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Galv-etching brass and copper

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  • Holescreek
    Member
    • Jul 2011
    • 242

    Galv-etching brass and copper

    I figured I'd past this tutorial here in case there's any interest. On a side note, a similar process can be done on steel using salt water and a different kind of applicator. I haven't tried the steel process yet since I have other means of marking steel, but others are doing it with great success.

    Here's my original post on WG, in parts due to the photo limit:

    One of the requirements for the builder's challenge this year is that the Weaponsguild logo has to be on the gun. I wanted to try something new and opted for trying to electro-etch the logo into some brass. I had seen a link someone had posted and luckily had saved the link for future reference. Here it is: http://steampunkworkshop.com/electroetch.shtml

    I read through the thread a couple of times and it occurred to me that there was some info missing. I noticed at the end of the thread there was a link to yet another more comprehensive site: http://www.greenart.info/galvetch/contfram.htm
    It was there that I found the information I needed to construct a cathode for the etching process.

    Today was my first day to electro-etch anything ever. For technical questions see the greenart link above.

    Per the steampunk link instruction I put some glossy inkjet photo paper into the feed tray of a laser printer. The idea of combining the glossy paper with the laser toner is to not allow the toner to get a bite into the paper so it sits on top .

    I already had the artwork supplied from the "Weaponsguild Logo Discussion thread: http://www.weaponsguild.com/forum/in...0988#msg300988 The first order of business is to flip the image so that the words read backwards. This way it will read correctly after you iron it onto the metal. Next problem was to reverse the colors of the image so that the black areas are white and visa-versa. It will make more sense later after the voided areas are filled with paint.

    Look at the bottom stencils. The white one would read backwards after ironing and the etch would have to eat a lot of area off of the metal:


    Tonight I used copper sheet because it was all I had. I bought a brass kick plate from HD that turned out to be brass plated aluminum that won't work. I found some sheet in the shop and used it since I was already set up to etch. I used scotchbrite to remove all of the corrosion and imputities from the sheet copper then wiped it down with denatured alcohol to remove any dirt or oil. I cut the pieces to the size of my pictures:



    Next you flip the picture over onto the copper and iron it on with the iron set on high. Make sure that you don't let the paper slide around and smear the laser toner and ruin your image. I also used an old ink roller to press the paper firmly onto the metal.



    After the metal cools enough for you to touch it, drop it into a bucket of water to soften the paper. After about 10 minutes the paper will soften enough start peeling it off



    Remove as much as you can till it starts to dry then drop it back into the bucket. Leaving it in water will not hurt the toner at all. I just keep rubbing the paper with my fingers to keep from scratching through the toner. I end up with this:

  • #2
    Holescreek
    Member
    • Jul 2011
    • 242

    If you look closely at the small letters above you will see that they aren't cleared out all the way. The reason is that the image wasn't a true black and white image but rather black and light grey. I used a scriber to clean out the lines that were still filled with toner.



    Next is to secure an anode lead to the metal. I stripped the ends of some copper wire and used clear shipping tape to attach it to the back of the copper. I covered the whole back with the tape to keep it from dissolving. Leave the plastic on the wire, it'll keep the wire from dissolving.



    Now you have your metal masked and have an anode attached. You need a cathode to make this work.
    I had already decided to use an old plastic ice cream bucket for this because it was the right size and had a lid. I used some scrap brass and brass welding rod to make a brass cathode that looks like a ladder. It just fits into the bucket and will hang over the submerged copper plate.



    The Greenart instructions call for using a DC power supply. I keep meaning to buy one but always end up using my Sam's Club battery charger. Keep it set at 6 volts or you will literally eat holes through everything. Seriously. My charger says 6V-15A That is a ton of amperage!



    I set my cathode on the bucket to use it as a guide for how much liquid I needed. After reading the greenart thread I decided to do my plates laying down to keep from having to make a lot of extra etchant. The Root Kill cost about $12 at HD. I poured root kill (copper sulfate) into the water until it was so saturated that it wouldn't disolve any more.



    Next I set my plate in the bottom of the bucket and set the cathode over the top of it. Attach the positive lead from the charger to the wire on the plate and the negative lead to the cathode tray then plug in the charger. Don't start looking for anything to happen, you won't see anything.

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    • #3
      Holescreek
      Member
      • Jul 2011
      • 242

      My first piece was pretty rough looking. I kept playing with the voltage thinking I should see something happening and I left it in too long. Here's how it cam out:



      I learned some things from that one. First, leave it set at 6 volts. Second, stop the process about every 10 minutes and wipe the copper areas with the tip of a rag wetted with some of the copper sulfate solution. Cleaned areas seem to etch faster.

      Here's what it looks like right out of the bath. Wipe it down and put it back in:



      After about 30 minutes it will have gotten pretty deep. You have to decide whether to go deeper and risk pitting or stop where you are at and figure it's good enough. I tried to get a shot to show how deep it gets:



      Next step is to scotchbrite the face of th eplate to remove the toner, then paint the entire face of the plate. I had some cheap flat black paint handy and used it. I may go back later and strip it off to use Duracoat if the paint doesn't stick.



      Here's the other one before painting:



      The last step will be to sand the high spots of the metal down to bare metal to complete the plaque. I won't do that step until tomorrow, stay tuned.

      Comment

      • #4
        Holescreek
        Member
        • Jul 2011
        • 242

        This morning the paint was dry and I tried to remove it where needed. The new design was much easier to do since all the paint sits in grooves. I scratched up the paint on the background of the regular logo, so i touched it up with a blach marker just to give you the idea. I'll have to figure out a better way to remove the paint on the high spots.

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        • #5
          straykiller
          Veteran Member
          • Feb 2010
          • 2573

          very cool thanks for the write up


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          • #6
            smird
            CGN/CGSSA Contributor
            CGN Contributor
            • May 2009
            • 8309

            Very cool, thanks

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            • #7
              7,62x39
              Member
              • Feb 2010
              • 345

              nice, this could make for some fun projects

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              • #8
                Holescreek
                Member
                • Jul 2011
                • 242

                nice, this could make for some fun projects
                I had the same thought after I finished what I needed for the rifle I was building. We have a metals recycling center downtown that buys and sells brass, copper and aluminum (you know those places where people are lined up to sell aluminum cans).
                I went into the brass room and found 6 thick solid brass door kicks and bought 3 of them for $24. Not sure exactly what I'm going to do yet, but it's so easy to do that it's hard to just stop.

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                • #9
                • #10
                  Holescreek
                  Member
                  • Jul 2011
                  • 242

                  Thanks for posting that! I tried some brass plated aluminum and got no reaction at all, even after giving it a light sanding to remove any varnish. I had no idea that I could use the copper sulfate on steel, most of what I've read has people using a saturated salt water solution.

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