POLIGRAT

Chemical Polishing
and Deburring
Chemical Polishing
In conjunction with the base material,
the actual surface will primarily deter-
mine the appearance and performance
of metallic parts.
There is a substantial difference between
mechanically polished and chemically
­polished surfaces. Each mechanical treat-
ment will cause evident thermal and
­mechanical effects as well as deformation
within the material of the upper surface
layers. The results are changes in
structure, cracks, stresses and embed-
ded impurities such as oxides and abra-
ded particles from tools and lubricants.
Additionally burrs, scale and particles are
created, which might detach during ser-
vice and cause malfunctions.
Every mechanical attempt to remove
such layers, will again produce a similarly
damaged layer.
The Principle and Effect of POLIGRAT­-
Processes
POLIGRAT-Processes for chemical poli­
shing and deburring will remove material
from the surface by chemical dissolution
without any thermal, mechanical or other
effects and will remove deformed layers
including burrs, splinters and particles.
The Processes produce a metallically
clean smooth and homogenous surface,
free of splinters and particles. The result
is a complete and consistent fine debur-
ring of edges and surfaces.
Visual appearance and surface feel are
improved, friction and wear are reduced
by the smoothing and rounding of micro
structures. The life time of dynamically
loaded parts is multiplied by the removal
of crack initiating structures. The adhe-
sion and homogeneity of layers subse-
quently applied by plating or CVD-pro-
cesses are significantly improved.
Rotor of a fuel injection pump before and after
­processing with CARBOCHEM to remove burrs and
achieve a particle-free surface. (approx. half full size)
POLIGRAT-Processes for chemical poli­
shing will smooth, debur and polish metal
surfaces essentially independent of the
shape of the parts, even in barely acces-
sible areas and structures. All dimensions,
as well as the overall shape and structure
will remain within close tolerances.
POLIGRAT-Processes for chemical
­polishing and deburring work without
electrical current at ambient temperature.
Controlled chemical material removal
smooths and deburs the metal surface
and also removes scale and particles.
The treatment is effective on the whole of
the wetted area, including the inner side
of bores, piercings and recesses.
The Processes also work by immersion in
barrels, baskets or on racks, as well as
by pumping through tubes and into deep
bores or by continuous coil processing of
wires and chains.
The Application
POLIGRAT-Processes for chemical
­polishing and deburring are both safe
and economic in application. They are
successfully used in many industries:
• Turned milled or stamped parts
• Hydraulic and pneumatic components
• Fuel injection systems
• Tubes, fittings, nozzles and filters
• Fasteners, screws and clamps
• Formed parts made from wire and
strip
• Ball bearings and dented wheels
• Springs and contact elements
• Apparatus and armatures
• Wires, chains and strips
• 3-D surfaces and laser cut profiles
• Needles and components for textile
machinery
Ground needle point smoothed using the
CARBOCHEM Process (enlarged approx. 190 times)
Materials and Processes
POLIGRAT-Processes for chemical
­polishing and deburring are based on
aqueous solutions, which essentially con-
tain an acid matched with the metal to be
treated, hydrogen peroxide and a special
stabilizer, but no complexing agents.
Delivery comprises a concentrate divided
into two components which are mixed
with water to form the solution ready for
use. The concentration and mixing ratio
will determine the overall material removal
rate, final gloss and deburring activity.
The processes are exothermic and work
within a temperature range between
18°C and 35°C (cooling).
In addition to the chemical mixture, the
removal rate is also influenced by tempe-
rature and relative motion between the
solution and the surface of parts being
treated.
Mild Steel: CarboChem C 600
CarboChem C 600 is a high performance
process for the treatment of a wide
­variety of Carbon Steels and Iron, both
hardened and unhardened. Up to a car-
bon concentration of 0,5%, shiny surfa-
ces are achieved. At higher carbon
content the resulting surfaces are darker,
but fully deburred.
CarboChem C 600 is easy to use. Even
at an Iron content up to 60g/l, it has
good stability and a wide range of remo-
val rates, which can be selected. The
­treatment only produces oxygen, but not
hydrogen,which prevents any embrittle-
ment of the Steel.
CarboChem C 600 does not contain
­ammonia, complexing agents or sulfates.
It tolerates high metal loadings and does
not form unwanted salts. This substanti-
ally reduces the costs of waste water
­treatment and waste deposits.
Drilled edge of two cross ports before and after
deburring with the POLIGRAT Process (enlarged
approx. 30 times)
Brass: BrassChem
BrassChem is a new high performance
process for the polishing and deburring of
Brass. The resulting quality is comparable
to good electropolished surfaces. The
application is considerably faster, less
complicated and more economic.
The treatment time is in the range of
0,5 to 5 minutes, dependent on the size
of burrs to be removed and the desired
levelling of the surface.
Copper and Copper Alloys:
­CupoChem
CuproChem is a very efficient process for
the deburring and polishing of Copper
and Copper Alloys. It is economic, simple
and safe in application.
When in use CuproChem does not deve-
lop nitrous gases. It contains sulfuric acid,
hydrogen peroxide and a special paten­
ted stabilizer, which keeps the baths
­stable at metal contents up to 50g/l and
at temperatures up to 40°C. This enables
a regeneration of the bath liquid, recycling
of rinse water and the recovery of Copper
as Copper Sulfate.
Aluminium: AluChem
AluChem is an economic process easy in
application for the smoothing and debur-
ring of Aluminium and Aluminium Alloys
up to a Silicon content of 3%. The resul-
ting surfaces are metallically clean and
show a gloss dependent on the alloy.
Titanium and Titanium Alloys: TiChem
TiChem is a highly efficient and economic
process for the smoothing and deburring
of Titanium and Titanium Alloys. The ap-
plication does not produce any hydrogen
and so avoids the danger of embrittle-
ment.
Sheared edge of a stamping (ball bearing cage)
before and after deburring with the CARBOCHEM
Process (enlarged approx. 300 times)
TiChem is also used to work filigree parts
to the final dimensions and to remove the
-case. The main applications are in
­medical and surgical fields, the aircraft
and aerospace industry, the automotive
industry and architecture.
Zinc Diecasting: ZinChem
ZinChem is an efficient process for the
fine deburring and smoothing of die-cast
and machined parts. ZinChem can be
used wet in wet as pretreatment to pla-
ting. ZinChem is free of hazardous chemi-
cals like fluorides, nitrates, chromates
and chromic acid.
Ziconium and Zirconium Alloys:
ZirChem
ZirChem is an efficient and proven pro-
cess for the polishing and deburring of
parts made from Zirconium or Zirconium
Alloys, such as Zircalloy. The treatment
significantly improves the corrosion resi-
stance and reduces the tendency to
­fouling. The main applications are heat
exchangers and nuclear fuel elements.
Costs, Environment and
Sustainability
Economic efficiency, sustainability and
minimum environmental impact are signi-
ficant principles for the development of
POLIGRAT-Processes for chemical poli­
shing and deburring.
Reduced consumption of chemicals by
the use of solutions tolerant to high metal
loads, simple and safe treatment of waste
water & waste and the potential for the
recycling and recovery of precious ele-
ments are important objectives for the
development and improvement of our
processes.
Hydraulic piston valve treated with the CARBOCHEM
Process to achieve fine deburring and micro-smoo-
thing, (approx. full size)
The avoidance of dangerous substances
such as ammonia, complexing agents,
nitrates and chromates improves safety in
use and minimizes the costs of waste
­treatment. The processes are all in con-
formance with REACH.
POLIGRAT has its own specialists for
­REACH and is a member of BLUecoM-
PETENCE at the German Association of
Machinery and Plant Manufacturers
(VDMA).
Supply and Delivery
Together with our customers we define
the requirements and develop the best
solution. In our application laboratory we
can demonstrate the achievable results
on original parts from the customer,
which we guarantee for the subsequent
fabrication.
The final outcome is in accordance with
the requirements and preference of the
customer through:
• Supply of a turn-key installation inclu-
ding chemicals, environmental tech-
niques and the training of staff.
• Quality assured sub contract work in
one of our modern subcontract com-
panies or on site at the customer
­premises.
Saw teeth before and after fine deburring with
CARBOCHEM (enlarged approx. 20 times)
 ADDED VALUE
THROUGH SURFACE TECHNOLOGY

