I have read electro stripping articles that describe the stripping action on gold plate or bullion. The gold never goes into solution in sulfuric. The underlying base metal is attacked through microscopic imperfections in the gold plate. These metals oxidize and go into solution. This loosens and breaks up the gold plate into fine bits. You can see the yellow glitter falling or floating.
Hey, Al,
I would suggest you read the original patent on this: #2185858.
http://www.google.com/patents?id=L3FVAAAAEBAJ&printsec=abstract&zoom=4&dq=2185858
According to this, the gold momentarily dissolves due to the presence of persulfuric acid. It then immediately precipitates. I have read elsewhere that this is due to the presence of small amounts of sulfurous acid, which is basically a sulfite. Also, there is no such thing as the existence of gold sulfate in the strong sulfuric.
It has nothing to do with the acid penetrating though the porosity of the gold plate and attacking the underlying base metals. In fact, the underlying base metals are hardly attacked at all. According to the patent, this is due to the formation of an oxide coating on the base metals. In practice, there will be very, very minor amounts of base metals co-mingled with the precipitated gold. This assumes that the concentration of the sulfuric is above a threshold strength. The patent says this threshold is 60%, but I really don't like it that weak - I would keep it much higher. Also, the patent suggests using nickel sulfate as an accelerator. I think this would be a big mistake, since too much nickel will completely stop the stripping of gold. If this happens, the solution is dead and you'll have to start with fresh solution.
I should also mention that there's no glycerin in the original patent. Down the line, some yo-yo added glycerin for some reason and this myth has perpetuated itself. Reminds me of the lady who always cut the end off on a big ham before putting it in the oven. She said she did this because her Mother had always done it. Come to find out, her Mother's oven was too small to hold a big ham.
The Merck Index assumes that the metals are just soaking in the acid. This is much different than when a voltage is applied. The voltage maintains this oxide film on the base metals. To prove this to yourself, make up a small amount of the conc. sulfuric with 10% water and run a piece of clean copper in it, at about 6V for, say, 30 minutes. After mixing the sulfuric, let it cool down first. Weigh the copper before and after. I would also suggest first to attach the lead and apply some voltage, before putting the copper into the solution. In other words, go in live.
Someone said that this is an art and not a science. I don't believe this at all. An art becomes a science when you can always predict the outcome. In this case, using the strong sulfuric, with a little experience, the outcome is 100% predictable.
I never worried about the build up of heat in the solution. Probably, this was due to my using a 50 gal tank. With your 3 gal tank, you probably won't have problems with heat if you use the strong sulfuric. With weak sulfuric, the current is always high and the solution will continue to heat up. With the strong sulfuric, the current goes to zero, when the gold is stripped. This should also give you a clue that the base metals aren't dissolving.
I still hate the use of large glass containers, especially when heat is involved. In the early days, we used 5, 7.5, and 10 gallon Pyrex battery jars for aqua regia. Every so often, one would break - all by itself, it seemed at the time. It wasn't a pretty sight. The use of a steel container and making the container the cathode is much, much better. What if you accidentally dropped the steel cathode into the glass container, e.g.? Shatter city, with 3 gallons of sulfuric in your lap. According to this link (about 2/5 down the page), 100 deg F, 88% H2SO4, will attack mild steel at the rate of .03" per year. Certainly not enough to worry about.
http://www.resistoflex.com/sulfuric_graphs.htm
Forget the Merck Index and do your own experiments in small beaker sized quantities. Collect your own data. The Merck Index and the data in the CRC Chemistry/Physics Handbook are based on pure, simple, isolated systems. Quite often, when the system is more complex, as this one is, the results can be totally different, especially in electrolytic systems.
I think you're making this thing a lot more complicated than it really is. Just try the strong sulfuric. No more dissolving of base metals. No more large amounts of base metals sludge. No more cleaning of the solution itself - just use it over and over, as is. And, as a bonus, the amps go to zero when the gold is all stripped - it tells you when it is finished! When the gold sludge gets so high that it creates a partial short between the electrodes (you can tell when - the amps won't go to zero), let it settle, syphon or decant, and remove the gold. The solution is then reused, as is, without any treatment required. If there's a little gold sludge left combined with the solution, don't worry about it. You'll get it next time.
The magnetic pins are most likely Kovar - 54% iron, 29% nickel, and 17% cobalt. The nickel and cobalt don't dissolve much in the strong sulfuric. Probably due to the high iron content. The only base metals I've had problems with are the high Ni or Co superalloys - inconel, hastelloy, waspalloy, rene, stellite, etc.