Electropolishing for the

Table
of
e INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

TECHNICAL SUMMARY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

DEBURRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CORROSION RESISTANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FATIGUE LIFE IMPROVEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SURFACE PREPARATION FOR PENETRANT TESTING . . . . . . . . . . . 12

MICROFINISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

ULTRACLEANING FOR SURFACE CLEANLINESS . . . . . . . . . . . . . . . 16

ABOUT US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ABLE DIFFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PREVENTING PREMATURE PART
FAILURES AND INCREASING
CYCLE LIFE FOR COMMERCIAL AND
MILITARY AIRCRAFT
Design engineers in the aerospace industry are constantly challenged to improve fit
and function of components used in commercial and military aircraft. Parts used in
these aircraft must withstand high stress corrosive conditions with long-term use,
and must meet highly demanding cycle life specifications.

Engineers working in the aerospace industry use electropo-
lishing on a regular basis to improve the fit and function of
components made from various materials including stain-
less steel, aluminum and titanium. Whether these parts are
stamped or machined, they will almost certainly contain
surface anomalies. These surface defects in the form of
fissures or micro-cracks can drastically shorten the cycle life
of these parts, resulting in premature failure of flight-critical
components. This is even more crucial when components
used in aircraft must withstand high levels of stress and cor-
rosive environments.
In addition to maintaining a long cycle life and withstanding
high stress, parts used in commercial aircraft must meet
stringent standards and regulations set forth by the U.S
Federal Aviation Administration. These regulations establish
guidelines for the manufacturing process, surface finishing
and assembly of various types of aircraft.
Electropolishing, typically the last operation in the metal fin-
ishing process, is a metal removal process that offers tight
controls over material removal from part to part, within a
lot, as well as from one order to another. The process not
only improves surface finish, but by removing the superfi-
cial exterior layer electropolishing effectively eliminates
imbedded particulate, contaminants and micro-cracks that
can otherwise become initiation sites for corrosion. Improv-
ing fatigue life is key for design engineers working in the
aerospace industry.
Increasing cycle life for components used in aerospace
applications is critical for preventing premature part failures.
In many cases, adding the electropolishing process has
enabled parts to pass fatigue testing while eliminating costly
redesigns and delays.

4 Electropolishing for the Aerospace Industry ableelectropolishing.com

 Able Electropolishing has established ongoing relationships with numerous aerospace vendors helping these
suppliers of commercial and military aircraft components produce high-quality, reliable parts.

Our ISO 9001 certification and associated quality program allow us to deliver quality parts time after time. Able
is an approve supplier for Boeing, earning the prestigious gold level performance rating.

COMMONLY ELECTROPOLISHED PARTS

• Brackets • Gears • Fasteners

• Flanges • Nozzles • Housings
• Bushings • Reflectors • Springs
• Seals • Ball Nuts
• Fittings • Ball Screws

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TECHNICAL SUMMARY

Electropolishing is often referred to as a “reverse plating” process. Electrochemical in nature,

electropolishing uses a combination of rectified current and a blended chemical electrolyte bath to
remove flaws from the surface of a metal part.

Since the development of electropolishing in the 1950’s, substantial refinements have taken place.
Able has numerous electrolytes to allow for electropolishing on a broad range of metals. These
newer electrolytes, combined with advanced parts handling techniques, have improved production
yields on a wide range of metal products.

The metal parts used in aerospace applications must be able to withstand the high stress and
corrosion associated with long-term use.

Today, commercial and military aircraft manufacturers utilize electropolishing as the

final step of production to improve cycle life and prevent premature part failures.

Following treatment, metal parts are free of micro-defects and have an ultraclean surface, which
results in enhanced corrosion resistance.

