Historical Review During World War Il, the late A.R. Lindsay was directing the Lindsay Engineering Company. In this capacity, he was called to Washington , D.C. as a consultant to the Army Air Corps. It was determined that failures of aircraft engine components were due to fractures in the metal at the location of part number identification. This molecular disturbance was caused by stamping the part identification into the metal With this knowledge , Mr. Lindsay returned to Cleveland and established a laboratory for research in marking metal by electrolysis. As @ result of the success achieved , the name of the company was changed to Lectroetch. The new firm, established in 1943, was formed solely for development and manufacture of equipment and supplies for the electrochemical metal marking process.TYPE OF MARK Trademarks Part Numbers Bar Codes Inspection Symbols Serial Numbers Date Codes Grid Marks Depth Guages TYPICAL APPLICATIONS Advertising Specialties Aircraft Components Alkaline Battery Cases Appliances Automotive Parts Ball and Roller Bearings Broaches Bushings Carbides Castings Collets Crystal Cans Customs Knives Cutlery Cutting Tools Dies Disc Brakes Drills and Taps Electronic Components End Mills Fittings Gages Gears Grid Marking For ‘Strain Analysis Hand Tools Medical Devices Missile Parts Saw Blades Scissors, Shears Slitting Knives Spacers, Washers Sporting Goods Springs Surgical Instruments Tool Bits Tubing, Piping Utensils Valves and many more,TABLE OF CONTENTS ‘Typical Applications __ ‘Technical Data ‘Marking Facts Why Use It? How It Works Basic Equipment and Supplies Power Units. __ Bench Fixture _ _ - Hand Pads .— Cartridge-Type Markers. _ Saddle Markers __ Rocker Markers Roller Markers _ Electrolytes. _ Electrolytes Chart ___ Cleaners-Cleaning Procedures Stencils. - Automatic Markers —__ Special Applications ‘Anodized Aluminum — ‘Supplemental Coatings . ular Grid Marking Deep Etching ‘Making A Mark___ Help Hints _ Questions and AnswersTechnical Data Electroplating is the art of covering a surface or object -- usually metalic with a thin, adherent coating of metal To accomplish this, the object to be plated is made the cathode (2) in an electrolytic cell. A solution of metalic salts, called an electrolyte, is used in the cell The passage of Direct Current (DC) from the anode (+), through the electrolyte to the part being plated, results in the metalic ions moving toward the negatively-charged BASIC PRINCIPLE OF LECTROETCH PROCESS electrode (cathode). As metal is deposited from the solution onto the cathode, metal is dissolved from the anode. If the anode were partially smusked, metal would be dissolved only from the exposed area, This basic principle of electro: chemistry is the fundamental theory 4 Electrochemical of electrochemical marking,as first introduced by the Lectroetch Process. In practice, the work (surface to be marked) is anodic (+), while the marker -- which also conveys the lectrolyte to the work - is cathodic ©), A stencil (mask) carrying the design image (trademark part number, tc.) is placed between the marker and the work. A low voltage current passes through the openings in the stencil, via the electrolyte, to etch away the metal in the design contained on the stencil Marking Facts Bleettochemical marking is accepted as the best way to permanently mark conductive metal parts or surfaces without stress, strain, deformation, or burs. Its permanent because metal is actually etched away from the surface, through a stencil containing the desired design. The depth of etch can bbe controlled from less than ,0001" to as deep as .010". ‘The type of mark can be varied by switching the output of the Power Unit-Direet Current (DC) produces « clear or white eich on most metals, while Altemating Current (AC produces a dark or contrasting mark fon most metals, On DC, metal. is etched away; on AC, metal is etched faway during one hal the eycle, and a Stable compound of the base metal is redeposited into the etch during the other half cycle. This deposit, or oxide, will withstand corrosive action, as evidenced by its ability to stand up under salt spray tests for long periods. It is also possible to plate a deposit oa a purl, without an etch, by reversing the leads to make the part cathodic (-) and the marker anodic (+), and by using the proper plating solution. A combination of etch and plate may also be obtained with special equipment. (See SupplementalMarking Manual Coatings Scetion, Page 15.) In order W0 remove an electrochemical etch or mark, it would bbe necessary to remove metal from the marked surface to the depth of the ‘mark (0001" 010". Tae color of the mark depends basically on the composition of the metal being marked (assuming AC current and the proper electrolyte is used). Most stainless steels produce a brownish