Meanwhile, the negatively charged Cl- ions are attracted to the positively charged anode. At the anode, electrons are removed from the Nickel metal, oxidizing it to the Ni++ state. Thus the nickel metal dissolves as Ni++ into the solution.
Research piece 2, secondary information
Electroplating
Electroplating is the electrochemical process of depositing a metallic coating on the base material of an object when it is immersed in a plating solution in such a manner that a suitable low voltage electric current flows through it, causing the metallic coating to be attracted to the object to be plated. HMQ offers a wide-variety of electroplated finishes, including:
Chrome plating, Copper plating, Nickel plating, Sliver plating, Zinc plating brass plating, cadmium plating, chromium plating, hard chromium plating, gold plating, tin plating and zinc plating.
Research piece 3, secondary information
Section 2, Research and recording of information
WHAT IS METAL FINISHING?
Metal finishing is the process of changing the surface of an object; for the purpose of improving it's appearance and/or durability.
ELECTROPLATING
Electroplating is an electrochemical process used to deposit a metallic coating on the base material of an object by immersing it in an electrically charged solution so that a suitable low voltage electric current flows through it, causing the metallic coating to be attracted to the object being plated.
This is the edited material that will not be necessary for my relevant information, which I will analyse in section three.
ORGANIC COATING
Organic coating involves the process of depositing a pigmented coating on the surface of an object by dipping, flow coating, conventional spraying, electrostatic spraying and powder coating. Powder coating is the only technique that involves application of a powder; the remainders use a liquid paint. Application techniques include dip coating, conventional spraying, electrostatic spraying and powder coating.
POWDER COATING
One of the newest and most environmentally sound applications in the industry. Applied electrostatically or by fluidised bed, these plastic coatings come in an almost unlimited range of colours. As there are no volatile thinners used, the entire over sprayed materials are recovered and reused. The coatings are applied dry, melted, flowed and fused, making a pinhole free finish for beauty, long wear and superb corrosion resistance.
ELECTROLESS PLATING
Electroless plating is the chemical deposition of a metal coating on a substrate by immersion in an appropriate plating solution. Electricity is not involved in this process, therefore heavy and uniform deposits can be easily obtained which posses unique mechanical, chemical or magnetic processes. The process can be applied to properly treat non-metallic objects such as plastic and glass.
Section 2, Research and recording of information
Section 2.1
In this part of section two I have written my structured questions, which I asked the employees and have gained answers from them.
I derived a list of question that I had asked the employees at the electroplating company so that I can gain the relevant information for the process of electroplating
Questions I asked the employees at the electroplating company
- What is the process of electroplating?
- How does it work?
- What types of chemicals, materials and solution are used in the coating of certain types of metals/ products?
- What types of products are made from the electroplated metal?
- How much raw materials are used when electroplating and how are they used?
- What types of environmental issues arise from the chemicals used and where are they then deposited after use?
The answers I had received
Question 1- The process of electroplating is similar to that of electrolysis. The electroplating process involves raw components being coated with a layer of metal so that it can give it a protective and decorative finish depending on what raw material is being used. For example electroplating a steel component with chrome to give it a decorative finish rather than protective finish.
Research piece 4, Primary information. Photo of the product after electroplated
Section 2, Research and recording of information
Research piece 5, primary information. Photo of electroplated product
Question 2- The way electroplating works is when direct current passed through the anode and cathode. The direct current is converted from alternating current by using a rectifier.
The cathode has the raw component that is being electroplated. It first needs to be cleaned to remove grease on the raw component; an agent called acoustic base aqua solution is used to remove it. Then any rust and scale on the raw component is removed by putting it into hydrochloric acid. Then after the raw component has been cleaned it is wired up to the cathode, negative end of the circuit. The anode, positive end has the raw material, which could be a number of materials like zinc if steel is being electroplated but it could be nickel chrome etc for other materials.
The raw material like zinc is dissolved into the solution and is attracted by the raw component because it has a negative charge thus the raw base being electroplated.
Section 2, Research and recording of information
Research piece 6, primary information.
Photo of the bath used for the process of electroplating from start to finish
Research piece 7, primary information
Photo of the cleaning of the raw component using a degreasing agent
Section 2, Research and recording of information
Research piece 8, primary information
Photo of the cleaning bath containing hydrochloric acid to remove rust and scale from the raw components
Question 3- The types of chemicals, raw materials and solution used to coat the different types of raw components are a number of things. To clean the raw component a substance called acoustic base aqua solution is used to degrease it. Then hydrochloric acid is used to remove the rust and scale. The raw material used to electroplate the raw component could be nickel, chrome, zinc, gold, sliver etc many types of raw materials but the widely used raw material is zinc. This is because it is used to coat steel for protective purposes.
Research piece 9, primary information. This is a photo of the raw materials used in electroplating.
Section 2, Research and recording of information
Website:
An attractive alternative to chrome
Nickel has become a very fashionable finish in recent years. It is bright silver like metal and is hard wearing. With heavy deposits it will give good corrosion protection, however it does need to be kept polished if the bright lustre finish is to be maintained.
