.
As the component and plating solution is enclosed inside the tooling, exposure to chemicals is limited. For example, in comparison to tank plating which uses large quantities of chemicals, encapsulated plating uses significantly less solution and creates less effluent waste. This also creates minimal risk to the environment.
The small footprint of the process means that it can take place at the customer site. 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.
Applied to a wide range of industries
While encapsulated plating was developed for the automotive industry, it can be used in a wide range of industries where operators may be required to plate components that are difficult to get to, have axi-symmetric geometries or are intricate in their designs. For example, Gold Plated Resonators in aerospace and Heat Exchangers in power generation applications, electronics and compressors are complex and difficult to get to, thus benefiting from encapsulated plating.
If you’ve got an intricate part that needs plating or a non-line of sight application, get in touch with one of our engineers today.
As industries continue to look at ways to drive down costs, increase the lifespan of machinery and bring worn components back to their OEM specifications, remanufacturing is on the rise.
Predominantly used in the mining and engineering sectors for off-highway vehicles (OHVs) and heavy equipment, it’s predicted that the market size for remanufacturing components in the mining industry will reach $5 billion by 2027 (MarketsandMarkets™).
However, as the demand for mining activity across developing countries increases so does the need for equipment, and site managers want to drive down the total cost of ownership of expensive equipment. In order to do this, they need to reduce repairs and replacements, while enhancing agility throughout the mining industry – this is where remanufacturing comes in.
Why does the mining industry need remanufacturing?
Every piece of equipment in the mining industry, from the tiniest component to the largest machines are subject to unpredictable field conditions, constant stress and harsh operating environments – all of which increases the risk of wear and tear, corrosion and damage to everything from long walls to hydraulic systems and final drives.
When components and machinery aren’t properly maintained, they will break down quicker and may need to be scrapped, increasing capital equipment costs and downtime. Scrappage of these worn, corroded, or damaged components contribute to the 73 million metric tons of ferrous metal, and millions more tons of non-ferrous metals and stainless steel in the US scrap rate.
However, site managers and manufacturers can head off component failure and remove the need for scrapping equipment by introducing remanufacturing.
How can selective plating help extend operational lifespan?
While remanufacturing will help extend the operational lifespan of equipment, components and machinery still need maintenance and repairs. Without this, machinery and components will break down, causing downtime.
Selective plating is a method of repairing and restoring critical dimensions and surface properties of worn components back to OEM standards, using an array of solutions specific to the mining industry such as copper, nickel, nickel-tungsten and cobalt. Even more crucially, selective plating can be completed on site, to reduce the downtime associated with disassembly, transport and reassembly. This is ideal for components that are too large for tank plating, an area too small to mask the component for tank plating, or an in-situ repair required.
The benefits of selective plating in mining
Increased wear resistance, surface hardness and low electrical contact resistance, or corrosion protection, are just some of the benefits of the process. Other benefits include:
Maximizing uptime – and minimizing costs
Because selective plating doesn’t require extensive masking or special fixtures, this electroplating process can plate deposit between 30 to 60 times faster with no risk of part distortion thanks to the process taking place at room temperature. All of which combines to make this particular remanufacturing process a faster, more cost-effective and lower-risk option.
Remanufacturing and selective plating present a distinct way to do things better in this fast-moving industrial landscape: returning vehicles, machines, and equipment to operational effectiveness for a longer life of efficient and reliable service, with minimal downtime in the process.
Reducing environmental impact
Sustainability is at the heart of remanufacturing and brush plating fits the bill here – especially given its far lower impact compared to other surface coating methods.
Using less solution and chemicals, and generating very little waste, as well as reductions in the carbon costs of emissions, transport and shipping, it’s a more sustainable option at an ecological level. Even for workers’ health and wellbeing, the reduction in fumes and hazardous waste requiring disposal delivers a safer, healthier working environment.
With over 50 years’ expertise, a dedicated team of technical engineers, and an innovative R&D department, SIFCO ASC is the world’s largest selective electroplating and anodizing partner. To learn more, get in touch with the experts.
The US Navy is increasing their subsea footprint. The American submarine fleet recently purchased four Orca robotic submarines from Boeing. As the Navy continues to decommission older vessels, they are finding alternatives to increase the gap in the fleet.
The Orca is an Extra Large Unmanned Undersea Vehicle, or XLUUV. It is 51 feet long, displaces less than 2,000 tons of water and “can operate autonomously while sailing up to 6,500 nautical miles without being connected to a manned mother ship,” according to the Navy. In comparison the average U.S submarine is 400 feet long and displaces 6,000 tons, making them too large for shallow water operations and countermeasures.
Since the Orca is cheaper to build, small enough for shallow operations, and, being unmanned, is essentially expendable, these XLUUVs could help the Navy rapidly grow to address the increasingly advanced threats from the nation’s enemies including mine countermeasures, anti-submarine warfare, anti-surface warfare, electronic warfare, and strike missions.
Yet the being expendable for the sake of limiting the amount of lives lost is not the same as being disposable. At $10.75 million dollars each, maintaining the XLUUV is critical for its service longevity.