ALLOYS WE ELECTROPOLISH
Able specializes in providing electropolishing services for a variety of common and specialty metal
alloys. Here is a partial list of alloys we can electropolish:

• 200-300 Series Stainless Steels • Titanium

• 400 Series Stainless Steels • Nitinol
• Precipitating Hardening Grades • Specialty Alloys
• Unusual Stainless Steels • Nickel Alloys
• Copper Alloys • Specialty Steels
• Tool Steels • Carbon Steels
• Aluminum

6 Electropolishing for the Aerospace Industry ableelectropolishing.com

WHAT IT DOES
While electropolishing is best known for the bright polish left on a
surface, there are some important, often overlooked, benefits of this
metal finishing method. These benefits include deburring, size control,
microfinish improvement, ultraclean finishing, corrosion resistance
and others. These metal improvement benefits are highly desirable
to design and production engineers for cost savings and product
lifespan improvement.

HOW IT WORKS
The typical electropolishing installation is deceptively similar to a
plating line. A power source converts AC current to DC at low voltages.
A rubber-lined tank, usually fabricated from steel, is used to hold the Figure 1
chemical bath.

A series of copper or stainless steel cathode plates are lowered into

the bath and installed to the negative (-) side of the power source. A
part or group of parts is fixed to a rack made of titanium, copper or
bronze. That rack in turn is fixed to the positive (+) side of the power
source. As the adjoining illustration depicts, the metal part is charged
positive (anodic) and immersed into the chemical bath.

When current is applied, the electrolyte acts as a conductor to allow

metal ions to be removed from the part. While the ions are drawn
toward the cathode, the electrolyte maintains the dissolved metals in
solution. Gassing in the form of oxygen occurs at the metal surface,
furthering the cleansing process.
Figure 2
Once the process is completed, the part is run through a series of
cleaning and drying steps to remove clinging electrolytes. The result-
ing surface is ultra clean and bright. In fact, the bright surface is the
most identifiable trait and is what helped coin the process name:
electropolishing.

Figure 3

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DEBURRING
Electropolishing has become a common metal finishing
process used in the aerospace industry to help improve the
overall quality of metal components. These components
come in many forms, including high-performance fasteners,
fittings, nozzles, housings and welded assemblies. In order
to maintain reliable performance, these components must
be precisely manufactured and have an impeccable surface
finish free of burrs and other contaminants. The electro-
polishing process is suited for use on nearly any alloy and
removes a uniform amount of material from the surface.
At Able, we have been electropolishing a
variety of parts used in aerospace applica-
tions since the early 1980s.
CORROSION RESISTANCE
One of the most valuable benefits of electropolishing is resis-
tance to environmental hazards such as corrosion. Because
the process removes a thin, uniform layer of surface material,
it creates a passive, clean exterior, free of the iron deposits
that can appear after welding or other secondary operations.
Deterioration resulting from premature corrosion can change
the metallurgical structure of a component, weakening its
interior and damaging or loosening adjacent parts. Electrop-
olishing, therefore, is specified to inhibit or retard corrosion
and increase overall wear resistance.
8 Electropolishing for the Aerospace Industry
Electropolishing is an effective solution for deburring and
maintaining part integrity. It can remove the most marginal
amount of metal from parts and adhere to precise specifi-
cations-such as keeping corners sharp or preserving sealing
surfaces and other critical features.
It is critical that the components used in the aerospace
industry be free of contamination so as not to interfere with
the functioning of the assembly. Premature failure due to the
presence of foreign material can lead to equipment being idle
or even critical in-flight problems. Electropolishing effectively
removes any flecks of metal or contaminants that may be
present from machining operations.
Electropolishing leaves a stainless steel part with a chro-
mium-rich, passive surface that is much more resistant to
corrosion. While electropolishing is often used to inhibit cor-
rosion on stainless steel, it can be used on many other alloys
as well. Numerous companies use the procedure to delay or
hinder the corrosion properties of aluminum, copper, brass,
carbon steel and more.
ableelectropolishing.com
 CASE STUDY
Problem: Our customer was experiencing corrosion problems in an
isolated, critical area of a brazed seal ring. The isolated area was on
the recessed surface of the formed ring, and the customer needed to
remove the rust while maintaining the integrity of the copper brazing
material. The relatively small, interior critical area and the copper brazing
meant that mechanical polishing was not an option.

