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What are the reasons for the unqualified quality of electroplating coatings?
March 20th at 3:54pm
Electroplating, as a fundamental industrial process technology, has a wide range of applications in processing. Industrial parts are processed using electroplating technology, and a electroplating layer with special physical and chemical properties is coated on the surface of the parts. On the one hand, it can increase the protection and wear resistance of the parts, and on the other hand, it can also play a certain decorative role. The electroplating process can significantly improve the performance of component products. In the manufacturing industry, some parts are mainly electroplated with chromium and zinc. Chromium plating can improve the wear resistance of workpieces; Galvanized parts can enhance anti-corrosion performance and play a beautifying role. The quality of electroplated components plays a decisive role in the quality of equipment. Therefore, it is necessary to analyze the main reasons that determine the quality of electroplated layers and take targeted improvement measures. The author analyzed the main reasons that determine the quality of electroplating from the perspectives of internal and external factors.
Internal factors that determine the quality of electroplating layers
(1) The degree of adhesion, aesthetics, and anti-corrosion ability between the pre-treatment coating of components and the surface of components are closely related to the quality of pre-treatment work on the surface of components. The residual oil stains, metal oxide scales, and rust on the surface of the components hinder the contact between the electroplating layer and the surface of the metal components, which can have a great impact on the electroplating quality. If there is a very thin oil or oxide film on the surface of the plated part, although the appearance of the electroplated layer will not be greatly affected, it will greatly weaken the adhesion of the electroplated layer. Therefore, properly implementing the pre-treatment of components is an important prerequisite for obtaining high-quality electroplated products. In pre-treatment work, oil, dirt, and rust removal solutions with appropriate concentrations should be used, and any floating oil stains on the surface of the solution should be promptly removed. As the usage process continues, the impurity content in the liquid increases, and the cleaning ability will continue to decrease. Therefore, it is necessary to replace it regularly during processing.
(2) The influence of electroplating solution on the quality of electroplating layer
The ratio of different components in the electroplating solution needs to be maintained within the optimal electroplating process range. In electroplating production, it is necessary to regularly conduct laboratory analysis of the drug content in the tank to ensure that the distribution ratio of each group is within the allowable range of the process; Secondly, based on the different production tasks, timely supplement various components according to laboratory analysis. Before the impurity content in the plating solution exceeds the appropriate range, timely treat and purify the plating solution to maintain it within the most suitable operating range. In addition, during the electroplating process, harmful impurities may be mixed into the plating solution for various reasons. Due to the different types and characteristics of these impurities, as well as the varying degrees of impact of the same impurity on different electroplating solutions, it is necessary to combine the actual electroplating production situation, use a Hertz bath to analyze the specific impact on the performance of the electroplating solution and the quality of the electroplating layer, and promptly handle impurities in the electroplating solution.
(3) Control of Electroplating Process Conditions
The control of electroplating process conditions largely determines the quality of the electroplating coating. Therefore, reasonable control of the process conditions for different electroplating tasks is the key to improving the quality of coatings, which requires practical work experience. The adjustment and selection of electroplating process parameters such as current density, temperature, and pH environment are very important. Taking chrome plating as an example, when the current density and temperature conditions are not suitable, it has a significant impact on the cathode current efficiency, coating tightness, and appearance of the plating solution. In case of high temperature, the current density should be appropriately increased to meet the appropriate coating requirements. The various conditions will constrain each other, so the inability to control the process conditions correctly and reasonably will greatly affect the overall quality of electroplating products.
The main external factors affecting the quality of the electroplating layer
(1) The storage and packaging of products in atmospheric environments, black metals usually use a galvanized layer to avoid corrosion. However, once the galvanized layer comes into contact with materials such as alkyd paint, phenolic paint, phenolic plastics, plywood, and damp wood, it will rapidly corrode the galvanized layer, and over time, the corrosion products will gradually thicken. In an environment with a small amount of organic volatile gases, the process of atmospheric corrosion is accelerated, commonly referred to as atmospheric corrosion. Materials such as paint, resin, and plastic can all cause atmospheric corrosion. The higher the concentration of organic volatile atmosphere in the atmospheric environment, the more severe the corrosion caused to the electroplating layer. In addition, organic volatile atmospheres only cause corrosion to the galvanized layer under humid conditions. That is to say, corrosion is usually difficult to occur in dry air. Therefore, isolating the organic volatile atmosphere and keeping the air dry has a positive effect on the protection of the galvanized layer. Therefore, when storing electroplated products, it is necessary to control the warehouse environment to prevent corrosion of the parts atmosphere. Moreover, in the transportation process, the packaging of the product can have a direct impact on the corrosion resistance of electroplated components. For galvanized parts, they must be packaged in wooden boxes and an appropriate amount of desiccant added to the inner packaging to ensure that the components do not corrode and ensure product quality.
(2) The impact of human factors on electroplating quality is the most significant and significant factor in the entire electroplating process. In the electroplating production process, it is not difficult to find that under the same conditions of electroplating process, production equipment, and raw materials, the appearance quality of electroplated products may also vary due to differences in operators, and there may even be product quality problems. Avoiding or reducing the impact of human factors on the quality of electroplating layers. Therefore, in actual electroplating work, the first step should be to establish and improve standardized operating procedures to promote the standardization process of electroplating work. Secondly, it is necessary to fully exercise the management rights of management workers, regularly supervise and inspect the implementation of electroplating process specifications on the production site, and timely improve the supervision and inspection files. And higher attention should be paid to the laboratory analysis position, and efforts should be made to improve the professional skills of the analysis team to ensure that all components of the electroplating solution are maintained within the most suitable range. Again, it is necessary to organize regular professional skill training and assessment for electroplating operators to ensure that their operational skills meet the relevant requirements of electroplating production.
(3) The impact of the production system of electroplating enterprises on the quality of electroplating. In the production of electroplating enterprises, the production process of some parts needs to go through the cooperation of multiple different departments, and electroplating is the final process. Often, there are scratches, tight schedules, and continuous rush of goods, which leads to electroplating time not meeting the process requirements and restricts the quality of electroplating products. Coordinate the effective transportation and processing schedule of the production department, reserve sufficient processing time for the electroplating process, to ensure the quality of the electroplating products.
(4) The impact of design drawings on electroplating quality. Parts that usually require electroplating treatment are only marked with the plating type on the drawing, and there are relatively few markings on the plating surface, which often leads to defective products during electroplating processing. In critical areas, the electroplating process should ensure the adhesion and appearance of the plating layer, and there should be no obvious defects. Therefore, it is necessary to clearly indicate the key positions of electroplating on the drawings in order to better select hanging tools and mounting positions, in order to ensure the quality of electroplated workpieces. The improvement of electroplating product quality will better serve the actual needs of the manufacturing industry and greatly promote the overall development of China's electroplating industry. In summary, we should pay attention to and respond to the impact of internal or external factors on the quality of electroplated components in electroplating production. The author has conducted a simple analysis and discussion on the reasons that determine the quality of electroplating layers based on their own work experience. However, how to improve the quality of electroplating products still depends on the joint efforts of workers in the entire electroplating industry.