Nickel will dull off if not regularly polished just like silver but because it is such a hard metal, almost all proprietary metal cleaners can be used without causing damage to the finish. Many people have nickel because they like the attractive finish produced as it ages.
Common uses are taps (faucets), bathroom & kitchen accessories and many household items like tea trays etc.
Website:
A durable and decorative finish.
Decorative Bright Chromium Plating
Chromium plating is now applied to so many different types of article that the brilliant bluish white appearance of the metal is familiar to everyone, and description of it is rendered unnecessary. The deposit does not tarnish and requires but occasional washing with soap and water, or wiping with a soft cloth or damp wash leather, to remove any accumulation of dust and dirt from the surface.
The term 'Bright Chromium Plate' is used to describe a layer of nickel followed by a final deposit of bright chromium. Direct chromium deposits are not generally used for decorative purposes as to provide a reasonable degree of protection very heavy deposits would be required.
Experience over many years has confirmed that nickel is the most suitable undercoat for decorative deposits because of the ease with which bright chromium may be applied, the white colour and good corrosion resistance of the nickel deposit and the relative simplicity of the nickel-plating process. The nickel deposit gives protection to the basis metal, and is itself preserved from surface oxidation by the bright chromium deposit.
Finish Thickness: The usual thickness of bright chromium deposits is 0.25 to 0.8 microns (0.00001 to 0.00003 in) onto a base coat of a minimum 8 microns of bright nickel.
Section 2, Research and recording of information
Finish Properties: Chromium plating provides a hard, non-tarnishing, corrosion resistant, blue-white finish. The plate is extremely hard and has excellent wear properties. (950 1250 hardness on the Vickers Scale.)
Decorative Chrome plating may be preceded by a copper and/or nickel plate to provide desired decorative characteristics and corrosion resistance.
Industrial Hard Chrome plating is applied on bearing surfaces, film and paper tracking surfaces and shafts. It is also used to build up worn tooling, shafts and spindles and usually will be machined after plate.
Website:
Process: Zinc Plating/Chromate Conversion Coatings
Finish Properties: Electrolytic zinc coatings are used to protect and improve the appearance of iron and steel products. Zinc coatings protect ferrous metal in two ways. First, as a corrosion barrier and second, as a sacrificial layer when the zinc coating is broken or damaged. The application of chromate conversion coatings give additional protection against corrosion particularly under high humidity and moisture conditions.
Clear, yellow, olive drab and black chromates are available for application on zinc plate. Final appearance of the chromate film depends on base metal smoothness and quality of plate deposited.
Finish Thickness: A minimum of .0003" per surface produces satisfactory results; although heavier deposits increase the protective value of the finish system. General range is .0002" to .0004" (we do not suggest plating over .0005").
Size and Weight Limitations: Rack Zinc largest piece 24" x 10" x 24"
Special Notes: HMQ's bath is chloride zinc solution
Section 2, Research and recording of information
Question 4- Usually the electroplated raw base are already manufactured into a product before it has been electroplated. What this means is that if the electroplate raw base was going to be moulded into the product after it has been electroplated the electroplated would become damage and be no good so it is done after the product has been made.
There are so many products that are electroplated so that it can give it a protective and decorative finish. Here are some examples.
- Decorative cutlery
- Trays
- Kitchenware such as toasters, kettles, etc.
- Bells
- Alloy wheels
- Mainly decorative and functional objects
Research piece 13, secondary information
Section 2, Research and recording of information
Question 5- The amount of raw materials used when electroplating depends on what is being electroplated. For example if a small raw component was being electroplated only a certain amount of raw material would be used but if the raw component was larger the raw material would increase. The amount of raw material depends on the surface areas it is covering, the larger the surface area the more raw materials needed to coat it. The raw materials are anodic in the electroplating process, which, dissolves into the solution causing them to become positive ions, which are attracted by the cathodic raw component that has a negative charge.
Question 6- The types of environmental issues that arise from the chemicals used are that, it causes pollutants, which damage the environment. When the raw materials are dug up from the ground it lowers the percentage of raw materials in the world, which becomes a major factor in the long run. There are harmful and corrosive acids used when cleaning the raw component that could be dangerous to the environment if it gets into the water table because it will kill crops and make people very ill. The metal raw materials are used up in the electroplating but the chemicals are evaporated into the environment that causes different types of pollutants that are defiantly damaging for the environment.
Section 2, Research and recording of information
Research piece 14, primary information
Drawing of the layout of electroplating company
Section 2, Research and recording of information
Research piece 15, primary information
This is a photo of the electroplating company
The address of the electroplating is:
Pro-plate metal finish company
Manor trading estate
17, Armstrong road
Benfleet Essex
SS7 4PW
Tel: 01268 752037
I will ring this number to organise a time and date to visit.
Research piece 16, secondary information
The company is not very far from my location but will require a transport service to get there. I have looked into several transport system that will be best suitable.
Section 2, Research and recording of information
Section 2.2
Evaluate and record progress, adapting the original research plan if necessary to meet new challenges.
I have a compared the research with questions in the research plan and have commented on the progress and relevance of the information.
