1. Raw Material Selection & Pre-Treatment
1.1 Material Specification
Cathode Plate Sheet: 316L stainless steel (00Cr17Ni14Mo2), thickness 3.0–5.0 mm, with excellent corrosion resistance, high flatness and smooth surface.
Conductive Beam: T2 copper core with 316L stainless steel cladding, ensuring high conductivity and acid resistance.
Insulation Components: PP/PO/PEEK edge strips and high-temperature adhesive, preventing edge growth and short circuit.
1.2 Pre-Treatment
Degreasing & Pickling: Remove oil, oxide scale and impurities from the stainless steel surface.
Precision Leveling: Use roller leveling machine to control flatness ≤1.5 mm/m and verticality ≤5.5 mm/m.
Surface Finishing: Control surface roughness Ra 0.25–0.6 μm for uniform metal deposition and easy stripping.
2. Cutting & Machining
Precision Cutting: Laser or CNC cutting to fixed dimensions, with tolerance ±1 mm, diagonal error ≤2 mm.
Edge Deburring & Chamfering: Remove burrs and chamfer R0.5–1.0 mm to avoid damaging insulation strips.
Hole Machining: Drill lifting holes at the top for hanging in electrolytic cells.
Bottom Grooving: Mill V‑grooves at the bottom to improve stripping performance.
3. Conductive Beam Processing
Composite Forming: Copper core and stainless steel sheath are processed by extrusion or rolling to form a metallurgical bond.
Finishing: Mill the contact surface to expose pure copper, ensuring low contact resistance.
Slot Processing: Machine positioning grooves for stable assembly with the stainless steel plate.
4. Assembly & Welding
Precision Assembly: Fix the stainless steel plate into the conductive beam with specialized fixtures to ensure verticality and concentricity.
Automatic Laser Welding: Double‑sided full laser welding without welding flux, featuring small heat‑affected zone and minimal deformation.
Weld Inspection: Ensure full penetration, smooth surface, no porosity, cracks or inclusions.
5. Surface Passivation & Polishing
Passivation Treatment: Form a uniform, dense protective film to enhance corrosion resistance.
Fine Polishing: Improve surface smoothness to ensure easy stripping of cathode deposits.
6. Insulation Installation
Paste and fix PP/PO insulation strips on both sides and bottom.
Ensure tight bonding, no gaps or warping to prevent edge crystallization.
7. Inspection & Packaging
Dimensional Inspection: Flatness, verticality, length, width, thickness and welding quality.
Conductivity Test: Verify low contact resistance and stable performance.
Packaging: Anti‑scratch packaging for safe transportation.