Due to the significant time and cost savings it can offer in extending maintenance intervals and service life, selective plating can play a vital role on-board military vessels – manned or unmanned. The SIFCO Process® has already been adopted by naval forces across the US, UK and Japan, and is used on a wide range of components across the fleet.
While the process can be used in the shop to repair worn bearing journals and housings on small generators, pumps and fans; it can also be taken aboard the vessel for in-place repairs of large, hard to move, components such as propeller shafts, bearing seats, hydraulic rams, torpedo tubes and turbine casings.
For more information on our marine services, visit us at
With the winter months come freezing temperature, frozen roads, and delayed shipments, so it’s time to start thinking about stocking up on the solutions that you need.
While preparatory solutions are not affected by extreme cold temperatures; plating solutions, when exposed to freezing temperatures – in storage or in transit – may freeze completely or “salt out”, i.e. the formation of a slush or solid crystals at the bottom of the container.
This slush can usually be re-dissolved with vigorous shaking once the solution has been returned to room temperature. In some instances, heating the solution may help, although the maximum operating temperature should not be exceeded. If the salts do not re-dissolve, the solution is not usable. Perform a quality control test in the manufacturing process, as the re-dissolved solutions also may not pass and therefore also be deemed unusable.
This table shows the results of testing conducted on 20 of our most commonly used plating solutions. Testing was completed to determine the effects of exposure to extreme cold temperature for 60 hours at 20 degrees Fahrenheit to determine their usability.
If you are still unsure about the usability of a solution, contact Technical Service at SIFCO Applied Surface Concepts at 800-765-4131.
With the price of oil hitting a 13-year low of $28 per barrel we are looking at ways the oil and gas industry can significantly reduce costs, waste and environmental impact through effective repair and refurbishment of offshore equipment.
Offshore equipment operates in the harshest of environments and has to be designed and treated to withstand wear, corrosion, high temperatures and pressure. But, repairs can be carried out in-situ without significant disassembly using the SIFCO Process®.
What equipment can be repaired and refurbished?
Using the SIFCO Process® engineers have a cost-effective way to extend the service life of a wide range of equipment including:
Drill Bits
Tubing Hanger Bodies
Inner Mandrels
Small Port Repairs
Outer Cylinders
Casing Hangers
Riser Spanner Joints
Tension Joints
Tubular Connections / Threads
Ensuring all services are provided by an oil and gas industry certified supplier is essential. Conducting additional testing such as; non-destructive testing and pressure testing where appropriate also helps to ensure your equipment is refurbished to the highest standards.
If you would like to find out how we can help you extend equipment service life through our repair and refurbishment services, visit our web page or contact us now.
Some may think that lower gas prices would boost the economy. By not spending as much on your tank, hopefully you’ll spend those savings elsewhere. But according to Matt Egan from CNN Money, there are 10 reasons why you should worry about cheap oil prices.
It’s affecting your retirement account: Due to the crash in oil, it’s caused energy profits to plummet.
Oil companies are going out of business: Driven by expensive drilling technology, these companies are no longer seeing the return on investment, forcing them to close their doors.
Big banks are bracing for losses: The large U.S. banks that helped fund the energy boom are already setting aside billions to cover potential loan losses in the oil industry (refer to #2).
People are losing jobs: The energy industry cut 130,000 jobs in 2015, job losses within oil-related businesses are likely even higher (refer to #2).
Cheap oil could signal trouble in the global economy: “When economies are booming, they consume lots of oil — and vice versa.”
Emerging markets could be in trouble: “Many economies like Brazil, Venezuela, Colombia and Russia are powered by energy exports. […]The U.S. has deep trade relations with many of these countries, and that will undoubtedly take a blow.”
More trouble in the Middle East: Tensions are on the rise OPEC, which can’t help the already-volatile regions of Saudi Arabia and Iran.
Home foreclosures are rising in oil states: Foreclosures have increased by 16% in in 2015, the same is expected for Oklahoma and North Dakota (refer to #2).
Lack of U.S. energy independence: With U.S. oil companies closing shop, production is now expected to decline, forcing the U.S. to rely once again on the Middle East.
People are saving, not spending: “The idea that cheap oil is a net positive for the U.S. hinges on the consumers spending the money they’re saving at the pump.[…] U.S. retail sales actually fell slightly in December despite the fact that gas prices continued to fall at the end of last year.”
Graphene is a man made material that was discovered by two professors at the University of Manchester in 2004.
A mere atom-thick, graphene is incredibly thin and yet has also proven to be incredibly strong. One study has suggested that graphene-coated spiders’ silk would have enough strength to catch a falling plane.
As a relatively recent discovery, graphene continues to spark new and exciting research projects around the world with new lightbulbs, batteries and building materials just some of the applications where the material is set to be used.
Surface engineering is a core area where the attributes of graphene can be utilized and we at SIFCO ASC, along with sister companies across Norman Hay plc, are excitedly exploring how we can use this material to help improve our customers’ cars, planes, medical equipment, subsea oil and gas equipment and much more.