Theses are some of the research plan questions I compared the information with:
- What types of materials, chemicals and solutions are used in the coating of a certain type of metal/product?
This information is located in research 10 – 14. There is some other research in the answers given by the employees at the interview but the main research is located in 10-14.
- What types of products are made from the electroplated metal?
This information is allocated in question 4 and research 15. There is substantial material that can be analysed in section three.
- I want to know how much the electroplating company uses on raw materials and what is it used for?
This information is allocated in question 3 and research 9.
- What types of environment issues arise from the chemicals used and where they are then deposited after use?
This information is in question 6 and is primary information gathered at the interview
- Why coat the metals?
This information is located through out the researches and will be totally analysed in section three.
Section 2, Research and recording of information
Section 2.3
Record relevant, edited information, suitable for later analysis and referencing
This information below contained all the research that will be analysed in section 3
Research 1- 9 will remain the same and will not need to be edited because all the photos and research will be analysed.
The research below will all be analysed in section 3
Research piece 10, secondary information
Website:
An attractive alternative to chrome
Nickel has become a very fashionable finish in recent years. It is bright silver like metal and is hard wearing. With heavy deposits it will give good corrosion protection, however it does need to be kept polished if the bright lustre finish is to be maintained.
Nickel will dull off if not regularly polished just like silver but because it is such a hard metal, almost all proprietary metal cleaners can be used without causing damage to the finish. Many people have nickel because they like the attractive finish produced as it ages.
Common uses are taps (faucets), bathroom & kitchen accessories and many household items like tea trays etc.
Research piece 11, secondary information
Website:
A durable and decorative finish.
Decorative Bright Chromium Plating
Chromium plating is now applied to so many different types of article that the brilliant bluish white appearance of the metal is familiar to everyone, and description of it is rendered unnecessary. The deposit does not tarnish and requires but occasional washing with soap and water, or wiping with a soft cloth or damp wash leather, to remove any accumulation of dust and dirt from the surface.
The term 'Bright Chromium Plate' is used to describe a layer of nickel followed by a final deposit of bright chromium. Direct chromium deposits are not generally used for decorative purposes as to provide a reasonable degree of protection very heavy deposits would be required.
Experience over many years has confirmed that nickel is the most suitable undercoat for decorative deposits because of the ease with which bright chromium may be applied, the white colour and good corrosion resistance of the nickel deposit and the relative simplicity of the nickel-plating process. The nickel deposit gives protection to the basis metal, and is itself preserved from surface oxidation by the bright chromium deposit.
Section 2, Research and recording of information
Research piece 12, secondary information
Website:
Process: Zinc Plating/Chromate Conversion Coatings
Finish Properties: Electrolytic zinc coatings are used to protect and improve the appearance of iron and steel products. Zinc coatings protect ferrous metal in two ways. First, as a corrosion barrier and second, as a sacrificial layer when the zinc coating is broken or damaged. The application of chromate conversion coatings give additional protection against corrosion particularly under high humidity and moisture conditions.
Clear, yellow, olive drab and black chromates are available for application on zinc plate. Final appearance of the chromate film depends on base metal smoothness and quality of plate deposited.
Section 3, analysis of information and conclusions
SECTION 3, ANALYSIS OF INFORMATION AND CONCLUSIONS
Section 3.1
Analyse edited research material to identify the effectiveness of the system including, as appropriate, the key issues of management, quality assurance and control, and the role in the system and any sub systems of features such as input, process and output.
In this section all the research in section two will be analysed as accordingly. The research in section two with the headings research 1, research 2 etc will be written below and analysed.
Research piece 1, secondary information
This research was found from a website that gave the process of electroplating and how it works.
It basically explains what electroplating is and what its function is in the process of electroplating. A section from this website gives detail parts of how electroplating works:
“Electroplating is the deposition of a metallic coating onto an object by putting a negative charge onto the object and immersing it into a solution, which contains a salt of the metal to be deposited. The metallic ions of the salt carry a positive charge and are attracted to the part with a negative charge. When they reach it, the negatively charged part provides the electrons to reduce the positively charged ions to metallic form”
This research explains how electroplating works on a small scale and how it does its job of coating the component with a layer of metal.
Below is the description of how electrolysis works. This process is identical to the electroplating but the electrolysis process is in a small scale, as shown below in the diagram
The information below gives a brief description of electroplating nickel from start to finish.
“Imagine that we have an object that is made of copper or steel, and that it has been properly cleaned, and that we now want to plate it with nickel. A wire is attached to the object, and the other end of the wire is attached to the negative pole of a battery (the wire is blue in this picture). To the positive pole of the battery we connect the red wire; the other end of the red wire we connect to a rod made of nickel.
Now we fill the cell with a solution of a salt of the metal to be plated. It is theoretically possible to use a molten salt, and in rare cases that are done, but most of the time the salt is simply dissolved in water. The NiCl2 ionises in water to Ni++ and two parts of Cl-, because the object to be plated is negatively charged, it attracts the positively charged Ni++. The Ni++ reaches the object, and electrons flow from the object to the Ni++. For each atom of Ni++, 2 electrons are required to neutralize it or 'reduce' it to metallic form”.