mark, while most other steels, non-ferrous metals, and platings produce black marks, Some metals, such as hard chrome and magnesium, cannot be color marked, but produce only a clear or white etch, Insulated surfaces - such as paint, anodize, and some supplimental coatings -- cannot be marked, Aluminum can be marked prior to anodizing, with the mark showing through the anodize. (See Anodize Aluminum Section, Page 15.) Why Use It? Electrochemical marking is fast — the average mazk is made ia from a fraction ofa second to 1 oF 2 seconds, depending on the depth desired. The depth caa be closely controlled so that only avery light etch s obtained, Even the most fragile part will not be ‘Weakened ot distorted. The etching takes place only while the current is flowing, and stops as soon asthe current is broken Blectrolytes are near-neutral water bated salt solutions, armless operators and surounding equipment Power Units supply low voltage current (about 26 volts), with “no hazard to operators, The marks are sharp and clearly defined, and the same stencil may be used for up 0 Several thousand identical marks, Pars need not be chemically clean before marking — only dit and grit need be removed Hardened parts can be marked with ease, climinating the necessity of stamping parts "in the green”. Even ibides can be easily marked. Thin sections and assembled parts can be permanently marked with no danger of distortion. All conductive metal surfaces, including plated surfaces and most supplemental coatings, can be marked. Electrochemical marks will not rub off (as with rubber stamps) , pee! off (as with decals), or become lost (as with tags), Parts can be marked immediately after manufacture or assembly, for storage identification, in-plant identification, or identifica tion in the field; or they can be stored unmarked, then quickly and easily ‘marked prior to shipment, where the same part may carry different identifi- cation for different customers Electrochemical marking is simple and easy to use. Operators require no special skills or training, Its economi- cal equipment is inexpensive, and supply items are priced to provide the very lowest possible cost per mark. A wide selection of equipment is evail- able to fit specific requirements, from a few marks per day to thousands of ‘marks per hour How It Works There are five basic components required for electrochemical marking 1. Power Unit ~ A device to reduce standard 110-120 volt, 60 eyele AC current to a variable 0-26 volts, and provides AC or DC output selectively 2. Application Fixture or Marker = These devices, in the form of hand or bench-type ‘markers, hold the stencil and carry the electrolyte and proper current to the part being marked.3. Stencil- A thin sheet of ‘material with a coating of high dielectric value, and which con- tains the design image to be marked on the part. 4. Electrolyte - A solution which serves as the conducting ‘medium for the etching current, and provides the necessary salts Electrochemical to etch the metal and deposit oxides for a contrasting mark. 5. Cleaner - A solution used to remove the electrolyte and excess oxides from the part after marking, and to provide a temporary protective film on the part, Typical Marking Set-up 4. Power Unit 2. Marker 3. Stencil 4. Electrolyte Basic Equipment POWER UNITS - The Power Unit is available in a wide range of sizes, from a small 2 ampere AC unit to 2 45, ampere unit with two timers. Their function is to provide the necessary voltage and amperes for the size and depth of mark required, Most of these units are cquipped with an ON-OFF swich, AC-DC switeh to produce AC marks or DC etches, a variable transformer or rheostal to control the output, a circuit breaker to protect the unit in the event of an overload, and a ccord set with leads to the marker and. ground. Many units have ammeters and/or voltmeters So the output can be ‘more easily checked and regulated, current interrupters to speed up etching and reduce gassing caused by electrolysis, and timers to assist the 4 operator in obtaining uniform results bby regulating the etch cycle, SeveralMarking Manual units have nwo timers for an automatic DC-AC cycle, to combine a deep etch ‘with contrasting mark. ‘These Power Units are remarkably twouble free, and with proper care will provide good service for many years. Refer to the instruction bulletin provided with each unit for complete deals. BENCH FIXTURE - This marker is used for small flat or round parts, especially where the location of the ‘mark on the part is somewhat critical. ‘The Bench Fixture consists of a flat base with the necessary electrical ‘connections, and a well or reservoir for electrolyte. ‘The plate and pad which ft into this well provide the marking. surface. Electrolyte is fed to it by absorption. “A stencil is placed over