Solution: Able electropolished the inside of the seal, removing rust in the
critical area while keeping the copper braze intact. By electropolishing
to remove free iron at the braze joint, we enhanced the corrosion resis-
tance of the part at the same time.

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 CASE STUDY
Problem: One of our customers was experiencing a problem with
a part failing prematurely in a flight critical rotorcraft application.
The part was stamped out of a heavy gage material and the ellipti-
cal areas at the end of their narrow slots were developing fissures
and cracks after stamping. After extensive testing, they determined
that these defects were the root cause for the parts not reaching
their desired stress requirements.

Solution: Able worked with the customer in electropolishing a

number of test lots to determine the proper material removal
and processing parameters. In the end, Able was successful in
removing the fissures and cracks enabling the part to pass the
stringent bench testing. The electropolishing success was an
important factor in the company being awarded a large contract
for its new part design. The ability of the part to function longer
without wear, greatly improved the length of time the rotorcraft was
able to remain in operation.

CASE STUDY
Problem: One of our customers had a problem with extraneous
noise in the electric motors they manufacture. After extensive
investigation, they determined that the noise was coming from the
gear surfaces in their drive system. The gear teeth were slightly
oversized and required a precision, uniform removal of surface
material.

Solution: Through electropolishing, we removed a total of .0005”

of metal from the gear teeth. Our process not only improved the
microfinish but we were able to keep the teeth size in spec. The
resultant finish provided a gear that ran more quietly. The customer
now includes Able Electropolishing in the design of their carbon
steel motor gears, allowing for the necessary material removal in
their manufacturing specifications.

10 Electropolishing for the Aerospace Industry ableelectropolishing.com

 FATIGUE LIFE
IMPROVEMENT

The most significant benefit that aerospace engineers experience from electropolishing is fatigue
life improvement. Metal parts used in helicopters and airplanes must be able to withstand stress
and corrosion with long-term use, and must meet highly demanding cycle life specifications.
Whether the parts are machined or stamped, they will most likely exhibit surface anomalies that
can lead to premature failure.

These residual defects from manufacturing, often in the form of micro-cracks or pits, can become
initiation sites for crack propagation or corrosion. By removing these imperfections on the surface
of metal parts, engineers have found electropolishing to greatly improve the surface quality of
components, which in turn leads to significant fatigue life improvement.

Improving overall cycle life for flight-critical components is crucial for the industry.

Before:
SEM of raw part shows surface
imperfections and micro-cracks
before electropolishing.

After:
After electropolishing a
majority of the imperfections
have been removed.

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SURFACE PREPARATION FOR
PENETRANT TESTING

It is common, especially in the aerospace industry, for parts
that are fracture critical to be Liquid Penetrant Inspected (LPI)
prior to installation. Also known as Dye Penetrant Inspection
(DPI) or simply Penetrant Testing (PT), this method is used
to detect micro-cracks or other defects that could serve
as an initiation site for failure. In order to properly execute
a penetrant test, the surface of a metal part must be thor-
oughly clean of any debris, smeared metal, or any amorphous
layer that may be hiding a hairline crack thus yielding a false
reading.
etching in that some material alloys do not respond favorably
to chemical etching. It has been reported that A286 material,
for example, was completely destroyed by a chemical etch
bath which had worked fine on other materials. Volume 2
of the Liquid Penetrant Testing Non-Destructive Testing
Handbook states also that “abrasive cleaning methods should
be avoided” as these methods smear the metal and close dis-
continuities that the penetrant test would have detected