This information explains how nickel is plated onto a raw component. It describes how the raw component that is being electroplated is attached to the cathode (negative part) in the circuit. The anode is just the positive part in the circuit and is not attached to anything apart from the solution
After the attachment of the component there is a salt of nickel chloride NiCl2 in the solution. This will dissolve to form ions, Ni++ and Cl-. The nickel ions will be attracted to the cathode, which has the raw component e.q. steel, thus coating the metal on the cathode part with nickel. The chloride ions will then be attracted to the positive part, anode and therefore the process is complete.
The reason that nickel is attracted to the raw component is because the cathode, containing the raw component has a negative charge and the nickel has a positive charge and therefore opposite attract.
Section 3, analysis of information and conclusions
Research piece 2, secondary information
This research describes how electroplating works and what types of electroplates are available.
“Electroplating is the electrochemical process of depositing a metallic coating on the base material of an object when it is immersed in a plating solution in such a manner that a suitable low voltage electric current flows through it, causing the metallic coating to be attracted to the object to be plated. Electroplated finishes, including:
Chrome plating, Copper plating, Nickel plating, Sliver plating, Zinc plating brass plating, cadmium plating, chromium plating, hard chromium plating, gold plating, tin plating and zinc plating”.
The description of electroplating is the same as the research in research 1, but this research has the types of coating available.
Research piece 3, secondary information
This research was obtained from a website that gave relevant information on what a metal finish and what electroplating is.
WHAT IS METAL FINISHING?
”Metal finishing is the process of changing the surface of an object; for the purpose of improving it's appearance and/or durability”.
A metal finish is the altering or changing of the surface by a process, to improve the appearance and the resistance of the metal.
ELECTROPLATING
”Electroplating is an electrochemical process used to deposit a metallic coating on the base material of an object by immersing it in an electrically charged solution so that a suitable low voltage electric current flows through it, causing the metallic coating to be attracted to the object being plated”.
Electroplating is a process to coat a raw component with a layer of metal to protect it from corrosion and other factors. It also helps to improve the appearance and function of the raw component.
Question 1, Primary information
This information was obtained from an interview, which took place at the electroplating company by the manger or head employee.
This information gives the relevance of electroplating and how it does it function. The information describes the technique used to coat the raw component with the metal.
“The process of electroplating is similar to that of electrolysis. The electroplating process involves raw components being coated with a layer of metal so that it can give it a protective and decorative finish depending on what raw material is being used. For example electroplating a steel component with chrome to give it a decorative finish rather than protective finish.”
From this research the raw component used to electroplate is usually steel. What this shows is that steel need to be protected from factors such as corrosion by being electroplated, so this means that electroplating steel will be beneficial because it protects it from factors.
Section 3, analysis of information and conclusions
Research piece 4, primary information
This is a photograph of the electroplated produced. It has been electroplated with zinc. The raw component used was steel. The reason this material has been electroplated with zinc is because it is highly resistant to corrosion and protects it from damage.
The effectiveness of the coating of this raw component is to protect it from corrosion. It does this by forming a layer of metal, which is highly resistance that does not let the inner metal be exposed to factors.
The quality control that is kept to insure this product has no faults is a member of staff that checks the items once they have been electroplated. If there is a fault in the electroplated product it will have to go thought the whole process of electroplating from start to finish again so that all faults are whipped out.
The quality assurance of the electroplated products to the user is that it will be made to high standards to insure that quality control has been kept throughout the whole of its process and there have been no faults.
The input of this process is the raw materials, raw component the solutions etc. The process of the electroplated product is being electroplated under conditions that are quality controlled and the output is the quality assured product.
Research piece 5, primary information
This is another photograph of an electroplated product that has been electroplated with black zinc on a steel component. The effectiveness of this is to keep it protected from major facts such as rust, corrosion. This is because it may be used for purposes that may have factors that can damage the inner metal so thus it is coated in a better metal.
The quality control over this product is to keep it fault free. It does this by checking each electroplated product to insure it is not damages in anyway. Once it has been approved that it is fault free it is quality assured and the products then sold or given back to the company that asked for it to be electroplated.
The input is the raw material, raw component, and solutions of zinc. The process is to coat the raw component with a layer of metal to protect it from major factors like corrosion. The output is the electroplated product with no faults.
Question 2, Primary information
This information was obtained from an interview done at the electroplated company by the manager.
It explains how electroplating works and what types of electroplates it does.
“The way electroplating works is when direct current passed through the anode and cathode. The direct current is converted from alternating current by using a rectifier.
The cathode has the raw component that is being electroplated. It first needs to be cleaned to remove grease on the raw component; an agent called acoustic base aqua solution is used to remove it. Then any rust and scale on the raw component is removed by putting it into hydrochloric acid. Then after the raw component has been cleaned it is wired up to the cathode, negative end of the circuit. The anode, positive end has the raw material, which could be a number of materials like zinc if steel is being electroplated but it could be nickel chrome etc for other materials.
The raw material like zinc is dissolved into the solution and is attracted by the raw component because it has a negative charge thus the raw base being electroplated”.
