Springs may seem like simple components, but their role in countless applications — from medical devices to aerospace— demands perfection. Even the slightest defect in the metal surface can drastically shorten a spring’s lifespan or lead to catastrophic failure in mission-critical environments.
Electropolishing is a precise finishing process that can enhance the performance and durability of metal parts in ways that traditional metal finishing methods can’t match, elevating the finish, fit and function of critical parts like compression, torsion and flat springs.
The Basics of Electropolishing
Electropolishing is an electrochemical process that removes a microscopically precise amount of material from a metal surface, smoothing imperfections that include microcracks, microburrs and other defects. Metal parts are carefully placed into racks and submerged in a chemical solution with an electric current that gently strips the metal’s surface of defects. Through this carefully controlled process, manufacturers can enhance the surface finish, improve corrosion resistance, and significantly extend the cycle life of springs.
Springs are subjected to rigorous use — bending, flexing, and twisting thousands of times. Every micro-defect on a spring’s surface can become a point of weakness over time, leading to cracks, corrosion and, ultimately, failure. Electropolishing addresses these potential pitfalls by creating a uniform, ultrasmooth surface that can withstand the wear and tear of repetitive use.
Extending the life of your springs
Springs are designed to flex and compress repeatedly, but even the most well-designed spring can fail if its surface is marred by imperfections that become initiation sites for cracking and corrosion.
Electropolishing eliminates surface defects including notches and burrs left behind after wire forming and cutting operations. By eliminating these stress concentrators, electropolishing allows springs to perform more cycles without succumbing to part fatigue. Electropolishing also removes discoloration left behind by heat treatment, leaving behind a bright, decorative finish while enhancing the material’s corrosion resistance.
For example, 17-7 stainless steel is a commonly used alloy in spring manufacturing. When heat-treated, this alloy can develop discoloration and surface roughness that not only detracts from its appearance but hinders its performance. Electropolishing gently and effectively removes both discoloration and roughness, leaving behind a bright, decorative finish with enhanced resistance to corrosion.
Electropolishing vs. Tumbling for Critical Metal Springs
For manufacturers, the choice of finishing process can be a make-or-break difference in the performance of their metal springs. Tumbling is a commonly used method for deburring, but it comes with significant downsides for springs: parts can become distorted or tangled, especially small, delicate springs.
Electropolishing uses careful and sometimes custom racking to ensure that parts do not come into contact with other parts and receive even, consistent exposure to the electropolishing bath.
Another advantage of electropolishing over tumbling is its ability to reach tiny, hard-to-access areas that are often missed by traditional bulk finishing methods.
The Able Electropolishing Advantage
As pioneers of the electropolishing process, Able’s team has perfected the art and science of electropolishing for critical metal springs (among other critical metal parts). Whether you’re working with stainless steel, music wire, Inconel, or specialty alloys like Elgiloy, we have the expertise and equipment to enhance your springs’ performance, longevity and appearance.
Our in-house testing and inspection capabilities, which include advanced 3D profiling, provide a detailed view of the microscopic surface improvements that electropolishing achieves. The before-and-after images of an electropolished springs reveals the smooth and defect-free surface that electropolishing creates.
Meet the Electropolishing Experts at CASMI’s SpringWorld
If you’re attending the SMI SpringWorld symposium in Rosemont Oct. 2-4, be sure to stop by Booth #827 and speak with a member of the Able Electropolishing team to learn how electropolishing can improve the cycle life and performance of your springs.
Send us a sample part to electropolish at no charge to see how electropolishing can improve the cycle life and performance of your springs.