the pad. The part is placed on the stencil, land is grounded by one of several ‘means 10 complete the etching circuit, ‘A cylindrical part is rolled over the steneil_with a ground plate to com: plete the mark, Rolling cylindrical Parts should only be considered when the mare encompasses more than 120° Of the circumference of the part. Less than this, see the section on Saddle Markers, “A location plate is provided, which can be cut or milled to the contour of the part, to provide accurate and consistant location of the ‘mark, See the Bench Fixture Bull 92MU for complete details. HAND PADS - Hand Pads are designed for marking flat surfaces on larger parts, or for "hard-to-get-at" areas. Generally, they are for low volume applications. The marker has a fan electrical connection at one end, and a pad or "sereencloth” at the fother, © conduct the current and also hold sufficient electrolyte for a num- ber of marks. ‘The Hand Pad must be dipped in the electrolyte to replenish the supply, so normally the stencil is laid in position on the part and the Hand Pad brought down on the stencil legend to complete the mark. These markers are available in many standard sizes, and special sizes ean be made to forder, ‘The Hand Pad should be slightly larger than the mark being made, but smaller than the stencil sheet, to prevent the marker fom contacting, the part over the edges of the stencil. ‘The stencil may be attached to the Hand Pad, but it is difficult to wet the pad. sufficiently with the stencil attached. CARTRIDGE-TYPE MARKERS- ‘These markers are similar to the Hand Pads in function, but are provided with reservoirs to continually feed electrolyte to the marking surface. ‘They are available in a variety of shapes, sizes, and styles, and are used with the stencil attached. Some of theElectrochemical styles include: and wick suspended between ther, Cartridge Open Hand Pads (COP), When the partis pressed onto the which are rectangular, and range in sereen(over the stencil), the side arms size from "4" x %" to 74" x 4". They flex and the pad und stenel form utilize an"O” ring to attach the stencil themselves around the part. This Cartridge Hand Pads (CHP)anging produces a sharp, clear mark, as op- in size from 14" round to 14" x 24" posed to the furry mark often obta- rectangular, They feature molded ined by rolling ® cylindrical part over a fat surface. ‘A. big advantage of the Saddle ‘Marker over, “contour blocks" is that ‘one saddle can handle wide range of part diameters, while the contour blocks can iandle only one, ora small retainer rings with which the stencil is attached. ‘Cartridge Markers (3L-CM), which are similar tothe Cartridge Hand Pads range of diameters The Saddle Mark- in size and style, but are furished et can be furnished as hand markers, complete with a formed photographie _ 10 be placed over larger diameters, ot stencil containing the required mark as bench markers for smaller diame- design tors A wide range of sizes are available ‘The Cartridge Open Hand Pads and ROCKER PADS - Wheo large or Cartridge Hand Pads can be used either broad Lie marks are to be made, whica with dis impression stencil, processed would draw high amperage, its often fon a typewriter in your plant, or with recommended that a Rocker Pad be flat Long Life stencils processed used. These are convex markers, and photographically by Leetroetch to ae rocked over stencil placed on the Your specifications. part. As the Rocker Pad is slowly ‘SADDLE MARKERS -For cylin- rocked over the stenel, only a narrow dvical parts on which the mark encom- _bandis being etched at atime, so the passes about 120° oF less ofthe eireu- current requirements are less, and a tnferance (approximately the diameter smaller Power Unit ean be used. Also, ofthe par), the use ofa Saddle Marker when a broad Tine mark is being made, is recommended. The design of this ga bubbles are sometimes. trapped marker penis the partobecradled under flat pad, using misses or un- 50 the complete mark is made atone smacked spots is the opaque arca. A time. The side arms of the marker Rocker Pad overcomes tis by squcez~ are flexible, as i8 the sereen img out these pockets and pushingMarking Manual them ahead of the marker, The stencil may be attached to the Rocker, but it is usually more convenient to lay the stencil in place on the part, and rock the Pad over it. Because of the size or heavy line weight of the mark, it may be necessary to rock the Pad over the stencil several times until the desired contrast is attained. ROLLER MARKER - This marker serves the same function as the Rocker Pad. It is used for marking. large arcas, for marks with heavy lines oF opaque areas. It consists of a stainless steel roller, with bracket and attached handle. With the Roller Marker, the stencil must be positioned on the part, and a