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Electro-Polishing: Prepared by
Electro-Polishing: Prepared by
Prepared by: Paidpilli Mahesh kumar (08120034) Aurobindo Mahanty(08120013) Nirvesh Biswas(08120029)
This removal of discontinuities in the edges of the grain boundaries will also remove sites for chemicals, dirt and microorganisms to be trapped.
The reduction of the total surface area of the grain boundaries exposed to the process which significantly reduces exposed to Material and Applications series, Vol.6,(The Mechanical Finishing of stainless chemical attack.
MM100
MM100
is a chemical surface-finishing technique by which metal is electrolytically removed, ion by ion, from the surface of a metal object. When current is applied, the electrolyte acts as a conductor to allow metal ions to be removed from the part. While the ions are drawn toward the cathode, the majority of the dissolved metals remain in solution. Some ions are deposited in sludge form on the cathodes The quantity of metal removed from the workpiece is proportional to the current applied, the efficiency of the electrolyte and the exposure Protection,, Vol 13A, ASM Handbook, ASM International, time
MECHANISM OF ELECTROPOLISHING:
The process is generally considered to include:
1. leveling (or smoothing) action 2. brightening action.
The electrical potential of the power supply or potentiostat causes electronic conduction to the WE and CE and ionic conduction in the electrolyte. This may result in controlled anodic dissolution of the anode material and cathodic deposition on the CE of some species present in the electrolyte. During the electrolytic process, a viscous liquid layer immediately adjacent to this surface is produced by the reaction between the metal and the electrolyte. This layer of solution, known as the polishing film As such, it controls the smoothing action. The brightening action is related to the elimination of irregularities as small as approximately 0.01 m and to the suppression of etching on the metal surface. This behavior is generally attributed to the formation of a thin, partly passivating film directly on the surface of the metal and following its contours
Int.J.Electrochem.sci.,4 (2009) p-238-246
ANODE FILM
The electrochemical reaction is under diffusive mechanism. Due to the diffusive mechanism, a viscous layer will be formed on the anode. With respect to the bulk of the electrolyte, one proposed by Jacquet this layer has higher viscosity and greater electrical resistivity. The thickness of the insulating layer is greater in crevices () than on projections (B).
Int.J.Electrochem.sci.,4 (2009) p-238-246
Lightning Rod Effect Ben Franklin proved that a piece of material that is charged tends to have very pronounced concentration of charge at edges and irregular or sharp points significantly greater charge concentration on them as compared to the valleys of the work surface then the points in the metal with the greatest ionic charges will have a greater electromotive potential for ionization into solution The rate of the electrochemical reaction is directly proportionate to the current density. The increased current density at the raised points forces the material to dissolve faster at these points and thus tends to level the surface.
The Osmosis Effect: The metal ions in solution at the edge of the "Anode Film" will naturally migrate into the main body of the electro polishing solution. This loss of ions into the main body of the solution reduces the ion saturation of the electro polishing solution at the surface of the anode film. This results in the outer layer of the anode film becoming more active than the inner layer. This creates a situation where metal can still be removed in the regions of the anode film farthest away from the surface of the work piece Gas Mixing/Pump Effect: The oxygen is generated at the outermost edge of the anode film since this oxygen is generated as a gas, it will form bubbles and rise to the surface. This bubbling works as a pump and moves the main body of the electro polishing solution along the surface of the anode film. This movement causes the electro polishing solution to mix with the "Anode Film Solution" at the surface of the anode film. The mixing allows fresh electro polishing solution that is not at saturation to mix with the anode film and reduce its outer layer below the saturation point. Again, with the outer layer of the anode film active,
Anodic Processes
Anodic dissolution processes are complex. Depending on the nature of the dissolving metal (M), the electrolyte composition, and the current density, the following anodic (oxidation) reactions may occur:
Transfer of metal ions into the electrolyte: Me Me2+ + 2eFormation of oxide layers: Me + 2OH- MeO + H2O + 2eEvolution of oxygen: 4OH- O2 + 2H2O + 4e(Eq 3) (Eq 2) (Eq 1)
M. Ziomek-Moroz, Electro polishing, Corrosion: Fundamentals, Testing, and Protection,, Vol 13A, ASM Handbook, ASM International,
M. Ziomek-Moroz, Electro polishing, Corrosion: Fundamentals, Testing, and Protection,, Vol 13A, ASM Handbook, ASM International,
Original surface
500x
CASEV,E.J.AND R.E.BERGERON(1953) The electrolytic polishing of metals.Can.Jour.Chem.31,422. M. Ziomek-Moroz, Electro polishing, Corrosion: Fundamentals, Testing, and Protection,, Vol 13A, ASM Handbook, ASM
Etched surface(Active dissolution) after treatment with less than critical voltage
500x
CASEV,E.J.AND R.E.BERGERON(1953) The electrolytic polishing of metals.Can.Jour.Chem.31,422. M. Ziomek-Moroz, Electro polishing, Corrosion: Fundamentals, Testing, and Protection,, Vol 13A, ASM Handbook, ASM
Indicating unstable conditions on the metal surface. This represents active-passive behavior.
