Perfect electrolyte mixtures for dry electropolishing

Our surface refinement experts precisely adapt the electrolyte granules to your equipment and your process. In this respect we focus on three essential factors: Material, required finish and work piece geometry.

Generally, the following metals and metal alloys are suitable for dry electropolishing: Aluminum, cobalt-chrome, copper alloys, nickel alloys, titanium alloys, steel and carbide metals. Key factors for matching a suitable electrolyte medium to the respective metal are the metal composition, its density and hardness. In our main Customer Experience Center we stock a wide variety of media. This allows our dry electropolishing experts to perfectly match the medium to the metal, respectively, metal alloy that you are using in your production. In the next step we define, jointly with you, the desired finishing quality and adapt the process parameters to these required results. Along the way we ensure that the results are consistent and repeatable, the process runs efficiently with short cycle times and, above all, is gentle to the work pieces. Of course, the special design of our machines guarantees that these results are consistently achieved. They allow stable and precise surface finishes, irrespective of the size and shape of the work pieces. The overall process safety and stability is ensured by our versatile submersion and projection systems and the optimal flow of media and electrical current over the work piece surface. All these features guarantee perfect results!

Overview over the available electrolyte materials

The DLyte systems can be operated with dry and gel-type electrolytes. Dry, macro-porous electrolytes are generally more effective and can quickly smoothen rough surfaces. But they are more aggressive and can easily create burn marks on the work pieces. Gel-type electrolytes work more gently, because they are augmented with an oil suspension containing tiny particles. The oil suspension protects the work piece surface during the finishing process.

Size and shape of the electrolytes

Depending on the work pieces and the required surface finish, the users can choose from a range of different sizes and shapes of electrolyte granules. Dry electropolishing processes are particularly effective when they are run with multiple electrolyte particles in different sizes and shapes. Such a particle mix guarantees that the media reaches surface areas that are difficult to access. This results in a highly homogeneous and thorough finishing process.

Gel-type electrolytes vs. dry electrolytes

The electrolytes have not only different shapes and sizes, but they are also available in different physical conditions, for example, with different degrees of elasticity. Dry electrolytes generally work faster. But because of their poor flow characteristics they tend to leave burn marks on the work piece surface. Because of the cushioning effect of the added silicone oil, the processing times with gel-type electrolytes are marginally longer. However, their better flow characteristics are gentler on the work piece surface and, overall, they produce higher-quality surface finishes. For processing of hard metal components mainly gel-type electrolytes are utilized.

Chemical composition

In order to achieve high-value finishing results, minimize the metal removal rate and maximize productivity, the adaptation of the acid concentration to individual electropolishing tasks is indispensable. Because the composition of electrolyte materials can be easily adapted to specific finishing tasks and industry standards,  the DryLyte technology offers  efficient and versatile solutions to a broad range of surface finishing applications.

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