wick pad, ‘dampened with electrolyte, placed over the stencil legend. ‘The Roller, connected to the Power Unit with the black wire, is then rolled back and forth over” the wick and stencil until the desired results are obtained, Advantages ofthe Roller Marker over the Rocker Pad are that it is more compact, is easier to hhandle, and can mark larger areas in a shorter time. ‘Tae Roller Marker is available in several standard widths, and can be ‘made to any size on special order. ELECTROLYTES - The clectro- lyte used depends on the metal being marked, and the type of mark required. Generally, there are different ‘electrolytes for each family of metals, such as steel, aluminum, copper and brass, plated’ surfaces, supplemental ‘coatings, etc. Mowever, since there are ‘countless alloys, platings, and coatings in use today, it is often difficult t© ‘make a firm recommendation unless @ sample is submitted for test marking. ‘The Electrolyte Chart, Pages 10 and 11, ean be used as. reliable guide, but should any problem develop with the ‘quality of the mark, samples should be submitted. Electrolytes used in the electro chemical metal marking process are ‘aqueous solutions of certain metallic salts, wetting agents, and in some cases ingredients to keep oxides in. suspen= jon to prevent them from clogging the stencil openings. These solutions are hharmless to. skin, clothing and sur- rounding equipment when used as directed, The electrolyte serves the following functions:Electrochemical LECTROETCH ELECTROLYTE AND CLEANER CHART. = oe mace Arafat rte ie FsnemRON one carb ANOALLOTS, = mm orm 1. This the conducting medium for 3. Ieserves as a heat dissipant. the etching current. 4. It provides the necessary inhibitors, 2. It provides the necessary metallic depolarizers, surfactant, and stencil saits 10 eich the metal and, when cleaning media, the exact balance of desired, to develop the dark oxides for which is the result of years of research, ‘contrasting marks. development, and experiance. 10Marking Manual LECTROETCH ELECTROLYTE AND CLEANER CHART. 8 Cal apo ee ton uve stveRPUTE weg ra a8 TmnmTasON Capone Tn iro a alejslslelelslslslalelsisle = z 5 ales 8 Electrolytes are available in three series those with an "A" suffix are for low ‘volume, general purpose markings those with an "LNC" prefix (Lectroetch Non Clog) ae for high volume application; and Nuclear Grade electrolytes ae for those applications specifying 250 ppm or less of Halogens i (Chilocie), Sulhpur, Lea, etoCLEANERS AND PROCEDURES ~ Cleaning parts AFTER Marking is necessary to remove the electrolyte remaining on the part, as well as the excess oxides from the mark, itself, ‘The electrolytes contain metallic sats, which will accelerate staining oF corrosion if left on the part. When making AC marks, the oxides deposit- ed into the mark will often build up until they are higher than the plane of the part surface. These oxides are loosely packed and porous in this duiltup stage, and are hygroscopic. Unless removed, they tend to absorb moisture from’ the atmosphere and ‘cause corrosion. Proper cleaning will remove the excess oxides, and those ‘that remain will be stable and not cause Lectroctch has a variety of cleaners: 41 All Purpose Cleaner (all metals) #2 Cleaner (ferrous metals ), #3 Cleaner (non ferrous metals }, and Neutralyte cleaner are all for use with 2 wiping operation, LIC Cleaner is a concentrate which is diluted with tap ‘water in a 3:1 10 9:1 ratio, and may be used for immersion or wiping methods. The recommended procedure for ‘wiping parts after etching is as followed: 1. Wipe the electrolyte from the part after marking, with a clean cloth. 2. Apply the proper cleaner 1o the part, concentrating on the ‘marked area, 3. Wipe the part dry. 4% Apply @ light film of suitable oll or other protective coating if parts are to be stored. Be sure to use clean tissues or cloths for each step, and change them frequently 10 prevent cross ‘contamination. When using LIC Cleaner for immer- sion, provide a suitable container fitted with a wire basket, There should ‘bea minimum of one inch clearance 12 Electrochemical between the bottom of the basket and the bottom of the container. This is where the oxides and electrolyte from the marked parts will settle, and if parts remain in this residue, they will become badly stained, =e ae Ne jae sa ‘The container is filled with the proper mixture of LIC concentrate land water. After marking, the parts are placed in the container for approxi- mately 5 minutes. The basket of parts is removed from the container when full, the parts allowed to drain and air dry, then are dipped in or wiped with oil, or stored, depending on the corrosion properties of the metal. The LIC mixture should be tested acca- sionally, using a pit meter or pi (pHydrion) paper. When the pH falls t0 