On-Site Brush Plating & Selective Electroplating

Localised metal repair and dimensional restoration without dismantling

Wear, corrosion, scratches and dimensional damage do not always require replacement of an industrial component – or even removal from the machine.

Brush plating, also known as selective plating or selective electroplating, is a portable electrochemical process that deposits metal onto specific areas of an existing component.

PR Rolls provides on-site brush plating for the repair and restoration of critical industrial components, including rolls, shafts, bearing seats, journals and other worn or damaged metallic surfaces.

Because the treatment can be concentrated on the damaged area, brush plating can often restore a component without extensive dismantling, transportation or heat-intensive repair methods.

Typical objectives include:

• Restoring worn dimensions
• Repairing scratches and scoring
• Repairing local coating damage
• Rebuilding bearing and seal surfaces
• Improving wear resistance
• Providing corrosion protection
• Restoring damaged roll surfaces
• Extending the service life of existing components

For large or critical equipment, the ability to perform the repair directly on-site can significantly reduce maintenance lead time and production downtime.

What Is Brush Plating?

Brush plating is a form of selective electroplating.

Unlike conventional tank electroplating, the complete component does not need to be submerged in a plating bath.

Instead, the plating solution is applied selectively to the required area using an electrode – or anode – covered with an absorbent material containing the electrolyte.

An electrical current passes between the anode and the workpiece, causing metal ions in the solution to be deposited onto the prepared component surface.

The result is a controlled metallic deposit applied only where it is needed.

This fundamental difference makes brush plating particularly useful for:

• Large components
• Installed machinery
• Localised wear
• Dimensional restoration
• Emergency repairs
• Components that are difficult to dismantle
• Components where only a small area requires repair

Selective plating is widely used as a portable repair technique because components can be treated in situ rather than transported to an electroplating facility.

Brush Plating vs. Conventional Tank Electroplating

The most important difference is selectivity.

Traditional electroplating generally requires the component to be placed in a plating bath.

Brush plating brings the plating process to the component.

This makes selective electroplating particularly attractive when only a limited area of an otherwise serviceable component is damaged.

SIFCO similarly identifies selective plating as particularly relevant when tank plating is impractical because a component is too large, difficult to move or requires only accurately controlled local deposition.

What Problems Can Brush Plating Solve?

Brush plating is particularly valuable when a component is fundamentally serviceable but a localised surface has become damaged or dimensionally incorrect.

Typical problems include:

Wear
Continuous mechanical contact can gradually remove material from journals, bearing seats, shafts and other functional surfaces.

Scratches and scoring
Mechanical damage can create grooves or scratches that prevent a surface from functioning correctly.

Corrosion
Localised corrosion can damage critical surfaces while the remainder of the component remains usable.

Incorrect dimensions
Wear or machining errors can result in a diameter, bore or contact surface falling outside the required tolerance.

Damaged coatings
A locally damaged metallic coating does not necessarily require complete recoating of the component.

Bearing-seat damage
Bearing areas can wear or suffer fretting, resulting in loss of the required fit.

In these situations, selective plating can rebuild the required area instead of replacing the complete component.

Dimensional Restoration with Brush Plating

Add material exactly where it is needed
One of the most valuable applications of selective plating is dimensional restoration.

Industrial components can gradually lose material through:

• Wear
• Fretting
• Corrosion
• Scoring
• Previous machining
• Incorrect machining

Brush plating allows metallic material to be deposited onto the affected area until the required dimension can be restored.

This makes the process particularly relevant for components such as:

• Shafts
• Journals
• Bearing seats
• Bores
• Housings
• Seal surfaces
• Roll journals
• Cylindrical surfaces

Dimensional restoration is also a major application identified by established selective-plating providers, particularly for bearing housings, journals, bores and other precision machine components.

The objective is straightforward:

Repair the worn surface rather than replace the complete component.

On-Site Repair of Roll Surfaces

Local repair of worn, scratched and damaged rolls
Rolls and cylinders are particularly suitable candidates for on-site brush plating because they can be large, heavy and expensive to dismantle.

