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Heef 25 Hard Chrome Plating process

 HEEF 25 is a fluoride-free hard chromium process that offers high current efficiency. It can be adapted for various applications, including normal hard chromium plating, duplex hard chromium plating, and chromium plating of rotogravure cylinders. The process provides advantages such as excellent deposition efficiency, reduced rectifier electricity costs, and good deposit metal distribution. HEEF 25 is known for its bright, hard deposit with high resistance to abrasion. The process also results in a microcracked deposit that enhances corrosion resistance. Regular maintenance and adjustments are necessary to ensure optimal sulfuric acid content and chromic acid concentration in the bath.

To make up the HEEF® 25 - Liquid hard chromium plating bath, follow these steps:

1. Clean the tank thoroughly.
2. Fill the tank to 35% or 40% full with deionized water and heat it to the desired temperature of 55-65 °C.
3. Add the required amount of Chromic Acid Solution (500) while stirring thoroughly.
4. Add the required amount of HEEF® 25 M while stirring thoroughly.
5. Fill the tank to its operating level with deionized water.
6. Analyze the bath for sulfate concentration.
7. Carefully add sulfuric acid to achieve the desired concentration (3.5, 3.22, or 3.68 g/l) while stirring.
8. Place dummy cathodes into the tank and then add the anodes with current for about 4-6 hours at 40 A/dm² (not necessary for hard chromium plating of rotogravure cylinders).
9. Use a mist suppressant from the non-PFOS Fumetrol®  range to reduce spray mist and drag-out losses.
10. Conversions of conventional hard chromium bath to HEEF® 25 - Liquid should be done only after analysis AT ESS ESS TRADING LAB, Coimbatore. ( Contact 9843019701) Email: info@essesstrading.in)
11. Always observe all regulations regarding operations with chromic acid carefully.

Remember, the bath maintenance requires adding Chromic Acid Solution (500), HEEF® 25 A, sulfuric acid, and mist suppressants. Barium carbonate is used for sulfate precipitation in case of excess sulfate.

To make up 100 liters of the Hard Chromium Plating solution using the HEEF® 25 - Liquid process, the following components are required based on the information provided:

A. Conventional Hard Chromium Plating:

• Water fully demineralized: approximately 45 liters
• Chromic Acid Solution (500): 50 liters
• HEEF® 25 M: 5 liters
• Sulfuric acid, chemically pure: 0.19 kg or 190 ml

B. 2nd Step for Duplex Hard Chromium Plating:

• Water fully demineralized: approximately 37 liters
• Chromic Acid Solution (500): 58 liters
• HEEF® 25 M: 5 liters
• Sulfuric acid, chemically pure: 0.2 kg or 200 ml

C. Hard Chromium Plating of Rotogravure Cylinder:

• Water fully demineralized: approximately 37 liters
• Chromic Acid Solution (500): 58 liters
• HEEF® 25 M: 5 liters
• Sulfuric acid, chemically pure: 0.175 kg or 175 ml

These are the quantities needed to make up 100 liters of each type of hard chromium plating solution as per the provided information .

The working parameters for the HEEF® 25 - Liquid hard chromium process are as follows:

• Temperature:
  • Conventional and Duplex: 57 °C (55 - 65 °C)
  • Rotogravure cylinder: 60 °C (55 - 65 °C)
• pH: < 1, does not need to be monitored.
• Densities:
  • Conventional: approx. 1.18 g/cm³ (22 °Bé) at 20 °C
  • Duplex and Rotogravure cylinder: approx. 1.2 g/cm³ (24 °Bé) at 20 °C
• Current densities:
  • Cathodic: 50 A/dm² (30 - 70 A/dm²)
  • Anodic: 25 A/dm² (15 - 35 A/dm²) (about 50% of cathodic)
  • For Rotogravure cylinder, the cathodic and anodic current density depend on the plant in use.
• Current efficiency:
  • Approx. 25.0% at 50 A/dm²
  • Approx. 26.8% at 70 A/dm²
  • Approx. 27.7% at 90 A/dm²
• Rate of deposition:
• Approx. 1 μm/min at 55 A/dm²
• Rate of deposition may be lower when using rotogravure cylinders, depending on the depth of immersion.

  For the maintenance of the HEEF® 25 - Liquid hard chromium process, the following products and chemicals are necessary:

  1. Chromic Acid Solution (500) - Used to maintain the chromic acid concentration in the plating bath.
  2. HEEF® 25 A - A liquid additive containing special HEEF® 25 - Liquid additives, without chromic acid or sulfuric acid, added to maintain the normal amount of additives in the bath.
  3. Sulfuric acid, chemically pure - Used for additions to achieve the required sulfate content.
  4. Barium carbonate - Used for maintenance to precipitate sulfate in case of excess.
  5. Fumetrol® 21 range of mist-suppressants - Can be used for make-up and maintenance to reduce the bath's surface tension and meet local regulations regarding Chromium-VI compounds in the air .

