ACRYLYTE  -025 

 HIGH PERFORMANCE ACRYLIC CATHODIC ELECTROPHORETIC LACQUERING PROCESS

PRODUCT DESCRIPTION 

ACRYLYTE-025 is a stable production proven cathodic electrophoretic lacquering process suitable for use over polished base metal such as Brass, Sliver and over plated deposits of most metals to protect and enhance.

ACRYLYTE-025 is applied as a clear coating at the end of the plating without any drying . Coatings fully cured are capable of high corrsion resistance and are stable without yellowing over long periods of time. Typical applications include jewellary, giftwear. House ware, hardware, consumer  durables and a wide variety of decorative finishes which require protetion in service.

ACRYLYTE  is deposited electrophoretically  by the passage of current similar to plating. Operation is simple and with understanding of process requirements the ACRYLYTE-025 system will run smoothly and trouble free continuously.

MACHINERY AND EQUIPMENT REQUIRED   

ACRYLYTE-025 

PROCESS SEQUENCE

Parts  which have been plated, electro polished or simply cleaned can be processed in an automatic or manual line confirming to the following Sequence. Old plated deposits will require adequate activation and cleaning to provide absolutely clean fully active surface auditable for plating. 

JIGGING UP/RE  JIGGING

PRETREATMENT   : Polishing compound, oils soils must be removed completely. Two stages ultrasonic cleaning is ideal and strongly recommended.

CONDITIONING PRE RINSE  :  Thorough rinsing prior to ACRYLYTE coating is essential to protect the ACRYLYTE bath from metallic contamination by drag in. Only DI  water below 5 micro siemens must be used. A pre -dip using TRANSOLV –014, after the third pre-rinse before the ACRYLYTE  stage is used to condition the work piece. 

RACKS AND JIGS :PVC or plastisol coated jigs usually stoving temperatures of 180 ^o C., however cuts in the coating will carry plating solution thereby enabling metallic ions to enter the ACRYLYTE bath,causing a rinse in conductivity. If there is any doubt regarding jig coat quality it is safe to re-jig using bare SS or Copper jigs after the last plating stage.    

ACRYLYTE – 0 25

POST RINSE : 

The drag out is recovered by suspending the rack above the bath to drain directly into the main solution before proceeding to the first drag out (static) rinse. This helps greatly in controlling consumption of the ACRYLYTE lacquer, since water from the drag out is added back to the main bath as needed. Drag out should be replaced when conductivity exceeds 25 micro siemens. Through post rinsing is required to ensure that all the lacquer solution is completely rinsed off from the coated object. There must be no water break or runs on the surface of the object. Only DI water tested below 5 microsiemens must be used to make up and replenish the drag out baths.

SOLUTION  COMPOSITION FOR A 100 LITRE BATH

TOTAL BATH FINAL VOLUME : 100 LITRES 

OPERATING CONDITIONS :

ACRYLYTE - 025 

OPERATIONAL INFORMATION –PROCESS

FILTERATION : Continuous 10-20 times capacity per hour recommended. Filter must have a bye pass arrangement so that pump can connect directly to agitation coil in tank for mixing.

Another bypass on outlet feeds the inlet of ultra filter with filtered solution for long U/F cartridge life.

ULTERAFILTER  :  Solution enters via bye pass from filter outlet thereby ensuring dust free solution enters U/F. Working of U/F must correspond to plating hours worked

AGITATION :  The return pipe from the filter is mounted lengthwise along the bottom side of the tank and holes are pointed at the opposite wall so that the return flow creates a swirling motion gently agitating the solution before exiting via the over flow back to the filter.

CONSUMPTION OF ACRYLYTE-025

Dragout losses will determine actual consumption. Plating will consume one liter ACRYLYTE-025 CLEAR FOR 10 MICRONS over 25 square meters. This figure is only a guide regular solution tests to determine replenishment needed are best carried out once every 60 working hours. Small periodic replenishment are recommended ,preferably at the end of the working period.

BATH MAKE UP PROCEDURE

CLEANLINESS IS AN ABSOLUTE ESSENTIAL :  Tanks, filters, all parts coming in contact with the solution must be rinsed with deionised water and the last rinse must be with DI water tested to below 5 micro siemens.

The bath is filled to half with deionised water tested to below 5 microns siemens. A low speed mixer is required (60-80 Rpm) and is used continuously during make up.

