Midlands Aerospace Alliance’s technology manager Peter Knight, describes how an Aerospace UP programme grant has helped precision engineering company, CBE+ take a fresh look at the electroless nickel plating process.

In a world where the push for automation seems to be almost entirely driven by the bottom line, it is nice to see applications where the introduction of robotics can also deliver other benefits including higher quality and more environmentally friendly solutions. A timely grant from the Aerospace UP programme has helped precision engineering company CBE+ to take a fresh look at an old process – electroless nickel plating.

Engineering supply chain solution provider CBE+ has recently completed the relocation of its five divisions together under one roof in a 100,000ft² state-of-the-art manufacturing facility in Chesterfield. Relocating the Electroless Nickel Plating (ENP) division, formerly known as Nitec UK, was the final piece in the jigsaw which allows CBE+ to offer a full, more streamlined  and efficient supply chain solution from a single location.

During this five-year, £4 million project, CBE+ considered the environmental impact of the business at every step. Investment included the installation of a combined heat and power system which captures the heat generated as a by-product of electrical power generation. This excess heat is used to heat the group’s ENP tanks, reducing the need to purchase more energy for heating and significantly reducing the company’s carbon footprint. The combined heat and power system installation, along with a number of other energy saving initiatives, coupled with the benefits of operating from a single location, means CBE+ has managed to reduce its carbon footprint by more than 50%.

Promoting the coating

Installation of the ENP process line has provided opportunities for CBE+ to also consider whether the traditional approach was appropriate for today’s more demanding customers. ENP is a widely used surface finishing technique that provides excellent corrosion resistance, wear resistance, and solderability to various metallic substrates. The process, which was patented by Brenner and Riddell in 1946, involves the deposition of a uniform layer of nickel-phosphorous (Ni-P) alloy onto a substrate surface without the use of an external power source. The process equipment has changed little in the past 70 years. It involves the immersion of parts into a series of cleaning, activation, plating and rinsing tanks, and is completely manually driven, with assistance from cranes for heavier parts.

By good fortune, the timing of the ENP process line relocation coincided nicely with the Aerospace Unlocking Potential (Aerospace UP) programme. This £20 million, ERDF-supported programme (2020-2023) is being delivered jointly by the University of Nottingham and the Midlands Aerospace Alliance, helping the aerospace supply chain in the Midlands to unlock its innovation potential. CBE+ was awarded a grant to undertake an ENP automation R&D project which would see the introduction of robotic parts handling system, the first of its kind in Europe.

The new automated line comprises a line of 26 tanks served by a Fanuc robot supplied and installed by Sidasa Engineering. The robot, which translates along a 25m track, has a lift capacity of 700kg and the line can accommodate parts with immersion volumes up to 1.2m x 0.75m x 0.9m. It can also barrel plate 100kg of parts at a time, with six barrels on the line. The line has two loading stations for jigs and two loading stations for barrel plating, which allows operators to remain outside of the working area and permits the robot to transfer, raise and lower parts at maximum speed.

Although the new ENP line results in a considerably more efficient process, the introduction of automation also brings other major benefits, including improved quality control. For industries such as aerospace where quality assurance is key, it is process capability which helps ensure that manufacturing processes are capable of consistently producing components within specified tolerances and requirements, minimising the risk of defects or failures that could compromise safety. By tasking a robot to control all part movement through the line, the process becomes fully programmable. Unlike manual systems, the times for part ‘filling’, immersion, emptying/drainage and transfer are entirely deterministic, and thus consistently repeatable.

Robot’s deft touch

However, more consistent product quality is not the only benefit of automation. Perhaps surprisingly, there are significant environmental benefits. The Fanuc 6+1 degrees of freedom robot manipulator is nothing if not dexterous. Unlike manual driven loading, the rotation of awkward parts with fluid retention areas is simple, speedy and can be optimised for every part no matter how heavy. This means that fluid transfer between the various tanks in the process line is minimised, ensuring that contamination is minimised, and that concentrations are maintained. The new nickel-plating line will be linked with the newly commissioned effluent water treatment plant which neutralises all waste chemistry on-site and allows for environmentally safe disposal and recycling. Hence there is both a significant reduction in both fluid wastage, and the costs associated with disposal of waste.

From an operator perspective, robotic handing reduces the need for manual lifting. Introducing automated chemistry control of the tanks means that manual testing of tank solution chemistry is eliminated, and combined with automated tank lids which open and close following loading, the potential for exposure to fumes is minimised. Furthermore, introducing automation to replace manual tasks can also help the business upskill its workforce in other areas.

CBE+ chief executive officer, Marie Cooper, says: “Automating these tasks means we can redeploy skilled employees to projects that require higher levels of expertise. As well as freeing up time from the plating line, we are also automating parts of the jigging process in partnership with the Manufacturing Technology Centre (MTC). This will enable the team to use their skills and expertise on projects that will interest and challenge them, as well as helping to drive the business forward.”

As the new ENP line comes on stream, Cooper believes that the company’s investment in ENP automation is leading the way within Europe.

“This process was long overdue for a major rethink, and automation brings a win-win for both CBE+ and our customers,” she concludes. “We are able to significantly increase our ENP capacity, reduce operating costs while delivering improved quality assurance and a reduced environmental footprint.”

www.midlandsaerospace.org.uk