PR Rolls specifically uses brush plating for the repair of worn and scratched roll surfaces.

Depending on the damage and component requirements, brush plating can be considered for localised defects such as:

• Scratches
• Scoring
• Wear
• Corrosion damage
• Local coating damage
• Dimensional deviations

Instead of removing the complete roll for workshop repair, PR Rolls can evaluate whether the affected area can be restored directly at the customer's site.

For printing industry, paper, pulp and steel mills, this can be particularly valuable where roll removal would otherwise require significant dismantling and production downtime.

Brush Plating for Roll Journals and Bearing Seats

Roll journals and bearing seats require accurate dimensions and surface condition.

Wear, fretting or corrosion can gradually affect the fit between the journal, bearing and surrounding components.

Replacing a large roll because of a locally damaged bearing surface can be disproportionately expensive.

Selective plating provides another option.

Material can be deposited specifically onto the damaged area to restore the required dimension and functional surface.

Because the process is localised, the remainder of the roll does not need to be coated.

This is one of the fundamental advantages of brush plating:

repair only what needs to be repaired.

Repair Scratches, Scoring and Local Surface Damage

Not every damaged surface requires complete recoating or extensive machining.

A scratch or scored area may affect only a small percentage of the total component surface.

Brush plating allows PR Rolls to focus the repair on that specific area.

The damaged region is prepared, selectively plated and, where required, finished to achieve the specified final surface.

This makes the technique particularly useful for localised repair of expensive industrial components where the surrounding surface remains in good condition.

Corrosion Protection with Selective Plating

Brush plating can also be used to improve the corrosion resistance of selected component surfaces.

The appropriate metallic deposit can create a protective layer between the underlying component and its operating environment.

PR Rolls currently identifies corrosion protection in power plants, paper mills and steel mills as a typical brush-plating application.

Selective plating is useful when:

• Only certain areas require protection
• Existing corrosion damage must be restored
• The component cannot easily be removed
• Full tank plating would be impractical
• Localised surfaces require a different material property

Corrosion protection is also one of the established industrial purposes of selective plating.

A Cold Repair Process with Minimal Heat Input

One of the major differences between brush plating and welding-based restoration is heat input.

Brush plating is an electrochemical process rather than a welding process.

This can be valuable for precision components where excessive heat could potentially affect:

• Geometry
• Dimensions
• Material properties
• Surrounding surfaces

For precision repair, this can make brush plating an attractive option when the component must retain its existing geometry.

Brush Plating as an Alternative to Welding

Welding is an effective restoration technique for many applications, but it is not always the most appropriate method for local surface repair.

Selective plating may be preferable when:

• The repair area is small
• Precise dimensional build-up is required
• Heat input should be minimised
• Distortion must be avoided
• Only a thin metallic layer is required
• The surrounding component is already within specification

The technologies should not be viewed as universal substitutes for each other.

PR Rolls can evaluate the damage, component material, required dimensions and operating conditions before selecting the appropriate repair method.

Brush Plating vs. Thermal Spray

PR Rolls also provides thermal spray coating solutions, but brush plating and thermal spraying solve different types of problems.

Brush plating
Best suited to localised metallic repair and controlled dimensional restoration.

Thermal spraying
Often more suitable when a larger functional surface requires a wear-resistant, release, traction or other engineered coating.

For example, a large roll requiring an entirely new wear-resistant functional surface may be better suited to thermal spraying.

A roll with one small damaged or worn area may be a better candidate for selective brush plating.

The correct technology depends on the size of the damaged area, required coating properties, geometry and operating conditions.

Selective Plating for Inside and Outside Diameters

The ability to treat specific geometries makes selective plating useful for many different industrial components.

Depending on access and component design, applications can include:

Outside diameters, such as shafts, journals and cylindrical bearing surfaces.

Inside diameters, such as bores, housings and cylindrical internal surfaces.

Flat surfaces, such as sealing areas, housings and machine surfaces.

This versatility is well established within selective electroplating.