around 6.0, the LIC mixture should ‘be discarded and a fresh batch mixed. “Treated cleaner tissues (CT) can be used for light marking, and on material not highly susceptible to corrosion. Use a separate tissue for each part, wipe the part thoroughly with the tissue. Oil for storage if necessary, Cleaner tissues are available in pack- ages of 1,000 - 434" X 414" sheets. Powder Cleaner (PC) is available in 1 pound bags for use in cleaning highly polished parts, such as knife blades, marked with DC. Normal cleaners leave a light film on parts, marring the high finish, while powder cleaner effectively removes the electro-Marking Manual lyte without affecting the mirror finish, REMEMBER ~all cases of rusting of ‘corrosion afler marking can be raced back to poor cleaning techniques. part marked ‘with the electrochemical process, and pro- perly cleaned will be no more susceptible to corrosion than the same part not marked at all. Be sure your cleaning media (tissues.cloths ) do aot become ‘contaminated with electrolyte. Be sure parts are thoroughly dried aller cleaning. Do not oil parts while they are wel, unless they are immersed or liberally coated with a good water displacing oil. Most oils will trap the moisture, and parts will still rust. When dry, oil ferrous parts thoroughly, as electrolyte or even normal perspiration on the fingers can ‘cause corrosion on parts STENCILS -In selecting the type of steneil to be used for your application, these factors should ‘be taken into consideration: 1. Overall size of mark 2. Type of mark ~ fine ine, broad line, or combination of both 3. Whether mark is to be shallow AC or DC mark (0001 0003"), or deep etch (.001" or more). 4. The number or quantity of parts to be etched with the identical mark, and whether or not frequent copy changes will be involved (chaning part nun bers, serial numbers, date codes, etc) A. DIE IMPRESSION STENCILS - ‘These ate available in roll or sheet form and, as the name implies, are processed by impressing the required ‘copy into the stencil. This is usually done inthe customer's plant on a typwiter, ‘Varityper, steel die, or ~ in some cases — with a stylus or ball-point pen. This type ‘of stencil can produce only fine line marks, since the coating must be displaced by impact or pressure without ‘upturing the stencil fibers. These stencils ‘can be furnished with a trademark or other ‘constant data, processed by Lectroeich, 0 which part numbers, serial numbers, or other variable data can be added by the customer. A pin-feed stencil paper isalso available. This material is used jin conjunction with a dot -matrix printer to create text and simple graphics through your computer, ‘This material is available in three stan- dard widths, in rolls. up t0 1,000 feet. 13 B. THERMAL STENCIL MATERIAL- Also known as stencil on demand paper. This stencil is created using a thermal printer and software to create text and ‘graphics with a computer. Suitable for oxide etches only, Not for deep etching, €.3L LONG LIFE STENCILS- These stencils are photographically produced at Lectroetch plant with the desired trademark, part number, orother data. They are used for high volume marking where many parts will be etched with the same mark. These stencils cannot be modified once they are processed. They require artwork and a photographic “plate”, prepared by Lectrovich to customers specification, ‘at nominal cast. Long Life Stencils ‘are fumished in an infinite variety of sizes, shapes, and styles, Electrochemical ‘They can be formed into round or rectangular "caps", or furnished flat in almost any size up to 12" x 20" ‘They can be furnished with a paper base (3L), of fabric base for standard marks or deep etch marks (200-31). These stencils can reproduce anything that ean be drawn, and are capable of making many thousands of marks, Automatic Markers In many applications, it is desirable to use semi-automatic or competely ‘automatic equipment. These factors, should be considered: 1. High Production -- Auto- ‘matic Markers can be provided with, or attached to, feeding devices such as conveyors, chutes, or vibratory bowls to feed parts onto index tables, ‘shuttles, or other locating ‘means. Cleaning and oiling tanks with conveyors can also be supplied to provide a completely automated marking station. These can mark up (0 2,000 parts per hour with a minimum of supervision. 