Ken:
Progress! good deal.
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I've got an old 8ohm, 50watt power resistor that I can experiment with. Can I use a "non-inductive" resistor?
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High resistance is too limiting, stick with 1 ohm or so. 8 ohms will drop a lot of voltage, eg. at 2 amps, you'll get 16 volts across the resistor alone (V=IxR). At 10 amps, you'd need 80 volts. Can your power supply handle high voltages? At high amps, you may not need the resistor at all.
Non-inductive is good. Any kind of power resistor will do, the wattage is what's important.
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Have you ever seen parts where, even after a thorough rinse out of plating bath, you chromate and the chromate will actually not cover some areas? It's almost like someone rubbed the chromate off in that area. Like it's broken or scratched off. Very weird.
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Are you using the zinc brightener? If so, you almost have to use an acid bright dip afterwards. The brightener seems to leave some sort of film on the parts, which can interfere w/conversion coatings. I have stopped using it.
Check this out:
Blackener & brightener
Sean