BENEFITS OF ELECTROPOLISHING FOR

PENETRANT TESTING
Electropolishing is the ideal process for this essential pre-
clean step because it can be easily controlled to remove a
precise amount of material in order to achieve the goal of
eliminating displaced metal and exposing the true surface.
Other types of chemical etching baths that do not involve
electrical current are harder to control. As the bath heats up
the chemicals can become more aggressive and the material
removal rate may vary and be harder to keep under control.
Parts with close tolerances can be easily turned to scrap with
an etching procedure. Electropolishing uses an electrolytic
solution in combination with rectified current. As soon as the
current is turned off there is no more electropolishing action/
material removal taking place, even while the parts are still
within the electrolytic bath. With these controls, electropol-
ished parts can be expected to have a tolerance of +/- .0002”
stock removal from part to part or lot to lot. For example, if
the aim is to remove .0006” total off of a given diameter or
thickness, the range of total stock removal expected over the
course of the production run should never vary outside of
.0004” - .0008”. Electropolishing is also superior to chemical

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 CASE STUDY
ELECTROPOLISHING PREPARES/PRE-CLEANS
PARTS PROPERLY PRIOR TO PENETRANT TESTING

Impeller electropolished to properly penetrant test:

An aerospace component manufacturer approached Able and
asked if we had the ability to electropolish their various sized
Impellers made from 17-4ph Stainless as well as Aluminum and
Inconel. Besides obtaining a better microfinish via electropolish-
ing, the customer was concerned with pre-cleaning their parts
thoroughly and uniformly prior to fluorescent penetrant testing
to avoid missing any critical defects. We were able to handle all
shapes, sizes and material types they were interested in electrop-
olishing. We developed a process to remove a specific amount
of material +/-.0002” from all outside surfaces of the part. Some
of the impellers had extremely tight tolerances on a specific bore
which we were able to mask at the customer’s request. In the
end, the customer found that electropolishing was a cost effec-
tive, consistent and quick method for meeting all of their metal
finishing goals.

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MICROFINISHING
In all aerospace systems, liquids and gases must be readily Electropolishing can deliver these benefits to the following aero-
available and flow easily through pipes, tubes, or hoses. From space components:
fittings to valves and nozzles, aerospace applications require
reliable and continuous operation. In operations where met- • Gears
al-to-metal surface contact is critical, improvement of that
metal surface becomes essential. • Pinions
• Housings
Virtually all metalworking operations such as cutting,
stamping, welding and forming, will affect surface quality. • Shafts
When these metal surfaces are forced to work in critical • Springs
sealing or friction zones, product performance often suffers.
In order to prevent this, those components must be free of • Nozzles
micro defects on the surface. This task can be accomplished • Seals
with electropolishing, which can improve the RA value by as
much as 50%. • Bushings
• Fittings
Unlike mechanical or hand-polishing, electropolishing is a
precise electrochemical process that dissolves an even layer • Fasteners
of surface metal across a metal part. This saves both time • Etc...
and resources by creating a uniform finish when manufactur-
ing parts with complicated or delicate shapes.

Other important benefits include:

• Elimination of peeling or abrading.

Unlike plating, painting or Teflon coating,
electropolished parts will not cause any coating
abrasion issues.
• No surface distortion, weakening or stressing of
the part. This makes electropolishing an ideal
choice for even the most fragile of parts.
• Resistance to staining and corrosion.
Imbedded impurities are removed, resulting
in a finish that is more resistant to corrosion,
tarnish, and oxidation.

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 CASE STUDY
Problem: We work with a customer whose main objective was to
remove the EDM recast layer on their 15-5 stainless steel parts
used in cockpit controls. The customer was concerned that the
remolten metal on the surface might interfere with other mating,
moving parts. In addition, the parts were not falling into specified
size tolerances called out on the print.

Solution: Unlike less precise, controlled methods of metal polish-

ing, electropolishing removes a pre-determined amount of surface
material from the metal part. Able was able to solve both of the
customer’s problems in one operation. We were able to remove
the recast layer, smooth the surface and size the part to within the
strict tolerance range required.