CASEV,E.J.AND R.E.BERGERON(1953) The electrolytic polishing of metals.Can.Jour.Chem.31,422. M. Ziomek-Moroz, Electro polishing, Corrosion: Fundamentals, Testing, and Protection,, Vol 13A, ASM Handbook, ASM
The acid chemically dissolves any Oxide layer formed into solution by: MeO + 2 H(+) =Me(2+) + H20 500x
while new Oxide layer continues to form electrochemically on the high points of the anode Me+2OH(-) =MeO+H2O+2e(-)
CASEV,E.J.AND R.E.BERGERON(1953) The electrolytic polishing of metals.Can.Jour.Chem.31,422. M. Ziomek-Moroz, Electro polishing, Corrosion: Fundamentals, Testing, and Protection,, Vol 13A, ASM Handbook, ASM
500x With excessive voltage ('overvoltage'), the diffusion and dissolution processes cannot keep up with the electrical current, and the excess current is expended in the dissociation of water, with O2(gas) formed at the anode per H2(gas) formed at the cathode.
CASEV,E.J.AND R.E.BERGERON(1953) The electrolytic polishing of metals.Can.Jour.Chem.31,422. M. Ziomek-Moroz, Electro polishing, Corrosion: Fundamentals, Testing, and Protection,, Vol 13A, ASM Handbook, ASM
(10um)
The MEP process involves performing the standard EP technique under the influence of a constant magnetic field. In the EP process, an externally applied magnetic field works in two ways: the field either enhances or retards the dissolution rate of processed material.
T Hryniewicz, R Rokicki, and R Rokosz, Magnetoelectropolishing Process Improves Characteristics of Finished Metal Surfaces, Metal Finishing 104, no. 12 (2006): 2633.
Atomic Force Microscopy (AFM) The dissolution rate depends on the strength of the applied magnetic field, but it is independent of the dissolved materials magnetic properties and the electrolyte used.
In addition, a constantly applied magnetic field oriented parallel to the cathode surface during MEP suppresses hydrogen evolution. This minimizes the hydrogen embrittlement of magnetoelectropolished material. .
T Hryniewicz, R Rokicki, and R Rokosz, Magnetoelectropolishing Process Improves Characteristics of Finished Metal Surfaces, Metal Finishing 104, no. 12 (2006): 2633.
PROCEDUR E:
The work must be performed in three major operations:
Metal Preparation
Electro Polishing
Post -Treatment
Metal preparation: To remove surface oils, greases, oxides and other contaminants that interfere with the uniformity of electro polishing
Metal Preparation
Cleaning
Rinsing
Pickling
Rinsing
Electro Polishing
Electro Polishing
Drag-out/Neutralisation
Rinsing
Post-treatment: To remove residual electrolyte and by-products of the electro polishing reaction and dry the metal to prevent staining.
Post -Treatment
Acid Treatment
Rinsing
Hot Rinsing
Drying
NOVEL CHARACTERIZATION OF THE ELECTROPOLISHING OFNIOBIUM WITH SULFURIC AND HYDROFLUORIC ACID MIXTURES*H. Tian + #, S. G. Corcoran *, M. J. Kelley +#, C. E. Reece+#Applied Science Dept., College of William and Mary, VA 23187, USA+Thomas Jefferson National Accelerator Facility, VA 23606,
2.Surface Conditions can result in less than optimum electro Base metal conditions that
polishing finishes include :
The presence of non-metallic inclusions large grain size
3.Effect of area
Fig 8. I-V curves with different cathode areas, the blue curve is normal. Much small area of cathode let the green curve like a line
WEP65 Proceedings of SRF2007, Peking Univ., Beijing, China662
4.Effect of stirring speed 5.Effect of voltage confirming is difficultly polishing, but the temperature
High stirring speed will lead high current density as well as high speed of
NOVEL CHARACTERIZATION OF THE ELECTROPOLISHING OF NIOBIUM WITH SULFURIC AND HYDROFLUORIC ACID MIXTURES* H. Tian + #, S. G. Corcoran *, M. J. Kelley +#, C. E. Reece+#Applied Science Dept., College of William and Mary, VA 23187, USA +Thomas Jefferson National Accelerator Facility, VA 23606, USA *Material Science & Engineering
are more easily extracted from the crystal lattice than are chromium atoms. That is, iron and nickel are attacked preferentially during the electrolytic process leaving behind an enhanced surface layer of chromium,
which then forms the passive enrichment layer.
This process Conditions : Operating also tends to smooth the surface finish ft2)dependent on alloy shape of article. used and : 10 to 20volts dependent upon the size of the density applied : 60 to 90` C (140 to 195`F).
Time. : 4 to 10 minutes. Comparing the characteristics of surfacepassivated and electropolished 316L stainless steel Patrick Lowery, Unit Instruments; and Daryl Roll, Astro Pak
and1,000Xmagnification) of representative surface areas to assure maximum electro polished surface condition.
Surface will show no evidence of grain boundaries.
