Hydraulic Rod Repair Using Brush Plating Technology

Sterling Impreglon Asia recently completed another successful hydraulic rod repair for one of our long-standing customers. Over time, these rods had developed multiple corrosion pittings, a common issue in hydraulic systems operating under harsh environments. Left unattended, such damage can lead to seal failure, oil leakage, and unplanned downtime.

Replacing hydraulic rods is expensive and time-consuming. Instead, our customer turned to Brush Plating—a proven, cost-effective repair solution that restores performance while extending service life.

Understanding the Damage

Both hydraulic rods showed widespread surface pitting caused by corrosion. These pits, although localized, were deep enough to compromise smooth rod movement and sealing performance. Precision repair was required to restore the rods without altering their original dimensions.

The Repair Process

Our trained technicians carried out the repair using a controlled and step-by-step Brush Plating procedure:

1. Controlled Grinding
   The damaged areas were carefully ground open to remove corrosion and prepare the surface—widening the pits without deepening them to maintain dimensional integrity.
2. Proper Masking
   The surrounding areas were meticulously masked to prevent chemical leakage and to ensure plating was applied only where required.
3. Thorough Cleaning & Surface Preparation
   All prepared areas were cleaned and activated to remove contaminants, ensuring optimal adhesion for plating.
4. Brush Copper Plating Build-Up
   Using our proprietary Brush Copper Plating process, the damaged zones were rebuilt layer by layer to the required dimensions with high precision.
5. Blending & Surface Levelling
   The plated areas were blended seamlessly into the original rod surface, restoring smoothness and functionality.
6. Nickel Capping (Final Finish)
   A nickel cap was applied to enhance wear resistance, corrosion protection, and overall appearance—returning the rods to a “like-new” condition.

Quality Assurance & Inspection

Before completion, each rod underwent strict quality checks:

• Dimensional verification using a cylinder gauge to confirm compliance with specified tolerances
• Tape adhesion test to ensure excellent copper bonding and long-term durability

Only after meeting all requirements were the rods released for service.

The Result

✔ Fully restored hydraulic rods
✔ Extended service life
✔ Significant cost savings versus replacement
✔ Minimal downtime for the customer

This repair once again demonstrates how Sterling Impreglon Asia’s Brush Plating Technology delivers precision, durability, and reliability for hydraulic components—trusted by customers across industries.