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ULTRACLEANING FOR SURFACE
CLEANLINESS
Surface finish is important for aerospace applications, but a project to tweak racking methods and stock removal to
the level of surface contamination and cleanliness is also ensure maximum surface finish improvement in critical
crucial. Machining and the subsequent secondary finishing areas. If electropolishing is added during the design stage,
operations introduce free iron, as well as, other exogenous customers can allow for the recommended material removal
surface contamination to the workpiece. Electropolishing is to receive the full benefits of the process.
an effective means for removing not only the surface contam-
inants but also the imbedded particulate. The resultant finish Electropolishing, though most commonly employed on 300
is clean and passive and the component ready for assembly. series stainless steels, can also be used on nearly any metal
alloy. We electropolish various alloys for aerospace applica-
Electropolishing effectively creates a clean part that has the tions, including aluminum (5052, 6061, 7075), stainless steel
following characteristics: (17-4 PH, 17-7 PH, 13-8 PH, 15-5 PH, AM 355), titanium, and
others.
• Non-coating
Unlike other metal finishing processes, elec-
tropolishing does not require a coating. Unlike
paints, plating or Teflon coatings, electropol-
ished parts do not peel or abrade.
• Non-distorting
This makes electropolishing an ideal choice for
even the most fragile of parts.
• Stain and corrosion resistant
Parts undergoing electropolishing have en-
hanced corrosion resistance that is 30x greater
than passivation alone.

At Able, we work with our customers in the early stages of

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 CASE STUDY
Problem: The customer manufactures a copper can that holds
chemicals that produce oxygen on demand for emergency breath-
ing masks on commercial airliners. The part has to be completely
clean and contaminant-free. Contaminants could potentially com-
promise the integrity of the chemicals stored inside. Because the
part is designed to be stored for extended periods of time, it must
also be highly resistant to oxidation and corrosion.

Solution: Electropolishing is a single-step solution that efficiently

cleaned the parts for safe use. Electropolishing copper removes
the outermost layer of metal from the material, clearing away any
surface contaminants lingering after drawing or normal handling
during manufacturing. The resulting finish is more resistant to
corrosion, tarnish or oxidation. In this case it gave the part an
extended life, meeting or exceeding all design and testing speci-
fications. Although some non-ferrous alloys can have shelf lives
for years before oxidation occurs, it is important to realize that
electropolishing is not a substitute for platings or coatings.

CASE STUDY
Problem: One of our customers had a “hermetic assembly” made
from 304 stainless steel and molybdenum. The two pieces were
glass-fused in an oven – an operation that created a green oxide
layer, which needed to be completely removed. The part was sub-
jected to a variety of tests to detect leaking and sealing breakdown,
and it is part of a critical aerospace battery component.

Solution: Electropolishing removed the green oxide layer, leaving

behind a uniform, oxide-free and ultraclean surface. Able has a
long history of success removing the discoloration caused by heat
treating operations. After electropolishing, the hermetic assem-
blies were subjected to stringent leakage testing. The parts met
the necessary criteria and passed all testing.