Correcting Machining Errors and Manufacturing Deviations with Brush Plating

Restore incorrectly machined components instead of scrapping them

Brush plating is not only a repair method for components that have become worn during operation. It can also be used to correct dimensional errors that occur during manufacturing, machining or refurbishment.

If too much material has accidentally been removed during turning, grinding, boring or another machining operation, an otherwise new or valuable component may become undersized or fall outside the specified dimensional tolerance.

Depending on the component, material and extent of the deviation, selective brush plating can rebuild the incorrectly machined area by depositing a controlled layer of metal onto the surface.

Typical applications can include:

• Undersized shafts and journals
• Incorrectly machined bearing seats
• Oversized bores
• Excess material removed during grinding
• Dimensional errors after turning
• Local machining mistakes
• Seal surfaces machined below specification
• Components outside specified dimensional tolerances

Instead of manufacturing a completely new component, the affected surface can be evaluated for dimensional restoration using selective electroplating.

From Machining Error to Correct Final Dimension

A typical restoration can involve:

Measurement → Damage/deviation assessment → Surface preparation → Selective plating → Final machining or grinding → Dimensional verification

The amount of material required is determined from the dimensional deviation. Metal is then selectively deposited onto the affected area to rebuild the surface.

Where necessary, the plated area can subsequently be machined or ground to the specified final dimension and surface finish.

This is particularly valuable for expensive, large or long-lead-time components where a relatively small machining error would otherwise result in significant material loss, production delays or complete remanufacturing.

Correct Machining Mistakes Without Replacing the Component

A machining error does not automatically mean that the component must be scrapped.

For example, if a shaft or bearing seat has accidentally been machined below its specified diameter, brush plating may allow the missing material to be restored. The surface can then be finished to the required tolerance.

This can provide several advantages:

• Save newly manufactured components that would otherwise be rejected
• Restore dimensional tolerances after machining errors
• Avoid complete remanufacturing
• Reduce material waste
• Avoid long lead times for replacement components
• Reduce production delays
• Repair only the affected area
• Combine plating with precision machining and grinding

For manufacturers and maintenance workshops, this makes selective plating valuable not only as a maintenance technology but also as a corrective manufacturing process.

PR Rolls can combine precision measurement, brush plating and machining to provide a complete dimensional restoration solution. If a component has been machined undersize or otherwise outside tolerance, PR Rolls can evaluate the deviation, rebuild the affected surface with selective plating and machine or grind the component to the required final dimensions.

On-Site Brush Plating for Pulp & Paper Mills

Pulp and paper mills contain large rotating equipment where dismantling can be both expensive and time-consuming.

Typical components that may be evaluated for selective plating include:

• Roll surfaces
• Roll journals
• Bearing seats
• Shafts
• Housings
• Cylindrical surfaces
• Seal areas
• Local corrosion damage

PR Rolls' combination of on-site machining, grinding, coating and measuring expertise is particularly relevant in these environments.

If a component requires more than plating alone, the repair can be evaluated as part of a wider mechanical restoration project.

Brush Plating for Power Generation

Power plants contain critical rotating and stationary components where dimensional accuracy and equipment availability are essential.

PR Rolls already identifies power plants as one of its typical brush-plating markets.

Selective plating can be relevant for localised repair of appropriate:

• Shafts
• Bearing areas
• Journals
• Housings
• Generator components
• Turbine-related components
• Corroded surfaces

The portability of the process is particularly valuable for equipment where removal and transportation would substantially increase outage duration.

Selective plating is also widely used internationally within power generation for wear resistance, corrosion protection, dimensional restoration and electrical applications.

Brush Plating for Steel Mills

Steel production equipment operates under demanding mechanical and environmental conditions.

Wear, corrosion and localised surface damage can affect large components that are expensive to remove or replace.

PR Rolls identifies steel mills as another typical brush-plating application area.

Where technically appropriate, selective plating provides a method for restoring specific damaged surfaces while retaining the original component.

Other Industrial Applications

Brush plating is not limited to pulp and paper, power generation or steel production.

