Each step is essential to ensuring a quality result during the metal component manufacturing process. From an initial design idea to the maintenance and upkeep of materials and everything in between, high-quality care and a well-thought-out strategy is key to a successful project. Surface treatment is one of the most vital stages of the manufacturing process as it provides the metal components with additional properties, such as durability.
That is why, in today’s blog, we’re providing you with everything you need to know about surface treatment and its importance. We will explore what surface treatment is, the various methods and processes, and the benefits of the different techniques.
Additionally, as expert spring manufacturers with over 70 years of experience in the springs and pressings manufacturing industry, we will offer advice on how our surface treatment services can benefit you and your project here at European Springs.
Surface treatment is when metal components are prepared for their individual usage. How a metal component is treated before use differs from how it operates – this is because the metal is primed during the surface treatment process to provide it with additional properties.
There are several surface treatment techniques that offer a range of additional properties depending on the desired use of the metal component in question. Here at European Springs, we are proud to provide a list of these treatments so you can get the desired usage out of your metal elements.
For example, we offer:
As mentioned, each method allows for different results, for example, rust prevention, heat protection, or increasing the strength and durability of the component.
Surface treatment is an essential part of metal component manufacturing as it protects the pieces from many factors, including rust, heat, weathering, and pressure. These additional features contribute to the longevity of the component, meaning that with the proper surface treatments, you are less likely to need to replace your parts. Similarly, this also means that the maintenance and upkeep of your components will reduce with the correct surface treatment.
Additionally, this process improves the functionality of the metal and is often used for aesthetic purposes. For example, metal can be treated in preparation for painting and coatings depending on the desired look of the components.
Here at European Springs, we offer a range of surface treatments for a variety of different metal components: Plating, Heat treatment, Barrelling, and De-Burring. Let’s look at what each of those entails and how you can use each method differently to add a range of additional features to your metal.
Metal Plating is a process that involves coating a metal component with a thin layer of metal. There are various reasons why someone would choose plating as their surface treatment, as it provides many benefits. For example, plating increases a metal component’s heat resistance, particularly if you prefer silver to coat the metal. As you’re adding another layer of metal to your part, plating also increases the durability and endurance of the end product. Metal plating is also chosen for its aesthetic benefits, as you can completely change the colour and texture of your component with this technique.
There are various types of heat treatment, all resulting in a different end product. As an overview, it is the process of heating and cooling metal to achieve the desired result. First, the metal is heated, kept at a specific temperature, and then cooled down – with different results occurring depending on the length of time the metal is heated and then cooled down. For example, heat treatment can strengthen, soften, relieve stress, or change grain structure. The most common heat treatments include:
Barrelling is often used for a large number of small metal components. This process removes the previous processing residues from the part. It effectively eliminates impurities and imperfections on the pieces, preparing them for further treatments and applications. Barrelling is also used for aesthetic reasons if it is the final step in the surface treatment process.
De-burring is similar to barrelling, as it involves removing imperfections and perfecting metal components. However, this process is more specific to eliminating sharp edges and smoothing out the pieces. In addition, this process is often done after other surface treatments, which may have left sharp edges or burrs.
We hope this blog has been helpful, and you now know a little more about the importance of surface treatment for metal components. We’re experts in our field and are more than equipped to help you with your surface treatment requirements.
Metal finishing is the process of treating metal surfaces with a thin material or polishing process to alter their exterior. There are many types of metal finishes that produce different effects. Some improve the appearance, durability and conductivity of a metal product or component, while others impart corrosion, chemical and abrasion resistance.
Each type of metal finish offers unique benefits and is suited to different types of metals and applications. They also have varying time, labor and money requirements, which makes it essential for you as a manufacturer to understand how to choose the best one for your specific project and substrate. Below, we get into seven common types of metal finishes and their appropriate applications.
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Electroplating is the process of coating a metal substrate with another metal or metal alloy, such as copper, zinc, silver or nickel. Also called electrodeposition, electroplating involves placing a metal part or component in a tank filled with a positively charged electrolyte. An electric current then splits the electrolyte to deposit the ions on the substrate. This process forms a thin metallic layer on the surface of the metal workpiece.
Manufacturers can use a combination of metals to form multiple layers on a product and maximize conductivity and strength. Electroplating enhances a metal’s resistance to wear and tear, corrosion, friction and abrasion. It’s often used when finishing automotive parts, coins, jewelry, tin cans, sink taps, pots and pans.
