DESCRIPTION OF THE TECHNOLOGY efficiency; replaces the conventional Cr+6 plating process; 

With support from the Environmental Protection Agency’s 

(EPA) Small Business Innovation Research (SBIR) Program, Faraday Technology, Inc., has developed a cost-competitive functional trivalent chromium (Cr+3) plating process to replace hexavalent chromium (Cr+6). The 

pilot-scale technology is validating Faraday’s electrically 

mediated Cr+3 plating process (the FaradaicTM Process) as 

a “drop-in” replacement for the use of Cr+6 plating. This 

manufacturing process validation is being executed with 

Moyno Industrial Products, a large manufacturer of industrial pumps, and the Naval Air Depot (NADEP) at 

Cherry Point, NC. 

The process uses modulated reverse-current electrolysis 

in conjunction with a Cr+3 plating chemistry and results in 

a performance-based, functional Cr+3 plating process to 

replace conventional Cr+6 chromium plating. The process 

incorporates Faraday’s E-CHANGETM In-Process Recycling 

System (also developed under EPA SBIR Program funding) for effluent waste management. A controlled Alpha 

test of the FaradaicTM Process was completed in a pilot-scale 

manufacturing cell designed and built by Faraday. This test 

was conducted using strut rods provided by a Tier 1 automotive supplier. 

Faraday’s functional Cr+3 plating process demonstrates 

equivalent or superior plating rate, hardness, and current 

and results in a more environmentally friendly and workersafe plating process. The FaradaicTM Process demonstrates 

a thickness of 10 mils (250 m) and a plating rate of 1.44-

2.25 μm/min; whereas, conventional Cr+6 plating processes 

demonstrate a thickness of 6-10 mils (150-250 m) and a 

plating rate of 0.76-1.27 μm/min. 

SIGNIFICANCE OF THE TECHNOLOGY 

EPA has identified Cr+6 as 1 of 17 “high-priority” toxic 

chemicals. These chemicals were selected based on their 

known health and environmental effects, production volume, and potential for exposure. Hexavalent plating baths 

operate at elevated temperatures and produce a mist of 

chromic acid. The Clean Air Act, as well as local constraints, 

regulate the emission of chromium to the air and water. 

Because Cr+6 plating produces hazardous air emissions, 

all of the Cr+6 platers must control and monitor the bath 

surface tension and report the results to EPA. In contrast, 

Cr+3 platers are not required to monitor bath surface tension. Use of Cr+3 in industrial and commercial processes is 

preferred over Cr+6 on the basis of the comparison of the 

toxicities. EPA has classified Cr+6 as a group A, known 

human carcinogen, and considers Cr+3 as being much less 

toxic and an essential element in the human diet. Cr+3 is 

classified by EPA as a Group D carcinogen, not classifiable 

as to carcinogenicity in humans. 

Ø Faraday Technology, Inc., developed a cost-competitive Cr+3 plating process to replace Cr+6 plating. 

Ø The process uses a modulated reverse-current electrolysis in conjunction with a reduced-cost Cr+3 

plating chemistry. 

Ø Faraday’s functional Cr+3 plating process demonstrates equivalent or superior plating rate, hardness,

and current efficiency. 

Ø To date, $219,723 in commercial revenue has been secured to support Faraday’s pilot-scale activity. 
A pilot-scale plating Cr+3 line (left) is being operated at the Faraday facility in Clayton, OH. 

This plating line is a small-scale version of a shop-floor full-scale line. This line is being 

used to validate the FaradaicTM Process on shock rods and pump rotors (right). 

The FaradaicTM Process is being widely implemented for: 

Ø FaradaicTM Industrial Coatings, such as functional 

chromium from a trivalent chromium bath. 

Ø FaradaicTM Edge and Surface finishing of advanced 

engineering alloys, such as stainless steel, aluminum, 

nickel, titanium, and the like without toxic, exotic 

electrolytes. 

Ø FaradaicTM Leveling—metalization without levelerbrightener additives for advanced electronics applications. 

Ø FaradaicTM Environmental Countermeasures—electrically mediated systems for in-process recycling of 

rinse waters and plating bath chemistry. 

The functional Cr+3 plating process supports the FaradaicTM Process technologies listed above, by providing 

environmentally conscientious reclamation and reuse of 

process solutions. 

COMMERCIALIZATION SUCCESS 

To date, Faraday has secured $219,723 in commercial revenue to support this pilot-scale activity. Additionally, Faraday is preparing samples for external evaluation by Concurrent Technologies Corporation and NADEP Cherry 

Point. Faraday has a successful track record of technology 

commercialization, with six strategic technology alliances 

currently under contract and 60 percent of its annual sales 

coming from commercial sources. Faraday has filed patent 

application #08/871,599 titled, “Electroplating of Metals 

Using Pulse Reverse Current for Control of Hydrogen Evolution” based on this SBIR-funded project. 

AWARDS AND COMPANY HISTORY 

Faraday Technology, Inc., is an electrochemical process technology development company 

focused on enhancing and commercializing the 

FaradaicTM Process, its platform electrochemical manufacturing technology. Founded in 

1991, Faraday has established itself as a 

noteworthy applied research and development company 

with approximately 80 publications and more than 30 

patents/patents pending. The company has been recognized with a number of awards, including: the U.S. Small 

Business Administration-sponsored Small Business/Enterprise Spirit Awards, the State of Ohio Governor’s Thomas Edison Emerging Technology Award, the Affiliate’s 

Society Council of Dayton Outstanding Technology Leadership Award, the Abner Brenner Silver Medal Award 

for a paper published in Plating & Surface Finishing, 

and the Ernst & Young Entrepreneur of the Year Award 

(High Technology Finalist for 2001).