2. To maintain consistant marks and production rates — Automatic Markers are furnished with timers, pressure controls, and locating fixtures to assure 14 consistent marks by completely regulating etch time, pressure of ‘marker on the part, current used, and location of the mark on the part. The units areMarking Manual provided with an etch timer, (0 consistantly control the marking cycle. With these, a predetermined ‘marking rate can be maintained. These units not only increase production, assure mark quality, and reduce operator fatigue, but also reduce cost by regulating eletrolyte usage and increasing stencil life. Special Applications ANODIZED ALUMINUM -Alumizum, cannot be marked after anodizing, as the surface is insulated and electrical contact cennot be achieved, However, in most cases, aluminum parts can be marked prior to anodizing with the marks showing through the anodize. If the unodize system ‘includes a non-etch cleaner, pars may bbe marked with standard equipment to apply a good black mark which will show dough clear or light eolored anodize. However, if the anodize systems includes a caustic cteh cleaner, or if the snodize will be dark or fopague, deep etch equipment must be used to obtain a mack at least (001 -.003"deep. This wall show through the anodize. SUPPLEMENTAL COATINGS - Many supplemental coatings, such black oxide or black magic, can be casily marked using standard equipment, eis ually Wosiable to submit Sample pars to ‘Lectoeth fo test mrmting to deo he proper =n eleeolyc, curen, and time del: In mmany cases, IDA cletolte used te AC wil give good res nother cee Da oe TNC els 15 used on DC, will be necessary. In all cases, an ample supply of electrolyte, and firm contaet between the part and stencil are required, Some coatings re- uire full voltage to break through the ‘base metal. Other coatings require re- duced vollage 10 keep the etch from re-oxidizing and turning. dark GRID MARKING ~ Sheet_metal formability, lubricant selection, and die design’ are currently being evalu- ated by the circular grid system. A. pattem of small diameter circles is etched on a flat blank. The blank is then formed, and the deformation of the etched "circles is measured and analyzed, In the past, a system was used whereby one-inch squares were ‘manually seribed onto the blank, then measured after forming. However, measuring the deformation of one-inch squares proved to be inadequate, since the squares were too large for accurate analysis, were seldom oriented properly. to indicate the maximum strain, and often introduced stress concentrations along the seribed lines. Other methods = such as ink stamps, photoprinting and silk screens -- proved to be too expensive, time-consuming, or not suf: ficiently permanent for satisfactory analysis, The best method for griding the blanks with small-diameter circles is clectrochemical marking. This, ‘method reproduces a grid of 0.1" or 0.2" circles up to 10" x 20%on the blank, ‘maintaining accurate tolerances and fine dotail, The marks are permanent, and arenot removed during forming. Also, they set up no stress concentration, and are applied in a matter of seconds For this application, a heavy-duty Power Unit is used in conjunct ‘with a Rocker Pad or Roller Marker, ‘The grid pattem stencil is laid in position on the blank. A wick pad, dampened with electrolyte, is placed lover the steneil, and the marker is rocked or rolled back and forth over the stencil and pad, producing a sharp, clear, permanent pattern in seconds, Electrochemical The blank is then cleaned, lubricated, ‘and formed, afler which the distortions ‘of the circles are measured and proper interpretations made, Large areas may be gridded by moving the stencil in steps along the blank, A flexible calibrated film strip is available from Lectroetch to facilitate measurements, and complete instructions are ipplied, Lectroctch Grid Marking Systems are compatible with all ‘electronic Stereo-Lithographic strain evaluation devices. The Lectroetch GMK Marking Kit 16Marking Manual DEEP ETCHING - Making deep ceiches requires special equipment. A heavy-duty Power Unit with a timer is usually recommended , the output de- pending on the size of the mark and the depth required. Also, a deep etch hand marker with deep etch wicking must be used, The marker has an open area above the metal plate at the mark surface, and the wicking is loose woven and porous. Both of these are designed to dissipate the gas and heat generated by the deep etching. The Power Unit is set on DC, and the Cur rent Interrupter switched on. The Inter- rupter breaks the current flow foi times per second, allowing a "surg. of current to accelerate the etching, as well as reducing heat and slowing the evaporation of the electrolyte, thus increasing stencil life. A #200-3L sten- cil should be used whenever possible, as it holds up much better than any other stencil for deep ctching. An ample supply of electrolyte should be provided to assure a continuous supply al the point of etching and to help cool the stencil 17 Depths of up t0 achieved, although .00: sufficiently deep for all practical purposes. In most cases, deep etches are made using light pressure, so that the electrolyte will not be squeezed out of the wick, increasing heat and