Indoor Air Quality (IAQ) and Electropolishing

How Air Filtration Can Keep Workers Safe

When the term electropolishing is cited, what often comes to mind are applications that require industrial sterility and corrosive resistance, such as the manufacturing of medical implants, surgical instruments, and highly sensitive airplane parts. But electropolishing is used to create and improve thousands of everyday objects including refrigerator parts, stainless steel cookware, window fixtures, and household cutlery.

When any metallic component makes its way through fabrication, there is generally some amount of surface finishing that needs to be done either to improve its appearance, provide corrosion resistance, or increase electrical or mechanical properties. While this process improves the quality of the item, it can have grave consequences on industrial workers if strict measures are not taken to protect them.

What is Electropolishing?

Electropolishing is a finishing process that reduces the surface roughness of a metal piece by removing its outer layer and smoothing out any imperfections.

Also referred to as anodic polishing, electropolishing is an electrochemical practice because both electricity and chemicals are employed. It is the opposite of electroplating (which deposits metal on a finished surface) and is sometimes called “reverse plating.” “Polishing” removes the outer layer of a metal part rather than “plating,” which deposits metal on a finished surface.

The Electropolishing Process

The metal part being electropolished (an anode) is immersed along with a negatively charged electrode (called a cathode) in an electrolyte bath. The cathode is necessary to produce the electrochemical outcome for the product needing polishing. In other words, the anode needs a cathode to provide a conductive path for electrons to flow through the electrolyte solution for the circuit to be complete. The process causes metal ions to dissolve on the original item, whereby creating a smooth, attractive, corrosion-resistant surface.

1. Pre-treatment – metal parts are cleaned

2. Racking – cleaned parts are put on a metal rack

3. Chemical bath – racked pieces are submerged into an electrolyte solution

4. Electrical current – a direct current is applied causing metal ions on the surface of the workpiece to dissolve, then oxidize 

5. Surface smoothing – roughness is removed leaving behind a uniform surface

6. Post-treatment – all parts are rinsed to remove all chemicals, then dried to prevent oxidation

Electropolishing and Indoor Air Quality

The same chemicals that ensure a product’s smooth finish can pose an occupational hazard to manufacturing workers. Chemical offsetting, such as fumes from sulfuric acid, ethylene glycol, and other harmful chemicals, can enter a worker’s breathing space where they can be inhaled. These substances are toxic and dangerous if not contained.

In addition to the threat of toxic inhalation, electropolishing can produce trace amounts of hydrogen gas, which, if not eliminated, can be an explosion risk if an ignition source is nearby.

Practical IAQ Solutions

To avoid chronic exposure to electropolishing chemicals at work, workers should take the following precautions:

1.  Use personal protective (PPE) equipment such as gloves, masks, and goggles.

2.  Keep work areas clean and dust-free.

3.  Ensure proper ventilation.

4.  Remove dust particles and fumes at the source, by using air filtration equipment.   

 At AIRSInc., we protect our customers by offering exceptional air cleaning products, such as our SP-800 Portable Fume Extractor and HEPA filter option. Dust collectors (also known as air purifiers, air cleaners, and filtration systems) can help improve IAQ by removing potentially hazardous emissions at their source before they can enter a worker’s breathing space.

Contact us today for a free consultation with one of our indoor environmental specialists to find out which one of our air cleaning products is right for you.