The Basics of Electrocoating:Electrocoating is a process critical to every segment of
metalworking industries. Advanced electrocoating systems allow
product designers greater latitude in the choice of materials,
improve the performance and wear properties of critical components,
and give metals a high quality, nonporous, high-adhering surface
for the subsequent application of liquid or powder topcoats, where
Definition: Electrocoating uses electrical energy to apply organic finishes.
The part is grounded and immersed in paint that has been charged
with the opposite polarity. Resin and pigment migrate to the part,
and a uniform film is irreversibly deposited. The part is rinsed,
Critical Processes: Successful film deposition depends on four simultaneous processes:
·Electrophoresis - the movement of colloidal materials dispersed in
liquid under the influence of a potential gradient.
·Electrolysis - the dissociation and movement of ions.
·Electro-osmosis - (the reverse of electrophoresis) the extraction
of water from the deposited film.
·Polarization - the ability of the deposited film to exhibit
electricity resistance, thereby insuring even coverage.
E-Coat Advantages: Properly engineered systems offer precise control over film
thickness, highest film integrity and an unblemished appearance.
The process offers extremely high repeatability of results, and is
a practical alternative for metal parts of virtually all sizes and
shapes, gauges and grades.
The most common applications of electrocoating include
underhood/underbody components, recreational goods, cooking and
laundry appliances, HVAC products, and aerospace products.
Recently, manufacturers of upscale consumer products have
popularized electrocoating as a primer for powder-coated goods.
E-Coat and the Environment: Electrocoating benefits the user in several important ways. Closed
loop rinsing, ultrafiltration, and the applications process itself
allow material utilization of virtually 100%. Many electrocoat
paint formulas are now available which are free of heavy metals;
many are also near-zero in VOCs and HAPs.
Electrocoating may not require a dry-off oven, thus exhaust air and
makeup needs are minimized. Finally, because the paint is 80-90%
water, the risk of fire - the ultimate environmental disaster - is
The Anodic/Cathodic Debate: Anodic systems deposit a negatively charged polymer onto a
positively charged part; in a cathodic system, the reverse is true.
We can demonstrate, and help you compare these options in terms
relevant to your plant, your product, your production, and your
future requirements. Today, acrylic, epoxy and hybrid
electrocoating are the alternatives. Of these, cathodic epoxy
deposition systems are widely regarded as the ultimate in terms of
delivering high hardness, excellent salt spray and other
We have extensive experience with all these systems, and can help
you consider what level of performance you need. Would a system
that delivered slightly less performance, at significantly less
cost, better serve your needs? Exploring all options, objectively,
and in detail, is, we believe, the most important due diligence you
can perform in making an e-coating decision.