This process is exactly similar to the electrolysis process but is in more detail. It explains briefly that there is a raw component at the cathode side and a raw material at the anode side. There is a solution of the metal coating, which is ionised by a current flowing through. The metal ions are attracted to the cathode due to the opposite charge and this forms a layer of metal on the raw component thus the electroplating process.
Throughout the process there is quality control kept so that there are no problems when electroplated. There is a member of staff that checks the products thoroughly to insure there are no faults. Once this has been done it is quality assured.
Section 3, analysis of information and conclusions
Research piece 6, primary information.
This is a photograph of the baths used for the process of electroplating from start to finish. There are a number of baths for different purposes. In the first bath there is a solution called acostic aqua solution. This solution is used to clean the raw component from any grease, so it is a degreasing bath. The second bath contains hydrochloric acid. This acid is used to remove any rust or scale on the raw component before it is electroplated. Finally the furthest bath from the photograph is the electroplating baths. Theses baths are used to electroplate the raw component with the layer of metal. The person who manages theses baths is skilled so that they can electroplate the raw component. They ware safety apparatus so that the dangerous chemicals and solutions do not injure them.
There is quality control kept through the whole process so that the product that is being electroplated is not damages in anyway. Quality control is performed by a trained member of staff that checks each raw component from start to finish from different periods of time within the electroplating stage. Once the products have been checked they are quality assured by another member of staff, which certifies the product to be safe and efficient for the end user.
Throughout the whole stage of the raw component getting electroplated there are subsystems with in the systems. This is because the whole electroplating process is a system but in this system there are different subsystems like the cleaning of the raw component that make the whole electroplating process.
Research piece 7, primary information
This is a photograph of the baths used for removing grease from the raw component. Inside this bath there is a chemical called acostic base aqua solution, which removes the grease. The raw component is put into this chemical and left for a few minutes; this allows any grease partials on the component to fall off thus degreasing the raw component for the next stage of electroplating.
The degreasing of the raw component is necessary in the stage of electroplating. This is because if the raw component is not degreased and is electroplated straight away, the metal layer it is being coated with will not be able to attach it self and will fall off thus making the raw component exposed to the environment.
The quality control that is checked over this stage is a member of staff that feels the raw component to see if there is any grease left on it. If there is any grease left on the raw component the next stage after the degreasing is the hydrochloric acid, which will remove any grease remaining. This is quality assured because then the raw component is fully degreased and is fault free so when it is electroplated its is carried out correctly where the metal layer attaches it self to the component.
Research piece 8, primary information
This is a photograph of the bath used for removing rust and scale from the raw component. Inside this bath is hydrochloric acid that removes the scale and rust. The raw component is put into this acid for a few moments. This is to react the acid with the rust and scale. When it reacts it forms a cream foam that floats on the surface of the acid, this notifies a staff member that the rust and scale has been remove. Once this foam appears the raw components are taken out and cleaned with neutral water.
Acid is extremely corrosive and very harmful to humans but in this photograph the acid is left exposed to anyone. This is a safety measure that is taken seriously. The acid is only left exposed when there is work being preformed on removing the rust and scale from the raw component. After the acid has been used there are specialised covers that are used to cover the acid baths so that no acid is exposed and thus no injury.
The quality control that is performed to ensure that there are no faults is that the raw component when being acidified has been removed of rust and scale. This is then quality assured by the foam forming on the surface of the acid then by being checked by a member of staff to make sure there is no rust or scale present.
The input of this system is the raw component, the process is when the acid is reacting with the scale and rust and finally the output is the raw component with no rest or scale that can then be electroplated.
Section 3, analysis of information and conclusions
Question 3, primary information
This research was obtained from an interview at the electroplating plant, it was answered by one of the employees.
The answer explains the different chemicals, solutions and raw materials used in the coating of the raw component. A section from this explains this:
“ The types of chemicals, raw materials and solution used to coat the different types of raw components are a number of things. To clean the raw component a substance called acoustic base aqua solution is used to degrease it. Then hydrochloric acid is used to remove the rust and scale. The raw material used to electroplate the raw component could be nickel, chrome, zinc, gold, sliver etc many types of raw materials but the widely used raw material is zinc. This is because it is used to coat steel for protective purposes”.
This research explains the different types of chemicals, solutions and raw materials used when electroplating the raw component. It explains what each chemical is used for and the function it performs. The names of theses chemicals have been written in this section and have been analysed in parts of the research. It explained on the function it does in the electroplating process and the different types of plating there are available.
Research piece 9, primary information
This is a photograph of one of the raw materials used when the raw component is being electroplated. The raw material that is seen in the photograph is zinc rods. These rods are used in the electroplating bath where they are attached to the anode site (positive end) of the electroplated circuit. This is the main element that is used in the zinc plating when it is attracted to the raw component due to the raw component being negatively charged in the electroplating circuit.
Zinc is extremely resistant to corrosion and rust. Therefore it is used to coat the raw component, mainly steel that it can protect it against the environment, which contains factors that can damage a metal. This coating is usually used on metals that will be exposed to conditions that may damage the inner metal.
