| Abstract: | ![]()
In partnership with the US Department of Energy’s Office of Industrial Technology, Whyco Technologies, Inc., has developed an innovative perforated plating barrel used in the plating of metal parts. This new technology employs a thin-walled construction, differing from the traditional thick-wall design required to provide adequate structural integrity. The thicker walls lowered the efficiency of transferring plating solution into and out of the barrel and diminished the electrical current pushed through the holes and onto the parts being plated. By machining pockets out of the traditional thick-walled perforated structure, Whyco produced a ‘honeycomb’ of staggered cells, allowing for the greatest number of holes per open area while maintaining structural integrity. Hydrodynamic pumping occurs during barrel rotation to create greater solution transfer than in traditional barrels. The Whyco barrel has higher current density plating, which leads to faster plating cycles, reduced bath concentration, and better plating of difficult chemistries such as in alloys. This new technology has helped the company reduce energy use by 16%, eliminate more than 480 tons/year of solid waste, and reduce wastewater by more than 17 000 gallons/day. The resulting cost savings total more than $500 000 annually. The company has manufactured and sold more than 275 of these barrels to other electroplating companies that are reporting up to a 40% increase in plating productivity and similar energy and environmental impacts. |
