Have you ever thought what is common between a spoon and thousands of things that surround you?
The investment project The electrolyte-plasma polishing — the first world’s ecologically clean method of conducting materials’ processing 2 ¡
The existing alternatives Mechanical polishing Cons of the polishing: Restrictions on the complexity 1 of the surface Abrasives are introduced into 2 the structure of the metal Harmful 3 Resource using 4 - Number of stages - Various settings Types: Sandblasting, abrasive disks, tapes with - High time costs polishing paste, drum and vibration machine - Complexity of the process managing 3 ¡
The existing alternatives Chemical polishing Cons of the polishing: The technological complexity 1 A high percentage of defects 2 Toxicity and flammability 3 Corrosion of equipment 4 Costly waste disposal 5 4 ¡
The existing alternatives Electro-chemical polishing Cons of the polishing: High energy using 1 Toxicity, explosion, flammability 2 The technological complexity 3 Limitations of the range of metals 4 The long process 5 5 ¡
Comparison of the technologies Mechanical ¡ Chemical ¡ ¡ Electro- Electrolytic Plasma ¡ Chemical Productivity Medium Low Medium High The restriction on the Simple profile Complex profile Complex profile Complex profile geometry Changing of is possible Exposure to implementation Unevenness of Poor handling of Hardening of the the material of accidental particles treatment, etching flat surfaces material The complexity Medium Medium High Medium of processing Ability to automatisation Yes No No Yes The cost of materials Low High High high Amortization period 25 years 5 years 20 years 20 years Occupied manufacturing Low Medium Medium Medium area Ecological level Low Low Low High Flammability Low High Medium Low Energy Consumption Medium Low High High Qualification of workers Low Medium Medium Medium 6 ¡
The history of development of the method 1972 — the effect of heating in the electrolyte. 1985 — the first result, "it shines!", was obtained in BNTU. 1989 — the first introduction of EDO "Orgstankinkprom“. 1992 — the first implementation of the technology of 4 power plants 250 kW, manufactured by Research Laboratory, "Sosni" in Nytvinskiy Metallurgical Complex (city Nytva, Permskiy region). 1992-2011 — The technology is suitable for 50 types of metals, alloys and more than 1 000 species of plants. The implementation of up to three installations a year at the plants in Russia, the Ukraine and Belarus. Technological maintenance. 7 ¡
Application The finish polishing Reduction of surface roughness up to Ra = 0,04 m Polishing with an accuracy of up to 12 Improvement of the reflective properties of the surface up to 70% 8 ¡
Application Cleaning of the surface The processing time from 30 seconds . The opportunity to polishing right after the cleaning simply by changing the regime (mode) Removal: – oil – colors – scale – rust/oxide – abrasive implants 9 ¡
Application Blunting of the edges and deburring Fast processing of deburring up to 0.3 mm Treatment of complex shapes Treatment of great quantities of products for large stamping lines The rapid process for non-ferrous metals (30-50 seconds) 10 ¡
Application Preparation for the application of vacuum-plasma coverings Three effects in one operation: Deoiling 1 Etching process 2 Activation of the surface 3 11 ¡
Application The sharpening of tools Pre-sharpening without heating and the physical impact Polishing and sharpening at the same time С ost reduction of the operation of mechanical sharpening 12 ¡
Application Treatment of Semiconductors High accuracy class of polishing Exception of several operations Treatment of ultrathin wafers 13 ¡
Advantages of the technology Ecological compatibility & safety Does not require the utilization 1 of hazardous wastes Does not harm to the health 2 of workers Reduces industrial injuries 3 Compliance with sanitary 4 and fire regulations 14 ¡
Advantages of the technology Economic efficiency The speed of processing 1 (an average of 2-5 min.) A minimum of manual operations 2 (the possibility of full automation) The increase in productivity 3 up to 700% Low resource intensity 4 The universality of equipment 5 15 ¡
Advantages of the technology Technological effectiveness of the process Low consumption of materials 1 Compactness of the installations 2 The low percentage of defects 3 The absence of multiple stages 4 Automation and ease 5 of management 16 ¡
