Metal Finishing

Metal Finishing: The process in which a thin layer of metal of uniform thickness is deposited on
the surface of the substrate (metal, plastic etc.) to modify the surface properties is known as
metal finishing.
Electroplating and Electroless plating are two important techniques of metal finishing.
Technological importance of metal finishing: Metal finishing is carried out to obtain
technologically important surface properties.
These properties are:

1. A decorative appearance.
2. An improved corrosion resistance.
3. An improved heat resistance.
4. An improved surface hardness. (An improved resistance to wear and tear & abrasion)
5. An improved solderability.
6. Good thermal conductivity.
7. Good electrical conductivity.
8. Good thermal reflectivity.
9. Good optical reflectivity.

Metal finishing also finds applications in the following areas.

1. Manufacture of electrical and electronic components such as
printed circuit boards, capacitors etc.
2. Electrochemical machining, etching and polishing.
3. Electroforming of objects (manufacture of metal articles entirely by electroplating)
4. Electrotyping (to reproduce finely engraved dies, e.g. gramophone records)
5. Material restoration.

Electroplating:

Electroplating is the process of deposition of a thin layer of metal on another metal, alloy or any
other conducting material by passing direct electric current through an electrolytic solution
containing suitable salt of the metal to be plated.

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The principal components of electroplating process are
1. Electroplating bath: It contains a suitable salt solution of the metal being deposited. it also
contain other additives to improve the electrodeposition.
2. Anode: Anode should be electrically conducting, it may be inert electrode or the metal to be
plated. The reaction occur at anode is
M Mn+ + ne-
3. Cathode: The object to be plated is made as cathode. It should have an electrically
conducting surface. The reaction occurring at the cathode is
Mn+ + ne- M
4. Inert vessel: It is basically container and contains above mentioned materials. It may be a
vessel made of rubber lined steel, plastic concrete or wood.
5. D.C. power supply: The positive terminal of the power supply is connected to the anode and
the negative terminal is connected to the cathode.

Surface preparation:
Importance of surface preparation before electroplating: A good adherent deposit is obtained
only if the substrate surface is free from dirt, grease, oxide scale and rust. Therefore it is
necessary to clean the surface thoroughly before electrodeposition. If bright deposits are
required, the surface must be smooth.

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Surface cleaning involves following steps:

1. Removal of organic substances – solvent cleaning, alkali cleaning.

2. Removal of inorganic substances – mechanical cleaning, pickling.
3. Rinsing with water.

1. Removal of organic substances – degreasing process

a) Organic solvent cleaning: It is used to remove oils, greases etc. from the surface. For
cleaning, organic solvents such as trichloro ethelene (CCl2 = CHCl), methelene chloride
(CH2Cl2), carbon tetra chloride (CCl4) etc. are used.

In vapour phase degreasing method, vapours of the solvent (trichloro ethylene) are allowed to
condense on the metal surface. The condensed liquid washes away the oil, grease and other
organic matter from the surface.

b) Alkali cleaning: Residual oil and grease from the surface is removed by treatment with
alkaline solutions (NaOH, Na2CO3 etc.) Alkali cleaning is made more effective by making the
metal cathodic in a hot alkali solution. The hydrogen gas liberated at the cathode helps to
dislodge the greasy matter.

2. Removal of inorganic substances – descaling process:

a) Mechanical cleaning: It is used to remove oxide scales and rust from the metal surface.
Simple mechanical cleaning involves hand cleaning using sand paper, bristle brush etc. Other
methods involve polishing the surface i) using grinding wheels, ii) by sand blasting and iii) by
electropolishing.

b) Pickling: It is used to remove oxide scales and rust present on the metal surface by
dissolution. Pickling involves dipping the object in dilute acids (HCl, HNO 3, H2SO4 or a
mixture) for considerable period of time.
3. Rinsing with water: The object is finally rinsed with deionized water.

Polarization:
Definition of polarization: Polarization is a process in which there is decrease in electrode
potential due to inadequate supply of ionic species from the bulk of the solution to the electrode
surface.
The electrode potential can be calculated using the Nernst equation.
E = Eo + 0.0591 log10 [Mn+]
n
Explanation: Consider an electrolytic cell under operation. When current is being passed,
positive ions are produced at the anode and are consumed at the cathode. If the diffusion of ions
in the electrolyte is slow, there will be an accumulation of positive ions in the vicinity of anode.