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ABOUT US
METAL FINISHING EXCELLENCE SINCE 1954 Our entire company is tuned to the concept of doing the job
right the first time. We have long recognized that metal fin-
Production and engineering breakthroughs achieved during
ishing is the “last step” for many companies designing and
WWII led to new and exciting metal finishing technologies
producing metal parts, and we are often the lifeline for com-
as industry shifted from the war economy. Our founder, Zen
panies faced with assembly line shutdowns due to parts that
Pokvitis, was on the leading edge of those developments and
are late or malfunctioning. Being part of the solution and
focused his chemical background on production applications
meeting tough deadlines has established Able as the pre-
for electropolishing. That experience in chemical formulation
ferred vendor for so many companies.
and equipment design led to the founding of Able Electropol-
ishing Company in 1954, which began focusing on the needs
of metalworking companies nationally. ADDITIONAL METAL FINISHING &
IMPROVEMENT SERVICES
A COMMITMENT TO ENVIRONMENTAL While electropolishing is our signature service, we also have
SUSTAINABILITY other metal finishing capabilities to enhance your parts. In
Able continues to make large investments in our facility to addition to electropolishing, our other services include:
make sure we are in compliance with the stringent environ-
mental guidelines now being enforced by federal, state and • Passivation
local regulatory agencies. Our investment in practices that
• Contract Cleaning
support environmental sustainability means we’re ready to
serve our customers today and in the future. • Titanium Color Anodizing
• Laser Engraving
THE NEXT GENERATION OF INNOVATION,
SERVICE & EXPERTISE • Bake Out
Today, Able Electropolishing is America’s largest electropol- • Custom Packaging
ishing specialist, employing more than 160 people on three
shifts at our 40,000 sq. ft., state-of-the-art facility in Chicago,
Ill. Thousands of companies in nearly every industry world-
wide utilize Able technology for their metal parts.

Though our technology plays a vital role in serving custom-

ers, the traditions of service and attention to quality are what
make Able Electropolishing a unique company.

18 Electropolishing for the Aerospace Industry ableelectropolishing.com

THE ABLE DIFFERENCE
EXPERTISE & EFFICIENCY By meeting or exceeding the various standards and quality
management system requirements set by these organizations, we
Able Electropolishing takes pride in our exceptional, expedi-
can provide services like electropolishing, passivation and more
ted electropolishing process. By providing our signature metal
while giving our clients a sense of true security and consistency in
finishing service aerospace component manufacturers in a timely
our quality.
manner, we assist our customers who need fast and accurate
results.
When you work with Able Electropolishing, you can enjoy the peace
of mind that we are meeting high standards, whether you’re sending
INDUSTRY STANDARDS
us one part or thousands.
We meet the following industry standards:
We continue to add state-of-the-art equipment to keep at the fore-
front of our industry.

• AMS 2700 • ASTM A967

• ASME BPE • ASTM B912
• ASTM A380 • ASTM F86
We are also an ISO 9001 and ISO: 13485 registered company. These
standards allow us to provide finishing services for critical parts
in industries like pharmaceutical, medical device manufacturing,
aerospace, automotive and more.
QUALITY STANDARDS & CERTIFICATIONS
At Able Electropolishing, we strive to satisfy our customers with
every metal finishing job we complete. This includes adhering to
international standards of excellence, ensuring that we consistently
provide a variety of high-quality metal finishing services. We meet
standards set by:
SUPERIOR SERVICE
When you call Able with technical questions, you will speak with a
knowledgeable representative who will have the most up to date
information at their fingertips to accurately discuss your part and
application. Over sixty years of electropolishing history combined
with an equally staffed three-shift operation ensures that your parts
will be processed as quickly and accurately as possible.
As an ISO certified company, we keep extensive processing records
from the initial sampling/R&D process all the way through production.
Once we work with a customer to customize our process for their
part and application, detailed engineering records are maintained
electronically. If the customer initiates any changes over the life of
the job, those changes are documented and remain permanent on
the electronic engineering record.

• ASTM (The American Society for Testing and Materials)

• ASME (The American Society of Mechanical Engineers)
• SAE (The Society of Automotive Engineers)
• ISO (The International Organization for Standardization)

ableelectropolishing.com Able Electropolishing 19

E: SALES@ABLEELECTROPOLISHING.COM

P: 888.868.2900

THE ABLE ELECTROPOLISHING DIFFERENCE

Since 1954, Able Electropolishing has been refining its tech-

nology to improve the fit and function of metal parts. No
matter whether your part is small or large or the industry
you work in, our electropolishing process gives you a
unique combination of benefits you won’t find with other
metal treatments.

Find out more at: ableelectropolishing.com