A pre calculated quantity of ACRYLYTE-025 is added to equal volume of deionsied water contained in a separate clean vessel using the mixer . After the 025 has been well mixed the mixture is slowly added to the plating bath with the mixer on and the filter on  bypass. The agitation created by the mixer and the return of the pumped solution will ensure adequate mixing. After the entire solution has been added to the tank, top with deionised water (below 5 microns siemens) and keep mixing for  24 to 48 hours, with chiller on temp 25 ^o C at all times.

After mixing is completed the ultrafilter is switched on and 10 percent of the bath volume is discharged as permeate, the bath topped up with deionised water, no solvent is required to be added. The circulation for 24-48 hours and running the ultrafilter is called “Conditioning the Solution” and is particularly useful in getting the solution to run well from the first test piece.

The solution is now ready for use. Volts can be set at  50 and tried out. Small adjustment will be needed to obtain acceptable results.

ACRYLYTE- 025

BATH OPERATIONAL INFORMATION

ACRYLYTE PLATING : After a new solution has been prepared and well mixed, plating with proper Pre and Post treatment can commence. Combinations of time, temperature and solid content factor will determine the thickness and shades obtained. A fresh piece will draw maximum current (within the prescribed 4-10 amps/sq.ft.range) at a lower voltage. As plating commences, bare HCD areas are the first to receive the coating in a gel form. Deposition continues into the bare LCD areas until the entire article attains an even unifirm coat of the same thickness, and is fully insulated from the electric filed . No current passed and volts remain constant. At this point (zero amps-constant voltage) it is time to remove the jig from the both . Dragout is recovered by suspending the rack above the bath to drain directly into the main solution, then shaking out the trapped solution from any cup shaped cervices before proceeding to the first drag out rinse.

TEMPERATURE : To get optimum results with best quality consistently it is important that the process operating range 24^o C –26 ^o C. In hot climates, where ambient temretures exceed 25 ^o C an air conditioned room usually helps in long term successful operation of the bath, in addition to the chiller which is required to maintain the solution temreture, as heat is generated during plating due to high voltage used. The solution must remain below 26^oC at all times or solvent losses during idling up set the MEQ and SOLN balance, leading to poor results.

CONDUCTIVITY :  The bath conductivity is an important factor and must remain between 400-800  microsiemens . Increase of solution conductivity is due to drag in metallic ions such as Se²+, Zn²+, Cu²+ during continuous production, which in spite of strict control and management are still dragged into the main bath from the pretreatment procedures. This leads to roughness, pitting, peeling and lifting off the plated film, thin deposits and reduced level of corrosion resistance of the deposit, Ultrafiltaration carried out regularly will maintain solution conductivity and keep the PH at recommended levels. Conductivity must be measured very regularly and recorded, preferably once every 8-12 hours.

ULTRA FILTER : Ultra-filtration is very essential to maintain long solution stability, and consistent plating quality. The working of an Ultra-filtration facility is to retain the high molecular weight and the paint particles on one side if the Ultra-filtration membrane permitting low molecular matter like water and water soluble materials like solvents and the inorganic contaminants to penetrate the membrane and from the Ultra-filtrate or permeate. Contaminants are therefore removed with water. De-Ionised water tested to below 5 microsiemens is added back to the bath to replace permeate loss. For eight hours production working, Ultra-filtration for 8 hours is recommended. As the solution ages or as contaminant levels increase, the Ultra-filtration time might need to be increase proportionately. An increase in solution conductivity rise of contamination level in the bath.

ACRYLYTE- 025

PRECAUTIONS : Metallic parts left in the bath too long can dissolve and enter the disperse phase (resin) . Such dissolved ions cannot be removed by Ultra-filtration. Frequent PH variation is indicative of contamination. Good quality water is essential for good results. Only DI  water tested below 5 Micro siemens conductivity should be used.

SOLUTION MAINTENANCE :

ACRYLYTE-025 REPLENISHMENT

A fresh solution contains solid calculated as below.

TOTAL BATH VOLUME    :                                                                                     100 LITRES

                                                                                                                                                                                                                                                                                                          6900 GMS
ACRYLYTE –0.25 CLEAR: 23 LITRES X 30 % SOLIDS AS SUPPLIED TOTAL SOLIDS= -----                                                                                                                                                             6900 GMS          

                                       6900 X 100  

SOLIDS CONTENT  :        --------------   = 6.9  PERCENT SOLIDS IN BATH

                                       1000 X 100        

RPLENISHMENT : CALCULATION OF ADDITION REQUIRED. 100 LITRES BATH.

