Powder Coated Guard Rail
How Durable is Powder Coating?
January 26, 2023
Machined Part with Threaded Holes
Masking Threaded Holes Before Powder Coating
February 16, 2023

Avoid Electrocoating Defects

Avoid Electrocoating Defects

Choose an Experienced Electrocoating Service

Electrocoating, also known as E-coating, is an immersion process used to apply a protective coating to  metal parts.

The parts are racked and lowered into a bath of paint and epoxy, then an electric current is applied to attract coating particles to the metal. After curing in an oven, the parts are ready to go, protected by a dent, scratch, and chemical resistant coating that is one of the most durable in the parts coating industry.

Electrocoating is relied on by manufacturers as diverse as those in the Automotive, Agriculture, Military, and Medical industries.

But reaping the benefits of electrocoating means avoiding the possible defects, and the answer to that is choosing an experienced electrocoating service.

Types of Defects

Electrocoating can be described simply as using electricity to attract a protective coating to a part; however, the actual practice has complexity. It’s chemistry and electricity, and for anyone who remembers chem class from High School, you know accuracy and precision are paramount to getting good results. Everything from detritus and contaminants to misaligned electrical components to an out-of-balance oven can cause defects like:

  • Cratering
  • Rupturing
  • Roughness
  • Pin Holing

If your electrocoating service isn’t delivering the quality that e-coating is famous for, don’t blame the process, find a more experienced electrocoating partner.

Troubleshooting Electrocoating

With expertise comes the knowledge to identify, prevent, and address electrocoating problems so that our e-coating services remain at the highest quality.

When a defect is noted, we first isolate the problem in a rigorous process. What is the end result of the problem (cratering, roughness, pitting), and does it occur on all parts? When did the defect start, and has it been noted as constant or sporadic?  Is the defect in a uniform position on all parts, or does it appear randomly placed?

The problem could be mechanical and related to calibration of the rectifier or wear on the electrodes. It could be related to contamination or a poorly formulated coating. Is the defect introduced in the electrocoat bath or during oven curing?

As you can see, assuring a good electrocoat requires the ability to keep a complex system in balance and to deductively find and correct issues expediently.

We start by dividing the system into its components: pretreatment, ecoat, and oven, then isolating which area introduces the defect. Once that is determined, the area causing the defect is divided into its sub-processes, like pretreatment cleaner, conditioner, and rinses.

Varying how the same parts go through the system and its sub-systems can often help identify where the problem is coming from.

An unusual or fussy problem can sideline an electrocoating system for an unacceptable amount of time, putting them behind schedule or forcing them to deliver sub-par results.

Delivering Excellence in Electrocoating

When you choose Great Dane as your electrocoating partner, we deliver the advantages of e-coating:

Advantages to e-coating include:

  • Enhanced corrosion protection
  • Improved edge protection
  • Lower cure temperature
  • Compliant with global environmental standards
  • Smoother finish

When it comes to industrial coatings, electrocoating is among the most cost-effective, durable, and environmentally friendly coating technologies available.

At Great Dane, our experience includes service for the HVAC industry, Manufacturing and Fabrication, Automotive, Appliances, Construction, Military, Medical, and more.

To learn more about how Great Dane can become a partner in e-coating your  parts and products, call us at 724-537-9709 or visit our Contact Us page.

Delivering Coating Excellence for over 29 Years!

At Great Dane Powder Coating, Inc., we have more than a quarter century of experience under our belts. We offer the benefits of a cutting-edge facility and high-end equipment for providing exceptional results.

It’s no wonder that we are trusted by fabrication facilities and manufactures across the country to deliver highly durable coatings on a wide variety of parts and components.

When you want affordable, reliable, and outstanding results, give us a call at 724-537-9709 or visit our NEW ELECTROCOATING CUSTOMERS page today.



Call us today at 724-537-9709 or click a button below.