shortening stencil life, The light pressure will usually cause a fuzziness around the edges of the mark. This ean be removed with eracus eloth, scouring powder, or light busing. Increasing the pressure will reduce this fuzziness, Dbut care must be taken to replenish the electrolyte supply which is reduced by the extra pressure, In addition to the Current Tnterrupter, good results are obtained by using " blotting " technique. The stencil is placed on the part, deep etch wicking is placed over the stencil (be sure the wicking is well saturated with electrolyte), and the deep etch marker is blotted on the wiek, ic., placed down and picked up at one -or- two-second intervals,Electrochemical Making A Mark To set up for general marking: 1. Plug the Power Unit into any 110-120 volt, 60 cycle, AC outlet 2. Plug the Universal Cord Set into the Power Unit. 3. Attach the red wire of the Cord Set to a ground plate on which the part will, rest; attach the black wire to the marker 4. Set the rheostat or vari- able voltage control at 50%, or 0 the dial pointer is straight up. 5. Turn the Power Unit "ON", and set the switch t0 either AC (for a dark mark on ‘most metals) , or to DC (fora clear mark on most metals) 6. If @ photographie stencil is 10 be used, position the stencil fon the part, or attach it 10 the marker with an "O" ring or 7. If a die impression stencil is used, place the stencil in a pypewriter with the colored 18 paper toward you, and the white backing’ paper against the platon. The type must strike the stencil paper first. Set the the typewriter to stencil-cutting position (or remove the ribbon). Use an electric typewriter when possible, set on medium pressure Ifa manual typewriter is used, try fo.use even pressure for all the cha- ractors, When the stencil is typed, remove it from the typewriter separate the stencil from the back- ing paper, and hold the stencil up to the light. The ped legend should show completely white and ‘translucent. Postion the stenell on the part, or attach it 10 the marker 8. Dip the marker in electro- Iyte, or fill the reservoir with electrolyte. Make sure the screen- cloth or wick is completely wet. Rub the stencil lightly if fattached to the marker, to be sure the electrolyte is coming through the stencil openings.Marking Manual 9, Place the marker on the part, using light pressure, Hold steady for I or 2 seconds, 10, Remove the marker and stencil from the part, If the Helpful When making the initial mark with a rnew stencil, mark on a scrap piece first. Occasionally a stencil must be “started” by making a few test marks, or by wiping the legend area with a ball of cotton soaked with electrolyte. This will also help determine if the mark has sufficient electrolyte at the marking surface, the power setting and time dwell are correct, and if the stencil is cut properly Use as little current and as short a time dwell as possible that will give you a satisfactory mark. High current and a long time dwell will shorten stencil life Never mix electrolytes. When switching from one electrolyte to another, change markers of rinse mark er thoroughly with tap water. Never pour used electrolyte back into the bottle. Keep bottles tightly capped, and store where it will not freeze or be in direct sunlight. Store stencils and steneil paper in a coo! place, away from direct sunlight. (On metals that stain easily (some aluminum, eadmium, zine and tin plat ing, etc.), wipe parts before marking with a film of light oil or kerosene, Some non-ferrous metals and plat- ings (copper, brass, cadmium, zine, or tin plate, silver, ete.) are so soit that oxides wipe off easily, Be sure to use the proper electrolyte, and set parts 19 ‘mark is 100 light, turn the power setting higher (clockwise), or increase the time dvell. 1. Clean the part according 10 directions outlined earlier Hints aside after marking to allow the oxides to harden. ‘Then wipe lightly with oil, If, when rolling a cylindrical part on the Bench Fixture, the mark blurred or fuzzy, place a thin piece of stainless steel ot perforated metal be- ‘ween the wick and sereencloth to pro- This will prevent a buildup of electro- Iyte ahead of the part as itis rolled pad, which eauses the blur- ring. Particular attention should be paid lo proper cleaning procedures during July, August, September, when higher humidity increases the chances of cor- rosion om parts, If you experience trouble with your equipment, check it over carefully be- fore calling for service. Be sure the unit is plugged in, and thet the outlet has current. Check the eireuit breaker to be sure it is fully depressed. Check all contacts carefully to be sure they are clean and tight. You ean check the output of the Power Unit by connecting a voltmeter across the output jacks and verifying voltage is available IF this functions