Galvanic processing
Galvanization is the process of electrolytically depositing metals on the surface of metal or non-metal products. Galvanic coatings are primarily used for protecting components against corrosion or providing specific properties to the surface of the product. Galvanic treatment is one of our strategic special processes – it allows us to be independent of subcontractors, thereby reducing production time.
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Dimensions of electroplating baths:
- Antifriction phosphating – 2000x820x965mm
- Tin plating – 1400x800x900mm
- Oxidazing – 1500x950x900mm
- Zinc plating – 2000x1020x965mm
- Etching – 2000x670x1000mm
- Electrochemical degreasing – 2000x900x1400mm
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Phosphate coatings belong to the group of chemical conversion coatings. These coatings are formed by transforming the outer layers of the metal substrate (steel, iron) into a non-metallic form through a reaction with a phosphate bath. Phosphating can be applied to steels with chromium content <5%. The thickness of the phosphate coating is 8-10 µm. The phosphate coating (after thorough drying) provides interim protection indoors for up to 7 days without an oil coating. The phosphate coating maintains corrosion resistance at temperatures up to 200°C. Manganese phosphating reduces the wear of interacting metal elements by creating a porous, black coating. The phosphate coating reduces the friction coefficient by approximately 2.5 times. It has significant porosity, allowing it to retain a significant amount of oil in the pores. Throughout the operation, the phosphate layer prevents direct contact between metal surfaces, preventing sticking, adhesive wear, and the formation of pits in the elements. Phosphate coatings are used to extend the life of moving machine parts.
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Galvanic tin plating is an electrolytic process of coating the surface of steel items with a layer of tin. Tin coatings are used, for example, to improve the solderability of joined components, reduce the friction coefficient, and provide corrosion protection for the components.
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Oxidizing is a chemical process that involves creating a layer of durable Fe3O4 oxides on the surface of steel. The coating provides the surface with a black, aesthetically pleasing appearance and enhances the corrosion resistance of the element. Steel with alloying additives <5% can be blackened. The thickness of the oxide coating does not exceed 1 µm, typically ranging from 0.6 to 0.8 µm. To improve corrosion resistance, oxide coatings are additionally protected with oils.
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Galvanic zinc plating is an electrolytic process of coating the surface of steel items with a thin layer of zinc to protect against corrosion. Steels with alloying additives ≤ 5% and roughness Ra ≤ 2 µm can be zinc-coated. Depending on the operating conditions of the element intended for zinc coating, the thickness of the coatings can range from 5 to 25 µm.
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Chroming is a process of creating a conversion coating on the surface of metal through a chemical reaction between the surface layer of metal and the components of the solution. It is used to enhance corrosion protection. Conversion chroming also allows for achieving protective-decorative effects, especially in cases where high wear resistance of the coating is not required.
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Etching is a chemical process of cleaning the surface of a component from corrosion products, often not visible to the naked eye, consisting mainly of metal oxides or alkaline salts. Etching is also used to remove improperly applied galvanic coatings.
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Electrochemical degreasing is the process of electrolytically removing contaminants from the surface of metal. Objects intended for coating with a protective layer are almost always covered with a certain amount of mineral or organic greases on their surface. Before applying a galvanic coating, this surface should be thoroughly degreased to facilitate direct contact between the metal and the coating. The electrochemical degreasing process can be carried out both cathodically and anodically. The downside of cathodic electrolytic degreasing for high-carbon steel objects is the significant hydrogenation of the metal. For such materials, it is better to choose anodic electrochemical degreasing, which does not cause metal hydrogenation, thus avoiding increased brittleness and fragility.
- Process capabilities
- Antifriction phosphating
- Tin plating
- Oxidizing
- Zinc plating
- Chroming
- Etching
- Electrochemical degreasing
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Dimensions of electroplating baths:
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Phosphate coatings belong to the group of chemical conversion coatings. These coatings are formed by transforming the outer layers of the metal substrate (steel, iron) into a non-metallic form through a reaction with a phosphate bath. Phosphating can be applied to steels with chromium content <5%. The thickness of the phosphate coating is 8-10 µm. The phosphate coating (after thorough drying) provides interim protection indoors for up to 7 days without an oil coating. The phosphate coating maintains corrosion resistance at temperatures up to 200°C. Manganese phosphating reduces the wear of interacting metal elements by creating a porous, black coating. The phosphate coating reduces the friction coefficient by approximately 2.5 times. It has significant porosity, allowing it to retain a significant amount of oil in the pores. Throughout the operation, the phosphate layer prevents direct contact between metal surfaces, preventing sticking, adhesive wear, and the formation of pits in the elements. Phosphate coatings are used to extend the life of moving machine parts.
Galvanic tin plating is an electrolytic process of coating the surface of steel items with a layer of tin. Tin coatings are used, for example, to improve the solderability of joined components, reduce the friction coefficient, and provide corrosion protection for the components. |
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Oxidizing is a chemical process that involves creating a layer of durable Fe3O4 oxides on the surface of steel. The coating provides the surface with a black, aesthetically pleasing appearance and enhances the corrosion resistance of the element. Steel with alloying additives <5% can be blackened. The thickness of the oxide coating does not exceed 1 µm, typically ranging from 0.6 to 0.8 µm. To improve corrosion resistance, oxide coatings are additionally protected with oils. |
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Galvanic zinc plating is an electrolytic process of coating the surface of steel items with a thin layer of zinc to protect against corrosion. Steels with alloying additives ≤ 5% and roughness Ra ≤ 2 µm can be zinc-coated. Depending on the operating conditions of the element intended for zinc coating, the thickness of the coatings can range from 5 to 25 µm.
Chroming is a process of creating a conversion coating on the surface of metal through a chemical reaction between the surface layer of metal and the components of the solution. It is used to enhance corrosion protection. Conversion chroming also allows for achieving protective-decorative effects, especially in cases where high wear resistance of the coating is not required.
Etching is a chemical process of cleaning the surface of a component from corrosion products, often not visible to the naked eye, consisting mainly of metal oxides or alkaline salts. Etching is also used to remove improperly applied galvanic coatings.
Electrochemical degreasing is the process of electrolytically removing contaminants from the surface of metal. Objects intended for coating with a protective layer are almost always covered with a certain amount of mineral or organic greases on their surface. Before applying a galvanic coating, this surface should be thoroughly degreased to facilitate direct contact between the metal and the coating. The electrochemical degreasing process can be carried out both cathodically and anodically. The downside of cathodic electrolytic degreasing for high-carbon steel objects is the significant hydrogenation of the metal. For such materials, it is better to choose anodic electrochemical degreasing, which does not cause metal hydrogenation, thus avoiding increased brittleness and fragility.