One recent study that has been of particular interest to us is the addition of graphene coatings to make steel corrosion-resistant. The research, conducted by a team at Deakin University in Australia, grew graphene nanoflakes on micron-sized fibres of stainless steel, enhancing the material’s resistance to corrosion and its electrical conductivity.
A full version of the Deakin University study; Growth of nano-textured graphene coatings across highly porous stainless steel supports towards corrosion resistant coatings, can be found in the Carbon Journal: https://www.sciencedirect.com/science/article/pii/S000862231500130X
Visiting MACH 2016? Here’s 5 reasons why a visit to SIFCO ASC on stand 5974 is a must
1. Improve end product performance: If you manufacture components that will be subject to heat, pressure, corrosion, wear, galling and friction then surface engineering is a must. The SIFCO Process® provides a wide range of chemical solutions to electroplate substrates with a material that enhances the component’s performance but, unlike other processes, is localised to the areas where coating is required. For many applications this means it is a process that offers a quicker, more efficient and cost effective method than masking and tank plating.
2. Enhanced production control: The scalability of the SIFCO Process® means it is a process that benefits manufacturers of all shapes and sizes, from tier component suppliers to OEMs. The SIFCO Process® provides a solution that enables manufacturers to keep more of their processes in-house and remove the logistics and scheduling issues of outsourcing to a third party for material plating and finishing.
3. Automation that is built to fit you: See SIFCO Process® automation in action on stand 5974 at MACH and discover why companies are enhancing their manufacturing process with automated SIFCO Process® technology. Benefits include reduced total product cost, assurance of consistent high quality, production traceability and efficiency.
4. Repair and refurbish rather than replace: The unique precise targeting of the SIFCO Process® means it is the most effective form of repairing and refurbishing worn or damaged material structures. Whether a component is worn or mis-machined, SIFCO ASC has a job shop service which regularly re-builds scored and damaged materials back to new. With a base in the West Midlands, as well as multiple sites in the US, France and Sweden, SIFCO ASC is well placed as a repair and refurbish partner for multinational OEMS.
5. Quality assurance: SIFCO ASC is certified to ISO9001:2008, AS9100 Rev C and ISO14001:2004. SIFCO ASC also holds multiple Nadcap accreditations and commercial specifications from manufacturers including; Boeing, Messier-Dowty, Rolls-Royce, GE Oil & Gas, Siemens, Pratt & Whitney and many more.
Are you struggling with wear and corrosion? Don’t wait until your spring shutdown to fix the problem.
The SIFCO Process is portable and can be performed directly on the area in place. Whether you need to disassemble the component, or not, the SIFCO Process is rapid and precise and can be performed by our certified technicians or yours, on-site or in one of our facilities.
The benefits of using the SIFCO Process versus other surface repair methods include:
The benefits of using the SIFCO Process versus other surface repair methods include:
• In-place Repairs – no disassembly required
• Faster Turn-around Time – 50-60x faster than tank plating
• No Part Distortion – most of our solutions are used at room temperature
• Precise Thickness Application – no post machining required
• Low Hydrogen Embrittlement Solutions Available
Contact us today at 800-765-4131 to schedule your service, training or product and equipment delivery.
Cadmium is a soft, malleable metal that is very light in color. In the plating industry it is used as sacrificial coating. Ideal for a corrosive environment, cadmium can protect the underlying base metal, such as steel, even when scratched or corroded.
While the nature of the deposit is well suited for the aerospace industry (particularly landing legs/gears), according to the EPA, cadmium is highly toxic and exposure to this metal and its compounds can cause health related problems including pulmonary irritation, kidney disease, and lung cancer in humans and animals. For these reasons the EPA is encouraging industries to discontinue using cadmium and switch to an alternative deposit.
At SIFCO ASC, we’ve been developing cadmium alternatives since 1992, to meet Boeing’s specifications and demand for an environmentally friendly alternative. Boeing began their research into cadmium alternatives in the early 1970’s as a response to Japan’s ban of the use of cadmium in 1969. According to Mary J. Nelson and Earl C. Groshart of the Boeing Defense & Space Group, “In 1990, Environmental Protection Agency’s (EPA) “33/50” Plan for reduction of 17 chemicals including cadmium and cyanide became a goal for Boeing to reduce its hazardous chemical usage.”
To date, SIFCO ASC has two cadmium alternatives which provide corrosion resistance, lubricity and low hydrogen embrittlement. Zinc-Nickel LHE, Code 4018 and Tin-Zinc, Code 4019 both meet aerospace spec AMS 2451, while 4018 also meets AMS 2417, and 4019 meets AMS 2434.
To determine which deposit is best for your application, contact SIFCO’s Technical Service today, 800-765-4131.
SIFCO Applied Surface Concepts uses cookies to give you a more personalized experience on our website. If you continue to use our services, we assume that you accept such use. Learn more about cookies and how you can refuse them on our Privacy Policy page.OkPrivacy policy
Chinese (Simplified) 
English 
French 
German 
Spanish 
Swedish 