POLIGRAT GMBH – Headquarter

Valentin-Linhof-Str. 19 Tel +49 (89) 42778-0 info@poligrat.de
D-81829 München Fax +49 (89) 42778-309 www.poligrat.de

Branches

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Branch office Pfungstadt: POLIGRAT France S.A.
POLIGRAT GmbH 2, Rue St. Eloi
Werner-von-Siemens-Str. 2 / Halle 5.5 F-71300 Montceau-les-Mines
D-64319 Pfungstadt Tel +33 (3) 8567 9999
Tel +49 (6157) 98632-0 Fax +33 (3) 8567 9988
Fax +49 (6157) 98632-119 infosud@poligrat.fr
ndl-west@poligrat.de www.poligrat.fr
www.poligrat.de
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Branch office Arnstadt: 25, rue Jean Perrin / ZI de Pessac
POLIGRAT GmbH F-33600 Pessac
Emil-Paßburg-Str. 2 Tel +33 (5) 56362816
D-99310 Arnstadt Fax +33 (5) 57268206
Tel +49 (3628) 6197-0 infosudouest@poligrat.fr
Fax +49 (3628) 6197-77 www.poligrat.fr
ndl-ost@poligrat.de
www.poligrat.de Canada

Branch office Hildesheim: POLIGRAT Canada Corporation

GUSTAV MORSCH GmbH 751 Lee Ridge Road
Utermöhlestr. 10 CAN-Edmonton, Alberta T6K 0P6
D-31135 Hildesheim Tel +1 (780) 686 5882
Tel +49 (5121) 7671-0 Fax +1 (780) 955 7121
Fax +49 (5121) 7671-39 brian.dahl@poligratcanada.ca
ndl-nord@poligrat.de www.poligratcanada.ca
www.poligrat.de
Hungary
Switzerland POLIGRAT Magyarország Kft.
POLIGRAT AG Céhmester u. 8.
Weidenweg 17 H-2170 Aszód
CH-4310 Rheinfelden Tel +36 (28) 553060
Tel +41 (61) 835 5080 Fax +36 (28) 553061
Fax +41 (61) 835 5085 info@poligrat.hu
marc.vernier@poligrat.ch www.poligrat.hu
www.poligrat.ch

United Kingdom
POLIGRAT UK Limited
2 Holder Road
Aldershot
GB-Hampshire GU 124 RH
Tel +44 (1) 252 336337
Fax +44 (1) 252 322791
info@poligratuk.co.uk
www.poligratuk.co.uk

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Subject to modifications. Printed in the Federal Republic of Germany. 03/2015