Electropolishing is widely specified to enhance corrosion resistance on a wide variety of metal alloys. Although most commonly used on stainless steels, electropolishing offers corrosion resistance on other alloys as well. Due to the versatility and superior effectiveness, electropolishing is fast becoming a replacement process for passivation.
Multiple stainless materials were compared for corrosion resistance using independent lab testing per the ASTM B-117 salt spray test. Electropolished parts don’t show signs of rusting after 888 hours of testing.
Passivation is a chemical process that has been used for years to help restore contaminated stainless steel to original corrosion specifications. Passivation is routinely specified by engineers because of the many sources of contamination. The intent of passivation is to remove free iron or other foreign matter from the surface of the metal and to create a chromium rich surface that is resistant to corrosion. However, passivation is generally not effective in removing embedded free iron and contaminants and will not remove heat tint or oxide scale on stainless steel.
Engineers looking to pass stringent salt spray and humidity tests have turned to electropolishing for a more aggressive replacement for passivation. The electropolishing process dissolves the outer skin of metal, removing deeply embedded contamination. Heavily contaminated surfaces such as machined parts, welded or brazed assemblies or other components that typically respond poorly to passivation alone, are good candidates for electropolishing. Unlike passivation, all stainless alloys including the 400 series and precipitating grades can be processed without distortion, flash attack or hydrogen embrittlement.
Just as electropolishing is used to enhance corrosion resistance on stainless steel, it offers corrosion resistance on other alloys as well. Many companies use the process to delay or retard the corrosion properties of copper, brass, aluminum, and carbon steels. On these and other alloys, the removal of surface skin and impurities enhances the corrosion resistant properties of the component.
The parts pictured on the right are made from type 303 stainless steel. After a series of machining operations, the parts needed to be decontaminated to remove embedded steel and other impurities.
Under 40X magnification using the scanning electron microscope, you can see the passivated part is actually rougher, due to the chemical attack of the 303 stainless steel by normal passivation. In contrast, the electropolished part is smooth and clean. By carefully monitoring the amount and rate of metal removal, electropolishing dissolves the surface skin and its impurities, including impinged steel flecks and other contaminants.
Contact us to learn more about electropolishing and corrosion resistance
From implantable devices to surgical instruments, electropolishing is a single-process treatment that results in biocompatible, safe and ultra clean parts.
We offer aerospace vendors and original equipment manufacturers our signature metal finishing services to increase fatigue-resistance for their metal parts, rendering them capable of withstanding the stress and corrosion that comes with long-term use.
Our strict adherence to industry standards ensures that pharmaceutical components are electropolished in accordance with ASTM B912 and ASME BPE specifications. These products are clean and smooth, corrosion resistant and contaminant free.
Corrosion resistance and microfinish improvement are essential for critical automotive parts, making electropolishing an increasingly beneficial option for automakers.
Our metal finishing services help increase corrosion resistance for these parts, and by removing the outermost layer of metal withelectropolishing the durability and longevity of these appliance components is increased.
Electropolishing materials for this industry eliminates the buildup of bacterial biofilms, as well as keeping the equipment free of contaminants like Salmonella. Electropolishing delivers the level of sanitation required by a number of regulatory agencies.
From robotics to mobile equipment, the uses of electropolishing in the hydraulics and pneumatics industry are many. By helping prevent premature part failure, electropolishing reduces downtime and increases the life cycle of these components.
Improving conductivity and performance is just one benefit electropolishing offers for electronics parts. The surface finish is improved by as much as 50%, removing imperfections from the material without material removal.
Contract manufacturers face intense pressure to keep their production processes streamlined, efficient and fast – without sacrificing quality.
In industries like medical device, aerospace, semiconductor, and automotive manufacturing, precision isn’t just a goal – it’s a necessity. A single imperfection, invisible to the naked eye, can result in catastrophic failures.
Carbon steel is widely favored in manufacturing for its affordability, hardness and ability to undergo heat-treatment to increase durability. Used in gears, springs, and other critical metal parts, it’s known for versatility and reliability.
Precision and reliability are non-negotiable standards in the aerospace industry, where every component must meet strict requirements for performance, durability, and safety.