The quality control that is preformed on the raw material is to ensure it is pure and that it has been correctly attached in the electroplating circuit. The quality assurance of the raw material is when it is totally dissolves in the solution and attaches it self to the raw component. This will allow there to be a layer of metal on the raw component and thus protecting it.
The input for this system is the raw material being attached to the electroplate circuit, the process is when the material dissolves into the solution and gets attracted to the raw component and finally the output is the finished product that has been electroplated with no faults.
Research piece 10, secondary information
This research was obtained from a reliable website. It explains how nickel is a good raw material to use for the plating of the raw component.
Nickel has become a very fashionable finish in recent years. It is bright silver like metal and is hard wearing. With heavy deposits it will give good corrosion protection, however it does need to be kept polished if the bright lustre finish is to be maintained.
Nickel will dull off if not regularly polished just like silver but because it is such a hard metal, almost all proprietary metal cleaners can be used without causing damage to the finish. Many people have nickel because they like the attractive finish produced as it ages.
Common uses are taps (faucets), bathroom & kitchen accessories and many household items like tea trays etc.
Section 3, analysis of information and conclusions
The research on the previous page describes the properties nickel offers for a plated product. It protects against corrosion but requires care so that the nickel does not dull off. Nickel is a hard metal than does not damage easily, it is a polished metal that is functional and decorative thus used for home feature such as taps, trays and bathroom and kitchen. All of theses places and items that nickel is used for are exposed to corrosion so this must mean that nickel it extremely good at protecting the inner metal.
The quality control that is shown on this research is that nickel must be cleaned to ensure the finish does not come off and expose the inner metal. The assurance that nickel gives is that it is a hard metal, which does not damage easily.
The effectiveness of this metal is that it is corrosion resistant that protects the inner metal from factors that can damage it.
Research piece 11, secondary information
This research was obtained from a website. It explains how chromium is a good raw material for the plating of a raw component. It also explains the properties of chromium plate.
“ Chromium plating is now applied to so many different types of article that the brilliant bluish white appearance of the metal is familiar to everyone, and description of it is rendered unnecessary. The deposit does not tarnish and requires but occasional washing with soap and water, or wiping with a soft cloth or damp wash leather, to remove any accumulation of dust and dirt from the surface ”.
The research above describes how chromium plate is a brilliant bluish white appearance. It also describes how the plate does not tarnish but needs occasional cleaning with a cloth to remove dirt.
“ The term 'Bright Chromium Plate' is used to describe a layer of nickel followed by a final deposit of bright chromium. Direct chromium deposits are not generally used for decorative purposes as to provide a reasonable degree of protection very heavy deposits would be required ”.
Bright chromium plate is explained from the research above as being a layer or nickel covered by a layer of bright chromium. The information also describes how chromium would not be a good protective finish by itself so it needs another metal layer to give it the proactive finish, which is nickel.
“ Experience over many years has confirmed that nickel is the most suitable undercoat for decorative deposits because of the ease with which bright chromium may be applied, the white colour and good corrosion resistance of the nickel deposit and the relative simplicity of the nickel-plating process. The nickel deposit gives protection to the basis metal, and is itself preserved from surface oxidation by the bright chromium deposit ”.
This information above explains how nickel plating is the ideal plating for the undercoat of chromium plating because nickel is corrosion resistance and is a bright white so chromium will also be similar properties to nickel due to the nickel in the chromium plate.
The quality control that is shown in this research is that the chromium is cleaned so that it does not tarnish. The quality assurance is that this metal plate gives is that it is a hard metal and does not become damaged. The efficiently of the metal plate is not completely better than nickel because nickel has better properties than chromium.
Section 3, analysis of information and conclusions
Research piece 12, secondary information
The information below was obtained from a website. It explains the properties of zinc.
” Finish Properties: Electrolytic zinc coatings are used to protect and improve the appearance of iron and steel products. Zinc coatings protect ferrous metal in two ways. First, as a corrosion barrier and second, as a sacrificial layer when the zinc coating is broken or damaged. The application of chromate conversion coatings give additional protection against corrosion particularly under high humidity and moisture conditions ”.
The research above explains how zinc plating is efficient on the coating of steel and iron because it offers a number of protections. The zinc improves the appearance and the protection of the raw component. It protects the inner metal by resisting against corrosion and if the zinc does become damages there is another undercoat of chromate, which gives it the additional protection against humidity and moisture.
“ Clear, yellow, olive drab and black chromates are available for application on zinc plate. Final appearance of the chromate film depends on base metal smoothness and quality of plate deposited."
The above research describes the different types of colour zincs that are available. It also explains the final finish of the product. It shows that raw component makes a big factor to the texture and appearance of the plat.
Question 4, primary information
This research was obtained from the interview at the electroplating company. Its been answered by a member of staff. It explains weather the product is made before of after it has been electroplated. It also described the different types of products available.
“ Usually the electroplated raw base are already manufactured into a product before it has been electroplated. What this means is that if the electroplate raw base was going to be moulded into the product after it has been electroplated the electroplated would become damage and be no good so it is done after the product has been made.
There are so many products that are electroplated so that it can give it a protective and decorative finish. Here are some examples.
- Decorative cutlery
- Trays
- Kitchenware such as toasters, kettles, etc.
