Electrocoating Complex Geometries

Electrocoating Complex Geometries

The Perfect Solution for Coating Complex Parts

Parts with difficult geometries pose a challenge to any coating process. Intricate parts can be a problem when paint or powder coating can’t reach an inaccessible angle or edge. In drying or curing, areas with minimal coverage can worsen, as the coating can shrink or pull away from critical areas.

Even experienced powder coating operators, for example, run the risk of applying too much or too little powder on complex surfaces. An inexperienced technician runs the risk of not recognizing when too much powder is coming out of the gun or not knowing the best techniques for powder coating coverage.

The Precision and Uniformity of Electrocoating

That’s where e-coating comes in. Electrocoating solves the problem of coating complicated shapes and doing it precisely, affordably, and with uniform repeatability.

E-coating is a process that begins by immersing the parts in a tank filled with a specially formulated coating solution. An electric charge is then applied, causing the coating particles to migrate and evenly disperse onto the parts, adhering to their surfaces through electrostatic attraction. This is a fundamentally better option for coating complex pieces; however, there are still techniques that can help improve the process and ensure the best result. Let’s take a look.

The positioning of the parts during the coating process is crucial. Parts should be arranged in a way that allows for maximum exposure to the coating solution, enabling it to reach into all the intricate areas.

The voltage used in the process needs to be carefully controlled. High voltages can cause the coating to build up too quickly on the exterior surfaces, preventing it from penetrating into the more recessed or shielded areas. A lower voltage can help ensure a more uniform coat on all surfaces.

Properly preparing the parts in pre-treatment can greatly improve the adhesion and coverage of the coating. This might include cleaning, degreasing, and phosphating. Using a zinc phosphate treatment can help to promote uniform deposition, especially on steel substrates.

To maintain uniformity of the e-coat bath and avoid settling of paint particles, it’s important to keep the bath agitated. This can also help to promote a more uniform coating on the parts.

Maintaining the right temperature of the e-coat bath is also essential. If the bath is too hot, it can cause the coating to cure prematurely, preventing it from effectively coating complex surfaces. Too cold, and the coating may not adhere properly.

Finally, the coating must be properly cured. This usually involves baking the part in a curing oven at temperatures between 300 °F and 390 °F and time ranging from 10 to 30 minutes. t’s important to note that the exact curing time and temperature will be determined by the coating manufacturer’s recommendations and the specific requirements of the coated parts.

Each electrocoating project can have unique challenges, especially when dealing with complex geometries. A combination of experience, experimentation, and continuous process control are essential to achieving the best results.

Your Electrocoating Experts

At Great Dane Powder Coating, we have extensive experience serving industry with electrophoretic coating services. Our experts can even evaluate your parts coating needs and help you determine if e-Coating is the right process for the long-term viability of your project.

E-Coating is often the most cost-effective solution and delivers: excellent corrosion protection, uniform coverage, good adhesion, and the aesthetic appeal you’re looking for.

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.

Over 29 Years of Parts Coating Excellence

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 auto manufacturers, medical suppliers, and appliance manufacturers 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.