A BATH IS FOUND TO HAVE A SOLID CONTENT OF 5.8 PERCENT. THIS IS 58 GMS/LIT. 

TOTAL  SOLIDS REQD IN GMS = BATH VOL X DEFICIENCY [100 X (5800-6900)]

                                                         = 110 GMS/LIT X 100 X 11 = 1100 GMS. 

LITRES REQUIRED :            1100
                                           ------    3.66 LITRES OF ACRYLYTE- 025
                                           300

SOLUTION LEVEL : Due  to  water  loss  from  evaporation and permeate removal, solution  levels  will  fall. Level  must be maintained adding DI Water (< 5 microsiemens) with through mixing.

ACRYLYTE- 025 

SOLVENT LEVEL :  The ACRYLYTE-025 (clear) concentrate contains solvent, and the bath solvent level is usually maintained when ACRYLYTE-025 (clear) is replenished in to the bath. Provide Temp is controlled. Direct replenishment of solvent is usually not needed unless there is prolonged exposure to temperatures is excess of 35 ^o C or prolonged mixing in summer. Under such circumstances addition of around 5 cc/lt of TRANSOLV-014 may be required. Solvent replenishment  would also be required to the main bath after ultra-filtration i.e.@ 20 mls of solvent TRANSOLV-014 for every one litre of permeate remove 

SAFETY & STORAGE 

Wear gloves while handling the concentrates and solvent. Do not inhale solvent vapor and no smoking in plating or storing area. The ACRYLYTE-025 plating solutions are water soluble and will not support combustion. Flash point of the ACRYLYTE-025 (clear) concentrate is above 60 Deg C and in case of fire, use water to extinguish. Solvent levels are usually between 3-4 % in working solution and sufficient ventilation is required in working areas, to extract vapors. If solution comes in contact with eyes or skin, splash with plenty of DM water, wash skin with soap and water. Seek medical advice if irritation persists. 

Eye  appeal is of prime importance for selling highly competitive mass-produced products. All these years the bright reflective Nickel Chrom finish was popular. However, the trend is changing and the consumer is looking for different finishes . Satin-Nickel / Chrome finish is fast catching the market.

To cater to these changing trends, PEARL SILK MATT NICKEL SATIN METALIC PROCESS has been developed to produce non-glaring silky, stain-free, attractive, satin nickel deposits. These deposits have a good Chrome reception to give an Anti-Tarnish top coat to the products. The process is suitable for plating of rack articles only.

The new process is similar to operate and dose not employ expensive equipments. The plating technique and equipment, even though generally the same, differ slightly from the conventional bright Nickel plating system.

Important changes in plating technique and equipment are :

Cathode movement is tade of air agitation. 

No filtration during actual plating since the additive which produces non-glaring effect of the deposit will be removed
partially by filtration.

Decomposed products have to be removed after idling of bath and also after continuos 16 hours of working of the bath by filtration.

The  plating process can not be continued in the same bath for more than 16 hours.

Before starting of plating operation, it is necessary to make up the concentration of additive which is removed filtration.

When immersing the articles in to the Pearl Silk matt  Nickel Satin  Metalic bath, care is to be taken that the current less exponation time may not exceed 10 seconds. High current less exponation time leads to bad adhesion.

Make-up:

Pearl Silk Nickel Salt                                   520-550 g/l

Pearl Silk Additive 045                                20 cc/I

Pearl Silk Additive 046                                5-6 cc/I

Pearl Silk Additive 047                                0.4 – 0.6 cc/I 

Operating Conditions 

                                             Optimum                     Range

PH  Value                               4.2                             4-4.3

Density                                   33 ⁰ Be                       32-35 ⁰ Be

Temperature                              53⁰  C                         50-60 ⁰ C

Cathode current density            6 A/dm²                      4-8 A/dm²

Anode current density              2 A/dm²                       1-3 A/dm²

Agitation                                    --                              Cathode movement

Filtration                                    --                              No filteration during                                        
Working of the bath.            

Maintenance : 

Nickel  Metal                                  106 g/l                          100-110 g/l

Chloride as Nickel Chloride               50   g/l                          40- 60  g/l

Boric acid                                       40   g/l                           35-45  g/l

As high quality salts are very necessary to maintain the bath conditions to obtain the optimum results. Hence, MAHAVIR Nickel sulphate and Nickel chloride concentration, pH value should be adjusted by adding 10% A.R. Sulphuric Acid or chemically pure Nickel carbonate.