The technology is widely used for repair and surface enhancement in industries including:

• Marine
• Oil and gas
• Petrochemical
• Power generation
• Industrial machinery
• Hydraulics
• Electric motors
• Printing
• Aerospace

The exact process and deposit must always be selected according to the component material, operating conditions and required functional properties.

Selective plating is used across these sectors because of its combination of portability, localised treatment and controlled metal deposition.

Which Metals Can Be Applied with Brush Plating?

Selective electroplating is a process rather than one specific coating.

Different metallic deposits can be used to achieve different surface properties.

Depending on the process system and application, commonly used selective-plating metals and alloys can include:

• Nickel
• Copper
• Cobalt
• Nickel alloys
• Silver
• Tin
• Zinc
• Other application-specific deposits

The Brush Plating Process

A successful selective-plating repair requires careful preparation and process control.

A typical project can include:

1. Inspection and Measurement
The damaged component and repair area are inspected to determine the extent of wear, corrosion or dimensional deviation.

2. Repair Planning
The required final dimension, surface properties and plating deposit are determined.

3. Local Surface Preparation
The repair area is cleaned and prepared to create the correct conditions for adhesion.

4. Masking
Areas that should not receive the metallic deposit are protected.

5. Electrochemical Preparation
The substrate is prepared and activated according to the material and selected plating process.

6. Selective Metal Deposition
The plating tool is moved over the prepared surface while controlled electrical current deposits the selected metal onto the component.

7. Controlled Build-Up
Material is deposited until the required coating thickness or dimensional build-up is achieved.

8. Final Finishing
Where required, the repaired surface can be machined, ground or polished to achieve the final dimensions and surface quality.

9. Measurement and Verification
The completed repair is measured and verified against the project requirements.

The exact procedure depends on the substrate, deposit material, geometry and repair requirements.

Combine Brush Plating with On-Site Machining and Grinding

PR Rolls can combine brush plating with capabilities such as:

Measurement → Machining/Grinding → Surface Preparation → Brush Plating → Final Machining/Grinding → Verification

This allows the repair to be designed around the required final component condition, rather than treating plating as an isolated process.

Why On-Site Brush Plating?

For large industrial components, the cost of repair is not determined only by the repair operation itself.

Dismantling can involve:

• Production shutdown
• Mechanical disassembly
• Heavy lifting
• Transportation
• Workshop lead time
• Return transportation
• Reinstallation
• Alignment and commissioning

Portable selective plating can eliminate several of these steps.

Because the process can be performed directly on the component, it can significantly reduce machine downtime and production delays. 

For critical industrial machinery, avoiding unnecessary dismantling can be more valuable than the coating operation itself.

Repair Instead of Replace

A locally damaged surface does not necessarily mean that the complete component has reached the end of its service life.

If the underlying component remains mechanically sound, restoring the damaged area can provide an alternative to replacement.

Selective plating supports a repair-oriented maintenance strategy by:

• Retaining the original component
• Adding material only where needed
• Reducing unnecessary material consumption
• Avoiding manufacture of a replacement component
• Reducing transportation
• Extending component service life
  
  

This makes brush plating relevant not only from a maintenance perspective, but also from a resource-efficiency and lifecycle perspective.

When Should You Consider Brush Plating?

Brush plating should be evaluated when:

• A critical surface is locally worn
• A roll or shaft has scratches or scoring
• A bearing seat has lost its required dimension
• A journal requires dimensional restoration
• Local corrosion has damaged a functional surface
• A component is too large or difficult to transport
• Only a small area requires coating
• Heat input should be minimised
• Welding is undesirable
• Tank plating is impractical
• A local coating repair is required
• Replacing the complete component would be unnecessarily expensive
• Production downtime must be minimised
• A shaft or journal has accidentally been machined undersize
• A bearing seat is outside dimensional tolerance
• Too much material has been removed during grinding or turning
• A bore has been machined oversized
• A manufacturing error would otherwise require the component to be scrapped
• A newly manufactured component requires local dimensional correction

The correct repair method depends on the component material, extent of damage, required build-up and final operating conditions.

