Development of Innovative Technology for Applying Hard Chrome Coating
Since 2010, the "Ural Engineering Center" has been developing innovative technology for applying hard chrome coating to the surface of rotating bodies – rods, rollers, sleeves. In 2019, with the participation of South Ural State University as part of the Federal Target Program, a sample of an industrial complex for applying hard chrome coating was designed and manufactured.
Main Characteristics of the Coating Obtained:
- Hardness: 950…1050 HV.
- Thickness: 20…42 microns.
- Sizes of chromed parts: Ø20…320 mm, L = 50…4000 mm *
* - It should be noted that, due to the design features of the complex, the length of the chromed part can be increased to 7000…12000 mm with minor modifications to the structure.
Brief Description of the Technology
The design of the complex ensures the rotation of the chromed product during the electrolytic process. Depending on the requirements of the technical specifications, the workpiece is either fully installed in the chroming bath, or (for larger parts) the chroming bath moves along the workpiece, applying the required thickness and strength of the coating in one iteration.
If necessary, the chroming cell can be equipped with special tooling for continuous mechanical impact on the workpiece during the coating application to improve the strength characteristics of the coating.
Between 2015 and 2020, studies on the obtained coating were conducted at the laboratory base of South Ural State University, as well as at the SMS Siemag Group (Germany) scientific partner institute, which showed its high operational characteristics.
Currently, "UrIC" LLC is working on creating an industrial technology for applying chrome coating to the internal surfaces of rotating bodies (sleeves for the oil industry, sleeves of hydraulic cylinders).
Competitive Advantages of the Developed Technology
- Environmental Safety. Closed chroming cycle. The process takes place in a closed cell with minimal contact with the environment. The equipment uses an innovative filtration system that allows the majority of harmful substances to be returned to the electrolyte container, thus ensuring minimal impact on the environment and personnel within the limits established by Russian legislation.
- Energy Efficiency. Due to the small volume of the chroming cell, the described technology requires significantly less energy for heating the solution compared to traditional immersion chroming methods.
- Coating Quality. The rotation of the workpiece during chroming prevents the increase of radial defects in the coating that are inevitable in traditional technology. Consequently, the obtained coating has greater strength and durability.
Equipment Composition:
- Installation with a movable (or stationary, depending on the technical specifications) chroming bath with mechanisms for rotating the workpiece.
- Electrolyte supply system.
- Filtration system for environmental protection.
- Control cabinet containing power supply elements and automation control system of the complex.
- Rectifier unit for ensuring the electrolytic process.
- Control panel (if necessary – operator workstation based on a personal computer. The level of process automation is specified in the technical specifications).
- Set of measuring instruments for controlling the quality of the obtained coating (if necessary).
- Surface preparation/final processing device for the workpiece (if necessary).
- Workpiece loading/unloading system (if necessary).
- Workpiece storage system (if necessary).
- Deionized water supply system for the electrolytic process (if necessary).
- Compressed air supply system (if necessary).
It should be noted that the equipment configuration for a specific technological line is tailored to the customer’s needs to maximize compliance with the technical specifications and can be simplified to reduce equipment costs or expanded to achieve maximum performance and broaden technological capabilities.
LLC "UrIC" offers the following services within this area of activity:
- Chroming of customer parts.
- Development of technology, issuance of design documentation, supply, installation, and subsequent service maintenance of industrial lines for coating cylindrical parts according to the customer’s technical specifications.