- Bells
- Alloy wheels
- Mainly decorative and functional objects ”
The research above is explaining weather a product is manufactured before or after it has been electroplated. The electroplating is preformed after the manufacture of the product because if the product was made before the electroplate then the plate would be damaged and thus fall off and expose the inner metal.
The quality control that is preformed to ensure that the products are fault free. They are checked by trained members off staff and by specialised machineries. The assurance that is given to people is that the plate will not fall off.
Section 3, analysis of information and conclusions
Research piece 13, secondary information
The pictures above are a few items that have been electroplate with different plates. They are plated with the same principle of the electroplated process
Question 5, primary information
This research was obtained from an interview at the electroplating plant, it was answered by one of the employees. The answer explains the amount of raw material that would be needed to coat a certain amount of raw component.
“ The amount of raw materials used when electroplating depends on what is being electroplated. For example if a small raw component was being electroplated only a certain amount of raw material would be used but if the raw component was larger the raw material would increase. The amount of raw material depends on the surface areas it is covering, the larger the surface area the more raw materials needed to coat it. The raw materials are anodic in the electroplating process, which, dissolves into the solution causing them to become positive ions, which are attracted by the cathodic raw component that has a negative charge ”.
The information above is basically describing how much raw material will be needed for an amount of raw component. What this means is that if there is a number of raw components that is being electroplating the amount raw materials needed to coat it will be depending on the size, shape of the raw component. Its also explains again how the process works of electroplating works.
Section 3, analysis of information and conclusions
Question 6, primary information
This information was obtained from an interview at the electroplate company by a member of staff. It describes the environmental problems that arise from the different chemicals, raw materials, and solutions used.
This is the answer I received:
“ The types of environmental issues that arise from the chemicals used are that, it causes pollutants, which damage the environment. When the raw materials are dug up from the ground it lowers the percentage of raw materials in the world, which becomes a major factor in the long run. There are harmful and corrosive acids used when cleaning the raw component that could be dangerous to the environment if it gets into the water table because it will kill crops and make people very ill. The metal raw materials are used up in the electroplating but the chemicals are evaporated into the environment that causes different types of pollutants that are defiantly damaging for the environment ”.
This information above explains that there are environmental problems that arise form the chemicals, solutions and raw materials used when electroplating. From the statement above the chemicals used are extremely corrosive and harmful to humans and other wildlife. This is because if it gets into the water table it will make people very ill and may cause death. When electroplating the chemicals can be evaporated into the atmosphere. This will cause acid rain that will kill crops.
The quality control that is done to ensure that none of these harmful chemicals or solutions is put into the environment is a number of factors. Theses are that there are waste procedures to clear up the solutions or chemicals. The assurance that will be done is that theses harmful materials will be thrown effectively and not wasted that would be harmful to the environment.
Section 3, analysis of information and conclusions
Research piece 14, primary information
This is a layout plan of the electroplating company. There are many features that make up this layout.
The drying room located on the left is used to dry the electroplated product
The raw materials jus below are used for the coating of the raw component and are stored there
The metal gates on the far bottom stop intruders from entering the premises
There are three baths used for different purposes, the bottom bath contains acostic base aqua solution used to clean the grease off the raw component, the middle bath contains hydrochloric acid and is used to remove rust and scale from the raw component and finally the top bath is the electroplating baths used to plate the raw component.
There is a cleaning bath used after the product has been electroplated. This is to remove any excess metal on the electroplated product.
There are a number of procedures that are taken to keep members of staff safe from the different types of things in the company. Theses are safety goggle, gloves, resistant clothing.
Research piece 15, primary information
This research contains the location, phone number, and photograph of the electroplating company I visited.
Research piece 16, secondary information
This research is an image of the London underground it was best suited for my transport to the electroplating company I visited. I found this image from a website
Section 3, analysis of information and conclusions
Section 3. 2
Present detailed conclusions, relevant to the original objectives, which identify the strengths and weaknesses of the system studied
1st objective
- I will need a basic knowledge of the process of electroplating and how it is used in the coating of metallic products or materials
Strengths
The strengths of this objective were that I was able to locate most of this research form the Internet and secondary information, but I also obtained a large majority from primary sources, an interview.
Weaknesses
The weakness of this objective was that it was very time consuming. It had taken a long time to organise a time to visit the electroplating company and I did not organise my time effectively.
Conclusion of objective
Overall I managed to gain more strengths than weaknesses for this objective because I was able to obtain large amounts of information that helped me to conclude this objective. In future I will try to organise my time more effectively so that I can spend more time on other sources of research.
2nd objective
- I want to find out why products are coated by electroplating rather than just being manufactures in the certain material they are being coated with.
Strengths
The strengths of this objective were that I was able to find out the difference between the two. I was able to see if electroplating the product is better then making the product from the material it is being electroplating with.
Weaknesses
The weaknesses of this objective were that I could not find enough information. I had to look at several sources of primary and secondary information to obtain anything close to the objective. This was very time consuming.