  The Chromic Acid Solution (500) addition rate is typically 80 to 110 ml of HEEF® 25 A per 1000 ml of Chromic Acid Solution (500) depending on the plating operation and parameters used.

  The nominal values for Conventional Hard Chromium Plating (Make-Up A) are as follows:

  • Chromic acid (CrO3): approx. 260 g/l during make-up, 235 – 270 g/l during operation.
  • Chromium-III (Cr3+): < 8 g/l.
  • Sulfuric acid, Chemically Pure (1.84 g/cm³): 3.5 g/l (1.9 ml/l) during make-up, 3.2 – 4.5 g/l (1.74 – 2.45 ml/l) during operation.
  • Chloride (contamination): < 50 mg/l.
  • Total Foreign metals (Cu, Fe, etc.): < 18 g/l
  • The current density for the conventional and duplex hard chromium processes ranges from 30 to 70 A/dm² for cathodic and 15 to 35 A/dm² for anodic. Specifically, the cathodic current density is recommended at 50 A/dm², whereas the anodic current density should be around 50% of the cathodic current density, which would be 25 A/dm². For the rotogravure cylinder process, the cathodic and anodic current densities are dependent on the specific plant in use.

The deposition rate and current efficiency for the HEEF® 25 - Liquid plating process are as follows:

• Deposition Rate:

  • At 40 A/dm²: 43.3 μm/hour
  • At 50 A/dm²: 57.7 μm/hour
  • At 60 A/dm²: 72.2 μm/hour
  • At 70 A/dm²: 86.5 μm/hour
  • At 80 A/dm²: 100.7 μm/hour
  • At 90 A/dm²: 115.0 μm/hour
  • At 100 A/dm²: 129.9 μm/hour (Page 11)

• Current Efficiency:

  • At 40 A/dm²: 23.5%
  • At 50 A/dm²: 25.0%
  • At 60 A/dm²: 26.0%
  • At 70 A/dm²: 26.8%
  • At 80 A/dm²: 27.3%
  • At 90 A/dm²: 27.7%
  • At 100 A/dm²: 28.1% 

Additionally, it is mentioned that the bath temperature should be adjusted respective to the current density, for example, 55°C for 40 A/dm² to 65°C for 100 A/dm² 

To buy this product please contact us 

at 9843019701 or Email info@essesstrading.in 

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ESS ESS Trading Authorised distributor MKS/Atotech

Innovations in Sustainable Decorative Plating: Insights from the Surface Coating Expo 2025

The Surface Coating Expo 2025 highlighted advancements in sustainable decorative plating, focusing on chrome-free and PAS-free processes. Key topics included health risks associated with traditional chrome plating, regulatory updates, and innovative techniques for plating on plastics. The conference emphasized the importance of environmentally friendly alternatives and showcased successful implementations in the industry.

The Surface Coating Expo 2025 brought together industry leaders to discuss the future of decorative plating, particularly focusing on sustainable practices. This blog post summarizes the key points discussed during the conference, including regulatory updates, health risks associated with traditional plating methods, and innovative chrome-free and PAS-free processes.

The conference commenced with a warm welcome to all attendees, setting the stage for an in-depth discussion on sustainable products related to decorative plating and plating on plastics. The agenda included updates on regulations, insights into decorative plating techniques, and a summary of the industry's outlook.

Health Risks of Traditional Chrome Plating

One of the primary concerns addressed was the health risks associated with traditional chrome plating. Exposure to hexavalent chromium, commonly used in plating processes, poses significant health hazards, including:

1.Lung cancer

2.Damage to the nose and throat

3.Respiratory system issues

Due to these risks, the European Union has set a sunset date for the use of chromic acid, with expectations for a complete phase-out by 2028. This regulatory shift is crucial for protecting workers and the environment.

The Challenge of Forever Chemicals

Another critical topic was the discussion of polyfluoroalkyl substances (PFAS), often referred to as "forever chemicals." These man-made chemicals do not naturally degrade and accumulate in the environment, leading to serious health concerns, including liver disease. The United States has already discontinued products containing PFAS, and other countries are following suit. As a responsible partner in the industry, the speaker's company has also removed PFAS-containing products from their portfolio.

Innovations in Plating on Plastics

Chrome-Free Processes

The conference highlighted advancements in plating on plastics, which traditionally present challenges due to their non-conductive nature. The new chrome-free process involves:

1.Surface Conductivity: The first step is to make the plastic surface conductive without using chrome.

2.Multi-Layer Plating: Following this, a multi-layer plating process is applied, typically involving copper, nickel, and chrome for aesthetic appeal and performance.

This innovative approach not only eliminates the use of harmful chrome but also reduces energy consumption, as the new process operates at a lower temperature (35°C) compared to traditional methods (65-75°C).

Adhesion Testing

Adhesion is critical in plating processes, especially for plastics. The new chrome-free process achieves a peel strength of 15 to 20 Newtons per cm, meeting industry standards. Two primary methods for testing adhesion were discussed:

1.Thermal Cycle Testing: This stringent test, based on VW standards, showed no blistering or delamination in the samples tested.

