Electrolytic polishing& mechanical polishing
Astro Pak offers a full range of surface cleaning and polishing services to meet the individual needs of each customer. Separately, mechanical polishing, electropolishing and electroplating can be separate processes. However, some requirements are best met by a combination of one or more of these services. when used with ourChemical cleaning and passivation services, customers will experience superior corrosion and contamination protection for longer-lasting, more reliable performance.
Astro Pak uses specially designed tools to ensure optimal contact with complex stainless steel surfaces, as well as proprietary chemicals for superior results. The surface roughness is reduced to a level equal to or lower than the originally specified surface finish. "Ra" or surface roughness is confirmed by microscopic and profilometric tests to ensure absolute quality assurance. Our profilometers measure surface roughness, while our ultrasonic testers measure container wall thickness. Documenting these measurements before and after restorations allows our highly trained technicians to produce results that meet or exceed industry standards.
From field technicians to office staff, customer service is always second to none. All demonstrate professionalism and excellent communication skills.
- project manager,Pharmaceutical Company, Devens, MA
Astro Pak performs all three of these services on-site to help clients maintain or improve surface finish conditions inside or outside the vessel while minimizing downtime. When used as part of ship pre-operational preparation, our services improve system reliability by overcoming problems arising from fabrication and installation. Specially trained personnel for confined space entry are highly skilled in repairing hard-to-reach equipment. They are available 24/7 to get process vessels, large or small, up and running quickly. In addition, we offer these services in our network of stores across the country.
ASTRO PAK electrolytic capabilities
| alloy | ability |
|---|---|
| Austenitic stainless steel | And |
| ferritic stainless steel | Small quantities available, please call for more information |
| stainless steel duplex | Small quantities available, please call for more information |
| Precipitation hardened stainless steel | Small quantities available, please call for more information |
| Nickel-based legumes (Hastelloy, Inconel) | Call for more information |
| aluminum | Yes |
| titanium | Yes |
| cobalt | Yes |
| bakar | Yes |
What is mechanical polishing?
Mechanical polishing is a surface finishing procedure in which abrasives are used for grinding and/or polishing the surface. This results in a uniform finish that meets or exceeds ASME BPE and ASTM B912 standards. Mechanical polishing removes corrosion, pitting, scratches or etching damagestainless steel passive layer,It creates a low chromium area that is more prone to corrosion. This damage can be the result of mechanical action or chemical reaction. Mechanical polishing also allows for smooth replacement or addition of valve rings and welds. For dry product containers, mechanical polishing alone is usually sufficient. For other applications, it is often the first step before electropolishing and passivation.
What is electrolysis?
Electropolishing is an electrochemical surface treatment process that uses direct current delivered through an electrolyte solution to melt a metal surface to a limited depth. The end result is a finish that meets or exceeds biopharmaceutical surface finish requirements. Can reduce Ra readings to half with mechanical polishing alone.
In addition, electropolishing removes impurities, inclusions and other embedded contaminants, also known as the Bielby layer, formed during mechanical polishing. The result is a smooth, mirror-like surface with no room for debris, dirt or even single-celled bacteria. Electropolishing is usually the final process in preparing a vessel for service. However, electropolishing combined with passivation results in a smooth chrome-rich surface with improved cleaning ability and excellent corrosion resistance. This finish is critical for high purity applications.
Advantages of electropolishing
- Improve cleanliness
- Increased endurance
- Improve sterility
- increase corrosion resistance
Electrolytic cleaning
Electrolytic cleaningis a short version of electropolishing that uses similar tools and chemistry. Redness and other metal surface contaminants can be quickly removed from austenitic stainless steel (300 series) by the ELC (electrolytic cleaning) process.
In fact, since these contaminants do not "stick" to the surface as tightly as ordinary metals, it takes much less time to remove them. Redness is released from the surface quite quickly compared to base metals, and the substrate is in a decontaminated condition before further polishing, passivation or fabrication can proceed. Weld color or heat tint can also be removed by electroplating, as this process is limited to the outermost surface of the metal and therefore does not require deepelectropolishing processremove.
a common problem
Electropolishing smoothes surfaces by removing material to create a smoother or glossier surface. Passivation improves surface chemistry to reduce corrosion potential by removing iron from the molecular top without affecting the surface finish.
Electropolishing excels at producing surfaces that are cleaner, smoother, and more representative of base metals than any other method currently in use. This is suitable for biopharmaceutical applications where a simple check of the cleanliness of containers and equipment is required. Electropolishing also reduces the surface (vacuuming), somewhat passivates the surface and removes any embedded impurities that may be present after mechanical polishing.
Electropolishing removes material, while electroplating deposits material. The two processes are very similar in that they both use electrolytes for charging, but with different polarities.
The electropolished finish is just as durable as the base metal itself. Rough handling and chloride damage are the two main types of damage we most often repair.
Most metals can be electropolished, but some of the chemicals required are very dangerous. With our current chemistry, we do not electropolish titanium or aluminum.
ASTM B-912 is the most commonly requested specification, but the current BPE SF4 specification is a close second. There are also many different semiconductor industry specifications.
Electrolysis removes peaks and clears valleys. It only removes surface material and does not fill gaps.
Mechanical polishing uses abrasives to cut the surface, while electropolishing uses chemicals and electricity to dissolve the surface.
Electrolysis removes peaks and clears valleys. Removes only the surface material, not the filling. Typically two-tenths to four inches of surface material is removed to meet BPE specifications.
Electropolishing can reduce existing surface roughness (Ra) by up to 50%, but Ra is only part of the story. The EP surface is flatter and smoother at the microscopic level, an order of magnitude finer than that explained by Ra alone.
The on-site Astro Pak method allows us to gradually polish very large containers. Complexity is often a bigger challenge than size.
It depends on your definition of "best". Electropolishing produces a smoother surface, but does not provide the improved chromium/iron ratio that proper passivation provides.
Not our current chemistry. Most metals can be electropolished, but some of the chemicals required are very dangerous.
- Process vessels and reactors from 2 liters to over 30,000 gallons
- Fermenter
- WFI, Containers for the preparation and storage of buffers and media
- Autoclave
- Laboratory equipment and accessories
- Cutlery, V-mixers and powder mixers
- stainless steel pipe
- All types of components such as packaging and transfer material
- Pumps, sprayers, dip tubes, mixers and many other peripherals
- Heat exchanger
- OEM and repair
- Accela-Cota tablet coating
- Fluidized bed dryer
- ASME BPE (standard for bioprocess equipment)
- ASTM B912 uses electrolytic passivation of stainless steel
- EFS 1 – 4 (Electropolishing Standard 1-4)
- ISO 15730
- SEMI F19-0304 Specification for Wetted Surface Treatment of Galvanized 316L Stainless Steel Components
- AMAT 0250-13605
- Biofarmaceutski
- Aviation, military and defense
- health care
- Distribution of water and waste water
- semiconductor
- Production of powders and tablets
- ocean
- nuclear
- petrochemical
- Technical documentation
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