Electropolishing

Electropolishing is an electrochemical process used to remove surface material and high points on metal parts. By removing the peaks of the metal’s surface, electropolishing is a metal treatment used to improve the surface finish, cleanliness and corrosion resistance of metal components. This is achieved through a process called anodic leveling where the metal part is immersed in an electrolyte bath and a controlled electrical current is applied to it. Electropolishing can be done to metal finishes such as Stainless Steel, Nickel, Aluminum and Hastelloy.

During electropolishing, metal ions are removed from the surface of the part, resulting in a smoother, more polished finish that has greater corrosion resistance capabilities. This is achieved through the selective dissolution of microscopic peaks on the surface, which helps to level the surface and remove any surface imperfections such as burrs, scratches or embedded contaminants.

The electrolyte bath typically consists of a mixture of acids and other chemicals, depending on the specific metal being treated and the desired outcome. The process parameters, such as voltage, current density, temperature and immersion time, are carefully controlled to achieve the desired surface finish and properties.

Electropolishing is commonly used in industries such as medical/dental, pharmaceutical, food and beverage, aerospace, automotive, marine and semiconductor, where high-quality surface finishes and precise dimensions are essential. It offers several advantages over mechanical polishing, including the ability to uniformly polish complex shapes, enhanced corrosion resistance and improved cleanliness.

Enhanced Surface Smoothness: Through the selective removal of material, imperfections such as minor scratches, burrs, and surface irregularities are efficiently eradicated. This results in a uniformly smooth surface that is not only aesthetically pleasing but also reduces the likelihood of particulate adhesion, a critical factor in industries requiring high levels of cleanliness and sterility.
Increased Cleanability: The smooth surface achieved through electropolishing significantly simplifies cleaning procedures. Bacteria, product residues and other contaminants are less likely to adhere to a smooth, clean surface, thereby reducing the time and resources required for cleaning. This aspect is particularly critical in the food, pharmaceutical and semiconductor industries, where hygiene and cleanliness are paramount.
Increased Corrosion Resistance: By eliminating embedded contaminants and surface irregularities, electropolishing enhances the corrosion resistance of metals. For industries operating in corrosive environments or requiring longevity from their metal components, this improvement in corrosion resistance is invaluable in an electropolish finish.
Improved Aesthetics: The process of electropolishing not only enhances the functional attributes of metal parts but also significantly improves their appearance. The glossy, reflective electropolish finish is often sought after for its visual appeal, making electropolishing an excellent final finishing step for consumer-facing products.

Piping/Tubing

Polishing the inside diameter, outside, or both greatly increases corrosion resistance, removes rouge and creates a sterile easy-to-clean surface.

Pharmaceutical

Meeting the ASME BPE standards, we are equipped to meet most pharmaceutical polishing needs such as tanks, fill needles, workstations, machinery/equipment components and more

Marine

Greatly increases corrosion resistance, protecting against rust, while leaving an appealing, lustrous finish. Perfect for boat equipment such as rail assemblies, anchors, anchor guides, boxes, ladders and more.

Food and Beverage

An electropolish finish on production equipment and machine components can greatly increase corrosion resistance as well as pathogen resistance by creating a smooth surface that bacteria can not adhere to, and it will also reduce the amount of time needed for cleaning.

Medical/Dental

Polishing medical tools and equipment will help deburr and remove blemishes while creating a clean sterile tool surface. Polishing implantable objects can create a sterile piece by removing the porous outer layer reducing the risk of bacteria and infection.

Semiconductors

An alternative way to polish with reduced risk of damaging the product.

What materials can be electropolished?

Stainless Steel, Nickel, Aluminum, and Hastelloy

What size items can be electropolished?

We can polish parts of all sizes! We have done small hardware, such as fill needles, including the inside diameter, all the way to large tanks and hoppers. If a part is too big to be dipped into our tank, we have a mobile hand polishing station ready to tackle even the largest jobs.

Will electropolishing remove scratches and dents?

No, electropolishing will not remove scratches or dents. To achieve certain surface RA’s (roughness average) the part needs to be prefinished to a certain extent. The lower the RA needed after electropolishing, then the lower the RA needed prior. However, scratches and dents can still be electropolished, but a certain RA cannot be guaranteed unless they are removed beforehand. In other words, the scratches and dents will still be present, just polished over.

Does electropolishing change the appearance of the part?

Yes! Electropolishing will create a bright and smooth finish. Depending on the material used and the quality of the pre-electropolish finish we can achieve up to mirror like finishes depending on the customers desired outcome. Different industries require various finishes and surface roughness which is all measurable and can be verified with calibrated measuring devices. If you are unsure what finish is best for you, feel free to reach out and contact us to help you through this process.

Does electropolishing create a smoother surface?

Yes, it does! Electropolishing can reduce a part’s “roughness average” or “Ra” by up to 25-50% depending on what material the part is made out of. This percent can also vary by the part’s starting Ra.