During electrolytic machining or polishing, residual electrolyte inside stainless steel electrolytic tubes can cause corrosion, contaminate subsequent processes, or affect product quality. Therefore, a multi-dimensional prevention and control system needs to be built, encompassing process design, operating procedures, equipment optimization, and post-treatment.
Pre-treatment cleaning and drying are fundamental. Residual oil, dust, or metal debris on the inner wall of the stainless steel electrolytic tube can hinder the uniform flow of electrolyte, leading to localized residue. During pre-treatment, thorough cleaning with organic solvents or alkaline cleaning agents should be used to remove adhering substances from the inner wall, followed by rinsing with running water until neutral to avoid cleaning agent residue. After cleaning, high-temperature drying or compressed air purging is necessary to ensure the inner wall is completely dry, preventing moisture from mixing with the electrolyte and exacerbating the residue risk. For example, one company shortened the drying time of the stainless steel electrolytic tube's inner wall and significantly reduced the residue rate by adding an infrared drying device at the end of the cleaning line.
Optimization of the electrolyte circulation system is crucial. During electrolysis, the electrolyte needs to circulate through a pump to remove reaction products and maintain compositional stability. If the circulation system is poorly designed, such as with excessively low flow rates, pipe bends, or insufficient filtration precision, electrolyte can stagnate or deposit impurities within the pipes. Circulation efficiency can be improved by increasing pump power, optimizing pipe layout to reduce right-angle bends, and using high-precision filters. Furthermore, regularly cleaning deposits from the electrolytic cell and pipes to prevent blockages and impaired electrolyte flow is also crucial for reducing residue.
Precise control of electrolysis parameters directly affects residue levels. Current density, voltage, and electrolysis time are key parameters. Excessively high current density leads to overly vigorous electrolysis, generating large amounts of gas and solid particles, increasing electrolyte viscosity and making it more prone to adhering to the inner wall of the pipe. Unstable voltage can cause localized overheating, resulting in electrolyte decomposition or carbonization and the formation of stubborn residues. Appropriate parameters should be set based on the material, diameter, and wall thickness of the stainless steel electrolytic tube, and voltage and current fluctuations should be monitored in real-time during electrolysis, with timely adjustments to maintain a stable reaction environment. For example, one company effectively reduced residue problems by introducing an intelligent control system that kept electrolysis parameter fluctuations within a very small range.
Thorough neutralization and cleaning are essential in the post-treatment stage. If residual acidic or alkaline electrolyte in the tube is not neutralized promptly after electrolysis, it will continue to corrode the tube wall or contaminate subsequent process media. During post-treatment, residual acid should first be neutralized with a weak alkaline solution (such as sodium carbonate solution), followed by repeated rinsing with running water to ensure the inner wall pH is close to neutral. For high-precision stainless steel electrolytic tubes, deionized water can be used for the final rinse to avoid secondary contamination from impurities in the water. After cleaning, drying is necessary to remove moisture and prevent residual electrolyte from reacting with water to form corrosive substances.
Equipment maintenance and regular inspections are indispensable. After long-term operation, problems such as worn pump seals, scale buildup on the inner walls of pipes, or clogged filters can reduce electrolyte circulation efficiency and increase the risk of residue. A regular maintenance system should be established to clean or replace pumps, pipes, and filters to ensure the equipment is in optimal operating condition. For example, one company reduced equipment failure rates and significantly improved electrolyte residue issues by implementing a maintenance plan of "monthly minor inspections and quarterly major inspections."
Skilled training and standardized implementation by operators are crucial for ensuring effective residue control. Operators' understanding of process parameters, proficiency in equipment operation, and emergency response capabilities directly impact residue control effectiveness. Regular training is necessary to ensure operators understand the hazards of electrolyte residue, prevention and control measures, and methods for handling abnormal situations. For example, one company implemented "Specialized Training on Electrolyte Residue Control," enabling operators to promptly identify and address issues such as poor electrolyte circulation and abnormal parameters, resulting in a significant reduction in residue rates.
Environmental factors must be effectively controlled. Temperature, humidity, and ventilation conditions in the electrolysis workshop affect electrolyte performance and residue levels. High temperatures accelerate electrolyte evaporation, increasing the risk of adhesion to the inner walls of pipes; high humidity can cause the electrolyte to absorb moisture, increasing viscosity and hindering flow. It is essential to control workshop temperature through air conditioning systems, reduce humidity using dehumidifiers, and install exhaust fans to promptly remove volatile electrolyte gases, creating a stable processing environment.