Powder coating is a modern style of finishing metal using a dry powder that includes pigments, leveling agents, flow modifiers and other additives. The process involves spraying the dry powder onto a charged substrate that attracts the particles to form a coating. It’s then cured using UV rays or heat to ensure the coat covers the metal part evenly, forming a matte, glossy or textured finish. A textured powder coat hides defects on a metal surface.
Powder coating is more durable and aesthetically pleasing than paint. It’s also more sustainable and environmentally friendly because the unadhered powder can be gathered and reused. Additionally, it does not require solvents that contribute to air pollution. Powder coating can withstand harsh environmental conditions because it’s resistant to alkaline substances, fading and chipping.
A powder-coated finish is suitable for various automotive, agricultural and electrical applications. These include coating metal parts for:
Also known as chemical or autocatalytic plating, electroless plating is a metal finishing technique that involves coating metal substrates with metal ions via a chemical process rather than using electricity. This method involves dipping a metal component into a reducing chemical bath that’s catalyzed to deposit metals like copper, nickel, silver and gold to the part’s surface.
It requires no electric current to produce a coating of varying thickness and volume. Electroless plating can achieve matte, glossy or semi-glossy finishes that are hard, nonporous and resistant to corrosion. Some coatings can also reduce friction, which makes them ideal for components such as food and injection molds, brake pistons, pipe fittings, dies and pump housings. Electroless plating has multiple uses in the automotive, aerospace, oil and gas industries.
Commonly called e-coating, electrocoating is a metal finishing process that follows the same principles as electroplating. It involves immersing a metal substrate in an epoxy or water-based paint solution and using an electric current to deposit the suspended particles on the material’s surface. Technicians determine the thickness of the coating, and when satisfied, they rinse the substrate and cure it in an oven.
Electrocoating is best used for workpieces with many hard-to-reach interior surfaces requiring ultra-thin finishes. Generally, an e-coat is used as a primer for parts requiring high corrosion resistance, after which the manufacturer applies a more protective and UV-resistant finish, such as powder coating. The appliance and automotive industries are the most prevalent users of e-coating.
The galvanizing process involves submerging metals in molten zinc to form a thick protective layer. It relies on the chemical reactions between zinc, carbon dioxide and oxygen at high temperatures to form a durable silver zinc carbonate film. Galvanizing is an effective process for coating every edge of a material, especially after manufacturing. However, it limits your aesthetic options because it’s only available in one color.
Galvanizing metal yields a durable, high-quality protective layer that resists corrosion and rust. This characteristic makes it ideal for manufacturing long-lasting equipment for use in residential and commercial properties, agriculture, oil and gas, and consumer goods. In sports, it’s a preferred coating process for metal used to make gym equipment.
The anodizing process is an electrochemical procedure that involves oxidizing the outer layer of a metal workpiece by soaking it in chromic acid electrolyte and passing an electric current through it. The result is an attractive, durable and corrosion-resistant finish that increases the metal’s resistance to everyday wear and tear.
This process is often used to finish aluminum, magnesium, titanium and zinc parts used for mechanical and automotive applications. Anodized metal parts serve as many interior and exterior building fixtures, such as handrails and ladders.
Abrasive blasting is a metal finishing process that uses high-pressure air to blow a stream of abrasive material against the surface of a metal substrate. The abrasive materials used during this process may include corn cobs, steel shot, aluminum oxide, sand, plastic grit, silicon carbide, carbon grit or glass beads. These materials will strip away debris, rust and even old finishes, leaving a smooth surface behind. The abrasive media used during blasting will affect the resulting finish — aluminum oxide leaves a matte surface, while glass beads give the workpiece more of a satin look.
Blasting is a low-cost method of cleaning and preparing a surface prior to a plating or coating application. It produces a smooth surface that allows the manufacturer to move seamlessly to the next step of the process. This finishing technique is often used for automotive repair and restoration, warehouse cleaning and bridge maintenance.
PBZ Manufacturing is a metal manufacturer providing a variety of finishing services for many different metal parts and products. As an all-in-one solutions provider, we offer pre-treatment solutions ranging from blast-cleaning and surface preparation to primer and masking application before the finishing. We also perform quality testing, and we’re your go-to provider for assembling and custom-packing finished metal parts and components.
If you’re in the market for metal finishing for your components, request a quote online today. We’ll get back to you within 4 business hours. You can also call us at 717-584- to speak to one of our knowledgeable customer service representatives about your project.
If you want to learn more, please visit our website custom metal surface treatment.