CONSUMABLES

A perfect surface finish by selecting the best electrolyte to meet your machine and finishing requirements

Our surface finishing experts provide custom solutions by guiding our customers in selecting the best media from our wide range, considering the following crucial factors to identify the ideal solution

Material

The material being treated is a crucial factor in determining the appropriate electrolyte formulation and process parameters. At our test lab, we have developed consumables that enable us to precisely meet the requirements of our customers. There are many factors that must be considered when treating a material, such as its composition, density, and hardness. Our team of experts has extensive knowledge of various metals and alloys and can determine the best electrolyte formulation and process parameters for each material.

Requirements

Every part is unique, and achieving the desired surface finish requires a customized approach. That’s why we begin our projects by closely collaborating with our clients, evaluating their goals for their pieces, as well as the initial part condition and manufacturing process. Using our extensive expertise, we define the optimal process parameters, media formula, and geometry that will deliver the perfect solution. This meticulous attention to detail is what sets us apart and ensures that our customers always receive the best possible outcome.

Geometry

Our equipment uses mechanical movements and electrical parameters to ensure optimal media and electricity flow across the surface, achieving homogeneity on the part. The DLyte systems can process parts of various geometries, shapes, and sizes with precision. Our equipment is designed to provide precise and uniform results, regardless of the shape or size of the part being treated. Our immersion and projection systems are highly versatile and can meet the surface finishing needs of a wide range of industries and applications.

Electrolyte fundamental features to treat diverse materials, geometries and finishing processes
Solid electrolytes composed of particles are more aggressive and can more effectively reduce roughness than electrolytes in suspension. This is because the liquid that contains the suspended particles offers some protection to the surface from oxidation during the process. This characteristic makes solid electrolytes particularly suitable for treating materials that are highly reactive to oxidation and require protection.
Size and geometry
Using particles with varying sizes and geometries allows for treating pieces with different geometries effectively by reaching hard-to-reach areas, which maximizes the surface area in contact with the electrolyte and leads to a more uniform and thorough treatment of the material. This technique provides an efficient and versatile solution for various material finishing needs.

Type 01

Type 02

Type 03

Type 04
Elastic deformation
Tuning the elasticity of electrolyte particles allows for achieving outstanding finishes with exceptional precision and speed, characterized by differences in brightness, homogeneity, and material removal rate, among others. This technique provides excellent versatility in a range of material finishing applications, whether in single-step or multi-step consumable processes.

Macroporous

Gel
Chemical formulation
Customized electrolyte formulations are essential for achieving high-quality finishes while minimizing material removal and maximizing productivity. By tailoring the formulation to specific requirements and industry regulations, this technique provides an efficient and versatile solution for a wide range of material finishing needs, including aqueous or oil-based solutions, additives, and acids.

Formulation

Concentration

Environmental Benefits of DryLyte Technology

Waste Management

The DryLyte Technology and the equipment it powers, DLyte, do not require wastewater or sludge treatment machinery. Both allow labor and environmental license costs savings, since the dry electrolyte required can be easily handled by standard services. In its turn, all the metal removed from the work pieces remains in the media.

The previous feature offers a clear advantage in comparison to traditional abrasive surface treatments, which require wastewater treatment machinery and the adequate space to work. It also involves labor and environmental license costs. Moreover, abrasive surface treatments need a water treatment system in order to clean the water polluted with metals and compounds.

Liquid electropolishing requires additional safety measures to be put in place for proper disposal, due to environmental concerns related to highly corrosive and toxic mixtures of phosphoric and sulphuric acids and sludges containing metals.

In addition, several liquid electrolytes may generate certain amounts of sludge which require to be removed from the tanks to keep the process stable.

Liquid electropolishing needs replacement of a portion of the used solution for a good performance and to guarantee a high-quality metal surface finishing process. The disposal of the liquid requires a specific service to ensure environmental compliance conforming to regulations.

This surface treatment method may also require a post-dip to remove residual electrolyte and by-products from electrochemical reactions. The disposal of liquids used in the post-dip process may also requires hazardous waste management.

Handling and Storage of Media and Mixtures

DLyte only uses solid electrolyte media with a low acid concentration which can be handled and stored without additional safety measures. It is not harmful for workers and, since it is solid waste, its handling reduces the probability of discharge in drains and waterways.

Abrasive surface treatment usually requires compound and chemical accelerators in large amounts, which involves a danger for workers during handling, as well as an eventual risk of discharge into the environment.

Liquid electropolishing uses highly corrosive and toxic liquid mixtures of phosphoric and sulphuric acids. This may be dangerous for professionals during handling and for environment.

This metal surface treatment usually requires a post-dip to remove residual electrolyte and by-products of the electrochemical reactions.

The handling of liquids used in the post-dip may also suppose a risk for workers, and can cause a discharge in waterways or drains.

Water Consumption

The DLyte system requires low water consumption, as it only needs water to adjust conductivity of the media.

On the contrary, in abrasive surface treatment, large amounts of water are generally necessary to polish, especially for high quality surface finishing requirements. If different materials are processed in the same media, a heavy flow of water will prevent pollution.

Exposure of Workers during Polishing and Maintenance Processes

DLyte improves working conditions and drastically reduces the toxicity of current polishing processes, as it does not generate dust, heavy noise or contact the workers with highly corrosive and toxic liquids during handling and maintenance. Metals removed from the work pieces remain in the media, so workers are not exposed to the cathode.

Abrasive surface treatment generates dust. It can be dangerous for the health, since the particles that cause damage are often invisible to the naked eye. This is why the eventual health effects of exposure can take many years to be visible. Abrasive surface equipment is usually very noisy and can lead to hearing loss in case of inadequate hearing protection or prolonged exposure to noise in the workplace.

Handling of sludge and compounds with high concentration of metals may be also harmful for workers if protective measures are not strictly ensured.

Secondly, abrasive surface treatment requires in some cases a final manual buffing to achieve the required surface quality, which involves an additional exposure to dust and toxic particles to workers.

Liquid electropolishing uses highly corrosive and toxic liquid mixtures of phosphoric and sulphuric acids in tanks which carries a high risk for workers in case of accidental splashes. Metals removed from the work pieces remain in the liquid and partially attached to the cathode. Thus, it involves a risk of exposure for workers during handling and maintenance of the tank and the cathode cleaning operation.

The post-dip process is performed in tanks to remove residual electrolyte and by-products from the electrochemical reactions. It also means a potential risk for workers in case of splashes during operation or by accident.