Conclusion of objective
This objective was very difficult to find out about because I could not find the correct or relevant information, which lead me to say that this object was not entirely complete. I would have to make some major adjustments to find more information about his objective. In the future I will have to look at different types of relevant information to make sure this objective is completed.
3rd objective
- How the work force ensure there’s safety in the workplace is kept to high standards
Strengths
The strengths of this objective were that I found enough information relating to the safety and precaution of staff members in the workforce. I found this information from primary sources, the interview and observation. I had obtained large amounts of information from my visit at the electroplating company.
Weaknesses
The weaknesses of this objective were that I could not find any information from secondary sources, which meant that I had to wait for myself to visit the electroplating company. This was very time consuming.
Conclusion of objective
This objective was easily to find out about because the information was obtained in the interview. I had obtained large amounts of observational pictures that helped my to gain the maximum safety precautions in the workforce. If I had looked at other secondary sources I may have found the safety precautions but it would have taken even longer and I would not have been able to visit the electroplating company
.
Section 3, analysis of information and conclusions
4th objective
- How the employees take certain precautions to ensure quality control and quality assurance are kept when electroplating.
Strengths
This object was fairly easy to find about because I was able to obtain large amounts of information form secondary and primary sources. This led me to write a lot about the quality control and assurance.
Weaknesses
There were not many weaknesses about this objective because I was able to find most of the information from different sources. If there were one thing I would comment about it would be the time that I spent of finding the research.
Conclusion of objective
This objective was very easy to find out about because I was able to find the information from a wide rang of sources. I would just try to spend less time on finding the information and focus more of the time on the other objectives.
5th objective
- What raw materials are used and what their purpose are in electroplating.
Strengths
The strengths of this objective were that it was extremely easy to find out about because I was able to obtain it from a number of sources. I found most of the information from secondary sources like the Internet.
Weaknesses
The weaknesses about this objective was that I focused my time on the interview because I through that I would not be able to find enough information at the electroplating company. I was mistaken because there was not significant information at the company because the member of staff I spoke to did not go into detail about the process of electroplating.
Conclusion of objective
This objective, when finding the information out was pretty much easy because I was able to gather most of the information from secondary sources. I was mistaken when I had through that I would be able to get enough information from the interview. I was unable to get detained information that would have helped me to analyses the objective so therefore I had to look back on secondary information, which was time consuming.
6th objective
- I will need to find out if the metal objects are manufactured before or after electroplating. If they are manufactures after electroplating what would they be made into.
Strengths
The strength of this objective was that I was able to find the information straight away from secondary sources like the Internet. I did not have to wait for the interview to find this out and this left more time for me to look at other researches for the other objectives.
Weaknesses
The weaknesses of this objective was that I could have found more information relating to this objective but I through that once I had some information I would leave it and move on to more research about another objective.
Conclusion of objective
The information relating to this objective was found with ease but I could have spent more time trying to find more information out. This would have helped me to analyse the research more efficiently.
Section 4, proposals and personal evaluation
SECTION 4, PROPOSALS AND PERSONAL EVALUATION.
Section 4.1
Present realistic proposals for ways in which the system might be improved and/or demonstrate clearly why it is already so effective.
The cleaning and electroplating process is already an effective and successful procedure. The cleaning of the raw component could not be made any more effective than it is now but when the chemicals in the cleaning process are used they tend to cause environmental issues. If theses issues were taken care of, then there would not be any need to talk about the environment becoming damaged. The electroplating process of the raw component does not require much improvement because of the high standards where it has already been quality checked which means it completes its function. There could be a method to try and improve the electroplating process by not using so many raw materials and to use a substitute that is cheaper and less damaging to the environment.
If there is anything in the whole system that needs improving it must be the safety of the staff members. This is because there are extremely dangerous chemical and solutions used that can affect the employees if the chemicals are mistreated or used with no care. I think that the electroplating process to coat the raw component is already the best procedure and most successful to obtain efficient results. There is also another factor that could be improved that is in terms of the safety of people in the company is that there should be more visual warnings like a safety goggles notice or wearing gloves notice.
In the feature if this company wants to ensure it is reaching its full potential in the efficiently. It should use more types of subsystems to lower the cost, materials and chemicals used in the coating of raw components. What this means is that it should use better methods to clean and electroplate the metal instead of using method that work, but do not work as efficiently.
Section 4.2
Summarise the effectiveness of their approach to this study
There was defiantly some very effective procedure to this system that had enlightened me about the process of electroplating from start to finish. But there were some features in the processes that disturbed me like the removal of the hydrochloric acids and degreasing agent once it has been used. This made me think of the way it is dumped into sites and the environmental issues, which arise from theses chemicals.
I was delighted about the amount of quality control that had gone into the system because it assured me that the electroplated product would be fault free and effective to the user. This gave me a different perception on the many items that have been electroplated and the amount of work or labour that had gone into it to make sure it is fully assured for the end user. The company that I visited had made full use of the subsystems and had used them precisely and concisely to make sure they were efficient.
Overall I found this study to be interesting and successful because it challenged me to find new concepts that are around us. In future I would like to go into further detail with different types coating methods and the chemicals used as I have chosen chemistry and physic as my a levels and this will help me to understand the system more closely.