properly, the problem may be in the Cord SetAlways keep your equipment clean, Rinse out all fixtures, sereencloths, and wicks at the end of the day. Stencil life may be prolonged by keeping the stencil clean to provent buildup of oxides. Wipe the legend area occasionally with cotton or tissue saturated with electrolyte Stencil life is determined by many factors, including: type of stencil used, Electrochemical size and layout of copy, style of letter- ing, amount of current used, length of eich time, type of material being marked, depth of mark, whether or wil is kept clean, speed of marking, and many moze. Because of these factors, it is difficult to predict ahead of time how many marks a sten- cil will provide. However, once an average is determined over a period of time, it should not vary greatly. Your local Lectroetch representative can as- sist you in obtaining the maximum umber of marks per stencil Questions And Answers Are there cleetrolytes available which require no cleaning? Lectroctch CFX-2 electrolyte available for a dark mark on most ferrous Steels, and Brass. This is the only electrolyte which does not require neutralizing or cleaning. Marking accomplished with other electrolytes must always be cleaned after the etching process. Failure to do so will result in rusting or corro- What is meant by "pH" ? pH is a point of referance in determining the acidity or alkalinity of a solution, Anything below 7 becomes progressively more acid; anything above 7 becomes more alkaline, A reading on the acid side of the scale should not be taken to mean the solution is “acid”, such as Sulphurie or Hydrochloric Acid, as many popular Cola drinks register below 3.0 on the pH scale Does electrochemical marking meet government specifications? 20 Yes, it is called out on a number of standards as an accepted method of marking. Also, almost all government prime contractors list electrochemical marking as an accepted method. Are the clectrolytes harmful to use ? Since they contain metalic salts, they should not be taken internally, and normal habits of cleanlinesss should be obsreved, If spilled on clothing, blotting ‘with #2 Cleaner, then with water should prevent any stain, With prolonged use, some persons susceptible to skin problems may experience some dryness on the hands, due to the wetting agents contained in the electrolytes. Careful use, cleanliness, and use of @ hand lotion will minimize this condition, Refer to SDS for more information,Marking Manual What are Nuclear Grade Blectrolytes ? Some applications, notably those involving parts for nuclear reactors, prohibit any material containing Chloride, Lead, and ‘other materials from coming in contact with such parts. Nuclear Grade Electrolytes carry certification to contain less than 250 ppm of these materials, A certified trace analysis for teach lot is available at extra cost. ‘Conforms to MIL-STD-792E, Can colored marks be made? No. Only black marks, or clear, or white etches are possible. Can glass, wood , or plastics be marked electrochemically? No. Only conductive metals faces ean be marked, Is AC always used for dark marks and DC for white etches? With two notable exceptions: when making a dark mark on aluminum, #f 210A electrolyte is used with DC, When making @ white mark on black oxide coat- ings, #270 electrolyte is used with AC, How small a mark ean be made? Characters as small as .025" ean be etched, How long will a Power Unit last? Units are still in use that are over 30 years old 21 If a Power Unit does malfunction , can I get it repaired? ‘Your equipment can be repaired by our factory technicians. A loaner service is provided. Send a purchase order for the repair of your unit and request a loaner. This will be sent to you touse while your unit is being repaired. All you pay for the loaner are the transportation charges. How long is the warranty period? All Lectroetch Power units are ‘warranted against defects in material and workmanship for a priod of one year from ship date, Hand markers and fixtures are covered for 30 days, This warranty excludes wick pads, sereen-clohs, and damage due to corrosion or lack of ‘maintenance, How soon could I get equipment and supplies? Standard equipment and sup- plies are usually shipped the same day the order is received. Photo- raphic stencils requiring artwor and plates may take up to a week Replacement stencils can usually be shipped in a day or two. ‘Are quantity discounts available? Large quantity discounts are available for most items. Blanket Orders are also accepted, which allow quantity prices for a year’s usage, with releases as required.This document was created with Win2PDF available at http://www.win2paf.com. The unregistered version of Win2PDF is for evaluation or non-commercial use only. This page will not be added after purchasing Win2PDF.