Postby dognose » Thu Apr 23, 2015 10:53 am
Making An Electrotype
The first step in the production of an electrotype plate consists in the preparation of an impression in wax of the type form. The molding wax usually consists of ozokerite, to which various substances have been added to produce the desired consistency. The molten wax is poured upon one side of a metallic plate or “case,” either lead or copper. After taking the impression of the type form at a slightly elevated temperature by the use of suitable pressure, usually by means of a hydraulic press, the resultant “form” is "trimmed" and “built up” to produce the desired degree of relief in the finished plate.
The form is then coated with graphite, applied either by a wet or a dry process. After washing out the excess of graphite, the form is either introduced directly into the depositing bath, or in some cases is given a preliminary treatment (so-called “oxidizing”) with copper sulphate and iron filings, whereby a thin film of copper is deposited upon the graphite. The baths are usually contained in lead-lined wooden tanks, with copper crossbars, from which the anodes and cathodes are suspended. Electrical connection to the graphited cathode surface is made by means of the suspending hook by either of two methods. In the first, known as the “case connection," the hook is in direct contact with the metallic case, portions of the wax being removed in order to bring the case and the graphite surface in contact, while the back of the case is insulated with wax. In the second method, known as the “face connection,” the hook is in contact with a small copper plate inserted in the wax near the top of the form and in contact with the graphite surface. In the latter method the metallic case itself is not in the circuit, and there is less tendency for copper to deposit upon any accidentally exposed portions of the case.
After the copper is deposited to the desired thickness (usually 0.15 to 0.25 mm., or 0.006 to 0.010 in.) the form is taken from the bath and the copper “shell” is loosened by means of hot water. After trimming, the back of the shell is treated with soldering fluid (usually zinc chloride) and coated with tin foil, after which it is laid face downward upon a heated pan. After the tin foil is melted upon the back of the shells, molten electrotype metal (usually containing from 3 to 4 per cent each of tin and antimony and from 92 to 94 per cent lead) is poured over them The electrotype plates thus produced are cleaned, cut, and trimmed to the desired size and thickness and “finished” to a plane surface, which may be subsequently curved if desired.
Source: The Brass World and Platers Guide - December 1919
Trev.