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FEATURE MATERIALS IN DESIGN & PROTOTYPING
Despite being the go-to option for many industries, challenges still exist with standard tank plating – including the need to
break down parts and ship them out for repair. To overcome this, SIFCO ASC provides the SIFCO Process, a selective brush plating
application method of applying metal deposits to localised areas without using an immersion tank. Southwest territory sales manager, Tony Arana, looks into the benefits of switching to selective plating
Selective plating: a benefit for oeM coMponents and parts requiring refurbishMent
W
ithin manufacturing, downtime is a costly issue. During high-speed canning operations, for example, a bearing
spins on the shaft of the press, creating areas with excessive wear and pitting that, in time, require repair. Wear areas, or areas scored by grit and foreign materials, can cause the press to leak hydraulic fluid or not form the mould properly – potentially triggering a catastrophic event. Removing, breaking down and shipping these parts is both time-consuming and means increased operating costs. Traditional repair methods call for
disassembling the press and removing the crankshaft or press tool before assessing whether to replace the component or weld the damaged areas. However, with selective brush plating, metal deposits can be applied to localised areas in-situ, enabling stationary parts that are either difficult to move or disassemble to be efficiently plated. With repair work completed entirely on-site, the need to ship out parts is avoided, resulting in less downtime and reduced operating costs. As an example, a shaft of 3.53in in diameter
had a 2.5in area of wear. SIFCO ASC determined it needed 0.012in of Nickel to plate it back to size, with minimal disassembly of the press and no need to remove the shaft or post machining. This repair was completed in-situ in under five hours.
fast turnaround
With the manufacturing sector continually looking for ways to extend the operational lifespan of equipment, selective plating provides fast and efficient turnaround times. Industries like aerospace, marine and energy are already benefit from the SIFCO Process, which is significantly improving wear resistance on critical components and prolonging the life of their equipment. The company has the ability to evaluate what
components need to be repaired and devise a plan that allows this work to be completed both in-situ and around shutdowns. And, once the repair work is done, the machinery can
4 DESIGN SOLUTIONS MARCH 2023 2
immediately be used again, saving reassembly downtime. Another benefit of brush plating is
that it counts on minimal masking, which is a process that involves protecting areas on the components where plating should be avoided with special tapes and paints. Brush plating is designed to treat those specific areas of a component with a high level of accuracy, enabling in-situ repair and enhancement that is typically faster than alternative surface coating methods. Machine components need to be
properly maintained across all industries, including canning, given that the machines are subjected to wear and tear as a result of the exposure to harsh elements, corrosion and damage. If these components are not properly maintained, then there is a risk they will need to be scrapped which can prove very costly.
thinking about sustainability
In addition to the overheads faced, the scrapping of parts and components raises sustainability questions. Worn-out, corroded or damaged parts contribute to the million metric tons of ferrous metal, and millions more tons of non-ferrous metals and stainless steel, in the U.S. scrap rate. This can be significantly reduced if site
managers and manufacturers can find a way to head off component failure and remove the need for scrapping equipment. This is where remanufacturing comes into play, returning OEM parts back to original specification – or better – for a longer, more reliable, lifespan. With tank plating, the parts need to be
submerged throughout the process. Depending on the size of the part to be plated, some tanks can hold thousands of gallons of chemical solutions. A standard brush plating repair can, however, use less than two litres of solution. Finally, due to the large volume of toxic
material involved in tank plating, expensive and complex effluent systems are required in
order to treat the liquid prior to it entering the public waste water system. With brush plating, since the amount of solution is very small, the damage to the environment is significantly reduced, therefore providing a healthier working environment.
the process
SIFCO ASC has provided practical, cost-effective, brush plating solutions for both OEM components and parts requiring refurbishment in the aerospace, oil and gas, general industry and power generation sectors for over 50 years. At the heart of everything there lies the SIFCO Process – selectively electroplating localised areas without the use of an immersion tank. In addition to improving component
performance, minimising downtime and reducing manufacturing costs, the SIFCO Process also provides access to SIFCO ASC’s technical expertise from the initial concept and design phase right through to production and beyond. So, to conclude, selective brush plating
provides a proven, efficient and cost-effective alternative to standard tank plating.
SIFCO ASC
www.sifcoasc.com/canning
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