(AES) taken from representative surface areas to assure maximum electro polished surface condition. Depth of chrome oxide layer shall not be less than 20 (Angstroms)
Chemical Analysis (ESCA) taken from representative surface areas to assure that the maximum electro polished condition has been achieved. ESCA will be conducted in tandem with AES to confirm the quality of the Cr/Fe oxide profile
DELSTAR METAL FINISHING, INCESCA
S.S. Plate(1000 x)
Intermediate Quality (1000 Premium-Grade Electro polishing (1000 x DELSTAR METAL FINISHING, x)
Electropolishing
This process also tends to
of plating in that metal is removed from the surface rather than deposited Electropolishing also removes burrs and sharp edges; removes stress from springs and stampings by removing microscopic nicks and scratches from the surface.
Selection of Electrolytes
The ideal electrolyte for electro polishing must: Provide high quality polishing at low voltages and current densities Have the ability to function over a large range of current densities and temperatures Offer stability and long service life
Not dissolve the metal when no current is flowing; that is, no spontaneous corrosion occurs
Be inexpensive, readily available, and safe
Be recyclable
Have an ohmic resistance (IR drop) that is sufficiently low to obtain the desired current density at low voltage
M.
Provide good throwing power; that is, a sample with complex geometry should Ziomek-Moroz, Electro polishing, Corrosion: Fundamentals, Testing, and Protection,, Vol 13A, ASM Handbook, ASM International, dissolve uniformly over the entire surface
Copper Alloy
70% orthophospheric acid and 30% water 20 wt% KCN in water 1)25% perchloric acid(70%) in glacial acid 2) 2% perchloric acid in 2butoxyethanol. 12%H2SO4 in water 2%perchloric acid in 2butoxyethanol 10%HF in HNO3 80%NaNO3, 20%NaCl 15%H2SO4 in methanol
10-25 V DC 6V DC 25 V DC
Atom probe tomography: analysis at the atomic levelBy Michael Kenneth Miller
Magnetic properties of steel alloys are altered when the cold-worked layer is removed by electro polishing . Surface conductance is improved. The effect of electrolytic polishing on the corrosion Testing, and Protection,, Vol 13A,depends onASM International, M. Ziomek-Moroz, Electro polishing, Corrosion: Fundamentals, properties of metals ASM Handbook, the post-
Safety Precautions:
Generally, the chemicals and combinations of chemicals used in electro polishing are poisonous; many are highly flammable or potentially explosive. Only well-trained personnel who are thoroughly familiar with chemical laboratory procedures should be permitted to handle or mix the chemicals or to operate the polishing baths .
Mixtures of HClO4 and acetic anhydride are extremely dangerous to prepare and are even more unpredictable to use. These mixtures are highly corrosive to the skin, and the vapors of acetic anhydride can cause severe damage by inhalation. These hazards are considered sufficient reason for recommending that mixtures of HClO4 and acetic anhydride not be used, despite their effectiveness as electro polishing electrolytes. Electrolytes must be discarded immediately after use by flushing down a chemical waste drain with a large amount of water. Mixing, storing, and handling of electrolytes should be done using containers and equipment made of materials suitable for the chemicals used. Glass is resistant to nearly all chemicals.
ASM Handbook - Vol 09 - Metallography and
APPLICATION:
1.The Aerospace Industry The aerospace industry is one in which high reliability and flawless quality are a matter of life and death. Turbine blades Engine parts Vacuum chambers Piping and tubing systems Landing gear parts Doors 2.Automotive Industry In the automotive industry, improved quality has become a major competitive factor. Parts need to be durable, reliable, and resistant to corrosion.
APPLICATION:(contd.)
3.Food and Beverage Industry In the food and beverage industry, ease of cleaning and the maintenance of sterile and sanitary surfaces are critical. 4.Medical and Dental Applications Electro polishing metal objects for medical and dental purposes provides both short term and long term benefits Some of the objects that should be electro polished for medical use include: Surgical equipment such as scalpels, clamps, saws Prosthetic devices, bone and joint implants Tubing, needles
APPLICATION: (contd.)
6.Petrochemical Electro polishing will also result in increased heat transfer efficiency in heat exchangers, enhanced flow characteristics in piping and tubing, and the elimination of burrs from machined parts. Commonly electro polished parts in the petrochemical industry include: Reactor Vessels Heat exchangers Mixers Storage tanks
5.Water Purification In the semiconductor industry, for example, water needs to be extremely pure in the manufacturing of microchips. Without undergoing the electro polishing process, water purification systems may take six weeks just to achieve the level of purification necessary
Electro polishing is particularly well suited to softer metals, which may be difficult to polish by mechanical methods. Scratching does not occur in electrolytic polishing. The absence of scratches is advantageous in viewing high-quality electro polished surfaces .
DISADVANTAGES OF ELECTROPOLISHING
Electro-polishing Difficult for Some Metals. Not applicable to gray cast Iron. Critical Adjustment of Terminal Voltage for some metal is required
Metallographic preparation by electro polishing is subject to several limitations, which should be recognized to prevent misapplication of the method and inappropriate results
In multiphase alloys, the rates of polishing of different phases often are not the same and preferential attack may also occur at the interface between
THAN KYOU