In the last years, surface finishing in the automotive industry and motor racing experienced robust growth, a trend that is expected to consolidate with new challenges and opportunities related to fuel efficiency, gas emissions, longer part life, component downsizing and electric vehicles.
Dry electropolishing performs high-quality, fully automated surface finishing increasing efficiency, performance and lifespan of automotive components. Metal-to-metal contact power transfer components like gears, transmission parts, crankshafts and camshafts, bearings and other high value, delicate or complex parts are treated with precision following specific finishing requirements.
The technology is able to improve surfaces with smoothness, precision and negative skewness impacting positively in fuel consumption and CO2 emissions reduction of automotive vehicles.
DLyte surface finishing has also impact in the fatigue life and overall safety and reliability of the parts providing an ultraclean, corrosion resistance and free of burrs surface. Additionally, the process gives auto parts a uniformly bright, shiny and chrome-like appearance.
DLyte also improves the work environment of companies by replacing traditional polishing and hazardous materials. Surface finishing automation protects technicians from exposure to chemical agents in the workplace.
The consumables used are safe and clean, without the risk of generating liquid chemical waste or dust during the polishing process.
Benefits and applications of DLyte electropolishing processes
DLyte precisely surface smooths, deburrs, rounds and passivates parts made from any manufacturing method, including forging, casting, machining, in the automotive industry.
Common applications are gearbox and engine components, such as cylinder heads and engine blocks, transmission components, fasteners and exhaust systems, fuel lines, bearings, camshafts and crankshafts, injector nozzles, valves and decorative parts.
Among the key technical advantages of the DryLyte technology, it is worth noting the following:
- Extremely low and homogeneous roughness finishes (down to Ra 0.01 microns)
- Geometry preservation, tight tolerances and edge rounding in a controlled way
- Increased resistance to corrosion (30 times more than passivation)
- Reduced coefficient of friction up to 30%, and also reduced fuel consumption
- Noise and heat reduction
- Negative RSK leading to better lubrication and increase of bearing ratio
- Increased part durability
- Faster and absolutely reliable and traceable processes
Some applications
Propellers, impellers & hydro turbines
Material: Stainless steel
Manufacturing: Casting + turning and milling
Application: Mirror finish
Achieved Ra: < 0.2 μm
Processing time: 64 minutes (1 part)
DLyte equipment: DLyte PRO500
Common materials
01.
Aluminium
This is the most widespread metal on Earth. Aluminum is light, robust, durable, and functional, and one of the most common engineering materials of our time. It is widely used in the jewelry, automotive, aerospace and energy industries due to its main benefits: corrosion resistance, recyclability, and cost efficiency.
02.
Carbon Steel
An alloy made of iron and carbon. Its properties are mainly defined by the amount of carbon it has, determining the hardness, ductility, and tensile strength of the steel. The strength and durability of carbon steel make it suitable for many industries, as it withstands higher levels of wear and tear.
03.
Nickel alloys
It can be easily alloyed with other metals and alloys, including nickel brasses, bronze, copper, chrome, aluminum, cobalt, silver, and gold. Its alloys have outstanding resistance to corrosion and high-temperature scaling, exceptional high-temperature strength, shape memory, and low coefficient of expansion.
04.
Stainless steel
An iron alloy with a minimum of 10.5 percent of chrome, which produces a passive layer that prevents corrosion. This versatile material is widely used in the industrial sector, due to its strength, biocompatibility, durability, aesthetic attractiveness, hypoallergenic properties, and profitability. It withstands high temperatures.
05.
Titanium
An appealing and popular material that can be alloyed with iron, aluminum and vanadium, among others, to produce strong and lightweight alloys. Its most useful advantages are corrosion resistance, strength-to-density ratio, biocompatibility, durability, and hypoallergenic and aesthetically attractive properties.
Technical aspects
Defect-free surfaces and homogeneous finish
Preservation of geometry without rounding edges
Improved passivation and corrosion resistance
Assured reliability and repeatability
Drastic lifespan increase
Economic and environmental aspects
Short processing time in a compact design
No devices to manage sewage and sludge
High profitability and short payback time
Environmentally friendly
Protects workers' health
DLyte success cases in the automotive industry
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