PR Rolls can evaluate whether brush plating, machining, grinding, thermal spraying or a combination of methods provides the most appropriate solution.

Benefits of PR Rolls On-Site Brush Plating

The main advantages are:

Localised repair – metal is deposited only where required
On-site execution – suitable repairs can be completed without component removal
Dimensional restoration – worn surfaces can be rebuilt
Low heat input – avoids the thermal effects associated with welding
Corrosion protection – suitable deposits can protect critical surfaces
Wear resistance – surface properties can be improved according to the selected deposit
Reduced dismantling – large equipment can often remain installed
Reduced downtime – fewer logistics and maintenance operations
Component life extension – damaged components can be restored instead of replaced
Integration with machining – PR Rolls can combine plating with mechanical restoration

Why Choose PR Rolls for Brush Plating?

PR Rolls approaches brush plating as part of industrial component restoration, rather than simply as an electroplating service.

Our wider on-site capabilities allow the condition of the complete component to be considered.

Depending on the repair, PR Rolls can combine:

• Precision measurement
• On-site machining
• Grinding
• Turning
• Line boring
• Surface restoration
• Brush plating
• Coating
• Final measurement and verification

This is particularly valuable for large rolls, shafts, journals, bearing seats and other critical machinery where the final geometry matters just as much as the deposited coating.

The objective is not simply to apply metal.

It is to return the component to a reliable functional condition while minimising unnecessary downtime and replacement.

Frequently Asked Questions About Brush Plating

What is brush plating?
Brush plating, also called selective plating or selective electroplating, is an electrochemical process used to deposit metal onto specific areas of a component without immersing the complete component in a plating tank.

Is brush plating the same as selective plating?
Brush plating is one of the principal methods of selective electroplating. The terms are frequently used interchangeably when referring to portable localised electroplating.

Can brush plating be performed on-site?
Yes. Portability is one of the major advantages of the process. PR Rolls currently provides brush plating for coating repairs performed on-site.

Can brush plating restore worn dimensions?
Yes. Dimensional restoration is one of the established applications of selective plating. Metal can be deposited onto a worn area to rebuild a required surface or dimension.

Can brush plating repair roll surfaces?
Yes. PR Rolls specifically identifies worn and scratched roll surfaces as typical brush-plating applications.

Can brush plating repair bearing seats and journals?
Selective plating is widely used for dimensional restoration of bearing surfaces, journals, housings and bores. Suitability depends on the damage, substrate and final operating requirements.

Does brush plating cause heat distortion?
Brush plating is a low-temperature electrochemical process. Unlike welding-based build-up, it does not require high thermal input to melt the substrate. This makes it useful where heat-related distortion is a concern.

Can brush plating provide corrosion protection?
Yes. Corrosion protection is an established selective-plating application and is one of the applications specifically identified by PR Rolls.

Is brush plating an alternative to welding?
For some localised repairs, yes. Selective plating can be attractive where controlled dimensional build-up and low heat input are required. However, welding and plating have different capabilities, so the appropriate method should be selected according to the damage and component requirements.

Is brush plating an alternative to thermal spraying?
In some applications. Brush plating is particularly suited to localised metallic repair and dimensional restoration, while thermal spraying is often better suited to larger functional surfaces requiring engineered coating properties.

Which industries use brush plating?
Selective plating is used across pulp and paper, steel, power generation, marine, oil and gas, petrochemical, aerospace and general industrial applications.

Restore Critical Components Without Unnecessary Replacement

Wear, scratches, corrosion or dimensional damage do not automatically mean that an expensive industrial component must be replaced.

PR Rolls provides on-site brush plating and selective electroplating to restore localised damaged surfaces, rebuild dimensions and protect critical components against wear and corrosion.

For rolls, shafts, journals, bearing seats and other large industrial components, the process can often be performed directly at the customer's site, reducing dismantling, transportation and production downtime.

Combined with PR Rolls' expertise in on-site machining, grinding and precision measurement, brush plating becomes more than a coating process.

It becomes part of a complete strategy for repairing, restoring and extending the service life of existing industrial equipment.