2.PE Strength Testing: This method further validated the effectiveness of the new process.

The speaker shared that over 300,000 parts have been successfully plated using this new method, with positive results across various materials, including PP and PA.

Trichrome Plating: A Sustainable Alternative

The conference also introduced trichrome plating as a viable alternative to hexavalent chrome plating. Trichrome offers a variety of finishes, including:

1.Bright finishes (Trichrome Plus, Trichrome Ice)

2.Dark finishes (Trichrome Smoke, Trichrome Shadow, Trichrome Titan, Phantom Graphite)

These finishes are part of a multi-layer nickel system that meets all industry requirements for corrosion performance and adhesion. The trichrome process is already in production and has received approval from multiple OEMs.

Enhancing NSS Life

To further improve the durability of trichrome finishes, the company has developed two post-treatment processes:

1.Triseal 300: Designed for bright finishes to enhance neutral salt spray (NSS) life.

2.Triseal 500: Applicable for both bright and dark finishes, also enhancing NSS life.

Conclusion and Future Outlook

The Surface Coating Expo 2025 underscored the industry's shift towards sustainable practices in decorative plating. With the impending phase-out of hexavalent chrome and the introduction of chrome-free and PAS-free processes, the future looks promising for environmentally friendly alternatives. The speaker encouraged attendees to adopt these innovative processes to contribute to a healthier environment.

As the industry evolves, it is essential to stay informed and adapt to these changes.

In summary, the conference highlighted the importance of sustainability in decorative plating, showcasing advancements that not only meet industry standards but also prioritize health and environmental safety.

Authorized distributor for MKS Atotech India Ltd

Revolutionizing the Plating Industry: The Eden System at Surface Coating Expo 2025

The Eden system (Electro Dialysis for Electroless Nickel), presented at the Surface Coating Expo 2025, addresses significant challenges in the plating industry, including waste generation and productivity loss. This innovative electrodialysis technology enhances bath life, reduces costs, and maintains high-quality plating, making it a game-changer for industries like automotive and hydrogen applications.

At the recent Surface Coating Expo 2025, a significant focus was placed on the challenges faced by the plating industry. The presentation highlighted the innovative Eden system, which stands for Electrodialysis for Electrolytic processes. This technology aims to tackle the pressing issues of waste generation and productivity loss associated with traditional electrolytic plating methods.

Challenges in the Plating Industry

The plating industry has long struggled with several challenges:

1.Waste Generation: Regular dumping of plating baths leads to substantial waste, which is both environmentally and economically detrimental.

2.Downtime: The need to frequently replace baths results in significant downtime, adversely affecting productivity.

3.Quality Degradation: As baths age, the quality of the plating diminishes, leading to lower corrosion resistance and increased internal stress in the plated materials.

Overview of the Eden System

The Eden system offers a solution to these challenges by utilizing electrodialysis technology. This system is designed to:

1.Maintain consistent nickel concentration in the plating bath.

2.Reduce waste generation significantly.

3.Extend the life of the plating bath, potentially allowing for continuous operation if managed correctly.

Key Components of the Eden System

The Eden system can be likened to a human body:

1.Bath Module: Acts as the brain, controlling the overall process.

2.Working Module: Functions as the heart, driving the plating process.

3.Membrane Module: Serves as the kidney, filtering out by products and maintaining bath quality.

Benefits of the Eden System

Enhanced Productivity

The Eden system allows for:

1.Higher plating rates and loading ratios, which are crucial for automated production lines.

2.Consistent quality throughout the bath life, ensuring high corrosion resistance and minimal internal stress.

Cost Savings

The Eden system presents significant cost benefits:

1.Waste Volume Reduction: 35% less waste generated compared to traditional systems.

2.Hypophosphite Reduction: 75% less hypophosphite produced, which is a common by product.

3.Nickel Savings: Up to 65% less nickel waste, preserving this valuable resource.

4.Overall Cost Reduction: A total savings of approximately 20% in the cost of ownership.

Comparison with Traditional Systems

When comparing the Eden system to traditional and feed-and-bleed systems:

1.The feed-and-bleed system incurs 21% higher costs than traditional systems.

2.The Eden system can save up to 74% in operational costs compared to traditional methods.

Proven Technology in the Industry

The Eden system has been in industrial use for over a decade, demonstrating its reliability and effectiveness. It has been particularly well-received in the automotive industry, with 22 units currently operational—18 in Europe and 4 in Japan. Notably, 11 of these systems are utilized within the automotive sector, while one is dedicated to hydrogen applications, reflecting the growing demand for efficient plating solutions in high-volume production environments.

Conclusion

The Eden system represents a significant advancement in the plating industry, addressing long-standing challenges related to waste, productivity, and quality. Its proven technology and cost-saving benefits make it an essential tool for industries aiming to enhance their plating processes. As the demand for high-quality plating continues to grow, the Eden system is poised to play a crucial role in shaping the future of the industry. The anticipation for its adoption in regions like India further underscores its potential impact.

Authorized distributor for MKS Atotech India Ltd