PlatingIndustrial Hard Chrome

Roll Services

Roll Services

Pioneer partners with our customers to hard chrome plate new and refurbished rolls to defined specifications. We offer a complete roll refurbishment service that includes:

• Stripping existing coatings
• Welding shell or base metal defects
• Grinding/plating journals
• Grinding/polishing prior to hard chrome plating
• Comprehensive internal/external roll cleaning
• Acid flush and flow testing capabilities
• Industrial hard chrome plating to support required part dimensions
• Cylindrical polishing to a commercial grade mirror finishes up to 16 RA
• Cylindrical Optical polishing to an optically flawless mirror finishes down to 0-0.5 RA
• Cylindrical blasting for a coarse matte finish up to 500 RA
• Grinding/polishing after hard chrome plating to support required surface finish
• Our team has extensive experience hard chrome plating a wide variety of applications, including chilled and heated rolls, corrugated rolls, metering rolls, glue rolls, anilox rolls, embossing rolls, engraved rollsincluding

Standard Specifications
AMS 2460
MIL-STD-171 (1.2.2)
QQ-C-320
MIL-C-20218
OEM Custom Specifications
RoHS, REACH, ELV & WEEE Compliant

Roll Service Capabilities
Commercial Mirror Finish: 0-0.5 RA
Engineered Coarse Matte Finish up to 500 RA
Specialized pocketed finishes
Rolls up to 36” diameter, 222″ long and 10,000 lbs
Parabolic and Taper Crowned Rolls

Pioneer’s Roll Services Advantages
Best in class lubricity and durability
Development of custom roll finishes
Centralized Roll Services – new and refurbishment
24/7 Roll repair services
Journal repair services
Internal roll cleaning and flow testing

Production Capabilities
Our roll finishing capacity can handle rolls as large as 36″ in diameter and 222″ in length up to 10,000 lbs, with the ability to crown rolls up to 24″ in diameter and 144″ long.

Cylindrical grinders and capacities

• Landis-12″x48″
• Landis-14″x72″
• Landis-20″x96″
• Norton-24″x 192″
• Norton-30″x 144″
• Cincinnati-16″x144″
• Cincinnati-24″x162″
• Cincinnati-36″x288″

Lathes

• Poreba-42″ x 228″
• Poreba-53″ x 276″
• American Pacemaker-32″ x 240″
• Leblond-32″ x 192″
• Leblond-36″ x 192″
• Standard Process-25″ x 192″

Roll Finishes

Pioneer’s industrial hard chrome plating capabilities can produce finishes that range from a Coarse Matte to Flawless/Optical Mirror surface finishes. Our calibrated grinders and finishing lathes are equipped with a variety of different finishing heads allowing us to produce precise surface finishes to support roll applications that vary from a controlled matte, commercial mirror, optical mirror and mirror pocket finishes. We are experts in roll finishing and collaborate with our customers to provide the optimum finish for every application.

Internal Roll Cleaning (IRC)

Issues with roll overheating or coolant flow? Our internal roll acid flushing will help improve the heat removal properties of your chill rolls. We perform flow checks before and after cleaning and provide flow reports for you to help identify potential runnability issues. Our IRC process will remove scale and rust build up on the internals of the roll allowing them to run cleaner and improve their heat transfer performance.

Tolerance and Inspection Reports

All parts are finished to the tightest possible tolerances. Inspection reports are provided with every part processed which includes surface finish graphs, chrome thickness readings, Pro-Mic roll profile graphs, TIR/Taper reports and all the finished dimensions.

Roll Performance Consulting

We have the expertise and knowledge to help resolve roll related runnability, e.g., issues with release, product flow, drag, cooling issues and poor sheet pattern. Many of these problems are caused by finish design and wear issues, cooling, heating or plating issues on your rolls. With over 30 years of experience in finish design and application, we have the knowledge to help improve runnability, increase productivity, decrease downtime and simply make your rolls perform at optimal levels.

Large Diameter Cylinder Liner Services

Pioneer provides Engineered Micro-surface Solutions, with functional chrome, focused on the performance of large diameter Diesel Cylinder Liners.

Bearing Surface Plateau Finishes

Industrial Chrome combined with Plateau Honing provides an optimized cylinder liner surface finish for large bore diesel engines.  Pioneer offers design services to develop the ideal solution for each application.

Honing: Our cylinder liner work cells can accommodate a wide range of part dimensions. We have the capacity to hone liners up to 4’ in length and 10″ in diameter, with capabilities for both new and refurbished large diesel cylinder liners.

Benefits of Industrial Hard Chrome

Benefits of Industrial Hard Chrome

The extreme surface hardness (70+ Rockwell C) of functional chrome yields leading wear performance versus comparable products.  Like nickel, chromium has a natural lubricity which can be enhanced with mechanical surface treatment, such as honing and polishing, that produce precise dimensional and surface finish results.

Why Utilize Pioneer’s Engineered Surface MicroFinish Chrome solutions?

• As an upgrade over other coating options like PVD/DLC that are more expensive and difficult to control.
• Low coefficient of friction increase release performance combined with optimal wear properties.
• Ease of maintenance or replacement – refurbishment of industrial hard chrome plating produces excellent results and is economically viable.
• Interfacing substrate hardness. Hard chrome is naturally anti-galling.
• Reliable in harsh abrasive or chemical environments.
• High cycle count surface transfer performance common in roll/mold applications.

Ideal Applications

• Organic and metallic molding dyes (plastic, rubber, cast metal)
• Capital machinery
• Converting rolls
• Material transfer systems
• Product handling – logistics systems
• Pump Cylinders (ID plating)
• Tubes (ID plating) and cylinders (OD plating)
• Shafts and Spindles
• Axles and Bearings
• Firearm barrels, bolt carrier group (BCG), firing pins
• Aerospace landing gear, actuators, valve sleeves

Value Added Services

Value Added Services

Pioneer provides a complete Industrial Hard Chrome solution with the ability incorporate all critical chrome related process required for an optimal surface solution.

Degreasing: Fully automated degreasing unit to support required pre-cleaning for all products processed through our plant.

Stripping: Capable of removing prior hard chrome plating on parts up to 48” in diameter and 222” in length. Commonly required on hydraulic cylinders, pulp and paper baskets, food processing equipment, front and rear suspension systems for mining
trucks.

Baking: Ovens with significant available capacity to support both pre-and post-plate stress relief or hydrogen removal requirements.

Blasting: Blasting on a wide variety of alloys, including steel, stainless steel, brass and copper, and part geometries with our multiple blast cabinets and grit blasting lathes.

Polishing: Polishing equipment engineered for both pre-and-post hard chrome plating operations. We have large centerless roll polishers with traveling heads, several Rand Bright automatic units for the smaller/high volume parts, buffing heads and
numerous handheld polishing units flexible enough to support critical print dimensions.

Grinding: Diverse set of cylindrical grind equipment with the capability to produce repeatable dimensional and surface finish results to meet your specifications.

Environmental Controls

Environmental Controls

Strict control of potential environmental contaminants is key to Pioneer’s position as a leader in Industrial Hard Chrome Plating.

We are proud of our air and water handling equipment to keep up with our 24 hours a day, 7 days a week work schedule. Our large scrubbers support dozens of plating tanks, exhausting 120,000 cubic feet per minute of clean air. All scrubbers are equipped with HEPA filters, resulting in exhaust emissions that are 10x below the regulatory limit. The wastewater treatment system uses a super-efficient batch capacity that ensures chemistry consistency. Our 5000-gallon treatment tanks ensure that water is returned cleaner than it comes into our plant protecting both our employees and the community.