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Similarly, there will be a depletion of ions in the vicinity of cathode. Under these conditions, the
anode and cathode are said to be polarized. This type of polarization is known as concentration
polarization.

Electrode polarization depends on the following factors. 1. Nature (i.e. size, shape and
composition) of the electrode 2. Electrolyte concentration and its conductivity 3. Temperature 4.
Rate of stirring of the electrolyte 5. Products formed at the electrodes.

Definition of decomposition potential: A decomposition potential, in electrochemistry, is the

difference in the electrode potential between an electrolytic cell's cathode and anode in order for
electrolysis to occur. It is the minimum voltage produced from an electrolytic cell and is used in
the electrolysis process.

It is also known as decomposition voltage.

Decomposition potential is defined as the minimum external potential required to bring about
continuous electrolysis of an electrolyte.

Vo
lta
ge

ED
Current

Definition of over voltage (over potential) (η):

Over voltage is defined as the excess voltage that has to be applied above the theoretical
decomposition potential to start the electrolysis.
η = Experimental decomposition potential - Theoretical decomposition potential (back
EMF)

Example: For electrolysis of water using smooth platinum electrodes, the theoretical
decomposition potential is 1.23 V. The experimental decomposition potential is 1.7 V. The
difference, 0.47 V, is the over voltage.

Factors affecting the over voltage value:

1. Nature of the electrode.
2. Nature of the product formed at the electrode.
3. Current density (i.e. current per unit area of the electrode surface.)
4. Temperature

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5. Rate of stirring.

Electroless plating
Definition: the process in which a thin layer of metal from its salt solution is deposited on the
catalytically active surface of the material, in presence of a suitable reducing agent without using
electricity is called as electroless plating. Reduction of the metal ions and oxidation of the
reducing agent occurs simultaneously on the catalytic active surface of the material.

Electroless plating of Copper

Before electroless plating, the surface is cleaned thoroughly. Insulators such as plastics and
printed circuit boards are activated by dipping first in stannous chloride (SnCl2) and then in
palladium chloride (PdCl2).
Then, the electroless plating is done under the following conditions:

1. Plating bath solution : CuSO4

2. Reducing agent : Formaldehyde (HCHO)
3. Complexing agent and exaltant : EDTA
4. Buffer (pH = 11) : Sodium hydroxide and Rochelle salt (Na-K-tartrate)
5. Temperature : 25 oC

Formaldehyde and copper sulphate are added to the plating bath periodically.

Applications: 1. Used for metalizing printed circuit boards.

2. Used to produce through-hole connections.

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Distinction between electroplating and electroless plating:
Property Electroplating Electroless plating
Driving force Direct electric current Autocatalytic redox reaction
Anode Separate anode Catalytic surface of substrate
Cathode Object to be plated Object to be plated (pretreated to clean and
(pretreated to clean the make the surface catalytically active)
surface)
Nature of the Non-uniform or irregular Uniform on all region
deposit region
Reducing agents Electrons Chemical Reagents
Applicability Only to conductors Conductors and non-conductors

Advantages of electroless plating:

1. Electrical equipment is not required.
2. Semiconductors and insulators can also be plated.
3. Electroless plating baths have better throwing power.
4. Electroless coatings are harder than the electrodeposited coatings.
5. No levellers are required
6. Electroless deposits are free from holes and have unique chemical, mechanical & magnetic
properties.

Metal Finishing Questions

1. What is metal finishing? Give the technological importance of metal finishing.
2. Define the following terms: (i)Polarization, (ii) Decomposition potential, (iii) Over voltage
3. Explain the term ‘Polarization’. What are the factors affecting electrode polarization?
4. What is electroplating? What are the principle components of an electroplating process?
5. What is electroless plating? What are the components of an electroless plating bath?
6. Describe electroless plating of copper.
7. Distinguish between electroplating and electroless plating.
8. What are the advantages of electroless plating over electroplating?