Advantages of the technology Improvement of the material Process without overheating ( t max = 90°C) 1 The effect of surface hardening 2 3 No force action Polishing materials do not penetrate 4 in the structure of the metal 5 The surface takes on anti-corrosion properties Using to remove impurities from 6 the surface 17 ¡
Advantages of the technology The accuracy of polishing The possibility of polishing 1 the articles of small size The possibility of using 3 in specific industries – Nuclear Industry (polishing of fuel element) – Electronics (manufacturing of semiconductors) – Medicine (micro-implants) 18 ¡
Advantages of the technology Latitude of using Almost all metals and alloys 1 Easy integration with 2 automated production lines Non-waste technology for the 3 polishing of precious metals (the ability to recover the metal from the sediment) 19 ¡
Description of technology How does it work? Workpiece 1 Electrolyte 2 Operating cell 3 20 ¡
Description of technology The electrolyte-plasma mode Electrolysis Switching regime Allocations of hydrogen, ammonia, oxygen, water vapor. Electrolyte-plasma treatment 21 ¡
Description of technology The technological process of electrolyte-plasma polishing for non automated lines Preparation of a detail to the polishing Flushing in warm water 1 4 Manual loading to the suspension Drying with warm air 2 5 Automated operations: 3 Manual unloading 6 - Supply of voltage on a raised suspension - The slow descent into the electrolyte Monitoring 7 - Excerpt 2 ... 8 minutes - Lifting the suspension with the details - Off voltage 22 ¡
Description of technology Technical characteristics Time: 3 … 5 minutes. The current density: 0,2 … 06,6 A/ с m 2 Temperature: 60 … 90 ° С Voltage: 200 … 350 V Removal rate up to 1,5 … 3 microns/min. The acid intensity of the solution: pH 4 … 8 The concentration of salts in the electrolyte: 0,5 … 10% Achievable surface roughness up to Ra 0,04 microns 23 ¡
Types of materials to be treated Black (carbon) steel Precious metals (gold, silver) 1 4 High-speed steel Non-ferrous metals and 2 5 alloys: Chromium, Titanium, Monocrystal silicon 3 Nickel, Bronze, Brass, Aluminium, Melchior, Stainless and alloyed steels 4 Tungsten, Magnesium, Manganese 24 ¡
Products and their properties Only conducting materials Products in the loading area must not exceed the limit of the installation For each type of product is recommended to calculate the optimal treatment time, stress and chemical composition of the electrolyte Can not be processed silicon alloys (for example gray cast iron) The maximum class of accuracy is 12 , the improvement is not more than 3 classes The product can be processed by parts, and in several stages 25 ¡
Business strategy Business spheres for the implementation Aircraft industry Weapon industry 1 3 Shipbuilding 2 Machine tool building 4 Robotics 3 Production of interior items 5 Rocket and Space Industry 4 26 ¡
The patents 1995 – № 984 "The device for polishing of metallic hollow parts" 2005 – № 7291 “The electrolyte for the electrolyte-plasma polishing of products made of aluminum and its alloys" – № 7570 “The electrolyte for polishing products made of titanium and its alloys" – № 8424 "The method for electrochemical treatment of metal products, mainly copper and copper alloys for galvanic coatings" – № 8425 "The method of the finish electrolyte-plasma polishing of products, mostly from high- carbon steel and zinc alloys" 2007 – № 9204 "The device for electrolyte-plasma treatment of the inner surfaces of the hollow elongated articles with holes" 2008 – № 11206 "The method of electrolyte-plasma treatment of semiconductor materials" 2009 – № 11808 "The method of electrolyte-plasma polishing of metal products" – № 11809 "The method of electrolyte-plasma polishing of metal products" 2010 – № 12957 "The method of electrolyte-plasma treatment of metal surfaces before applying of a coating" 27 ¡
Success story Ltd. 'Morion' 2000 Had been solved the problem of polishing of stainless steel sheets, followed by the application of decorative coatings for the churches’ domes and church utensils, which is widely used in the restoration and construction of churches all over Russia The brand "Zlatosfera“. Trekhgorny, Chelyabinsk Region, Russia www.zlatosfera.ru www.morion.biz 28 ¡
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