Pearl Silk Additives 045 & 046 are primary brighteners and are required to be added at regular intervals. Pearl Silk Additive 47 produces the satin finish and is required to be added at regular intervals and also after complete filtration to make up quantity lost during filtration.

                 Pearl Silk Additive 045                50-100 cc/1000 Amp.hr.

                 Pearl Silk Additive 046               150-250 cc/1000 Amp.hr.

                 Pearl Silk  Additive 047              150-200 cc/1000 Amp.hr.

                                                                 0.2-0.3 cc/lit after complete filtration. 

Excess addition of Additive 047 leads to bad adhesive of the deposit to basis metal. 

IT IS IMPORTANT NOT TO ADD ANY OTHER ADDITIVES, BRIGHTENERS AND SETTING AGENTS in this bath since it is very sensitive to some organic compounds and it will be extremely difficult to rectify the bath which contains such undesirable elements. 

In-organic and organic impurities can be removed by dummy, high pH and activated carbon treatment same as in the case of normal  bright Nickel baths.

SSNE  L-300

SUPER SPEED, NON-ETCHING HARD

CHROME PLATING PROCESS 

SSNE L-300 is new generation Hard Chrome plating process which is far superior to both conventional and mixed catalyst bath. The make up and maintenance chemical are well balanced and are in liquid form for easy maintenance.

SSNE L-300 has several distinct advantages over the earlier Hard Chrome plating process and are enumerated below.

Higher Cathode efficiency 23-26 % resulting in saving of expensive electrical power by 30-40%

Increased Wear Resistance by 20-25% results in longer life of the plated compounds.

Produces micro-cracked deposits(600-1000 cracks per linear cm ) resulting in better corrosion resistance .

Bath operates satisfactory within a wide range of operating parameters without affecting the deposit characteristics.

Wide cathode C D operation 30-60 A/dm²

Bath Make-up                            Optimum                          Range 

SSNE L –300 Make-up                 500 ml/l                               460-550 ml/l 

OPERATING CONDITIONS

Density                                       21^o Be                                 20-23⁰ Be

Temperature                               55⁰ C                                    52-60⁰  C

Cathode Current Density              50 A/dm²                              30-60 A/dm²

Anode Current Density               17.5 A/dm²                            15-22 A/dm ²

Voltage                                      6                                          4-12 volts         

It is advisable that for getting hard chromium deposits,  the current density and temperature both are  maintained  at optimum levels   although SSNE L –300 process gives consistent quality results with wide operating conditions. 

The base metal surface has to be smooth and unifirm and surface imperfections are to be improved by mechanical polishing and burnishing operations. The components to be hard chromium plated should be pre-cleaned in suitable hot alkaline soak cleaner and rinsed well. To ensure good adhesion of hard Chromium deposit on mild steel component anodic etching in conventional Chromic/Sulphuric acid bath at 50^o to 65⁰C for 30 sec-120 seconds, should be carried out in a separate tank. The parts should be transferred into  the plating  bath  without rinsing . After plating, the parts are dipped in dragout neutralise followed by water rinse and hot water rinse.

SOLUTION PREPARATION:

The SSNE L -300 chrome solution preparation is very simple and is as under : 

1. Fill the cleaned plating tank with D.M. water to almost one-third of the operating levels.

2. Add the calculated quantity of SSNE L-300 chrome make-up solution with stirring .
   the solution should be added in small quantities and continue stirring. 

Add D.M. water up to the working level and stir for another 2-3 hours.

When the solution becomes homogenous, heat the solution to 55⁰ C. Place the anodes

And electrolyse the bath for 3-4 hours at operating temperature of 55^o and at A,C,D of 35-45 amps/dm² .

EQUIPMENT :

Chlorinated flexible PVC lined mild steel tanks suitable Lead lined tanks are not suitable and if the tanks are lead lined, they should further be lined with flexible grade PVC.

The plating tanks should be equipped with a suitable heating device and thermostat control to maintain the temperature within the specified range. Suitable exhaust system with scrubber facilities should be provided to keep the environment clean. Cooling is required to control the temperature of the solution since heat is evolved due to higher voltage and operating current. For direct heating and cooling titanium coils are normally used. Teflon of PVDF coils sre also suitable for heating and cooling.

ANODES :

The Anodes should be 7-10 % tin/93-90% leadalloy. Round anodes are normally preferred as compared to flat type. However, the life expectancy of tin/lead alloy anodes is comparatively less than in conventional Chrome plating solution. When the bath is not in use, anodes must be removed .Lead-Tin-Silver (93:6:1) anodes have longer life than Lead-tin-anodes.